DAIKIN　PMC

Energy-saving Hybrid Hydraulic System

SUPER UNIT
Development to General Industrial Machinery
Development of Energy-saving Hybrid Hydraulic System to General Industrial Machinery
DAIKIN　PMC

For machining tool market: Reducing waste power in pressure-retained

condition
Reducing rpm in pressure-retained condition can
considerably save energy consumption.

For general industrial machine market:

　　　　　　　　　　Energy saving in the whole operating range is required.
　　　　　　　　　　Pressure range should be increased.

ƒ Driving motor efficiency improvement System and component review is

ƒ Review of hydraulic system required.
Components of Hybrid Hydraulic System and Required Characteristics DAIKIN　PMC

Configuration of Hybrid Hydraulic System Required characteristics

1) Hydraulic system
Energy saving → Optimization for each
application
(High pressure: Dual pump system is used)

2) Pump
Control
制御弁valve Variable speed control
Pressure → Selection of optimum pump
(rpm range, efficiency, sound level)
Rotational Energy saving
Variable position → Optimization of rpm
speed (Machine efficiency)
motor

Fixed capacity
3) Motor
pump Quick response→ Low speed, large torque
Controller
Energy saving → High efficiency
(Inverter)

4) P-Q characteristic
Robust characteristic →
Smooth switching of control target
(pressure, horsepower, flow rate)
 Optimization of Hydraulic System DAIKIN　PMC

T (Torque required for motor) = p (Control pressure) × q (Pump capacity) ∝ Motor current value
2π × n (Torque efficiency)

(To reduce power consumption in high-pressure retained condition, the pump capacity must be reduced.)

Low pressure: Single pump system High pressure: Dual pump system

Discharge

Combination flow/single flow

switching solenoid valve
Discharge Pressure

Pressure
Rotational
Variable position Rotational
speed motor Variable position
Fixed- Fixed- speed
capacity capacity motor
pump pump

Low pressure, large High pressure,

capacity small capacity
Drain Intake Controller
Drain Intake
Controller
High-pressure Dual Pump System DAIKIN　PMC

„ Autonomous Switching between Combination Flow and Single Flow

Basic switching conditions

[Single → Combination] switching condition

Actual pressure < PL Low pressure,
QL
[Combination → Single] switching condition large flow rate control
Actual rpm < QH

Flow rate
High pressure,
Response switching condition (F.F → D.H. response) small flow rate control
Combination
output area
Development of surge pressure in combination
output range QH

Single output area

PL PH
[Combination → Single] switching is enabled even
Pressure
if the single switching flow rate (QH) is not
reached. Composition of P-Q Area
Characteristics Required for Motor DAIKIN　PMC

Required conditions
ƒLow speed, large torque output
Advantage of motor effectively using
ƒVariable speed range covering up
reluctance torque
to high speed rotation

Interior Permanent Magnet Synchronous Motor

(IPM motor)
ƒ Both magnet torque and reluctance torque are efficiently used.
Features: ƒ Motor characteristics can be easily customized by changing the
winding.
(Under mass production as compressor motor for DAIKIN energy-
saving air conditioner. Core diversion is enabled.)
ƒ Improvement of stability in low rpm range (Air conditioner motor does
Challenge: not need low rpm range.)
ƒ Response time improvement (Response time of air conditioner
compressor motor is extremely long.)
Improvement of Acceleration Response (Low rpm → high rpm) DAIKIN　PMC

In the range from pressure-retained

Air conditioner (compressor)
condition (low rpm) to discharge at
motor does not need quick
maximum flow rate (high rpm), 0.1-
response.
second order response is required.
↓
Sensorless control is applied.
Sensorless control cannot provide
(Positioning sensor is not used.)
such a response speed.

Improvement
Simplified encoder of 192P/R (without phase Z) is used.
However, incorrect polarity detection affects phase
weakening control in N-T area.

Development
Newly-developed maximum torque control ensures robust
performance against magnetic polarity detection error and
power supply voltage fluctuation.
Super Unit　　 DAIKIN　PMC

„ Outline
œ The energy saving IPM motor drive system is used.
Pursuing superior energy saving performance
and advanced functions
World First

ƒThrough combination of the air conditioning

motor and inverter technologies with the twin
pump switching control technology, the Super
Unit provides Δ50% energy saving performance
(during dwelling at 21 MPa).
ƒWith the highly efficient motor, the Super Unit enables
energy conservation even in the field of general industrial
machinery that frequently involves actuator operation as well
as dwelling.

œ Series of motors covering 7 MPa (15 L/min) to 21 MPa (60 L/min)

The Super Unit provides a wide range of applications, covering from

machining tools to general industrial machinery such as press.
Super Unit 　　 DAIKIN　PMC

„ FEATURES
[1] Energy saving performance (Δ50%: during dwelling, Δ40%: during actuator operation)
œHighly efficient IPM motor drive system is used.
œAutonomous-switching twin fixed-capacity pumps are used.
ƒ Using the twin fixed-capacity
pumps that provide small and large System configuration
capacities together with the Variable relief Discharge
selector valve, the Super Unit
enables autonomous control to
select combination or separate use
of the individual pumps according
to the load pressure. Drives the solenoid valve to switch
between combination and separate flows.
When a large flow rate is
required, the Super Unit selects
combination use of the large-
capacity and small-capacity
pumps, and operates the motor at Pressure sensor

a high rpm to discharge the fluid at

a large flow rate. IPM Rotating position
Fixed- Fixed-
During dwelling, the Super Unit capacity capacity motor
pump pump
selects use of the small-capacity
pump only, and operates the Low pressure / Large High pressure / Small
capacity capacity
motor at a low rpm, thus achieving
significantly high energy saving Drain Intake Controller
ratio.
Super Unit 　　 DAIKIN　PMC
Example of hydraulic press circuit configuration
[2]Multistage flow rate control/
Multistage pressure control Eliminating control valve by using
software-based control method
Incorporating shock-less
control function
Throttle valve Elimination of
œThe Super Unit enables throttle valve

multistage pressure/flow rate

control simply by receiving a General
purpose
PQ characteristic pattern input solenoid
to the contact terminal among Special spool Standardization of valve
shock-less solenoid valve
the four patterns registered in solenoid valve
the controller, and by receiving
a selection signal from the
sequencer.
œThe Super Unit enables Elimination of
proportional control valve Combination/
shockless control through separate flow
selector valve
Proportional relief valve
adjustment of the selection
signal rise/fall time, when Ｍ Controller Ｍ
switching the PQ
characteristic pattern. Driver

Sequencer
Conventional system configuration Super Unit system configuration

[3]Low noise level

60 dB (A) (during dwelling at 21 MPa) 70 dB (A) or less (for entire operating area)
Equipped with cover
œ With the twin phase-differential pumps, the Super Unit can reduce pulsation and noise level.
Examples of Advanced Functions of High-pressure Super Unit DAIKIN　PMC
Application of advanced Arbitrary speed
2-stage speed function setting
only Large shock
Speed during Speed Shockless
switching acceleration/
Advanced deceleration
function
Time Time

Actuator
Speed Pressure
control control
valve valve Simple Valve
circuit reduction

Directional
control valve

Unit
Total cost Unit
Motor pump reduction at 2-
stage or more
speed control
(including valve
reduction)
Conventional hydraulic unit Super Unit
 Examples of Multi-stage Pressure Control/Shockless Control DAIKIN　PMC
[Multi-stage pressure control]
Four patterns of P-Q characteristics registered in the controller can be selected with contact input from a host.
[Shockless control]
Through adjustment of the P-Q characteristics selection signal rising/falling time, shockless control is enabled.

P-Q P-Q P-Q P-Q

characteristic 0 characteristic 1 characteristic 2 characteristic 3

P-Q mode selection: 1 Pressure: MPa P-Q mode selection: 3 Pressure: MPa

P-Q mode selection: 0 Pressure: MPa P-Q mode selection: 2 Pressure: MPa

接点入力による多段圧力選択（加減速時間５０ｍｓ設定によるショックレス切換圧力データ）
Multi-stage pressure control using contact input (Shockless switching pressure data with acceleration/deceleration time of 50 ms)

20
18
16
圧力（ＭＰａ）(MPa)

14
12
10
Pressure

8
6 PQ選択0 PQ選択1 P-Q
PQ選択3
selection 3 PQ選択2 PQ選択0
P-Q selection 0 PQ選択1
P-Q selection 1 PQ選択2
P-Q selection 2 PQ選択3
P-Q selection 3 PQ選択1
P-Q selection 1 PQ選択0
P-Q selection 0 PQ選択3
P-Q selection 3 PQ選択0
P-Q selection 0 P-Q selection 1 P-Q selection 0
4
P-Q selection 2

2
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Time経過時間(秒）
elapse (sec)
Models/Specifications DAIKIN　PMC

Basic model SUT**S15 SUT**S30 SUT**D40 SUT**D60 SUT**D80

Maximum flow rate (L/min) 15 30 40 60 80
Maximum operating pressure (MPa) 7 7 16 21 21
Motor capacity (kW) 2.2 2.8 3.7 5.0 7.0
Pump configuration Single gear pump Dual gear pump
Pump capacity (cm3/rev) 4 5.7 3.5/5.5 5.0/9.5 6.5/12.5
Power supply (Motor) 3φ 200/200/220V, 50/60/60Hz
Power supply (Fan motor) 2φ 200/200/220V, 50/60/60Hz
7 inputs,
Input/output 7 inputs, 7 outputs 3 inputs, 2 outputs
7 outputs
16 PQ, Alarm,
Function 16 PQ, Alarm, Warning 4 PQ, Alarm, Warning
Warning
　30 L
Tank capacity
　60 L
100 L
160 L
*　Tank less type( Motor pump unit ):SUT00S15 / SUT00S30 / SUT00D40 / SUT00D60 / (SUT00D80)
Dedicated mineral hydraulic fluid/Abrasion-proof hydraulic fluid (Water-glycol
type cannot be used.)
Operating fluid Viscosity grade: ISO VG32 to 68
Viscosity range: 15 to 400 mm2/s
Pollution degree: NAS Class 10 or less
Tank oil temperature 0 to 60℃
Ambient temperature 0 to 35℃
Ambient humidity 85% RH or less
Installation place Indoor
SUT** series DAIKIN　PMC

Double Gear Pump with Oil Tank (SUT**D***) Double Gear Pump without Oil Tank (SUT00D****)

Power P (Mpa) Q (L/MIN) PQ

Power P (Mpa) Q (L/MIN) PQ 3.7Kw 16.0 40 4
3.7Kw 16.0 40 4 5.0Kw 21.0 60 4
5.0Kw 21.0 60 4 7.0Kw 21.0 80 16
7.0Kw 21.0 80 16 11.0Kw 21.0 110 16

Single Gear Pump with Oil Tank (SUT**S****) Single gear without Oil Tank （SUT00S****)

Power P (Mpa) Q (L/MIN) PQ Power P (Mpa) Q (L/MIN) PQ

2.2KW 7.0 15 16 2.2KW 7.0 15 16

7.0 30 7.0 30
2.8KW 16 2.8KW 16
10.0 15 10.0 15

10.0 30 7.0 40
3.7Kw 4 3.7Kw 4
16.0 15 10.0 30

16.0 30 16.0 15
5.0Kw 4
7.0 60 16.0 30
5.0Kw 4
7.0Kw 7.0 80 16 7.0 60
7.0Kw 7.0 80 16
Comparison data between current unit and super　unit【 machine　tool 】 DAIKIN　PMC

■ Comparison data between current unit 　

and super　unit
①application　to　automobile 2.50
　
　parts　manufacturing　company　 2.00 Energy　
Energy　

Power consumption
消費電力量(kwh)
saving
saving
1.50
Energy　saving　of　ｈｙｄｒａｕｌｉｃ　unit　：　90% 90%
90%
1.00 2.10kwh
　
Saving　electric　fee　￥129,960/year
Saving　electric　fee 　￥129,960/year
0.50
# Runnning time: 4560 Hrs/year
0.00 0.20kwh
Power rates : 15 yen/kWh
現状油圧ﾕﾆｯﾄ
Conventional　unit ｽｰﾊﾟｰﾕﾆｯﾄ
super　unit
Conventional　unit
現状油圧ユニット消費電力 super　unit
ｽｰﾊﾟｰﾕﾆｯﾄ置換後消費電力
6
　 6 　
5

消費電力量(kwh）
Power consumption

Power consumption
5
消費電力量(kwh）

4
4
3
3
2
2
　 　 1
1
0
0
1 61 121 181 241 301 361
1 61 121 181 241 301 361

時間(Sec) 時間(Sec)
Time　(sec)
Time　(sec)
油圧 その他 ｽｰﾊﾟｰﾕﾆｯﾄ その他
Comparison data between current unit and super　unit　【 press　machine 】 DAIKIN　PMC

■ Comparison data between current unit 　

and super　unit
②application　to　electric　parts 　 6
Energy　
Energy　

Power consumption
manufacturing　company　 5
saving
saving

消費電力量(kwh)
4 66%
66%
Energy　saving　of　ｈｙｄｒａｕｌｉｃ　unit　：　66% 3
　 5.37kwh

Saving　electric　fee　￥424,512/year-
2
Saving　electric　fee 　￥424,512/year-
1 1.85kwh
# Runnning time: 8040 Hrs/year
0
Power rates : 15 yen/kWh
現状油圧ﾕﾆｯﾄ
Conventional　unit ｽｰﾊﾟｰﾕﾆｯﾄ
super　unit

Conventional　unit
現状油圧ユニット消費電力 super　unit
油圧置換後消費電力
　 　
6 6

Power consumption
Power consumption

5 5

消費電力量(kwh）
消費電力量(kwh)

4 4

3 3
　 　
2 2

1 1
0 0

Time　(sec)
時間(Sec) Time　(sec)
時間(Sec)