All hydraulic systems are built to deliver power, but performance ability comes from how efficiently this power is used. When a hydraulic circuit runs efficiently, with minimal restriction and manageable heat levels, you get more power output from the same energy input. When it doesn’t, even a well-designed system can consume excess power, waste fluid and wear components faster than expected. Such a system is inefficient compared to one that generates less waste.
The best way to maximise efficiency is to design efficient processes into the system from the outset. However, with the right adjustments, any system can be made more efficient. For example, it is often possible to reduce a system’s energy consumption, improve its response speed, or extend the working life of valves, actuators, and hose assemblies.
In this article, we discuss five ways to optimise hydraulic performance, helping your systems run cleaner, cooler, and more reliably.
1) Improve your flow path design
Every restriction in a hydraulic circuit – such as a sharp bend, undersized hose, or inefficient connector – forces the pump to work harder for the same result. Optimising the route layout between valves, pumps, and actuators therefore helps to improve flow velocity and reduce turbulence. In applications where frequent line disconnections are required, using a quick release coupling with low resistance internal geometry can maintain flow efficiency without sacrificing ease of access.
2) Specify the right sized pump
Not many designers undersize their pump so there is too little power to drive their application, but oversizing is a common problem. Unfortunately, oversized pumps increase relief valve cycling, generate more waste heat, and demand more power than necessary simply to operate. By sizing your pumps to the average load instead of peak load, the system will consume less energy without compromising performance. Variable displacement units provide further efficiency gains by adjusting to changing system conditions in real time.
3) Keep your oil clean
Over time, hydraulic oil accumulates various contaminants drawn from atmospheric dust, leftover swarf from machining, dirt, grease particles, and everything in between. These contaminants increase friction inside the pump, valves, and brake cylinders, wasting energy and accelerating wear. The way to avoid this is simply to keep the hydraulic oil clean and free of contamination, such as by replacing filters on schedule and monitoring the oil condition. Clean oil also reduces the risk of internal leaks – the leading cause of premature component failure.
4) Control leakage
Internal leaks are bad news in any hydraulic system, but controlling them is easier said than done. While some fluid bypass is normal, excessive leakage lowers the actuator output and forces the pump to compensate, thereby expending more energy. The best way to control leakage is by using high quality seals and reliable hose assemblies, such as Gates fittings. Not only is the damage associated with leaks reduced, but your long-term energy overheads are lowered, too.
5) Use the appropriate viscosity fluid
Choosing the appropriate viscosity for your application is a tricky design question. Lower viscosity fluids reduce the energy needed to move oil through the system, particularly in cold start conditions. However, the viscosity must remain high enough to maintain film strength and lubrication. A widely accepted rule of thumb for hydraulic fluid viscosity is to choose a fluid thin enough to flow easily when cold, but thick enough to maintain an oil film under maximum operating temperatures in load. Getting this right reduces flow resistance within the system and prevents efficiency loss, while also protecting against wear.
Next steps
Incremental improvements can scale quickly in a hydraulic application, so that a single change in routing, filtration, or fluid viscosity can significantly reduce your lifetime energy usage over thousands of cycles, delivering long-term savings with no loss of capability. To find out more, please contact one of our specialists today by clicking here, or give us a call on 01353 721704.
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