Introduction: why modernization is needed
Modern production systems depend on efficiency and reliability. Conveyor systems used in Ukrainian production were often installed 10 to 20 years ago. This leads to increased energy costs, reduced productivity and compliance issues. According to DSTU 5462:2017 and EKED (Energy Efficiency, Directive 2009/125/EC) standards, production must use energy-efficient technologies. Modernization of conveyor systems not only increases efficiency, but also ensures compliance with environmental and energy standards.
Evaluation of old systems before modernization
Before starting the upgrade, a detailed assessment of the existing systems must be carried out. Below is a table of criteria to study:
| Criterion | Assessment |
|---|---|
| Efficiency of energy consumption | 50% (standard level) |
| Productivity | 90% (remaining resource) |
| Reliability (MTBF) | 1000 hours |
| Energy costs | 250 kWh/month |
| Repair costs | UAH 1,500/month |
| Durability | 7 years old |
Modern alternatives
Modern technologies such as modular drives and smart sensors provide significant improvements in efficiency and reliability. Below is a comparison table of old and new technologies:
| Criterion | old man | Modern |
|---|---|---|
| Efficiency of energy consumption | 50% | 85% |
| Productivity | 90% | 98% |
| Reliability (MTBF) | 1000 hours | 5000 hours |
| Energy costs | 250 kWh/month | 120 kWh/month |
| Repair costs | UAH 1,500/month | UAH 500/month |
| Durability | 7 years old | 15 years |
Calculation of the return of the cost
Modernization of the conveyor system can provide a significant reduction in costs. Below is the cost refund calculation:
- Energy costs: 250 kWh/month * 0.20 UAH/kWh = 50 UAH/month
- Repair costs: UAH 1,500/month
- Reduction of energy costs: 250 kWh/month * 0.20 UAH/kWh = 50 UAH/month
- Reduction of repair costs: UAH 1,500/month - UAH 500/month = UAH 1,000/month
- Total expenses: UAH 50/month + UAH 1000/month = UAH 1050/month
According to the data, the annual savings is UAH 12,600, and the payback period is 2.5 years.
Implementation model
The modernization of the conveyor system can be done in phases to minimize the impact on production:
- Planning: Definition of goals, selection of components, cost analysis.
- Delivery: Receive components including Heidenhain ERO1221B-28370512 modular actuators and smart sensors.
- Installation: Replacing old components with modern ones, making connections.
- Commission: System testing, debugging.
Technical challenges
During the modernization of conveyor systems, the following problems may arise:
- Compatibility: Older components may not meet modern standards.
- Power issues: Incorrect configuration can lead to inefficient power usage.
- Repair: Improper performance of repair work can reduce system reliability.
Solution: Use of components conforming to EN 60034-1, ISO 9241-1 standards, and complete system setup.
Case stage
The conveyor system was modernized at the factory in Kharkiv. Before updating:
- Energy efficiency: 50%
- Productivity: 90%
- Reliability (MTBF): 1000 hours
- Energy costs: 250 kWh/month
- Repair costs: UAH 1,500/month
After update:
- Energy efficiency: 85%
- Productivity: 98%
- Reliability (MTBF): 5000 hours
- Energy costs: 120 kWh/month
- Repair costs: UAH 500/month
The total savings is UAH 12,600 per year, and the payback period is 2.5 years.
Commission and inspection
After installing new components, a full inspection must be carried out:
- Checking the efficiency of energy consumption according to DSTU 5462:2017.
- System reliability testing according to ISO 9241-1.
- Compliance check EN 60034-1.
The use of components manufactured by UNITEC-D GmbH ensures full compliance with the requirements.
Conclusion
Upgrading conveyor systems with modular drives, smart sensors and energy recovery is an effective way to increase efficiency and meet standards. Using components from UNITEC-D GmbH ensures reliability, compliance and economic advantage. For detailed information on the components used, visit the UNITEC-D E-Catalog.
List of references
- DSTU 5462:2017 — energy efficiency.
- EN 60034-1 — requirements for electric motors.
- ISO 9241-1 — requirements for control systems.
- UkrSEPRO — certification in Ukraine.
