Rising oil and fuel costs, trends towards electrification, and overall concerns about sustainability across virtually every industry are driving an increased push for improved efficiency in the designs of hydraulic equipment.
One area where great opportunities for improvement lie is with the hydraulic tank. Due to inefficient designs, many machines operate with oversized hydraulic tanks containing more oil than needed.
Many benefits can be realized through tank optimization, including:
Increased energy efficiency
Overall machine weight savings
Steel and oil savings per machine
CO2 emission reduction
Tank downsizing
Additional machine space for other features
Read on to learn more about the benefits of optimizing your hydraulic reservoir, and how Schroeder Industries can help:
What Is Tank Optimization?
The goal of hydraulic tank optimization is to reduce the reservoir size and thus reduce its fluid volume. Two main factors determine how much a tank can be optimized:
Volume Utilization. In a suboptimal reservoir design, ‘dead zones’ can appear, where fluid stagnates and is not effectively utilized by the system. In a properly designed tank, every cubic inch of the hydraulic fluid should circulate within the reservoir. Dead zones can be detected by digital simulations, and are a strong indicator that tank optimization is needed.
Fluid Velocity. Fluid velocity impacts how well a tank can de-aerate, or release trapped air from within the fluid, and prevent new air from entering the fluid due to splashing. Increased air contamination causes a variety of issues within hydraulic systems, decreasing operating efficiency and component lifespan. Fluid velocity can be reduced through improved in-tank filtration and adjusting the structure of the hydraulic tank itself.
The Benefits of Hydraulic Tank Optimization
Here’s some of the ways optimizing a hydraulic tank design can benefit both OEMs and end users:
Cost Savings. Downsizing a reservoir with tank optimization means less steel and oil are needed upon initial construction, reducing up front manufacturing expenses for OEMs. Additional savings are passed on to end users, who will need less hydraulic oil to run the equipment over its lifetime.
Improved Energy Efficiency. A smaller reservoir with reduced fluid volume reduces the overall weight of the equipment, translating to improved energy efficiency. Lower fluid volume also reduces warmup time in cold start conditions. Any improvements in energy efficiency are especially important for electric-powered equipment, which relies on more limited battery power.
Increased Machine Space. A smaller hydraulic reservoir can allow overall downsizing of the equipment or make way for additional improvements to the design. Larger batteries or fuel tanks, cooling units and other beneficial modifications can be made when space is freed up within the machine.
Sustainability Benefits. Tank optimization reduces the carbon footprint of an operation in several ways:
1. By downsizing a reservoir, less hydraulic oil must be produced and then disposed of, reducing the emissions from both the initial manufacturing of the oil and lowering the amount of waste oil per machine.
2. The carbon footprint of initial construction is also mitigated by the reduction in materials needed to create the reservoir itself.
3. Improvements in fuel efficiency for diesel and other fossil fuel-powered equipment reduces CO2 and other harmful emissions overall.
4. Finally, the increase in energy efficiency and available machine space can open up avenues for electrifying equipment, or improving the performance of electric-powered machines, which are at the forefront of sustainable equipment.
The benefits of optimizing your tanks are clear, and the filtration experts at Schroeder Industries can help you get the most out of your reservoir.
Tank Optimization Services from Schroeder Industries
Schroeder Industries is leveraging our extensive experience in hydraulic system filtration components towards tank optimization. Through cutting-edge flow simulations, our experts can identify dead zones and inefficiencies in hydraulic tank designs and work with your company to develop a solution that suits your specific application.
The benefits of optimizing your hydraulic tank are more than just theory. In the following case study, learn how one OEM saw substantial savings with Schroeder’s tank optimization services:
An OEM customer producing stump grinding machines for the forestry industry came to Schroeder Industries searching for updated filtration solutions.
An engineering analysis of their fabricated tanks found that not only were they heavy and prone to weld cracks: The volume utilization was subpar.
Further testing concluded that the existing Schroeder TNK12 would provide equivalent deaeration performance to the customer’s current tanks with a 40% reduction in tank volume.
This resulted in substantial savings on both oil and tank production cost in their stump grinder manufacturing:
Schroeder’s tank optimization services are backed by expertly crafted reservoirs and filters. Learn more about these premium products:
Lightweight tanks, heavyweight performance! The Schroeder Industries series of rotomolded HDPE tanks are lighter than traditional steel tanks, but built to take a beating in the field with no risk of corrosion. Available in five performance optimized sizes, with custom options available, there’s almost certainly a TNK for your application.
Engineered with baffling that improves deaeration and cools returning oil by creating settling zones, these tanks are designed to assist in the ever-important degassing of hydraulic fluid.
Specifications:
Tank Materials:
High Density Polyethylene (HDPE)
Tank Volumes:
4 gal (15L) 7 gal (26L) 12 gal (45L) 18 gal (70L) 25 gal (100L)
Operating Temperature:
High Density Polyethylene (HDPE)20°F to 180°F(-29°C to 82°C)
Hydroforming is a specialized deep draw manufacturing process used to create a wide variety of metal components and is especially popular within the automotive industry.
In the sheet hydroforming process, highly pressurized water is applied into a mold, and the water pressure forces the metal to conform to the shape of the die.
Compared to conventional stamping methods, hydroformed parts can be created in more complex shapes with greater efficiency, thinner metal sheets, and high-quality surface finish.
Why is process filtration so important for hydroforming applications?
Like any process water application, contamination can greatly affect the lifespan and performance of the high-pressure hydroforming press.
To protect vital downstream components like high pressure pumps and manifolds from wear and tear, high-quality process filtration is a must for any hydroforming system. If left unchecked, contamination can wear out machine components, reducing operational efficiency and forcing expensive repairs and costly downtime. Additionally, defective/scrap material output can increase.
The process filtration experts at Schroeder Industries understand the impact that high-quality filtration has on a business. We can find a Schroeder solution for virtually any process filtration application, including hydroforming:
Why is an AutoFilt® RF9 from Schroeder Industries the best choice for your hydroforming application?
The AutoFilt® RF9 is Schroeder’s first choice for filtration in hydroforming applications. Already, the RF9 has seen great repeat success in the hydroforming division at one of the world’s largest automotive frame manufacturing plants.
Here’s what makes the RF9 so effective:
Super fine filtration with minimal pressure loss. When filtering process fluid or water for a high pressure application, it’s critical to both achieve the lowest micron filtration levels as possible while minimizing pressure loss. The RF9 is capable of filtering down to 5 microns in a standard hydroforming setup.
Eliminates costly, disposable cartridges. The automatic back-flushing mechanism within the RF9 cleans the re-usable filter elements in under a minute, with minimal interruption to the filtration process.
Low-maintenance and service-friendly. Elements are held securely in the RF9, but are easy to access and require no special tools or torque to change out.
Customizable with options like bypass filters, external heaters, backwash waste treatment units, and more.
Connection Sizes:
DN 32 to DN 350
Flow Rates:
1000 m3/h (4400 GPM)
Pmin / Pmax:
2.0 bar / 16.0 bar (29-232 PSI)
Max. Operating Temperature:
180° C (356° F)
Filtration Ratings:
3 to 500 μm
Filter Elements:
– Chemicron® metal fibre – Dutch weave – Square mesh
Filter Housing Materials:
EN-GJS-400-15 / DIN EN 1563 / AD-2000 W3/2
Material of Internal Parts and Filter Elements:
– Internal parts: steel and cast iron – Filter elements: stainless steel
Control Parameters:
Electronic or PLC control unit
The AutoFilt® RF9 is defined by its globally unique, patented hydropneumatic back-flushing technology with secure media separation.
Features
Back-flushing driven by external air system, rather than using system differential pressure
Large filter surface for its compact size
Low-maintenance, service-friendly design
Suitable for fuels, cooling lubricants, lubricating oils
External heater possible
Optional: bypass filter
Optional: Backwash Treatment Unit for back-flush volume treatment
Advantages
No mixing with the compressed air
Adjustable back-flushing intensity
Efficient hydraulic cleaning
High cleaning efficiency
No reduction in pressure during back-flushing
Low compressed air consumption
Low pressure drops
Intelligent control system
Let the experts at Schroeder Industries help find the perfect solution for your process application!
Backed by over 75 years of innovation, industry experience, and proven successes, Schroeder Industries can work with you to find the optimal solution for your filtration needs. Let us know how we can help you:
Is your hydraulic equipment experiencing more downtime than usual? Are you noticing that your equipment is operating less efficiently?
If your operation is paying a price for the inconsistent performance of your vital equipment, high contamination is most likely to blame.
Hydraulic fluid contamination from a variety of sources is by far the most common cause of system inefficiency and failures. In fact, approximately 80% of all hydraulic equipment failures can be directly attributed to the effects of fluid contamination!
Consistently clean hydraulic oil is vital to every operation that relies on hydraulic equipment. Additionally, systems that rely on process water or run on diesel fuel are also vulnerable to the effects of contamination. Proactive measures to analyze fluid and prevent contamination provide significant benefits to cost and productivity:
Prevent costly equipment failures and downtimebefore they happen by detecting and treating contaminated fluid.
Save money on repairs by protecting system components from contamination and extending their lifespan.
Get the most out of your hydraulic oil by detecting and treating contamination before the oil’s life is exhausted. As oil prices continue to rise and hydraulic oil supply lines remain unstable, it’s important to conserve the oil you have!
Increase fuel efficiency not just by filtering your fuel source, but by improving overall system efficiency when you reduce contamination-related wear. Clean fuel and efficient operation reduces fuel consumption, cuts carbon emissions, and saves your operation money.
Struggling with Fluid Contamination? Fluid and Oil Analysis Services by Schroeder Industries Can Help!
Backed by over 75 years of innovation, Schroeder Industries is a leader in developing filtration products and technology that detect, analyze and remediate contamination to protect hydraulic systems and other vital equipment.
When contamination is attacking your equipment, the first step towards an effective filtration plan is a thorough analysis of the affected fluid, be it oil, fuel, or water.
Our fluid health experts will test your samples and create a detailed report, identifying the type and potential sources of contamination in your system and giving recommendations on how to best protect your equipment.
Schroeder offers a variety of premium testing kits, including:
Offering a comprehensive look at your hydraulic fluid or water glycol condition, our bottle sampling Bottled Fluid Analysis Test Kits provide vital insights into your fluid health.
Use Filter Debris Analysis (FDA) Test Kits alongside traditional oil analysis methods to analyze wear particles and discover the root cause of premature equipment wear & failures.
Diesel analysis can identify potential causes for fuel filter plugging, smoking, loss of power, poor injector performance, malfunctioning throttle position sensors and sticking valves. Testing also confirms a diesel fuel’s sulfur content, biodiesel content and compliance with manufacturer specifications and standards for cleanliness that could affect equipment warranty requirements.
The WaterTest Kit (WTK) is used for quantitative analysis of the absolute water content in mineral-oil-based lubricating and hydraulic fluids. Use to perform quick, on-site analysis of water contamination and supplement on-site laboratories.
Monitor Contamination with Schroeder’s State-of-the-Art Fluid Care Portal
Regular testing is vital for monitoring trends in your fluid health and preventing problems before they arise. However, tracking results over time for many pieces of equipment takes time and hassle.
As part of our testing and analysis services, Schroeder Industries is now offering a smart digital solution for detecting trends in the quality of your hydraulic oil, diesel fuel, process water, and more.
The Fluid Care Portal is a new, powerful digital tool for easily tracking the health of your equipment’s fluid as you test over time:
All your data is in one place, versus scattered over spreadsheets or various paper reports.
Easily monitor trends in fluid testing data over time, allowing you to detect and resolve contamination issues before they begin impacting your bottom line.
Monitor as many equipment assets as you need. Whatever the size of your operation, the Fluid Care Portal allows you to individually monitor the testing results for each piece of equipment.
Receive alerts when ISO Code, Water Content, or other parameters are exceeded. In the Fluid Care Portal, users can set target limit profiles for various parameters, creating customized criteria for your most critical components
Once a proper diesel, fluid or oil analysis has unlocked the source and quantity of contamination, filtration is the next step.
If you aren’t prepared for the upfront cost of purchasing filtration equipment, Schroeder Industries makes our state-of-the-art equipment available through our Rental Program and Filtration Management as a Service. Learn more about how these services can benefit your operation!
Schroeder Rental Equipment Program
Enjoy the benefits of Schroeder Industries’ exceptional filtration equipment without a large capital investment. Superior filtration extends oil life and increases machine reliability and energy efficiency.
With this turnkey service, Schroeder Industries will plan, execute, and manage your filtration strategy and filtration equipment, allowing you to focus on running your business with peace of mind!
Our fluid care experts can help you determine the right test kit for your needs and provide vital insight into the health of your fuel, process water, or hydraulic oil. Contact us today!
