Methods to Increase Energy Efficiency in Hydraulic Systems

Methods to Increase Energy Efficiency in Hydraulic Systems

IntroductionEnergy efficiency is a critical factor today not only for sustainability but also for economic competitiveness. In this context, it is of great importance to increase the energy efficiency of hydraulic systems, which play a fundamental role in many industrial applications.
Hydraulic Circuit Optimization

2.1. Optimization of PipelinesIn hydraulic systems, the inner diameters, lengths and layout of pipelines should be carefully designed in order to reduce pressure losses and prevent the system from heating up.

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2.2. Inner Surface Roughness and Resistance ReductionThe smoothness of the inner surface of the pipe reduces friction losses. In the design, the total pressure loss within the system should not exceed 6% of the nominal pressure.
2.3. Pump Pressure Discharge in Idle ModeWith open-center distributors, the pump can be depressurized when the system is idling (see Figure 1).
2.4. Use of Hydropneumatic Accumulators
It can be used to save energy in the system and to compensate for pressure fluctuations (see Figure 2).
2.5. Systems with Two PumpsIn applications such as press machines, energy efficiency is improved by the use of different pumps in fast and slow modes (see Figure 3).

3.1. Pumps with Pressure RegulatorsWhen the pressure reaches a certain level, the pump flow is reduced to a minimum (see Figures 4 and 5).
3.2. Negative Controlled SystemsThese are the systems in which the pump flow rate increases as the control signal decreases. In this way, energy losses are reduced (see Figure 6).
3.3. Positively Controlled SystemsThe pump flow rate increases when there is a control signal with external hydraulic control (see Figure 7).
3.4. LS (Load Sensing) Systems
Load-sensing systems deliver only the amount of pump flow in the amount needed, so that the system is continuously optimized (see Figures 8, 9, 10).

ConclusionIn order to improve the energy efficiency of hydraulic systems, many factors must be considered, from circuit design to component selection. In particular, the use of controlled pumps and LS systems maximizes energy savings in modern equipment.

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