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Intelligent Energy-Saving Hydraulic Systems - System Overview
1.Energy Saving and Cost Reduction
Significantly reduces cooling and hydraulic oil costs, saving 50%-90% in electricity, and cuts labor andtime spent on maintenance.
2.High Efficiency
By utilizing proper energy storage, pressure holding, and acceleration/deceleration control, the systemgreatly improves pressure maintenance and stabilization times, resulting in a significant increase in cycletime compared to traditional hydraulic systems.
3.High Precision
The hydraulic system pressure, oil temperature, and oil level are all fully closed-loop controlled to meet awide range of process requirements.
4.Low Noise
The system consistently operates at around 50 decibels, improving the working environment's comfort.
5.Low OilTemperature
The intelligent energy-saving hydraulic station often operates with the motor in a low-speed,standby pressure-maintaining state. This reduces mechanical friction between the oil, pump, and valve.thereby lowering heat generation and maintaining a lower oil temperature.
6.Low Failure Rate
The inteligent energy-saving, hydraulic station minimizes unnecessary work. With lower oil temperatures.the motor and pump in the energy-saving system operate for shorter durations, significantly reducing thelikelihood of failure and extending the service life of key components such as the motor and pump. Thisalso facilitates easier maintenance.
HBY Hydraulic System Energy Consumption Comparison
1.In traditional hydraulic systems, inefective power losses are almost entirely converted into heat energy, which raises the oitemperature. To reduce the oil temperature, additional cooling measures such as air cooling or oil coolers are required,leadingto secondary energy losses.
2.The power eficiency losses in a hydraulic system primarily include: Efficiency of the prime mover, Pressure-flow matchingefficiency,Conversion efficiency,Transmission efficiency.
3.Among these, pressure-flow matching eficiency is the most significant. Since hydraulic stations typically completeoperations in a short amount of time and maintain pressure over extended periods, they avoid flow-pressure matching losses
and overflow.
4.The energy-saving effect of inteligent hydraulic systems is far superior to that of traditional hydraulic stations. We onlyrecommend these systems to clients when energy savings exceed 50% under standard operating conditions. in our on-sitemeasurements for clients working with complex machining components, we have recorded energy savings ofup to 95%. 0f course,in addition to enerey savings, the inteligent enerev-saving hvdraulic station ofers other advantages that make it a preferredchoice, even in conditions where energy savings are below 509. These advantages include ultra-low oil temperaturesexceptionally low noise levels, and low failure rates, among others.
HBY Hydraulic System Energy Consumption Comparison Chart
Low oil temperatures can reduce the temperature by 50% to 90%, which helps to slow down the degradation of hydraulic oil and extends the lifespan of motors.
Advantage
Electricity consumption is billed directly.
For example, a 1.5 kw hydraulic station operates approximately 300 days a year for 15 hours each day, consuming 1.5 kwh perhour (test value, with a cost of 1 yuan per kWh, Assuming a minimum eficiency of 70% for the energy-saving hydraulic station.the calculations reflect significant cost savings.
Standard Hydraulic Station Annual Electricity Cost: 300 days x 15 hrs x 1.5 kWh x 1 Yuan=6750 Yuan
Energy-Saving Hydraulic Station Annual Electricity Cost: 6750 Yuan x (1-70%)=2000 Yuan
Annual Savings: 4750 Yuan
Servo Energy-Saving Hydraulic Station
Model number:TOSY-50-SM1 A1-13-A
System Overview
1. By leveraging the characteristics of servo technology and integratinghydraulic principles, the system provides on-demand supply, achievingenergy savings of approximately 70%.
Compared to variable displacement pumps, secondary energy waste issignificantly reduced.
2. The application of servo technology greatly reduces wasted energyresulting in minimal heat generation.
With low operating temperatures, the lifespan ofhydraulic componentsis extended, and the accuracy of the equipment is improved, achievingzero-leakage pressure holding
3.Simple operation and easy maintenance.
4.Compact design, maximizing space efficiency.
5.Modular assembly for easy maintenance and installation.
3.The system's use of an energy storage tank provides power, achievinghigh efficiency for the main unit. This eliminates the need for a coolingsystem,effectively saving energy and reducing power consumption
4.The integration of an energy storage tank improves operationalcomfort. Low noise levels, along with high energy efficiency, areprioritized in manufacturing, with consideration given to both noisereduction and simplified equipment design.
5.The simple structure and high reliability ensure ease of operation andmaintenance. The compact design of the system saves space andenhances overall efficiency.
Technical Parameters
| Model |
TOSY-50-NXQ M1V1-11-A |
| Pressure Range |
1.5-7MPA |
| Pump Type |
Variable Vane Pump |
| Maximum Flow Range |
8-20L/MIN |
| Power Supply |
AC380V50HZ/60HZ AC220V 50HZ/60HZ
3-phase AC 380V50Hz/60Hz 3-phase AC 220V 50Hz/60Hz |
| Oil Specification |
ISO VG32-46NAS |
| Coating Color |
Black |
Note:
1. The above charts are for reference only; the actual product will be madeaccording to specific working conditions.
2. Additional components not shown in the diagram can be selected to meet variousoperationalrequirements.
3. This hydraulic system is customizable: each valve function can be individuallytailored, with independent circuit operation that does not interfere with one another.suitable for high, medium, and low-pressure ranges.
High-End Energy-Efficient Hydraulic Station
Model number:TOSY-95-NXQ-M2 A1-1 5-A
System Overview
1. The advanced tooling fixture high-end energy-efficient hydraulicstation is environmentally friendly with very low carbon emissions,designed to be energy-saving by only operating when additionalpressure is required.
2. During operation, the pump is activated, reaches the preset pressure,and then automatically shuts off.
3. During operation, as pressure decreases, the pressure switchautomatically activates the pump to restore the clamping pressure in thehydraulic system.
4. The pump should be operated according to requirements toreduce electrical consumption and prevent continuous operation thatmay cause excessive oil temperature.
Technical Parameters
| Model |
TOSY-95-NXQ M1A1-11-A |
| Pressure Range |
1.5-10MPA |
| Pump Type |
Fixed Displacement Gear Pump |
| Maximum Flow Range |
8-15CC/REC |
| Power Supply |
AC380V 50HZ/60HZ AC220V 50HZ/60HZ
3-phase AC380V50Hz/60Hz 3-phase AC220V50Hz/60Hz |
| Oil Specification |
ISO VG32-46NAS |
| Coating Color |
Black |
Note: 1. The above charts are for reference only; the actual product will be made according to specific working conditions
2. Additional components not shown in the diagram can be selected to meet various operational reguirements.
3. This hvdraulic system is customizable: each valve function can be individually tailored, with independent circuit operationthat does not interfere with one another, suitable for high, medium, and low-pressure ranges.
Single-Circuit Hydraulic Station
Model number:TOSY-40-M1 V1-10-A
System Overview
1.System Tank Capacity: 40l
2.Motor:0.75kW 4P380V/AC220V50Hz,factorysettingAc380V,speed:1420 r/min
3.Pump:Variable Vane Pump, Flow Rate: 15 L/min(1800cc/rev), factory preset working pressure: 3.0 MPa
4. Solenoid Valve Voltage: DC24V, Fan Voltage: AC220V
5.Inlet/Outlet Ports A1/B1: PT3/8
Technical Parameters
| No. |
Name |
Model/Specification |
Quantity |
Unit |
Remarks |
| 1 |
Oil Tank |
40L |
1 |
Set |
|
| 2 |
Variable Vane Pump |
VP-15FA3 |
1 |
Set |
|
| 3 |
Motor |
1HP-4P-20 |
1 |
Set |
0.75KW |
| 4 |
Air Cooler |
AJ0510T/220V |
1 |
Set |
|
| 5 |
Suction Port |
JL-04 |
1 |
Set |
|
| 6 |
Check Valve |
CVT-03-05 |
1 |
Pcs |
Optional |
| 7 |
Pressure Gauge |
Y60LA-1/4PT |
1 |
Set |
|
| 8 |
Pressure Switch Gauge |
GCLT-02 |
1 |
Set |
|
| 9 |
Solenoid Directional Valve |
G02-2B2-D2-DL |
1 |
Set |
|
| 10 |
Hydraulic Block |
YLK-80-70-70 |
1 |
Set |
Blackened |
| 11 |
Level&Temperature Gauge |
YWZ-80T |
1 |
Set |
|
| 12 |
Oil Fill Port |
HS-1163 |
1 |
Set |
|
| 13 |
Junction Box |
158*90*60 |
1 |
Set |
|
| 14 |
Casters |
Swivel with Brakes |
4 |
Pcs |
|
| 15 |
Hydraulic Fittings |
|
|
|
|
Dual-Circuit Hydraulic Station
System Overview
1.System Tank Capacity: 50L
2.System Motor: 1.5KW4P 380V/AC220V 50Hz, factorysetting Ac380V, speed: 1420 r/min
3.Pump: Variable Vane Pump, Flow Rate: 20L/min(1800cc/rev),factory preset working pressure:5.0Mpa
4. Solenoid Valve Voltage: DC24V, Fan Voltage: AC220V
5.Pressure Switch Configuration: Total pressure orelectromagnetic valve A port pressure monitoring, optionabased on specific requirements
6.Inlet/Outlet Ports A1-A2,B1-B2: PT3/8
Technical Parameters
| No. |
Name |
Model/Specification |
Quantity |
Unit |
Remarks |
| 1 |
Oil Tank |
50L |
1 |
Set |
|
| 2 |
Variable Vane Pump |
VP-20FA3 |
1 |
Set |
|
| 3 |
Motor |
2HP-4P-20 |
1 |
Set |
1.5KW |
| 4 |
Air Cooler |
AJ0510T/220V |
1 |
Set |
|
| 5 |
Suction Port |
JL-04 |
1 |
Set |
|
| 6 |
Check Valve |
CIT-03 |
1 |
Pcs |
|
| 7 |
Pressure Gauge |
Y60LA-1/4PT |
1 |
Set |
|
| 8 |
Pressure Gauge |
Y40LA-1/4PT |
1 |
Set |
|
| 9 |
Pressure Switch Gauge |
GCLT-02 |
1 |
Set |
|
| 10 |
Solenoid Directional Valve |
G02-2B2-D2-DL1 |
1 |
Set |
|
| 11 |
Solenoid Directional Valve |
G02-3C2-D2-DL2 |
1 |
Set |
|
| 12 |
Stacked Pressure Reducing Valve |
MBRV-02P3 |
1 |
Set |
|
| 13 |
Hydraulic Block |
YLK-180-70-70 |
1 |
Set |
Blackened |
| 14 |
Level&Temperature Gauge |
YWZ-80T |
1 |
Set |
|
| 15 |
Oil Fill Port |
HS-1163 |
1 |
Set |
|
| 16 |
Junction Box |
158*90*60 |
1 |
Set |
|
| 17 |
Casters |
Swivel with Brakes |
4 |
Pcs |
|
| 18 |
Hydraulic Fittings |
|
|
|
|
Triple-Circuit Hydraulic Station
System Overview
1.System Tank Capacity: 50L
2.System Motor: 1.5KW 4P 380V/AC220V 50Hz, factorysetting AC380V,speed: 1420 r/min
3.Pump:Variable Vane Pump,Flow Rate:20L/min(1800cc/rev),factory preset working pressure: 5.0 MPa
4. Solenoid Valve Voltage: DC24V, Fan Voltage: AC220V
5.Inlet/Outlet Ports A1-A3,B1-B3:PT3/8, with reservedreturn port PT3/8"
Technical Parameters
| No. |
Name |
Model/Specification |
Quantity |
Unit |
Remarks |
| 1 |
Oil Tank |
50L |
1 |
Set |
|
| 2 |
Variable Vane Pump |
VP-20FA3 |
1 |
Set |
|
| 3 |
Motor |
2HP-4P-20 |
1 |
Set |
1.5KW |
| 4 |
Air Cooler |
AJ0510T/220V |
1 |
Set |
|
| 5 |
Suction Port |
JL-04 |
1 |
Set |
|
| 6 |
Check Valve |
CIT-03 |
1 |
Pcs |
|
| 7 |
Pressure Gauge |
Y60LA-1/4PT |
1 |
Set |
|
| 8 |
Pressure Gauge |
Y40LA-1/4PT |
1 |
Set |
|
| 9 |
Pressure Switch Gauge |
GCLT-02 |
1 |
Set |
|
| 10 |
Solenoid Directional Valve |
G02-2B2-D2-DL |
1 |
Set |
|
| 10 |
Solenoid Directional Valve |
G02-3C2-D2-DL |
1 |
Set |
|
| 11 |
Stacked Pressure Reducing Valve |
MBRV-02P |
1 |
Set |
|
| 12 |
Hydraulic Block |
YLK-130-70-70 |
1 |
Set |
Blackened |
| 13 |
Level &Temperature Gauge |
YWZ-80T |
1 |
Set |
|
| 14 |
Oil Fill Port |
HS-1163 |
1 |
Set |
|
| 15 |
Junction Box |
158*90*60 |
1 |
Set |
|
| 16 |
Pressure Switch |
JCS-02NL |
1 |
Set |
Optional |
| 17 |
Casters |
Swivel with Brakes |
4 |
Pcs |
|
| 18 |
Hydraulic Fittings |
|
|
|
|
Maintenance and Servicing
ReqaiemteecesF/dale station.
| InspectionArea |
Inspection Item |
Inspection Period |
Inspection Method |
Oil Tank
(including working oil) |
Oil Leaks |
Weekly |
Weekly |
| Oil Leaks |
Weekly |
Weekly |
| |
Oil Cleanliness and Condition |
Every3Months |
LabAnalysis |
| OilTemperature |
Weekly |
Oil Thermometeror Touch |
| Displacement |
Every 3Months |
Drive speed measurement,Test station |
| Pump |
Pressure |
Every 3Months |
Pressure Gauge |
| Noise |
Every 3Months |
Listeningor Sound LevelMeter |
| Surface Temperature |
Every 3Months |
Thermometeror Touch |
| Seals,Gaskets,Leakage,orAir Intake |
Every 3Months |
Visual or Check for Bubbles/Noise in Tank |
| Coupling |
Oil Supply,Wear Condition |
Annually |
VisualInspection |
| Pressure ControlValve |
SetValue and Operation Status |
Every 3Months |
Pressure Gauge orActuator Movement |
| Flow ControlValve |
SetValue and Operation Status |
Every3Months |
Drive Speed Measurement |
| Direction ControlValve |
Operational Status |
Every 3Months |
Actuator Movement Check |
| Internal Leakage |
Annually |
NeutralActuator Movement or Test Station Measurement |
| Coil Insulation Resistance |
Annually |
Measured with a500MΩ megger. |
| Filter |
Cleaning |
Monthly |
Visual inspection. |
| Cleaning |
Every 3 months |
Cleaning as required. |
| Cooler |
Cooling Capacity |
Every 3 months |
Measured usinganoil thermometer ortouch. |
| Water Leakage |
Every 3 months |
Reference toworkingoilanalysis data. |
Pipingand Clamps
(including rubber hoses) |
Oil Leaks |
Weekly |
Visual inspection. |
| Looseningand Vibration |
Weekly |
Visual,tactile inspection orvibration meter. |
| Rotary Hydraulic Cylinder |
Cycle Time |
Weekly |
Measure the cycletime. |
| Vibration&Impact |
Weekly |
Visual inspection,tactile inspection,orvibration meter. |
| Oil Leaks |
Weekly |
Visual inspection. |
| Hydraulic Chuck |
Lubrication OilSupply |
Daily |
Immediately apply lubrication oilat the start of the workday. |
| Cleaning |
Every6months |
Fullydisassemble and clean. |
Hydraulic Oil Usage and Maintenance
The operating temperature should be kept below 70'c, ldeally, it should be below 60°c. Particularly inhigh-pressure conditions, the return oil temperature from the reliefvalve can be very high. Extra care should betaken if using heaters or localized heating. High temperatures will accelerate oxidation.
Control contamination, as contaminants in the working oil will speed up oxidation.
Prevent moisture from entering the working oil, as water will degrade the oil. Excess moisture can cause the oilto emulsify.
Diferent manufacturers' working oils should not be mixed, as using oils with different brands, types, or gradescan lead to the degradation of additives in the oil.
Prevent leakage between hydraulic equipment connections to minimize oil loss.
Regular inspection of the working oil.
Used oil that has begun to degrade cannot have its service life extended simply by adding new oil. it shouldbe completely replaced with fresh oil.
Product Certificate
Audited Supplier 
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