Siemens Introduces Sinumerik Ctrl-Energy
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Siemens Industry, Inc.
390 Kent Ave.
Elk Grove Village, IL, 60007
Press release date: August 2, 2011
TO MAKE ENERGY-EFFICIENT CNC MACHINES MORE ECONOMICAL AND PRODUCTIVE
CHICAGO, - The topic of energy savings is increasingly gaining importance in the machine tool industry because of the rising cost of energy, ever more stringent environmental regulations and efforts to obtain certification according to the international energy efficiency standard EN16001. According to a recent EU Commission report, industrial production accounted for 40 percent of total power consumption in the EU-27 in 2007, of which 70 percent was used by electrical drive systems. Depending on the company involved, machine tools can account for up to 68 percent of the total energy requirement. This fact makes energy efficiency in manufacturing a decisive factor in reducing plant costs and improving overall competitiveness. With this in mind, Siemens has carried out an energy analysis of individual machine tool components with the goal of achieving significant cuts in energy consumption through Sinumerik Ctrl-Energy.
With Sinumerik Ctrl-Energy, Siemens has opened up a broad range of solutions for the energy-efficient operation of machine tools, encompassing its Sinamics drive systems and motors, CNC and drive functions, PC software solutions and services. Sinumerik Ctrl-Energy offers energy-efficient solutions covering every aspect of the machine's lifecycle, starting from machine design and engineering through machine operation and partial or complete retrofit. This makes Sinumerik Ctrl-Energy a broad-based platform for efficient machine management, which will benefit both the machine tool OEM and end-user.
CTRL-E FUNCTIONS FOR ENERGY MANAGEMENT
Using a simple 'Ctrl' and 'E' key combination on the operator panel, Sinumerik CNCs can provide a fast evaluation of the machine tool's energy consumption and also manage energy consumption during machine downtime. Using the 'Ctrl-E Analysis' function, Sinumerik controls determine both the energy consumption of a drive system and the entire machine. They enable the user to analyze the amount of energy that goes into machining every individual workpiece as the basis for machining strategy improvements. The 'Ctrl-E Profiles' function also provides a configuration platform for the management of the machine's energy saving modes, helping to selectively shut down specific power loads during downtimes.
FREQUENCY CONVERTERS AND ENERGY-SAVING MOTORS - THE INTEGRATED DRIVE TRAIN AS A CORE ELEMENT OF OVERALL ENERGY EFFICIENCY The Siemens Sinamics S120 drive system permits dynamic energy management in the DC link and makes use of a highly efficient power recovery system, which initially stores generated braking energy in a DC link and optionally feeds it back into the grid rather than allowing the brake resistance to turn it into heat. Sinamics drives and Siemens motors have been designed with a clear focus on energy efficiency aspects. In this manner, integrated drive modules from Siemens reach a high efficiency rating of 97-99 percent.
With an efficiency of up to 94 percent in synchronous motors and up to 91 percent in asynchronous motors, the Siemens motor range also provides a basis for energy-efficient machine designs. In a typical machine tool, auxiliary assemblies such as hydraulic supply systems or cooling and lubrication units account for over half the total energy consumption. Energy-saving 1LE standard asynchronous motors have an efficiency rating of up to 97 percent and offer significant potential for auxiliary assembly improvement. The use of Sinamics G120 frequency converters helps adjust the speed and also the energy consumption of auxiliary systems to the level required at each stage of the process.
POTENTIAL SAVINGS: CURRENT FLOW REDUCTION AND POWER FACTOR COMPENSATION Sinamics S120 drive systems permit automatic current flow reduction in asynchronous spindles operating under part-load, avoiding unnecessary heat loss. The reactive power of a machine can be fully compensated using the smart infeed and feedback modules of Sinamics S120 drives, rendering costly and loss-prone reactive power compensation units on the end user's premises superfluous.
CONTROL CABINETS ALSO HELP EFFICIENCY Control cabinets, along with the required dissipation of heat, have a significant impact on the energy balance of a machine. Siemens can supply machine tool builders with a complete control cabinet that is designed with optimum energy management in mind. Various cooling options exist, including cold plate and direct fluid cooling, which reduce the need for air-conditioning in the control cabinet and make waste heat produced by the drive systems available elsewhere in the form of process heat.
SIZER - THE CONFIGURATION TOOL FOR ENERGY-EFFICIENT DRIVES Sizer is the Siemens software tool used to configure energy-efficient drives. It calculates energy consumption and losses incurred with the anticipated load cycles (ramp-up, idle running, running under load, braking, cycle times etc.), as well as the influence of regenerative feedback. This allows the energy efficiency of alternative motor/converter combinations to be evaluated. Using this information, configuration of the feed and main spindle axes can be optimized in line with the process and the anticipated cyclical work flows. Sizer also helps users to avoid over-dimensioning, also in terms of infeed, and to minimize energy consumption.
For more information about CNC solutions and services from Siemens, point your web browser to www.usa.siemens.com/cnc. Talk to us on Twitter: www.twitter.com/siemens_cnc_us and follow us on Facebook at www.facebook.com/SiemensCNC.
Siemens Industry, Inc. is the U.S. affiliate of Siemens' global Industry Sector business-the world's leading supplier of production, transportation and building technology solutions. The company's integrated hardware and software technologies enable comprehensive industry-specific solutions for industrial and infrastructure providers to increase their productivity, sustainability and profitability. The Industry Sector includes six divisions: Building Technologies, Industry Automation, Industry Solutions, Mobility, Drive Technologies and Osram Sylvania. With nearly 204,000 Siemens Industry Sector employees worldwide, the Industry Sector posted a worldwide profit of $4.7 billion on revenues of $47.3 billion in fiscal 2010. www.usa.siemens.com/industry
A division of Siemens Industry, Inc., the Drive Technologies Division is the world's leading supplier of electrical and mechanical products, applications and solutions that cover the entire drive train. Drive Technologies is the global leader in energy-efficient motors and drives, as well as products and services for production machinery and machine tools. Technologies include standard products, industry-specific control and drive solutions, as well as mechatronics support and online services for web-based fault management and preventive maintenance. Drive Technologies provides its customers with energy-efficiency, productivity and reliability in industries as diverse as clean and renewable energy, transportation, oil and gas, utilities, metals and mining, machinery manufacturing and machine tools. With nearly 36,000 employees worldwide, the Drive Technologies Division posted worldwide revenues of $9.5 billion in fiscal year 2010. www.usa.siemens.com/drives