Concrete Paving Machines Are Now More Efficient

15.06.2021
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Concrete Paving Machines Are Now More Efficient

Rextoth, which has been working as a solution partner for many years, has reduced its power consumption by 45% compared to the unit using a standard electric motor, by using Sytronix, that is, the variable speed pump drive system, in the hydraulic unit of the new model concrete paving stone machine of the company.

Energy efficiency has gained great importance in hydraulic systems due to the decrease in energy resources in the world and the corresponding increase in energy costs. Rexroth Sytronix variable speed pump drive and control systems are one of the systems designed to increase energy efficiency. Sytronix consists of a comprehensive system of pumps, controllers and motors, as well as software based on cycle characteristic and configuration. Variable speed pump drives reduce energy consumption by 30 to 80 percent in many different applications.

Mussan Machinery, one of Turkey’s most established companies in the sector in the production of construction machinery with its half-century history, produces fully automatic or manually controlled concrete paving stone machines of various types and capacities, all kinds of concrete paving stones, briquettes, hollow curb molds. Stating that they attach great importance to quality and trust in all their projects, the General Manager of the company states that they take care to use innovative technology in the machines they produce because they do special jobs, and that they always work with technology companies such as Rexroth, which are leaders in the sector.

With the use of high energy efficiency variable speed pump drive systems in concrete paving stone machines; Concrete paving stone manufacturers are provided with advantages in terms of energy consumption, cycle speed, noise, ease of maintenance and control performance, and these benefits are having an increasing effect on machine sales.

Two A10VZO28 pumps were used in the Sytronix variable speed pump drive system in the hydraulic unit of the new model concrete paving stone machine belonging to Mussan Machinery; These pumps were driven by MSK 101E servo motors. Extremely efficient and energy-free hydraulic power transmission has been successfully achieved at variable operating pressures and variable speeds.

System pressure is measured with the HM20 Rexroth pressure sensor connected to the pump pressure line. The control is done with the software in the controls section. The system has very high operating dynamics. System software includes closed-loop pressure and flow control. The control of the transition from flow control to pressure control or vice versa is done automatically by the software. The control part is optimized to prevent pressure shocks that may occur during the transition from flow control to pressure control. While controlling the pressure, the pressure set value is compared with the actual pressure information measured by the pressure sensor in the system. Control error is handled by special PID control. The output correction signal of the pressure control is controlling the drive speed of the servo motor.

Thanks to the variable speed pump drive system, the required flow and pressure are provided only when the system needs it. As long as the servo motor is not doing work, it can be completely stopped; It has a fast response time due to its dynamic structure. Apart from this, it is possible to control the pressure, volume and flow direction of the flow in the system without loss of energy, since it is possible to control the speed of the pump with the new variable speed pump driven unit. In addition, if the system needs energy in the new unit, the servo motor gives the energy to the system via the driver, that is, it works as a pump. When energy comes from the system (for example, when we try to stop or slow down the cylinder), the servo motor can give the energy back to the driver, so this time it works as a generator-motor. In this way, it is possible to recover, store and convert energy into electrical energy. According to the feedback we received from the last customer using the concrete paving stone machine, the power consumption of the hydraulic system is reduced by 45% compared to the unit where we used a standard electric motor in the previous version. Power consumption that can be reduced by up to 80% with the variable speed pump drive system; This happens at a rate of 45% as we mostly work with full flow rate in this unit. In addition, the unit with variable speed pump drive system performs very successfully by reducing the pressing time of 8 cm paving stone, which is 28 seconds on average, to less than 20 seconds. KPM 6036 variable speed pump drive system unit, which was added to the product portfolio by Mussan Makina after the prototype production was put into use within the year, thus started mass production.

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