As a hybrid technology that combines mechanical and electrical systems, electrohydraulic variable speed drives allow for motor speed adjustments to conserve energy and provide precise control over pressure and flow. They also easily integrate with existing systems.
Plastics injection molding application using an electrohydraulic VSD.
The manufacturing industry is at a crossroads, facing the critical challenge of maximizing efficiency. Meeting this demand requires optimizing energy consumption, reducing carbon footprints and improving operational precision. Electrohydraulic variable speed drives (VSDs) stand out as a versatile solution to this challenge, particularly in sectors such as plastics processing and machine tool applications.
Electrohydraulic VSDs are redefining performance standards by addressing potential inefficiencies inherent to some traditional hydraulic systems. By continuously and automatically adapting motor performance to real-time demand, they offer a compelling solution to today's energy challenges while paving the way for a more energy efficient and automated future.
The case for electrohydraulic VSDs
Traditional hydraulic systems — having long been the backbone of industrial machinery — experience limitations due to the use of fixed-speed motors that run at full capacity, regardless of demand. This inefficiency can lead to significant energy waste, excessive noise and increased operating costs. While reliable, these systems sometimes fail to meet the growing demands for energy efficiency and precision that are essential to moving the needle for modern manufacturers.
Bosch Rexroth Syntronix electrohydraulic VSD.
Electrohydraulic VSDs apply cutting-edge technology to promote variability in speeds to match real-time demand. This improves energy efficiency while enhancing system performance with less energy consumed when not operating. The responsive adjustment to motor speed significantly reduces wear on components and extends equipment lifespan, ultimately lowering maintenance costs. These systems deliver increased value for industries like plastics processing, where precision and energy savings are critical through the manufacturing and molding processes.
The benefits of electrohydraulic VSDs extend far beyond reducing energy bills:
Lower carbon footprint: VSDs optimize energy use and significantly reduce greenhouse gas emissions. This benefit is impactful for companies seeking to align with global carbon reduction initiatives.
Noise reduction: These systems operate quietly during low-demand cycles, creating safer and more comfortable environments for workers.
Precision and quality: Control of pressure and flow is essential for plastics processing in applications like injection molding. VSDs exercise advanced control over these parameters, improving product quality and sustained throughput.
Manufacturers striving to generate greater energy savings will benefit from the advanced ability electrohydraulic VSDs provide. While the benefits of operational efficiency, precision quality and maintenance reductions are clear, adopting this technology requires careful consideration of both the challenges and the alternatives available. To fully appreciate the advantages of electrohydraulic VSDs, it’s crucial to understand how these systems compare to other drive system options.
Electrohydraulic VSDs are a hybrid solution that combines the best attributes of mechanical and electrical systems. This advanced technology offers motor speed adjustments that conserve energy while minimizing heat and noise, and it integrates into existing systems to improve automation, machine control integration and real-time monitoring.
Electrohydraulic VSD challenges and comparisons
Adopting electrohydraulic VSDs can present challenges, mainly due to their higher upfront cost compared to traditional hydraulic systems. This cost arises from advanced components like frequency control drives or servo motor systems. However, their long-term savings make them a strategic investment. Utility rebates and energy incentives often help offset these starting costs, accelerating the return on investment.
For manufacturers evaluating drive systems, it is essential to consider the alternatives. Mechanical drives have long been a staple of industrial machinery, valued for their simplicity, durability and reliability. However, their fixed-speed motors operate at full capacity regardless of actual demand, resulting in excessive energy waste, elevated heat generation and consistent machine-generated noise. These outcomes can make them less suitable for modern manufacturing facilities.
Electrical drives are energy-efficient and provide greater flexibility but can ultimately lack precise control and operational efficiency compared to alternatives. This limits their effectiveness in demanding applications such as injection molding or machine tooling.
Machine tool application of an electrohydraulic VSD.
Electrohydraulic VSDs are a hybrid solution that combines the best attributes of mechanical and electrical systems. This advanced technology offers motor speed adjustments that conserve energy while minimizing heat and noise, and it integrates into existing systems to improve automation, machine control integration and real-time monitoring. VSDs also provide precise control over pressure and flow, making them indispensable for precision manufacturing and achieving energy saving goals. While the upfront cost of these drive systems may be higher, the long-term benefits make them worthwhile investments for manufacturers seeking to remain competitive and operationally efficient.
By bridging the gap between traditional hydraulics and full automation, these drives empower manufacturers to meet the growing demands of evolving industries and address the pressing challenges of efficiency and precision. Their ability to integrate seamlessly with advanced control systems enables real-time monitoring, predictive maintenance and greater operations standardization.
Chris Parisse is senior controls product engineer and Jonathan Lerner is application engineer at Bosch Rexroth.
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