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Efficiency in hydraulic systems

The current economic climate is prompting industry professionals to make the most of their hydraulic equipment in order to maintain decent production costs and keep up with the competition. Optimising hydraulic efficiency is a key factor in a company's economic success. Today we're going to look at this subject in detail. Whether you're an amateur or a seasoned entrepreneur, profits are where it's at!

Types of efficiency in hydraulic systems

First and foremost, we need to define the concept of efficiency in the field of hydraulics. Contrary to what the term might suggest, efficiencies do not correspond to a gain but to a loss. It refers to the loss of energy between what is absorbed and what is released. There are two types of efficiency.

Volumetric efficiency. This term refers to the leakage suffered by a component through which a flow passes.

To calculate the volumetric efficiency of a hydraulic system component, consider the difference between the quantity of fluid absorbed by the component and the quantity discharged by it. The difference between the flow absorbed and the flow discharged will represent the fluid leaks, which cannot be injected into the operation of the machines concerned.

For example, in the case of a pump that draws in 200 litres per minute and discharges 196 litres at the outlet, the efficiency will be calculated as follows: 196 / 200 * 100 = 98. The pump is therefore 98% efficient.

Volumetric efficiency is a natural part of a hydraulic system, as long as it does not exceed a certain ceiling. It is therefore necessary to take this into account before calculating the flow rate required to achieve the desired mechanical speed, otherwise you will obtain inconsistent results.

There are also two factors that can increase fluid loss:

  • Pollution of the fluids used. Operators can overcome this problem by regularly assessing the quality of the fluids. If the impact of this pollution becomes too great on the quality and quantity of production, a corrective maintenance operation will be required.
  • Volumetric efficiency will change as a function of temperature and pressure levels. Operators must therefore calculate their yields according to these factors.

The second major category, mechanical efficiency, corresponds to losses caused by friction generated by the operation of components. Mechanical efficiency will change with temperature and the drive speed of the mechanism.

How can the efficiency of a hydraulic system be improved?

The main variable when looking at hydraulic efficiency is the viscosity of the fluid and its lubricating properties. Logically, mechanical losses are proportional to fluid viscosity. A more viscous fluid naturally implies greater friction. So should you opt for a lower viscosity?

Yes... and no. A less viscous fluid would reduce mechanical losses on the one hand, but increase volumetric losses on the other. As you'd expect, excessive lubrication would facilitate leakage.

So it's a question of finding the right lubrication/viscosity ratio for the installation in question. What flow rate and pressure are required? After centuries of perfecting their skills, hydraulic system professionals have reached a certain level of excellence. There are oils for every type of installation and every production volume.

Certain additives can also be used to balance our lubrication/viscosity ratio, to ensure optimum performance.

In short, losses are inevitable in a hydraulic system, but it's up to you to minimise them with the right calculations and the right products!

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