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Your advantages

Scalability
Distributed DC and AC infrastructure in any combination

Cost reduction
This is ensured by: self-configuring components, greatly reduced peak power requirements of the application and savings in energy costs thanks to storage capacitors in the DC link

Reliability
thanks to the high availability of individual production cells, uninterrupted system operation in the event of power failure and reduced harmonic load in the grid

Flexibility
with quick adaptation of the solution to changing factory layouts

Control technology Control cabinet technology Decentralised drive technology Drive technology

Recognising and exploiting cost-cutting potential

The increasing requirements of the market and customers are changing the layout of factories. More modules, more flexibility, more automation and less rigid structures are the result.

Accordingly, automation technology and energy management must also take these developments into account with new technologies. In addition, there are high expectations with regard to improving sustainability and energy efficiency, which should pay off economically. We have therefore focussed on undiscovered or unused cost-cutting potential in the area of energy supply and have found what we were looking for: With Power and Energy Solutions, we are focussing on peak load reduction in order to reduce costs in the long term.

With a power and energy management system tailored to the application, you can take the necessary measures to make better use of the energy in your production. At the same time, the energy management system enables full transparency and detailed monitoring of grid and consumption data.
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Energy supply for multi-axis systems with memory

In the future, factories will have to be more adaptable than they are today. Digitalization, batch size 1, changing customer requirements and flexible production are just a few of the constraints that need to be met. Another factor that has an influence on the technical design of machines and production is the development of energy costs. And these are ultimately reflected in the question of return on investment. Therefore, focus on peak load reduction and utilise the advantages of energy supply through multi-axis systems with storage technology.

With Power and Energy Solutions, we offer you:

  • Reduction of power peaks from the grid
    By using storage capacitors in the DC link, the majority of the required power peaks are made available from the capacitor storage systems.
    This results in significant cost savings throughout the connection cabling and in the control cabinet. An example: A 75 kW system is equipped with 75 mm2 only with 6 mm2 in the supply system cable. This results in smaller mains connection components and the elimination of braking resistances.
  • Uninterrupted system operation in the event of power failure
    The rotational energy together with the energy in the capacitor storage unit also serves as an uninterruptible current supply (UPS) for the system. This supplies the drives, the motor brakes and the 24 V level of the open-loop control system and ensures a safe initial position at all times.
  • Reduced harmonic load in the grid
    The system achieves a power factor of 0.95. The power factor is already 0.09 from 20 % of the rated power. Even under difficult connection conditions, the system no longer places a load on the grid.
  • Power and energy measurement data for ISO 50001 energy management systems
    The power supply module measures performance data and provides energy meter values. These can be integrated into ISO 50001 energy management systems.
  • Reduction in energy costs thanks to storage capacitors in the DC link
    The energy from generator operating states is stored in the storage capacitor and reused for the next motoring operation.
  • Connection to external DC grids
    The DC link is connected bidirectionally to external DC grids via a DC-DC converter.

Application example

The goods are automatically raised or lowered at a lifting station between two transport levels.

Realisation:

Power and Energy Solutions, MOVIDRIVE® modular is used in power mode.

Result:

  • The power peak upwards during acceleration was reduced reduced by a factor of 15. factor.
  • The energy costs compared to an operation with braking resistance reduced to 60 % could be realised
  • In the event of a power failure, the energy in the storage capacitor is used to stop the downward movement completely. The upward movement is controlled until the idle state is reached and ended. Only then does the brake make contact.
  • For the ISO50001 energy management system, the modules for Power and Energy provide measured values that not only visualise the system consumption, but also detect deviations that indicate wear or stiffness by comparing them with reference cycles.

Energy saving kit
  • Nominal mains voltage: 3 x AC 200 - 500 V
  • DC link voltage regulated: DC 0 - 800 V
  • Rated power: 25 kW
  • Overload capacity: 160 %
  • Parallel connection possible
  • Input voltage: 1 x AC 200 V - 3 x AC 500 V or DC 150 V - 800 V
  • Nominal output voltage: DC 24 V
  • Nominal output current: 22.5 A
  • Parallel connection possible

Capacitor module: MDC90A-0120-50X-000

  • DC link connection
  • DC link voltage UMAINSDC 560 V
  • Operating voltage range: DC 0 C - 800 V
  • Maximum stress: DC 900 V
  • Nominal capacity: 11.8 mF ± 20 %
  • Usable energy: 2 kWs in the range 500 V - 800 V
  • Connection via DC rail
  • Parallel connection possible
  • Voltage range: DC 0 - 800 V
  • Energy content up to: 3000 kWs
  • Connection via DC cable
  • Parallel and series connection possible

Typical applications

  • Dynamic machine modules: Handling modules
  • Amusement rides: Ferris wheel
  • Logistics applications: Storage/retrieval systems for automated small parts warehouses

Topologies

With the MOVIDRIVE® modular application inverter, we enable four different topologies for optimised energy and power management of your system. Each can be implemented in AC or direct current operation.

Find out more: Topologies for power and energy solutions

Certifications / conformity

  • CE (European Economic Area)
  • EAC (Customs Union of Russia, Kazakhstan and Belarus)
  • RCM (Australia, New Zealand)
  • RoHS (China)
  • cULus (USA, Canada)
  • KC (South Korea)
  • UKCA (United Kingdom)
  • CMIM (Morocco)
  • WEEE (European Economic Area)

Power and Energy Solutions in use at NewCold

Requirements

NewCold, a leader in the development and operation of deep-freeze warehouses, was equipped with Power and Energy Solutions.

Solution


Curious? Video and details of the reference project!