Hydraulic System Optimization

Optimizing a hydraulic system, for both performance and efficiency, requires ongoing review of the system design.

For more information, ask for Bob Wojcik or any of our Fluid Power Specialists.

The Certified Fluid Power Specialists at Quality Hydraulics & Pneumatics, Inc. provide this system optimization by meticulous consideration of the system performance, life expectancy, energy efficiency, serviceability, and up-to-date technology and products.

A system performance review by the Specialists at Quality Hydraulics might include:

1. Identifying machine cycle and dwell times to determine whether the addition of a hydraulic accumulator would reduce the required pump size and thereby reduce the required electric motor size. These size reductions would result in the conservation of energy by the system.
2. Reviewing the pump type used in a particular circuit, which has a direct impact on overall system energy efficiency and heat generation. The pump review could compare a fixed displacement pump, with its pressure-limiting relief valve and unloading circuit, to a pressure compensated pump, with its integral pressure and volume control. It is important to evaluate the pump distinctions in order to maximize energy efficiency, minimize heat generated, and thereby increase component life through proper fluid handling.
3. Considering a variable frequency drive to operate the pump, which is another method to increase energy efficiency. The drive allows the pump to operate at varying speeds, which reduces flow, increases efficiency, and may provide lower operating costs.
4. Reviewing directional control valve sizes to ensure that proper flow rates are maintained and high pressure drops across the valves are avoided. Excess flow and the resultant pressure drop would contribute to circuit pressure instability, component malfunction, excess wear, and additional wasted heat.
5. Examining the ambient temperature conditions for the hydraulic system to help ensure that the appropriate operating temperature is maintained. A high ambient temperature requires the addition of a reservoir water/oil cooler, or a low ambient temperature means the addition of a reservoir oil heater. Both conditions should be considered in advance of system operation in order to maintain the optimum 105°F to 135°F reservoir fluid temperature for industrial systems.
6. Maintaining fluid cleanliness throughout the system’s working life, which is vital to ensuring long component life, reduced maintenance, and reduced component repair. The Specialists at Quality Hydraulics review each circuit to maintain optimum contamination collection and elimination and to meet the ISO code cleanliness levels required by the components in the particular system.

The highest-performing systems take all these factors into account. Making all these comparisons and examinations will provide a hydraulic system with the highest ongoing system performance, most cost-effective design, and greatest energy efficiency.