Hyper-Efficient Pump Motor Unit with Fully Integrated Permanent Magnet Motor and Motor Controls with Combined Liquid Cooling

The purpose of this study is to summarize the current state of hydraulic systems and to introduce a new technology to address past challenges. Methods to increase system efficiencies have been developed for decades, as well as systemic steps to reduce occupational hazards, environmental impacts, and typical procurement barriers. Despite these efforts, overall gains have been limited.

Substantial efficiencies through a novel product, the Hyper-Efficient Pump Motor Unit, demonstrate a ground-up product development approach that either eliminates or integrates common hydraulic system components. As a result, cost is greatly reduced and efficiency significantly increased, resulting in a viable bridge between a mature industry and a modern technology.

The integration and addition of embedded intelligence together generate several key benefits. Electricity reductions of up to 80 percent can be realized in some industry applications by replacing a traditional hydraulic power unit with the Hyper-Efficient Pump Motor Unit. Variations in application duty cycles and the effective use of computational logic available to end users will also affect energy use. Worker benefits were noted due to a demonstrated 10-fold decrease in noise energy generated by the unit.

Energy savings were demonstrated and quantified with a Fluke 1736 Power and Energy Analyzer meter. Using a 300-ton press and a repeatable cyclic profile between a 30-kilowatt Hyper-Efficient Pump Motor Unit and an equivalently powered hydraulic power unit, power and energy consumption data were collected. In this controlled experiment, this difference in energy use translated into annual savings of at least $2,000.

These quantifiable results and the empirical data collected for this project support adoption of this novel technology. This constructive first step underscores potentially labeling the Hyper-Efficient Pump Motor Unit as a disruptive technology and represents an evolutionary leap for hydraulic system design and use. This study concludes with proof of this novel technology’s benefits and sets the framework for next steps on its path to commercial adoption.