Hydraulic systems generate unnecessarily high energy costs in many production environments. Especially in presses, die-casting machines, and hydraulic power units, motors often run continuously at full speed regardless of the actual power demand.
With an intelligent retrofit solution consisting of frequency inverters, speed-controlled pump systems, and energy-efficient synchronous reluctance motor systems, energy consumption, heat losses, and operating costs can be significantly reduced.
Mitsubishi Electric frequency inverters achieve efficiencies of more than 98% and enable particularly low-loss operation. By dynamically adjusting motor speed to the actual load demand, typical energy savings between 20% and 50% can be achieved, depending on the application and load profile.
Why conventional hydraulic systems operate inefficiently
In many existing hydraulic systems, pump motors are often switched on via a contactor and run continuously at full speed. The actual load is then regulated using valves or throttling mechanisms. The excess energy is not utilized but converted into heat. This results in high thermal losses and additional energy demand for cooling systems or fans.
Typical problems:
- High power losses caused by throttle valves
- Overheating of the hydraulic oil
- Continuous full-load operation
- High power consumption during idle operation
- Unnecessary heat generation
- Increased cooling requirements
Especially in applications with fluctuating loads, a hydraulic retrofit offers significant energy-saving potential.
Practical trade fair demonstration: Hydraulic energy-saving application
This application visualizes the advantages of an intelligently controlled hydraulic solution.
Demonstrated functions:
- Switching between load and idle operation
- Dynamic frequency control
- Visualization of power consumption and motor current
- Manual and automatic operation
- Trend analysis of energy consumption
Typical parameters:
- High frequency under load
- Low frequency during idle operation
- Current-dependent switching point
Saving energy through intelligent speed control
By using a frequency inverter, the speed of the hydraulic pump is precisely adjusted to the actual demand.
For example, when a hydraulic cylinder retracts or the application is operating in idle mode, the Mitsubishi Electric frequency inverter automatically reduces the speed or stops the motor completely.
Even a small reduction in speed can have a significant impact on power consumption:
- Up to 50% reduced power consumption
Especially during idle operation of pumps or fans, this results in considerable energy savings.
Retrofit: hydraulic systems with frequency inverter
The combination of modern drive technology and intelligent control creates an energy-efficient overall solution.
Through speed-controlled operation of the hydraulic pump, performance is precisely adjusted to the actual demand. This results in significantly lower energy losses compared to conventional hydraulic systems with constantly running motors and throttle valves.
Typical applications for energy-efficient hydraulic systems
SynRM motors for maximum energy efficiency in hydraulic systems
In addition to intelligent speed control, the choice of motor also plays a crucial role in the energy efficiency of modern hydraulic systems. Synchronous reluctance motors (SynRM) have been specifically developed for highly efficient operation with frequency inverters and combine high energy efficiency with robust industrial performance.
This results in several advantages:
- High efficiency
- Low rotor losses
- Reduced heat generation
- Compact design
- Energy-efficient operation in partial-load conditions
Especially in hydraulic applications with fluctuating loads and long operating times, this technology offers significant advantages over conventional induction motors.
FAQ – Frequently asked questions about hydraulic retrofitting
When is a frequency inverter worthwhile in hydraulic systems?
The use of a frequency inverter is particularly worthwhile in hydraulic systems with fluctuating load profiles, frequent idle phases, or continuously running pump motors. Demand-based speed control can significantly reduce energy consumption depending on the application.
What energy savings are possible with a hydraulic retrofit?
The actual savings depend on the application, load profile, and operating times. In many hydraulic applications, typical energy savings between 20% and 50% can be achieved through speed-controlled pump systems and modern drive technology.
Can an existing hydraulic system be retrofitted?
Yes, many existing hydraulic systems can be efficiently retrofitted with frequency inverters and modern motor systems. This improves energy efficiency without the need to replace the entire machine.
What are the advantages of a speed-controlled hydraulic pump?
A speed-controlled hydraulic pump adjusts its performance precisely to the actual demand. As a result, energy consumption, heat generation, and mechanical stress are significantly reduced compared to conventional continuously running systems.
What are the advantages of synchronous reluctance motor technology in hydraulic systems?
SynRM motors offer high efficiency, reduced heat generation, and excellent efficiency in partial-load operation. In combination with Mitsubishi frequency inverters, they create a particularly energy-efficient overall system for modern hydraulic applications.
Modernize hydraulic systems efficiently now
Optimize existing hydraulic systems with intelligent speed control, modern drive technology, and energy-efficient motor systems. We will be happy to advise you. Contact us using the contact form and we will get back to you as soon as possible.
