As machine manufacturers and end users focus more on reduced carbon and other exhaust emissions, without compromising on performance levels, hydraulic leader Bosch Rexroth, locally represented by the Hytec Group, has implemented efficiency-optimised components, innovative modules and networked system solutions with BlueHydraulics. This program, which enables system designers to make a huge difference in the energy efficiency curve – even in the project planning phase - especially in respect to factory automation and plant equipment, was showcased at two of the world’s most foremost technology events, Hannover Messe and BAUMA.

Mobile applications
Mobile hydraulics can profit greatly from the digital networking of all compatible components and functional properties. These solutions cleverly facilitate the downsizing of diesel motors or reducing engine RPMs in order to lower diesel consumption, while maintaining at least the same performance levels as before.
Diesel Hydraulic Control (DHC) combines motor management with controls for implementation and travel drive hydraulics. Via the combined demand control, DHC can reduce diesel consumption by up to 20% without impacting on the power available to the machine prior to optimisation.

Other solutions, such as the Hydrostatic Regenerative Brake (HRB) system, exploit the braking process to allow the hydraulic storage unit to recover deceleration energy and make it available for the next acceleration. In practice, HRB reduces fuel consumption by up to 25%. Hydraulic Fly Wheel technology can, in addition to enabling energy recovery, be implemented for power smoothing or booster functions or can clear the way for a downsizing of the diesel engine.

Innovative functional properties can qualify well-known components for BlueHydraulics. Green valves, the load-holding and lowering valves, utilise the force of gravity rather than the diesel engine's valuable supply of energy, thus reducing the power requirements and freeing up a higher volume flow for functions working in parallel.

Increased efficiency for stationary applications
BlueHydraulics also means increased efficiency in factory automation and plant equipment. Variable-speed pump drives can cut energy consumption by an impressive 30 to 70%, translating to lower operating costs and return on investment within a year.

The innovative, patented cooling and lubrication KST-booster integrates the pressure supply for the high-pressure cooling oil circuit into the hydraulic power unit. With an additional linear pump replacing the conventional screw spindle pump, the KST-booster reduces the energy requirements of the high-pressure cooling oil circuit by almost 90% compared to conventional solutions. Combining variable speed pump drives and the KST-booster can enable cumulative savings. For machine tools, energy costs comprise around 15% of the total life cycle costs.

Via analogue, fieldbus or industrial Ethernet, BlueHydraulics solutions can be integrated perfectly into any automation environment. Commissioning is also simplified due to the pre-parametered software. The finely-scaled line-up of speed-variable pump (SVP) drives covers a wide range of applications, including machine tools, injection moulding machines, presses and all types of cyclically working equipment. In addition, SVP drives lower mid-range noise levels significantly, alleviating the need for special sound-damping enclosures. The demand control also reduces the amount of heat transfer to the hydraulic oil, and thus the energy required for cooling.

At the component level, BlueHydraulics means increased energy efficiency. The new internal gear pump PGH-3X, for instance, has been optimised to support SVP drives and can now muster up to 3 000 RPMs and more across the entire speed range.