What’s driving the move to electrified hydraulic systems?
As the focus on GHG emissions continues to drive legislation and consumer behaviour, OEMs in the construction, agriculture and materials handling markets are increasingly looking to electrified hydraulic systems as a solution to make their machinery ready for the leap to net zero. [1]
These electrified hydraulic systems are powered by an electric motor system, either as part of a full electric propulsion system or, more commonly in the current technical landscape, where a diesel engine remains the prime mover.
And whilst net zero targets do remain a factor for fleet operators considering a shift to electrified hydraulic systems, the additional benefits may prove a more significant driver for the move to a hybrid system.
“The bottom line is that fleet operators in these markets are always looking to maximise uptime whilst keeping operating costs to a minimum,” explains Peter Trueman, Market Head for Marine and Off Highway at Ricardo, “One of the biggest advantages of electrified hydraulics is the ability to eliminate parasitic load. The motor in a hybrid setup only runs when it is needed and. Tthis means that you you’re not wasting energy idling or running at low load. That’s a huge win for both fuel economy and engine health.”
Avoiding inefficient operating states, reducing fuel consumption and extending engine life,. eElectric motors also require less maintenance, again increasing uptime and lowering operating costs for fleet owners.
Noise reduction is another major benefit. In scenarios where the machine is stationary but still working hydraulically, the engine can be shut off entirely whilst the hydraulics continue to operate.ing. Without a large diesel engine constantly running, electric hydraulic systems are significantly quieter which is ideal for urban job sites, sensitive environments, and night work.
These intrinsic benefits of an electrified hydraulic system can be maximised by pairing them with a reduction gearbox to increase operating efficiency. Whilst electric motors deliver consistent torque across speeds, they’re most efficient at RPMs too fast for direct hydraulic pump operation. [2]
“A reduction gearbox allows you to use a smaller motor running at its optimal speed whilst still delivering the torque and output speed needed for hydraulic systems,” Peter adds. “It’s a smart way to extend battery life and improve overall system efficiency.”
Element Gearboxes: Motorsport-Derived, Industry-Ready
Whilst the benefits of electrified hydraulic solutions are clear, OEMs are also under pressure to meet the requirements of their end users whilst reducing product development time and cost.
“Ricardo’s Element range of epicyclic reduction drives are a great option for OEMs looking to make the leap to electrified hydraulic systems,” concludes Peter, “This range of pre-engineered gearboxes means that clients can use them to develop systems quickly and cost-effectively with low-engineering effort. Whether you're designing a hybrid excavator, retrofitting a wheeled loader, or building a next-gen electric platform from scratch, Element gearboxes offer a modular, high-performance solution that helps you get the most out of your electric hydraulic system.”
The range brings motorsport-grade durability and efficiency to industrial applications. Designed with packaging flexibility in mind, these units give hydraulic system designers a wide scope of specifications to work with making them ideal for electrified off-highway machinery.
Ricardo’s cross-sector expertise means we understand the demands of high-performance, high-reliability systems. If you're exploring electrification for your hydraulic applications, our team can help you select the right Element gearbox or develop a tailored solution to meet your operational goals.
References
[1] 2019. Top Reasons for Using Electrohydraulics [Online]. Power Motion
[2] 2018. Electro-hydraulic systems, potentialities and limits [Online]. Power Transmission
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