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Control Flow Rates More Energy-efficiently

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Control Flow Rates More Energy-efficiently
Control Flow Rates More Energy-efficiently

Video: Control Flow Rates More Energy-efficiently

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Using energy efficiently not only saves companies money, but also conserves resources and counteracts climate change. Pumps are an important starting point for increasing energy efficiency - they are among the largest industrial electricity consumers. In relation to the life cycle of a pump, the energy costs average around 45% of the total costs.

There is still a great deal of energy saving potential here, especially for pump applications and power machines based on hydraulic technology. However, the vast majority of the applications in use today operate at a constant motor and pump speed. For example, hydraulic power units, which are typically constructed from inexpensive asynchronous motors, motor starters and constant pumps, require only minor investments. But this is offset by a relatively high energy consumption: Because the entire hydraulic unit is designed for the maximum pressure and volume flow required - and delivers this performance even when it is not needed. In addition, the heat input into the hydraulic fluid from the continuously running pump is high, so that additional cooling capacity is required.

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Small investments can result in higher overall costs

In order to increase the energy efficiency of such a system, the elementary approach is not to operate the main pump of the system constantly, but with a variable speed: only the power that the system requires is made available. As a high-end solution, this can be achieved with a four-quadrant direct drive. A servo drive controls the speed of the pump and thus the pressure or the volume flow. Active oil cooling is only required to a small extent here. All in all, such a unit consumes significantly less energy than a system with constant pressure.

However, a direct drive can only supply one process. If hydraulic power is to be made available for several different processes, this requires a corresponding number of units. The four-quadrant direct drive with servo motors is a solution that is at the top end of the scale in terms of investment requirements.

Content of the article:

  • Page 1: Control flow rates more energy-efficiently
  • Page 2: Cost and energy efficient solution with speed control
  • Page 3: Retrofit with speed control saves 50% energy

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