Overview

Modern machine designs are increasingly based on Electrohydrostatic

Drive Systems (EAS) instead of valve-based throttle control.

The installed power of the EPU axes and their servo controllers often

exceeds the connected load of the previously used hydraulic power

unit, especially when conventional hydraulic accumulators are used.

Moog combines the best fitting power infeed with storage units to

reduce the installed power significantly. Together with the efficiency

gain of the EAS and the peak power reduction of the Moog Energy

Management System (EMS), hydraulic machines reach a new level

of attractiveness in terms of energy efficiency and reduced total cost

of ownership (TCO).

Benefits

• Reduces installed power significantly and thus in-line components

up to the transformer (peak shaving)

• Reduces energy and operating costs and extends the service life

of electronic components

• Maximizing machine efficiency through energy storing and minimizing

losses

• Modular approach: For each application the right infeed and storage

type

SMART ENERGY MANAGEMENT FOR ELECTROHYDROSTATIC

ACTUATION SYSTEMS

As an addition to the EAS portfolio, the Moog ESU Energy Management

System (EMS) offers machine operators and OEMs the opportunity to

significantly reduce energy and operating costs while increasing the

service life of electronic components. The EMS can also be used in

electromechanical drive systems.

HIGH PERFORMANCE DESIGN FOR SMART POWER MANAGEMENT

The Moog DE2020 energy management module improves the efficiency

of any machine and allows for a leaner and more cost-effective electrical

layout. During the regular load phase, a capacitor bank is pre-charged

carefully and a certain remaining capacity is retained.

The DE2020 meets peak loads by drawing energy from the capacitor

bank, while using the energy gains from braking processes and mechanical

inertia to recharge the capacitors by means of recuperation. 

Thus, the capacitors are ready for the next peak load. This helps increase

overall energy savings and, more importantly, allows for an overall smarter

electrical design of the machine.

Advantages

Among other advantages, there is a significant reduction in the dimensions

of the electrical panel (reduced by 50% compared to non-optimized systems)

and of the cable sections necessary to allow the currents to flow

(with consequent savings in wiring costs).

Furthermore, this system can also be used to compensate for fluctuations 

of the mains, using a pre-filter in combination with the capacitor bank, reducing

the risk of electrical malfunctions, while simultaneously increasing safety in the

event of a power failure, as it can supply the system with enough energy to

reach a safe-stop position.

TYPICAL WORK CYCLE

During normal machine activity, the DE2020 module will:

• Manage the input power profile, shaping the electrical power

coming from the input, leveling the peaks, and flatten the load

peak on the DC grid.

• Charge the accumulator energy banks and accurately control

the voltage across them.

• Provide additional energy during acceleration phases.

• Handle the kinetic energy obtained from running masses

during their braking phases.

• Provide the system with previously stored energy during

acceleration phases.

• Temporarily withstand DC grid failures or unexpected

disconnections of the DC power supply providing the system

with the necessary energy to bring the machine to a safe state.

DE2020 SYSTEM OVERVIEW

Modes of Operation:

• Power Leveling

In a typical machine cycle, accelerations require peaks of power; the

DE2020 can handle energy using energy storage accumulators in

order to guarantee a performance beyond the nominal power of the

electrical equipment.

• Energy Recovery

Usually while braking, the energy that motors give back to the

system is partially wasted as it is dissipated on the power supply

dynamic braking resistor. With the DE2020 module, this energy

is stored in  the accumulator energy banks, such as the Moog

Additional Bus Capacitor (ABC module) or larger in sizes, in order to

be saved and reused.

• Energy Backup

The DE2020 can use the energy stored in the accumulator energy

banks when the grid is down to ensure safe home movements of the

machine and/or to keep safely controlling critical axes during grid

failures. This feature makes the system more reliable and protected

against issues related to sudden losses of power from the grid.

Silencer® brushless controllers are available in a variety of voltage

and current ratings. All controllers have generous terminal blocks

to facilitate ease of wiring and they are designed for ease of mounting

in a small envelope, requiring minimal space in a cabinet / enclosure.

Silencer drives are compatible with Silencer Series Brushless DC Motors.

Silencer motors are available in sizes 12. 17. 23. 28. 34 and 42 in

standard frames with 1.2 to 4.15 inch diameters.

They offer speeds up to 20.000 rpm and continuous torques ranging from

1.2 to 519 oz-in. Standard options include gearheads, resolvers and encoders.

Features

• 2-quadrant speed controllers for brushless motors

• Feedback using Hall effect sensors

• Motor speed is set by either an internal or external potentiometer

• Motor rotation direction can be present by the direction control input;

the controller output stage can be activated and deactivated by the disable

control input

• Maximum constant current can be adjusted via an on-board potentiometer

• Internal thermal cutoff prevents heat overload

• Very high efficiency is achieved by using POWER-MOS-FET technology in

the controller output stage

• Efficient PWM speed control

• Operating temperatures from -10 to 45°C and storage temperatures from

-40 to 85°C

A MODULAR APPROACH TO MOTION CONTROL WITH MULTI-AXIS SERVO

DRIVES AND SINGLE-AXIS SERVO DRIVES

Higher performance machines can mean a real advantage in productivity

and profitability and Moog’s Multi-Axis Servo Drive System is a key enabler

in achieving this objective.  This integrated family of products provides

the highest levels of dynamic response, smooth performance and application

versatility.

This system includes both modular and single-axis servo drive options and

a common shared power supply to coordinate the motion across multiple

axes.

Advantages

• Higher machine productivity – From lowering cycle times in an injection

molding machine to increasing feed rates in a metal forming press, this

product delivers a significant increase in application performance

• Improved machine precision – More precise motion control such as smoother

movement in flight simulators and higher accuracy and finished part quality

in industrial machinery

• Higher machine flexibility – The modularity of the MSD coupled with the

ability to tailor customer-specific solutions provides the perfect flexible platform

for different machine types, putting them at the heart of today’s leading-edge designs

• Integrated safety function (per EN 61800-5-2) with Safety PLC available as an option

Markets

• Industrial Production Machinery

• Metal Forming Machinery

• Injection and Blow-molding Machines

• Simulation

• Gas and Steam Turbines

• Packaging and Food Processing Machines

Advantages

• The compact design and the multi-axis architecture, with shared power supply,

allow machine builders to reduce cabinet space and consistently cut wiri

• Maximum flexibility to work with different motor types and feedback devices

to meet all applications requirements

• Energy savings thanks to the shared DC BUS configuration that allows an

exchange of energy between the axes, reducing overall energy consumption

• Reduced electrical sizing of the machine controls thanks to the DE2020 Energy

Mangement System

• A user-friendly graphic interface allows easy access to all functions, simplifying

the settings, initial start-up and system monitoring

• Dual servo drive modules available in various sizes

Markets

• Industrial Production Machinery

• Metal Forming Machinery and Presses

• Injection and Blow-molding Machines

• Simulation

• Gas and Steam Turbines

• Packaging and Food Processing Machines

• Electric and Hybrid Vehicles

COMPACT, DIGITAL MULTI–AXIS SERVO DRIVES FOR TOP PERFORMANCE AND

MAXIMUM PRODUCTIVITY

The DM2020 is a state of the art servo drive designed to meet the requirements

of the most challenging machine builders. It unites flexibility, high performance

and simplicity of use. Its  modular design platform permits a high level of

customization to satisfy specific application needs. With its high-performance

control board and software for advanced control, the DM2020 guarantees

speed and faster cycle times, improving efficiency and ensuring maximum

productivity. The multi-axis architecture with a shared power supply unit

reduces the size of the axis module and overall dimensions of the system

by roughly 50% compared to a stand-alone similar configuration.

The DC-Bus is distributed among the axes through internal front panel

connections.

In addition to the shared DC BUS configuration that allows the exchange of

energy among the axes, specific modules are also available.

The capacitive ABC module, for example, increases the exchange of energy

among the different axes of the system, improving the efficiency of the machine.

By connecting external supercapacity modules, the peaks required by the

machine cycle can be delivered independently. By integrating Moog’s DE2020

Energy Management System >, it is possible to control the power absorbed

from the mains during peak times thus limiting the sizing of the system to

the nominal value required by the regular cycle.