“Energy savings in Hydraulic Presses by using variable speed drives instead of Conventional starters.

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by RAJIV GUPTA kgp_rajiv10@sancharnet.in

In Conventional Hydraulic Presses star / delta starters OR Auto transformers are being used to run Hydraulic pump
motors. These Hydraulic pumps are operated by sophisticated servo controlled system pilot operated using Servo
valves.

In this Advanced electronic age where in solid state Electronics play vital role in all fields such as
Telecommunication, Computerization and all Electrical Energy applications.

As on date Energy saving has been considered to be the top most priority all over the world.

In this context I present my thought.i.e. Conventionally Hydraulic Extrusions presses are operated by Hydraulic
pumps having Electric motors as prime movers. These Electric motors run at constant speed with respect to supply
voltage and frequency.

Basic configuration of Electric Hydraulic Servo System is as mentioned as block diagram.

Ei Is ______
Command Servo Servo Actuator
Unit Amplifier Valve

Ef

Amplifier Selector

Proposed Configuration using variable Speed drive for Electric motor for Hydraulic pump.

Ei Is
Common Amplifier Variable Speed Electric
Unit Unit Drive motor

Load
Ef Existing Hydraulic Pump With
Fixed Actuator Position

Feed Back Unit

Advantages of using Variable Speed drives to control Hydraulic Pump delivery :-

1. We get rid of sophisticated servo valve where in Hydraulic oil quality is prime importance i.e <10 Micron
filtration having NAS 6 – 8 standard .
2. Saving of Electrical Energy by operating the prime mover at varying speed depending on the load
requirements. Hence in turn Hydraulic pump delivery is controlled w.r.t load requirements, thus reduction in
oil temperature rise by not draining of oil back to the tank during pump idle condition. Which results in less
work down by the pump.
3. Less wear & tear of the pump thus increase in pump working life.
4. Hydraulic system will become more stable.
5. Servo Pump will not be required thus reducing the Auxiliary pump Horse power requirement.
6. Not much modifications required in order to Switch over from Conventional Electric Hydraulic Servo
System to variable speed drive for hydraulic Pump & Controls arrangement.
7. Reduction in KVA demand.
8. Considerable reduction in running cost per ton of production.
9. Reduction in unit cost per ton of production.
10. Stores inventory of keeping Hydraulic spares such as Servo Valves, Servo filter, Servo Pump, Micro filters
etc gets eliminated and above all.
11. Total Press will be energy efficient.