8 Tips for Ensuring Energy Efficiency in Hydraulic Systems
Hydraulic systems provide the driving force needed to operate machinery in manufacturing, construction, transportation, and a range of different industries. These machines are often heavy-duty and costly to run, so making sure their hydraulic systems are energy efficient is vital. Our experts have put together our top tips for ensuring energy efficiency in hydraulic systems. By periodically checking your systems and implementing these tips, companies can make substantial energy savings, all while protecting the integrity of their equipment, minimising their environmental impact, and reducing wear and tear.
How Energy Losses Occur in Hydraulic Systems
Before implementing energy-saving measures, it’s important to understand how and where energy losses occur.
Energy usage goes up as a result of pressure loss, excessive heat generation, and fluid leaks. Fluid leaks can lead to increased friction within pipes and components, causing the system to lose pressure. More energy is therefore needed to power it. If components are inefficient, they generate excess heat, and cooling systems need to work harder to reduce the system’s temperature.
Many of these issues can be easily mitigated through routine maintenance. However, there are additional steps you can take to ensure that everything is functioning optimally.
1. Check that your system is designed with efficiency in mind
Even if your hydraulic system has no pressure loss, no excess heat, and no leaks, an inefficient design can lead to energy losses. Oversized or undersized components can waste a lot of energy. Double checking that the parts of your system are the right size for their demands ensures optimal performance.
Overly complex circuits can also reduce efficiency, resulting in unnecessary pressure drops and flow restrictions. Engineers should always be looking for ways to simplify hydraulic circuits wherever possible.
2. Choose energy-efficient components wherever possible
New innovations and advancements in hydraulic technology have led to the creation of specifically-designed components geared towards energy efficiency. High-efficiency pumps and motors may require a more substantial initial investment. However, the energy they save in the long run justifies their higher price point.
These efficient components can be used alongside an accumulator, which ensures that hydraulic energy is stored when demand is low and released whenever it’s needed. Variable Speed Drives (VSDs) can also be used to adjust the motor speed to match the required load, minimising energy use during low-demand periods.
3. Implement advanced control strategies
The more control you have over your hydraulic system, the more you can tailor its outputs to its application. Load-sensing systems allow components to adjust the flow and pressure of fluid based on real-time demands, preventing energy from being wasted. Similarly, proportional or servo valves offer precise control over the hydraulic fluid itself, reducing unnecessary energy expenditure.
Smart sensors can also be fitted to systems to allow users to monitor the conditions of components and accurately predict when maintenance is needed.
4. Check your fluid
The hydraulic fluid within a system plays a key role in energy efficiency. Using fluids with the incorrect viscosity can increase friction within a hydraulic system and lead to energy loss. It’s also important to ensure fluid remains clean in order to prevent wear and tear on components. This not only maintains efficiency over time, but it also reduces the downtime caused by faulty or over-worked components.
5. Use Energy Recovery and Regeneration Techniques
While accumulators can be used to store energy, regenerative systems can be used to recover excess energy during operations like braking or lowering loads. Combining the two results in a system that puts all energy created to use.
While it’s important to preserve energy, it’s also useful to preserve heat. Use heat exchangers to reclaim heat generated by the system for other applications.
6. Use renewable energy sources
Once a system has been optimised for energy efficiency, why not consider incorporating the use of renewable energy sources into your processes? Solar panels can be fitted to reduce reliance on fossil fuels for all operations – not just your hydraulics.
7. Regularly maintain and inspect your systems
It goes without saying that routine maintenance is key to ensuring that systems are operating efficiently. By monitoring your hydraulics, you can prevent leaks, replace outdated or inefficient components, and identify potential problems before they have a chance to cause downtime.
8. Stay up to date on emerging technologies
Staying informed about new innovations in hydraulic technology will allow you to quickly seize opportunities that could further improve operational efficiency. Our experts at are well-informed on emerging innovations and industry trends. We’re happy to discuss ideas and updates on any aspect of hydraulic technology.
Firms that focus on energy efficiency in their hydraulic systems reap both economic and environmental benefits. By understanding energy losses, optimising designs, selecting efficient components, and embracing new technologies, companies can significantly reduce their energy consumption, save money, and mitigate their carbon footprint.
At Hydraulic Megastore, our team are on hand to support you in improving the efficiency of your hydraulic equipment. We’re equipped to both provide the components, and make sure you use them efficiently.
If you have any questions at all about anything to do with hydraulic efficiency, contact a member of our team today. We’re on hand to guide you through your options.