Designing Hydraulic Systems for Energy-Efficient Extrusion

The hydraulic system is the core power source of an extrusion press and a significant part of its energy consumption. The following design directions help reduce running energy while meeting process needs.

Demand-based supply and variable displacement

Conventional fixed-displacement pumps still consume considerable power under partial load. A demand-based supply or variable-displacement hydraulic solution adjusts flow to the actual working condition, reducing unnecessary power consumption.

Servo and variable-frequency control

Servo drives or variable-frequency control match load variation more precisely, balancing fast response with energy saving. This is effective for extrusion conditions with frequent cycle changes and noticeable load fluctuation.

Staged regulation of pressure and speed

Different phases of extrusion (fast approach, slow speed, dwell, return) have different pressure and speed requirements. Staged or segmented control avoids running the system at high power for extended periods.

System matching and thermal management

Good matching between the hydraulic design and the actuators reduces unnecessary throttling losses and heat generation. Effective oil-temperature control supports energy saving while extending component life and improving stability.

Process needs come first

Energy-saving solutions should be based on a stable fulfilment of the product process, not at the expense of forming stability or product quality. The specific saving and the choice of solution should be assessed by the engineering team against equipment specification, product and working conditions.