Power Drives Architectures for Industrial Hydraulic Axes: Energy Efficiency-based Comparative Analysis

Abstract

In hydraulic systems, energy dissipation can be significant. The pressure drops that can occur in the hydraulic circuit, influenced by the adopted drive architecture, result in an absorbed power often significantly greater than that required by the mechanical system. In this paper, a comparative study of energy efficiency among five drive common architectures in industrial hydraulic axes is carried out. The analysis is applied to a hydraulic blanking press with variable speed and force, a fairly frequent industrial system, e.g. in the production of semi-finished brass products. Standard, regenerative, high-low, variable displacement pump and variable speed drive for a fixed displacement pump configurations have been analysed and compared. An adequate and optimized sizing of the various components of the system has been carried out in each case and subsequently the energy consumption has been estimated for a load cycle common to all the considered cases. The results show that the choice of power generation architecture of the hydraulic system has a very significant impact on energy efficiency and consequently operating costs and carbon footprint. The performed quantification of the potential energy efficiency of the considered drive architectures can be very useful in guiding energy-conscious choices.