Simplified Impact, Author at Atlantic Hydraulic Systems

Hydraulic accumulators are important components in modern hydraulic systems, providing energy storage, shock absorption, and system efficiency. As industries demand more advanced and efficient hydraulic systems, innovations in accumulator technology are revolutionizing their capabilities. Here, we explore the top innovations in hydraulic accumulators and why they matter.

1. Advanced Composite Materials

Traditional accumulators rely on steel or aluminum, but recent advancements in composite materials have paved the way for lighter, stronger, and more durable options. Composite materials:

Reduce weight without compromising performance.
Improve resistance to corrosion and wear.
Extend the lifespan of hydraulic systems in harsh environments.

These features are especially beneficial in industries like aerospace, automotive, and renewable energy, where weight and durability are critical.

2. Enhanced Energy Efficiency

Energy efficiency has become a focal point for many industries, and hydraulic accumulators are no exception. Innovations include:

Low-friction seals that minimize energy loss.
Optimized bladder designs to improve responsiveness and energy transfer.
Systems integrated with smart controllers that regulate energy storage and release for maximum efficiency.

Such advancements reduce operating costs and align with global sustainability goals.

3. Smart Accumulators with IoT Integration

Integrating Internet of Things (IoT) technology has transformed hydraulic accumulators into smart components. Features include:

Real-time monitoring of pressure, temperature, and fluid levels.
Predictive maintenance alerts to prevent system downtime.
Wireless connectivity for seamless integration with centralized control systems.

IoT-enabled accumulators enhance reliability and operational insight, making them indispensable in industries like manufacturing and construction.

4. Miniaturization for Precision Applications

Miniaturized hydraulic accumulators are gaining traction in robotics, medical devices, and precision tools. These compact designs:

Deliver high performance in limited spaces.
Support applications requiring precise motion control.
Enable portability for specialized equipment.

This trend highlights the versatility of modern hydraulic technology.

5. Eco-Friendly Designs

Environmental sustainability is driving the development of biodegradable hydraulic fluids and eco-friendly accumulator designs. Innovations include:

Accumulators designed to work with biodegradable fluids without degrading internal components.
Systems with reduced environmental impact through improved energy efficiency and recyclable materials.

These eco-friendly solutions help industries comply with environmental regulations while maintaining top-tier performance.

6. High-Pressure Accumulators for Extreme Conditions

Advancements in high-pressure technologies have expanded the operational capabilities of accumulators. High-pressure accumulators now feature:

Reinforced shells to withstand extreme pressure levels.
Applications in offshore drilling, deep-sea exploration, and aerospace systems.
Enhanced reliability in harsh and volatile environments.

These innovations ensure safety and efficiency in the most demanding scenarios.

7. Modular and Customizable Designs

Modularity has become a game-changer in hydraulic accumulator technology. Customizable designs allow:

Integration of specific features tailored to unique applications.
Quick replacement of components for reduced maintenance downtime.
Scalability to adjust system performance based on changing requirements.

Such flexibility makes modular accumulators highly sought after in diverse industrial settings.

Why These Innovations Matter

The latest advancements in hydraulic accumulators drive improved performance, reliability, and efficiency across industries. Whether in manufacturing, renewable energy, or precision robotics, these innovations ensure:

Reduced operational costs.
Increased system longevity.
Enhanced adaptability to new technologies.

Investing in the latest accumulator technology optimizes your hydraulic systems and positions your operations for long-term success.

Conclusion

The future of hydraulic systems lies in innovation, and hydraulic accumulators are at the forefront of this transformation. From smart IoT capabilities to eco-friendly designs, these advancements cater to the evolving needs of industries worldwide. By embracing these technologies, businesses can stay ahead in efficiency, sustainability, and performance.

Hydraulic systems play a large role in many industrial applications, from heavy machinery to renewable energy solutions. A key component that significantly enhances the efficiency of these systems is the hydraulic accumulator. In this blog, we will explore what a hydraulic accumulator is, how it functions, and the benefits it provides in improving the overall efficiency of hydraulic systems.

What is a Hydraulic Accumulator?

A hydraulic accumulator is a pressure storage reservoir in a hydraulic system that stores energy as pressurized fluid. It functions like a battery, storing hydraulic energy that can be released to maintain system pressure, absorb shock, and provide additional flow. Accumulators are typically filled with hydraulic fluid and pressurized gas, separated by a piston, bladder, or diaphragm.

Types of Hydraulic Accumulators

There are several types of hydraulic accumulators, each with unique characteristics:

Bladder Accumulators: These have a flexible bladder inside the shell that separates the gas from the hydraulic fluid.
Piston Accumulators: These use a piston to separate the gas and hydraulic fluid, offering high efficiency and reliability.
Diaphragm Accumulators: These feature a diaphragm that separates the gas and fluid, suitable for low to medium-pressure applications.

How Hydraulic Accumulators Improve Efficiency

Hydraulic accumulators enhance both the performance and efficiency of hydraulic systems in several ways:

Energy Storage and Release: Accumulators store excess hydraulic energy during low-demand periods and release it during high-demand periods. This balancing act ensures that the system runs smoothly without the need for constant operation of pumps, thus saving energy and reducing wear and tear.
Pressure Stabilization: In hydraulic systems, pressure fluctuations can lead to inefficiencies and potential damage to components. Hydraulic accumulators help stabilize the pressure by absorbing shock loads and compensating for pressure drops, ensuring consistent operation.
Shock Absorption: Accumulators act as shock absorbers, cushioning the impact of sudden pressure spikes or drops. This reduces the stress on system components, extending their lifespan and minimizing maintenance requirements.
Flow Compensation: During peak demand, accumulators provide additional fluid flow, allowing the system to maintain optimal performance without requiring oversized pumps or motors. This contributes to the overall efficiency of the system by optimizing resource usage.
Emergency Backup: In case of power loss or pump failure, accumulators can provide an emergency flow of hydraulic fluid, allowing the system to continue operating temporarily. This safety feature can prevent costly downtime and protect critical equipment.

Applications of Hydraulic Accumulators

Hydraulic accumulators are versatile components used in various industries due to their ability to enhance system performance. In construction equipment like excavators, loaders, and cranes, hydraulic accumulators improve efficiency by smoothing hydraulic operations and lowering the engine’s energy demand.

In renewable energy applications, such as wind turbines and solar power plants, accumulators store excess energy, boosting the system’s overall reliability and efficiency. They are also commonly used in industrial machinery, where they help maintain consistent pressure and absorb shocks, ensuring precise and efficient operation in manufacturing processes.

Benefits of Using Hydraulic Accumulators

Using hydraulic accumulators in hydraulic systems offers several key benefits.

One of the main advantages is energy efficiency; hydraulic accumulators store and release energy as needed, which reduces the demand on pumps and motors, leading to substantial energy savings. They also enhance the performance of the system by maintaining optimal pressure and flow rates, which improves overall responsiveness and reliability.

Additionally, hydraulic accumulators help to reduce wear and tear on system components by absorbing shocks and stabilizing pressure, resulting in lower maintenance costs and a longer lifespan for the equipment. Ultimately, these improvements in efficiency and reduced maintenance needs lead to significant cost savings, making hydraulic accumulators a valuable investment for many operations.

Conclusion

Incorporating a hydraulic accumulator into your hydraulic system is a proven way to improve efficiency, stabilize pressure, and enhance overall performance.

Whether you’re operating heavy machinery or running industrial equipment, the benefits of using hydraulic accumulators are clear. By optimizing energy usage, reducing wear and tear, and providing emergency backup, hydraulic accumulators play a vital role in modern hydraulic systems.

Explore the potential of hydraulic accumulators in your operations and experience the difference in efficiency and reliability they can bring to your hydraulic systems.

Hydraulic pumps are essential for powering heavy machinery and equipment, yet they often go unnoticed. This guide aims to demystify hydraulic pumps, explaining how they work and the different types available.

We’ll explore gear pumps and piston pumps, detailing their unique designs and functions to give a clear understanding of their operation.

Discovering the Core of Hydraulic Pumps

A hydraulic pump is a device that converts mechanical power into hydraulic energy. This energy moves fluid through the system, transmitting force and power to different components. Hydraulic pumps are crucial for the functionality and efficiency of hydraulic systems, driving various industrial and mechanical operations. They ensure smooth and effective performance in tasks such as lifting, pressing, and moving heavy machinery.

Exploring the Diverse Types of Hydraulic Pumps

Hydraulic pumps come in various types, each with its own unique design, operating principle, and specific applications. The most common types include:

Gear Pumps: Known for their simplicity and cost-effectiveness, gear pumps have interlocking gears inside a casing. As the gears turn, they create suction that draws fluid into the pump and then pushes it out under pressure.
Vane Pumps: Vane pumps use a series of vanes on a rotor inside a circular chamber. As the rotor spins, the vanes extend and retract, moving fluid to create hydraulic flow. They are valued for their smooth operation and low noise.
Piston Pumps: Piston pumps, with their complex design and high performance, use pistons inside cylinders to draw in and compress fluid. Depending on the setup, the pistons move either axially or radially, providing high-pressure output with precision and efficiency.

Deconstructing the Key Components of Hydraulic Pumps

While hydraulic pumps vary in type and configuration, they consistently share several key components essential to their operation:

Housing: Serving as the structural framework, the housing encompasses the pump’s internal components, providing stability and protection.
Inlet Port: The inlet port serves as the entry point for hydraulic fluid into the pump from the reservoir, ensuring a continuous flow of fluid.
Outlet Port: The outlet port functions as the exit point, expelling pressurized fluid from the pump to the hydraulic system.
Drive Shaft: The drive shaft serves as the conduit for transmitting mechanical power from an external source, such as an electric motor or internal combustion engine, to the pump’s internal mechanism.
Rotor/Rotary Group: Made up of rotating elements such as gears, vanes, or pistons, the rotor or rotary group generates fluid flow within the pump by displacing and compressing fluid.
Seals and Bearings: Critical for maintaining fluid integrity and reducing friction, seals, and bearings prevent fluid leakage and ensure smooth operation by minimizing wear between moving parts.
Control Mechanism: In certain hydraulic pumps, a control mechanism regulates the flow rate and pressure output, allowing for dynamic adjustment based on system requirements and operational conditions.

Unveiling the Integral Role of Hydraulic Pumps in Hydraulic Systems

In hydraulic systems, pumps are crucial for circulating and utilizing hydraulic fluid to power various components and complete tasks. They are central to a closed-loop circuit, interacting with hydraulic cylinders, valves, and motors to pressurize the fluid, perform work, and return the fluid for recirculation.

Whether lifting heavy loads, operating machinery, or moving equipment, hydraulic pumps provide the necessary force and energy for these tasks. Understanding how hydraulic pumps work and their role in hydraulic systems helps engineers and operators maximize the potential of hydraulic technology, driving innovation and efficiency in various industries.

Understanding Hydraulic Pumps

In conclusion, hydraulic pumps blend mechanical expertise with hydraulic efficiency. With their various types, intricate components, and crucial role in hydraulic systems, hydraulic pumps are the unsung heroes driving the modern industrial world.

By exploring and understanding the inner workings of hydraulic pumps, we gain a deep appreciation for their vital contribution to engineering and manufacturing. Essentially, hydraulic pumps are the heart of hydraulic systems, driving progress and innovation, and ensuring efficiency, reliability, and performance in the ever-evolving field of mechanical engineering.

Have any questions? Send us a message or request a quote today.

Common Hydraulic Pump Problems and How to Solve Them

Hydraulic pumps are crucial components in various machinery and systems, converting mechanical power into hydraulic energy. Hydraulic pumps play a vital role in powering hydraulic systems, from heavy industrial equipment to everyday machinery. However, like any mechanical device, they are susceptible to problems affecting their efficiency and performance.

In this article, we’ll explore some common hydraulic pump issues and provide practical solutions and troubleshooting advice to address them effectively.

1. Fluid Contamination: One of the most prevalent issues with hydraulic pumps is fluid contamination. Contaminants such as dirt, debris, water, and air bubbles can compromise the performance and lifespan of the pump. Contaminated fluid can lead to increased wear and tear on pump components, reduced efficiency, and potential system failure.

Solution: Regularly inspect the hydraulic fluid for signs of contamination. The best way is to send fluid samples to a lab for spectrometric analysis. Ensure that the fluid is clean and free from impurities. Use high-quality filters and perform routine maintenance, including fluid changes and filter replacements, as the manufacturer recommends. Additionally, keep the hydraulic system sealed properly to prevent contamination from entering.

2. Leakage: Hydraulic pump leaks can occur due to worn seals, damaged hoses, loose fittings, or cracked components. Leakage results in fluid loss and reduces system pressure and efficiency.

Solution: Inspect the hydraulic system for any signs of leakage, such as puddles or damp spots. Replace worn seals, tighten loose fittings, and repair or replace damaged hoses and components promptly. Regularly check hydraulic connections and fittings for tightness to prevent leaks from occurring.

3. Cavitation: Cavitation is a common issue characterized by the formation of air bubbles or vapor pockets within the hydraulic fluid due to low pressure. These bubbles can implode near the pump’s surfaces, causing damage to the pump components and reducing efficiency.

Solution: To prevent cavitation, ensure the hydraulic fluid is clean and properly filtered to remove any air bubbles. Maintain the appropriate fluid levels and system pressure as recommended by the manufacturer. If cavitation occurs, identify and address the underlying cause, such as a restriction in the inlet line or excessive pump speed.

4. Overheating: Overheating is a significant concern for hydraulic pumps and can result from excessive friction, inadequate cooling, or insufficient fluid levels. High temperatures can lead to premature wear of pump components and seals, leading to leaks and decreased system efficiency.

Solution: Monitor the operating temperature of the hydraulic system regularly. Ensure proper lubrication and cooling of the pump by maintaining adequate fluid levels and using cooling systems such as fans or heat exchangers. Avoid overloading the pump or operating it at high speeds for extended periods, as this can contribute to overheating.

5. Noise and Vibration: Unusual noises or vibrations coming from the hydraulic pump can indicate underlying problems such as misalignment, worn bearings, or damaged components.

Solution: Inspect the pump for any signs of wear or damage, including loose or misaligned components. Replace worn bearings and realign the pump as necessary to reduce noise and vibration. Additionally, ensure that the pump is properly mounted and supported to minimize vibrations.

6. Loss of Pressure: Loss of hydraulic pressure can occur due to various factors, including leaks, worn seals, or pump inefficiency. Reduced pressure can affect the performance and functionality of hydraulic systems.

Solution: Conduct a thorough inspection of the hydraulic system to identify the source of pressure loss. Check for leaks, damaged seals, or worn components that may be causing the pressure drop. Repair or replace faulty parts and ensure that the pump is properly calibrated to maintain the required pressure levels.

In conclusion, hydraulic pumps are critical components in many industrial and mechanical applications, and encountering problems with them is inevitable. However, by understanding the common issues that can arise and implementing proactive maintenance and troubleshooting measures, it’s possible to mitigate these problems effectively. Regular inspection, proper fluid management, and prompt repairs are essential for ensuring the reliable performance and longevity of hydraulic pumps and systems. By addressing issues promptly and implementing preventive maintenance strategies, operators can minimize downtime, reduce repair costs, and optimize the efficiency of hydraulic equipment.

Have any questions? Send us a message or request a quote today.

The power plant’s Electrohydraulic Control (EHC) system plays a crucial role in the reliable operation of a power generation plant, and its efficiency depends on several key factors, including oil cleanliness and Total Acid Number (TAN). The EHC system utilizes EHC fluids like hydraulic oil, often a phosphate ester fluid, to precisely control and move critical components such as turbines, steam turbines, valves, and actuators.

The cleanliness of the oil is of utmost importance

Acting as a lubricant and coolant within the EHC system, any contaminants present in the oil, such as dirt, debris, or particles, can lead to abrasion, wear, and damage to both internal and external components of the hydraulic power unit. Such issues may result in increased friction, reduced efficiency, and, in severe cases, catastrophic failures. To prevent these complications, it is essential to conduct regular oil analysis and filtration to maintain the required cleanliness level. This proactive approach ensures smooth operation and extends the overall lifespan of the EHC system.

The Total Acid Number (TAN) of the oil is a critical parameter to monitor.

Hydraulic systems that contain acidic oil are prone to corrosion of metal surfaces and degradation of seals and gaskets. The presence of water and acids further accelerates the oil’s deterioration, compromising its lubricating properties and overall performance within the EHC system.

Regular monitoring of the TAN number

Monitoring through oil analysis allows for early detection of acid buildup, enabling timely maintenance actions like oil replacement or chemical treatment to neutralize acidity. By controlling the TAN within specified limits, the EHC system operates reliably, minimizing downtime, and mitigating the risk of costly repairs or unplanned shutdowns.

Use Fire Resistant Fluids

To address these challenges effectively, utilizing fire-resistant fluids, such as phosphate ester fluids, is highly recommended. These fluids not only offer improved fire safety in the power plant environment but also exhibit better resistance to degradation, reducing the risk of acidity formation (thereby, fluid degradation) and enhancing the longevity of the EHC system.

PIon Exchange Technology

Additionally, implementing ion exchange technology for water removal in hydraulic oil can significantly contribute to maintaining oil purity. Both old and new EHC systems can benefit from off-line oil filtration and water removal systems, which play a crucial role in ensuring the optimal performance of the EHC system.

In conclusion, the power plant’s electrohydraulic (EHC) system relies on various factors to operate reliably and efficiently. By focusing on oil cleanliness, controlling acidity levels with regular TAN monitoring, and utilizing fire-resistant fluids like phosphate ester fluids, the power plant can enhance the performance and safety of the EHC system. Additionally, incorporating ion exchange technology and off-line oil filtration further contributes to maintaining the purity of the hydraulic oil, ensuring uninterrupted operation and reinforcing the overall reliability and safety of the power generation plant.

For assistance in maintaining oil purity and optimizing EHC system performance, do not hesitate to contact us. Our expert team is ready to provide the necessary support and solutions to meet your specific needs.

In hydraulic systems, engineers often rely on hydraulic accumulators and nitrogen to address various challenges such as energy storage, pressure regulation, and shock absorption.

Nitrogen, a prominent element constituting approximately 78% of the Earth’s atmosphere, plays a vital role in hydraulic systems, particularly in hydraulic accumulators. These devices serve critical functions such as energy storage, pressure regulation, and system stability.

We’ll examine the reasons for the extensive utilization of nitrogen in hydraulic accumulators, considering its impact on performance, safety, and broader environmental considerations.

We will also explore related key phrases such as carbon dioxide, boiling point, ammonia (NH3), piston accumulators, liquid nitrogen, atmospheric nitrogen, nitrogen compounds, and diaphragm accumulators.

Energy Storage and Pressure Regulation:

One of the primary reasons nitrogen is used in hydraulic accumulators is its ability to store energy effectively. These devices store pressurized hydraulic fluid, and by compressing nitrogen gas, potential energy can be stored for later use.

Nitrogen’s high boiling point, which allows it to remain in a gaseous state under normal operating conditions, and its ability to withstand high pressure make it suitable for this purpose. When hydraulic power demand arises, the pressurized fluid is released, converting the stored potential energy into kinetic energy, thereby driving actuators or performing work.

Safety and Stability:

In addition to energy storage, nitrogen in hydraulic accumulators helps regulate pressure and maintain system stability. By serving as a cushion, nitrogen absorbs pressure fluctuations caused by variations in hydraulic pump flow or sudden changes in fluid demand.

This pressure regulation function helps stabilize the hydraulic system, safeguarding it against excessive pressure surges that could damage components or compromise safety. Additionally, nitrogen’s inert and non-reactive nature minimizes the risk of combustion or reaction with hydraulic fluid, further enhancing overall safety.

Nitrogen Compounds and Nitrogen Cycle:

While nitrogen gas (N2) is the most abundant element in the Earth’s atmosphere, it primarily exists as a diatomic molecule. However, nitrogen can be transformed into various nitrogen compounds, such as ammonia (NH3), through processes like the nitrogen cycle.

Although nitrogen compounds are not directly involved in hydraulic accumulators, understanding their role in natural systems highlights the versatility and significance of nitrogen in different contexts. The nitrogen cycle, which involves the conversion of atmospheric nitrogen into forms usable by living organisms, showcases the essential role nitrogen plays in sustaining life on Earth.

Environmental Considerations:

Considering the growing focus on environmental sustainability, using nitrogen in hydraulic accumulators raises important considerations. While nitrogen gas itself is not a greenhouse gas, its production process can contribute to carbon dioxide emissions. Industrial processes like fractional distillation of air are commonly employed to extract nitrogen from the atmosphere.

Consequently, manufacturers and engineers must strive to minimize the environmental impact associated with producing and utilizing nitrogen gas in hydraulic systems. Embracing energy-efficient manufacturing practices, exploring alternative nitrogen extraction methods, and optimizing hydraulic system designs can help mitigate this footprint.

Types of Accumulators – Piston, Bladder and Diaphragm:

In hydraulic systems, three common types of accumulators are piston accumulators, bladder accumulators, and diaphragm accumulators. These devices utilize nitrogen gas for energy storage and pressure regulation. In piston accumulators, nitrogen is compressed behind a piston, while in bladder accumulators & diaphragm accumulators, a flexible bladder or diaphragm separates the nitrogen and hydraulic fluid.

All designs leverage nitrogen’s compressibility and inert nature to efficiently perform their respective functions. Engineers carefully select the appropriate accumulator type based on the specific requirements of the hydraulic circuit and system design.

Nitrogen, an abundant element in the atmosphere and a key component of hydraulic accumulators plays a crucial role in enhancing performance and safety and considering environmental sustainability in hydraulic systems. Its properties, such as energy storage, pressure regulation, stability, and inertness, make it a preferred choice for maintaining system efficiency. By harnessing the unique characteristics of nitrogen, engineers can optimize the functionality, reliability, and safety of hydraulic systems, ensuring smooth operations in various industrial and mechanical applications.

As technology advances, researchers and engineers continuously explore innovative methods and materials to improve hydraulic system performance further and minimize environmental impact. While nitrogen remains a prevalent and reliable choice for hydraulic accumulators, ongoing research is being conducted to explore alternative gases, materials, and designs that can further enhance hydraulic systems’ efficiency, safety, and sustainability.

In conclusion, nitrogen’s abundance, properties, and inert nature make it valuable in hydraulic accumulators. Its role in energy storage, pressure regulation, system stability, and environmental considerations showcases its significance in the field of hydraulics. By incorporating nitrogen into hydraulic system designs and adopting sustainable practices, engineers can achieve optimal performance, safety, and environmental responsibility, paving the way for a more efficient and sustainable future in hydraulic applications.

Electro-hydraulic systems combine the benefits of electrical signal processing with hydraulic drives to create versatile and reliable control systems. These systems can be categorized into three groups based on functionality, each offering unique advantages and applications.

1. Solenoids

The first group of electro-hydraulic systems uses solenoids to open or close hydraulic valves. The signal processing is performed using relay technology, making it suitable for applications with sufficient simple on/off control. These systems are typically used in agriculture, construction, and transportation industries.

2. Proportional Valves

The second group of electro-hydraulic systems uses proportional valves that allow for continuous adjustment to changing setpoints, resulting in better compensation for the progression of processes. The setpoints can be retrieved via machine controls or a programmable logic controller (PLC), and the signal processing is performed electronically. These systems are ideal for applications that require precise control and adjustments, such as in the chemical, food processing, and pharmaceutical industries.

3. Servo Valves

The third and final group of electro-hydraulic systems uses high-response proportional or servo valves. These systems use continuous sensors and electronic control amplifiers to execute the program via machine controls, such as numerical control (NC), computer numerical control (CNC), or direct numerical control (DNC). These systems suit applications requiring high precision and responsiveness, such as aerospace, defense, automotive, and manufacturing automation.

Electro-hydraulic systems have numerous advantages, including high power density, low maintenance, and long service life. They can operate under extreme conditions, such as high temperatures, pressure, and corrosive environments, making them ideal for challenging applications. Additionally, they offer precise control and can be easily integrated into existing systems.

Examples in Different Industries

Aerospace

One example of an electrohydraulic system’s application is in the aerospace industry, where these systems are used in aircraft landing gears and flight control systems. Electrohydraulic systems’ high precision and responsiveness ensure the safe and reliable operation of critical components in these applications.

Construction

In the construction industry, electro-hydraulic systems are used in heavy machinery, such as excavators, bulldozers, and cranes. These systems provide precise control and enable operators to perform complex tasks efficiently and safely.

Manufacturing

The manufacturing industry uses electro-hydraulic systems in automated assembly lines, robotic arms, and packaging machinery. These systems offer high-speed and high-precision control, increasing productivity and reducing production costs.

Electro-hydraulic systems offer a reliable and versatile solution for various industries that require precise control and high performance. With their numerous advantages and applications, these systems continue to play a vital role in the advancement of modern technology.

If you want to replace or retrofit a Hydraulic Power Unit, you must understand the key components that have made modern HPUs smaller, quieter, and more efficient.

Gone are the days of being limited to a fixed-speed Hydraulic Power Unit. In fact, the new variable-speed HPUs are far more energy efficient, and they are starting to dominate the market. Add in the fact that these new units include built-in sensors, diagnostics, and even cloud capabilities, making them very easy to connect to an IoT (Internet of Things) environment, and it’s fairly easy to see why they have become so popular. The sheer amount of predictive maintenance data alone makes the investment worth it!

The most important part of replacing a Hydraulic Power Unit is understanding how the modern hydraulic system design differs from the older conventional systems in aspects like size, noise, energy efficiency, connectivity, and total cost of ownership. Let’s take a look at those differences…

The Main Differences Between Conventional and Modern Hydraulic Power Units

Hydraulic Power Unit Size

HPU size is often determined by the size of its hydraulic fluid reservoir. For traditional HPUs, the reservoir minimum is normally two to five times the maximum pump flow.

Conversely, modern HPUs can be designed to a 1:1 flow/reservoir size ratio due to pump controls, advanced manifold design, and the use of variable frequency-driven motors to drive the pumps. As a result, a unit that produces a max flow of 150 GPM per minute may only need a reservoir capacity of 150 gallons, or 75 percent less reservoir capacity than a traditional HPU.

Hydraulic Power Unit Noise

By operating at variable speeds, modern units are quieter because they don’t demand their full power at all times. Instead, they are only delivering the power needed at any given time.

Furthermore, modern systems can be built from materials that dampen sound and minimize vibrations using designs like a liquid-cooled motor, compact arrangement of components, unitary housing, and built-in sound-insulating mats.

Hydraulic Power Unit Energy Efficiency

A fixed-speed HPU operates at 100 percent motor speed at all times. In turn, any energy not being used to do work is converted to heat. This all results in higher energy costs and excess heat production that must be controlled using cooling – which requires even more energy.

Variable-speed systems adjust energy output to match the demands of the operation. As such, variable-speed HPUs have demonstrated energy savings of up to 80 percent. Lower, more controlled operating speeds also reduce the unit’s heat output, allowing it to run cooler and reduce or eliminate the need for additional cooling measures and their associated costs.

Hydraulic Power Unit Connectivity

With a modern HPU, access to cloud-based diagnostics and data analytics tools streamlines workflows and reduces the demand for personnel to capture critical data and troubleshoot equipment in person.

Some HPUs include case drain flow/temperature, particle counter, energy consumption, pump damage, and other monitoring parameters, with real-time access to performance and usage reports 24/7 via dashboards on a mobile device.

Hydraulic Power Unit Total Cost of Ownership

Modern variable-speed HPUs may be more of an investment upfront, but manufacturers with high energy costs driven by fixed-speed HPUs will see more value and a faster return on their investment.

Atlantic Hydraulic Systems has designed, manufactured, and commissioned many key elements in the fight against the rising tides of the world.

We live in a busy society that is dependent on our ability to travel, transact business, gather at social events, and connect with other humans on multiple levels. With each passing day, however, our need to connect is also contributing to adverse effects on our planet.

The Earth’s Temperature Is Slowly Rising And Our Water Levels Are Rising Along With It

Ultimately, the earth is getting warmer and that increase in temperature – however subtle or blatant it may be – is contributing to higher ocean tides and rising water levels on a global scale.

Our oceans absorb over 90% of the excess heat generated by our planet and that is throwing some major complications into the delicate ecosphere. Increases in temperature are adding to the overall water volume on the planet by melting giant ice sheets and glaciers. This, thereby, contributes to sea level rise.

As sea levels rise, there’s an adverse effect on our lands, weather, and the frequency of floods in areas that are otherwise usually free of flood dangers.

To that end, our society is placing ever more emphasis on stormwater management, flood protection, and water control gates to either mitigate damage or outright prevent damage from rising water levels.

Atlantic Hydraulic Systems Is Playing A Major Role In Mitigating And/Or Preventing Unnecessary Damage From Rising Tides

In turn, Atlantic Hydraulic Systems has designed, manufactured, and commissioned many key elements in the fight against the rising tides of the world including Hydraulic Power Units, Hydraulic Control Panels and Hoist Winch Control Panels for water control management systems like Crest Gates, Sluice Gates, and Tainter Gates.

Important aspects in the hydraulic power unit and control system design for Crest, Sluice, and Tainter Gates are:

Designing for emergency gate closure and opening in a no-power condition
The ability of the gate hydraulics to detect gate blockages while moving to protect the structure
Gate position feedback and monitoring
Design for no single-point failure event possibility using redundant pumps & controls
Ability to control operation locally or via a SCADA system – which is a control system architecture for high-level supervision of machines and processes.

Our Recent Projects To Help Combat The Effects Of Floodwater and Rising Tides

Atlantic Hydraulic Systems designed, manufactured and commissioned the floodgate hydraulics and control systems at Seabrook Gates in New Orleans. Atlantic’s on-site technicians directed the installation of the HPU, hydraulic cylinders, hydraulic plumbing, and both high voltage and control wiring.

The gates are controlled using a user-friendly graphic interface and provide closed-loop position control of the gates and safety interlocks with the gates locking mechanisms.

We even designed, manufactured, and installed the hydraulic system for the Orleans Avenue Gates in New Orleans, LA after Hurricane Katrina. Five hydraulically driven winches were placed to lift and lower massive gates to prevent water flow in the canal during a storm. The HPU is designed to communicate with the municipal SCADA systems as well as to be run manually.

Most Recently, after Hurricane Sandy, we were commissioned to design and manufacture both the temporary and permanent hydraulic systems during the Metropolitan Ave Bridge machinery replacement in New York, NY. Now, two of our 60 HP hydraulic power units and four 10″ bore x 96″ stroke cylinders drive the two massive leaves of the bridge in addition to four of our 7.5 HP hydraulic power units which drive the tail locks into place.

We at Atlantic Hydraulic Systems may not be able to control the earth’s temperature – but we are certainly at the forefront of how we can prevent or mitigate any damage of the rising tides or flooding that may be happening as a result.

Step outside the airport in Las Vegas and the sensory overload begins. Hard-charging lights and sounds create an incomparable experience for the entire time one is within that unique city.

So, if you are in the business of creating memorable entertainment in such a competitive atmosphere, how do you do it? In fact, how do you do it and keep it going for twenty years?

Well, for Cirque du Soleil and the MGM Grand Hotel, the show DOES go on… twenty years later.

In conjunction with McLaren Engineering, the stage for the Cirque show “KA” is still being lifted in the air by Atlantic Hydraulic Systems.

Now, the term stage may be an understatement. This is actually the world’s largest stage, weighing in at 200 tons and lifting 70 feet in the air at two feet per second as it tilts 100 degrees. It’s a marvel that truly challenges people’s perception… accomplished through a 4,000-horsepower hydraulic power unit and control system designed, engineered, and manufactured by Atlantic Hydraulic Systems.

Little did the audience know on opening night in February 2005 how long the stage took to become a reality… with a phone call three years prior. All they saw was a show that seemed to defy gravity… a fact that did not escape the New York Times as they entitled their review “Fire, Acrobatics and Most of All, Hydraulics.” And 20 years later, the show is still making people gasp with delight and terror at the same time.

So obviously, something so complex with functionality that was almost unthinkable had its share of challenges. The answer is a resounding “Yes”. Tuning a hydraulic system that sits on (4) 12” bore cylinders x 70-foot stroke had its “moments.” The stage, when in the elevated position, sits on about 1600 gallons of oil, rendering the hydraulic natural frequency of the system incredibly low (basically, it’s a big spring). However, system failure was not an option with a peak system flow of 2200 GPM at 4000 PSI. So, all hydraulic pumps, valves, and controls have redundant and/or soft-landing functionality in case of a component malfunction.

The Atlantic team spent months at the MGM Grand modifying the hydraulic system, fine-tuning the hydraulic motion control, and testing and retesting. The result was a reliable hydraulic system that has proven its reliability and resiliency 20 years later.

KA was just one of many entertainment projectsthat depend on Atlantic firepower utilizing its hydraulic power units & hydraulic controls. These include Broadway shows such as The Lion King, Wicked, Phantom of the Opera, Les Misérables and many more.