Hydraulic systems are used in everything from construction machinery to industrial applications. At the same time, a large portion of the energy in these systems is lost in the form of pressure drops and heat. A new generation of components is now attempting to capture this energy. One example is the hydraulic valve technology Energen, which can generate electricity directly from the hydraulic flow.
Energy recovery in hydraulics
In many hydraulic systems, energy is created that is not utilized. When oil returns to the tank through the return line, there is often a pressure drop that in practice represents wasted energy. The technology behind Energen is based on converting this energy into electrical power.
The valve is designed as a cartridge valve with an integrated generator, allowing hydraulic energy to be converted into electricity directly within the valve. The generator is driven by the flow in the system and can produce electrical power for various types of electrical components in the machine.
How the technology works
The principle behind the technology is relatively simple:
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Hydraulic oil passes through the valve
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The flow drives a small turbine inside the valve
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The turbine drives a generator
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The generator produces electrical energy
This energy can then be used for sensors, valve control, communication systems, or charging batteries in the machine.
In practice, the valve therefore functions as a micro-generator in the hydraulic system.
Power and technical data
The energy generated is not intended to replace the machine’s main generator. However, it can function as a local power source.
Typical performance data includes:
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Power: up to approximately 40 W
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Current: up to 3 A
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Flow: up to 200 l/min
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Installation: standard T-16A cartridge valve cavity
This allows the valve to be integrated into existing hydraulic systems or new designs without major changes to the system architecture.
Possible applications
The technology may be particularly interesting in applications where electrical power is needed locally in the system.
Examples include:
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mobile construction machinery
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hydraulic tools and attachments
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systems with sensors and IoT solutions
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remote monitoring of hydraulic systems
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applications where cable routing is difficult or risky
In some cases, the technology can also be used to recover energy during movements where braking already occurs, for example when lowering a load in a hydraulic system.
Part of a larger trend in hydraulics
Electrification is a clear trend in mobile hydraulics and industrial systems. At the same time, hydraulics continues to be a central technology for power transmission. Solutions that combine hydraulics with electrical functionality are therefore becoming increasingly interesting.
Energy recovery in hydraulic systems is one example of how technological development is trying to reduce energy losses while creating new functions in machines and equipment.
Summary
Hydraulic systems have long had limited possibilities to recover energy from return flows. With valves such as Energen, it becomes possible to convert part of this energy into electricity.
The result is a compact solution that can generate local electrical power without external generators or cabling. As machines become more digitalized and sensor-based, this type of technology may play an increasingly important role in future hydraulic systems.
