Power supply for multi-axis systems with a storage unit

Factories will have to be more flexible in the future than they are now. Digitalization, batch size 1, ever-changing customer requirements, and highly flexible production are just some of the requirements that have to be met. Another factor that affects production and the technical design of machines is the development of energy costs, which are ultimately reflected in the return on investment. That is why you should take advantage of peak shaving and the benefits of supplying energy through multi-axis systems featuring storage technology.

Our Power and Energy Solutions offer the following advantages:

• Reduction of power peaks from the grid
  Using storage capacitors in the DC link means most of the required peak power is provided from the storage capacitors.
  This leads to considerable cost savings both in the complete connection cabling and the control cabinet. Here is an example: Instead of 75 mm², a 75-kW system needs just 6 mm² in the supply system cable. As a result, line connection components are smaller and braking resistors are no longer required.
• Uninterrupted system operation in the event of a power failure
  The rotational energy, combined with the energy in the storage capacitor, serves as an uninterruptible power supply (UPS) for the system. The drives, motor brakes, and the 24 V level of the controller are powered in this way, allowing a safe initial position to be reached at any time.
• Reduced harmonic load in the grid
  The system achieves a power factor of 0.95. From as low as 20% of the nominal power, the power factor is 0.90. Even under difficult connection conditions, the system does not put the grid under further strain.
• Performance and energy measurement data for ISO 50001 energy management systems
  The power supply module measures performance data and provides energy meter readings. These can be integrated into ISO 50001 energy management systems.
• Reduction of energy costs due to storage capacitors in the DC link
  The energy of regenerative operating states is stored in the storage capacitor and is used again during motor operation.
• Connection to external DC supply systems
  The connection between the DC link and external DC supply systems is bidirectional using a DC-DC converter.

Application example

The goods are lifted or lowered automatically between two transportation levels at a lifting station.

Implementation:

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

Result:

• The peak power output during upward acceleration has been reduced by a factor of 15.
• Energy costs have been reduced to 60% of those incurred while operating with a braking resistor.
• In the event of a power failure, the downward movement is completed using the energy in the storage capacitor. The upward movement is brought to a halt in a controlled manner, at which point the brake is applied.
• The power and energy modules provide the ISO 50001 energy management system with measured values that both visualize system consumption and use comparisons and reference cycles to identify deviations indicative of wear or stiffness.

• Nominal line voltage: 3 × AC 200 – 500 V
• Controlled DC link voltage: DC 0 to 800 V
• Nominal power: 10 – 25 kW
• Overload capacity: up to 160% for 60 s
• Option for parallel connection

• Nominal voltage: DC 0 to 800 V
• Controlled DC link voltage: DC 0 to 800 V
• Nominal current: 20 – 75 A
• Overload capacity: up to 160% for 60 s
• Option for parallel connection

• Nominal line voltage: 3x AC 200 – 500 V or DC 150 V – 800 V
• Nominal output voltage: DC 24 V
• Nominal output current: 22.5 A
• Option for parallel connection

• Energy storage unit for installation in the axis system
• DC link nominal voltage: DC 560 V
• Operating voltage range: DC 0 to 800 V
• Nominal capacity: 7.5 – 12.5 mF
• Energy content: 2 – 4 kWs
• Option for parallel connection

• Energy storage unit for stationary and mobile applications
• Modular system
• IP54 degree of protection
• DC link nominal voltage: DC 560 V
• Operating voltage range: DC 0 to 720 V
• Energy content: 10 – 1000 kWs
• Option for parallel connection

• Energy storage system
• Turnkey solution
• DC link nominal voltage: DC 560 V
• Operating voltage range: DC 0 to 800 V
• Energy content: 1200 – 3300 kWs
• Option for parallel connection

Typical applications

• Dynamic machine modules: Handling modules
• Amusement rides: Big wheel
• Logistics applications: Storage/retrieval system / automated small-parts warehouse

Topologies

Our MOVIDRIVE®modular application inverter supports four different topologies to optimize your system's energy and performance management. Each topology can be implemented in alternating current or direct current operation.

Certifications/conformity

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