Power and Energy Solutions

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    Effortlessly save costs while enhancing your sustainability

Reduce power peaks in your supply grid with Power and Energy Solutions and you will ultimately achieve the ROI you desire. Is it really that simple? We think so. Using a clever power and energy management system boosts your system's energy efficiency and availability. This is down to MOVIDRIVE® modular application inverters paired with intelligently connected storage capacitors and a DC link coupling.

Identifying and using opportunities to reduce costs

Power and Energy supports peak shaving for low grid loads.
Power and Energy supports peak shaving for low grid loads.
Power and Energy supports peak shaving for low grid loads.

Increasing customer and market demands are changing the layout of factories, resulting in more modules, more flexibility, more automation and fewer rigid structures.

This means that automation technology and energy management must also take account of these developments with new technologies. In addition, customers expect a great deal from enhancing sustainability and energy efficiency – including economic benefits. We therefore took a close look at the issue of power supply, paying particular attention to undiscovered or unused opportunities to lower costs. Our research efforts led us to Power and Energy Solutions, which focus on reducing peak loads to lower costs in the long term.

Using a power supply and energy management system tailored to your application, you can take the necessary action to improve how energy is used in your production operations. At the same time, the energy management system offers complete transparency and allows for detailed monitoring of power supply data and consumption data.


Power and Energy Solutions in detail

  • Benefits & properties
  • Application example
  • Modular energy-saving system
  • Logistics applications Application options
  • Topology drawing Topologies
  • Product labels

Benefits & properties

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 the technical design of machines and production facilities 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. 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 the 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 0.09. 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 thanks to storage capacitors in the DC link
    The energy used in regenerative operations is stored in the storage capacitor and used again for the next motor operation.
  • Connection to external DC supply systems
    The DC link is connected bidirectionally to external DC supply systems using a DC-DC converter.

Your benefits

Scalability!

  • Distributed DC and AC infrastructure in any combination

Cost reduction!

  • Auto-configuring components
  • Strongly reduced peak power demand of the application
  • Reduction of energy costs thanks to storage capacitors in the DC link

Reliability!

  • High availability of individual production cells
  • Uninterrupted system operation in the event of a power failure
  • Reduced harmonic load in the grid

Flexibility!

  • Faster changes in the factory layout

Application example

Power consumption
Power consumption
Power consumption

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.

Modular energy-saving system

Power supply module with controlled DC link voltage

Power supply module with controlled DC link voltage
Power supply module with controlled DC link voltage
Power supply module with controlled DC link voltage
  • Nominal line voltage: 3 × AC 200 – 500 V
  • Controlled DC link voltage: DC 0 – 800 V
  • Nominal power: 25 kW
  • Overload capacity: 160%
  • Option for parallel connection

Switched-mode power supply module with AC and DC supply

Switched-mode power supply module with AC and DC supply
Switched-mode power supply module with AC and DC supply
Switched-mode power supply module with AC and DC supply
  • Input voltage: 1 × AC 200 V – 3 × AC 500 V or DC 150 – 800 V
  • Nominal output voltage: DC 24 V
  • Nominal output current: 22.5 A
  • Option for parallel connection

Capacitor module

Capacitor module
Capacitor module
Capacitor module

Capacitor module: MDC90A-0120-50X-000

  • DC link connection
  • DC link voltage Vsupply system: DC 560 V
  • Operating voltage range: DC 0 – 800 V
  • Maximum voltage: DC 900 V
  • Nominal capacity: 11.8 mF ± 20%
  • Usable energy: 2 kWs in the range from 500 V – 800 V
  • Connection via DC bus
  • Option for parallel connection

External capacitors

External capacitors
External capacitors
External capacitors
  • Voltage range: DC 0 – 800 V
  • Energy content up to: 3000 kWs
  • Connection via DC cable
  • Options for both parallel and series connection
Control cabinet housing the super capacitors
Control cabinet housing the super capacitors

Depending on the application and the energy required, the control cabinet housing the super capacitors can be customized in the ESS-R2 and ESS-R3 versions. Both versions can accommodate 6, 7 or 8 super capacitors.

Discharge unit

Discharge unit
Discharge unit

In order to optimize maintenance operations, thus limiting the impact on the environment and staff, a discharge unit has been developed that significantly reduces the discharge time of the energy storage unit and so permits faster access to the system.

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, New Zealand)
  • RoHS (China)
  • cULus (USA, Canada)
  • KC (South Korea)
  • UKCA (United Kingdom)
  • CMIM (Morocco)
  • WEEE (European Economic Area)

Further information