Best energy efficiency with “Drive-on-Demand”

In addition to its compactness, the servo-hydraulic SmartPower from WITTMANN BATTENFELD stands out for its user friendliness, and above all for its intelligent, economical use of energy. Its high level of energy efficiency is primarily due to the combination of a responsive, speed-controlled, air-cooled servo motor with a robust fixed displacement pump, known as “Drive-on-Demand” system. 

“Drive-on-Demand” means that the drive unit is only activated when this is required for movements and pressure generation. During cooling times and cycle breaks for parts handling, the servo drive is switched off and consumes no energy. In operation, “Drive-on-Demand” is the basis for highly dynamically controlled machine movements and minimized cycle times. One of the results is a high-quality control performance and consequently better repeatability, as well as saving time in axis movements.

“Drive on Demand” generates a verifiably lower energy consumption rate than systems using servo-controlled two-circuit pump technology or electro-hydraulic drives. “Drive-on-Demand” actually reduces energy consumption by up to 35% compared to modern control pump systems.

The SmartPower is also equipped with the same amplifier system as the all-electric  EcoPower. This drive technology makes it possible to use the KERS (Kinetic Energy Recovery System), originally developed for the EcoPower, in the SmartPower too. In braking processes, KERS transforms kinetic energy into electrical energy. The electrical energy thus gained is partly stored, partly transferred to barrel heating and partly used for control voltage generation. The entire deceleration energy is thus completely utilized within the machine.

The option with parallel machine movements comes with a second servo drive laid out specifically to meet the requirements for the ejector and core pull. This ensures optimal energy efficiency and dynamism for this type of application as well. 

Thanks to the significant reduction in heat generation achieved by using this modern drive technology, an additional amount of energy is saved through a reduced demand for cooling performance. This, in turn, results in less strain on the hydraulic oil, thus preserving the quality of the oil for longer and minimizing maintenance expenses.

Additional energy cost cuts are achieved by a reduction of electrical reactive power and an intelligent, performance-optimized control electronics system.

The long-standing WITTMANN BATTENFELD customer Thomas Dudley Ltd., UK, has based its decision to replace an older hydraulic machine model with a machine from the SmartPower series on solid figures. Thomas Dudley Ltd. reports an average cycle time reduction of 33% and massive energy savings compared to the older machine by using the SmartPower. They estimate an annual cost cut of about 2,200 euros.

Franz Wilfing, Head of the Technical Department at WITTMANN BATTENFELD