pump-speed control, potentially reducing the need for some traditional pressure and flow control valves. Beyond energy efficiency, this shift is helping manufacturers reduce heat generation, lower noise levels, simplify hydraulic architectures and, in some cases, reduce cooling requirements and overall machine footprint. Those factors are becoming increasingly important as industrial users seek both operational savings and more sustainable machine designs. Applications with highly dynamic duty cycles, where machine demand fluctuates significantly throughout operation, are proving particularly well suited to the technology. Injection moulding, rubber processing, machine tools, presses, die casting, metal forming and food processing are among the strongest adoption sectors. “In injection moulding, for example, adoption may already be around 40 to 50%,” says Bittner. “These industries are highly sensitive to energy consumption because efficiency directly affects the cost of the finished product.” The nature of the duty cycle is critical. Systems with frequent idle periods, load variations, peaks and pauses offer the greatest opportunity for savings because the drive can continuously adapt output to actual demand. Bittner compares it to driving a car: “Most industrial applications are not running at full power all the time, just like most cars are not permanently driven at maximum speed,” he explains. “You stop at traffic lights, you accelerate, you slow down. Industrial machines behave similarly, and that creates the opportunity for variable speed systems to save energy.” More conservative sectors such as oil and gas and primary metals production have generally adopted the technology more slowly. Historically, many of these industries prioritised reliability and durability over efficiency gains, while low-cost or self-generated electricity reduced the urgency around energy consumption. However, that mindset is beginning to change as sustainability targets and INTEGRATED SYSTEMS 26 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk hydraulic applications, with systems designed to address both lower-dynamic and high-performance machine requirements across discrete and process manufacturing environments. According to the company, VSD architectures can deliver energy savings of up to 60%, depending on the application and duty cycle, by continuously adjusting motor and pump speed to match real-time machine demand rather than operating at constant speed. “Ultimately, you are no longer providing anything more than what is actually needed,” says Bittner. “That means no waste.” The Danfoss approach includes both induction motor and servo motor configurations. Induction motor systems are aimed at applications with lower dynamic and control req uirements, while servo-based systems are intended for machines requiring faster response, higher precision and closed-loop pressure and flow control. Bittner says one of the most significant advances is the integration of p/Q control functionality directly within the drive system itself, simplifying commissioning and reducing the level of PLC programming required from machine builders. The latest servo-based architectures also allow more precise The rise of variable speed hydraulics Rising energy costs, tighter sustainability targets and growing demand for smarter industrial equipment are accelerating the adoption of variable speed drive technology in hydraulics. H&P’s Aaron Blutstein spoke to Juraj Bittner, Product Manager, Industrial Solutions at Danfoss Power Solutions, about how changing attitudes towards efficiency, electrification and machine control are driving a new generation of hydraulic architectures. With energy prices remaining volatile and industrial sustainability targets tightening worldwide, hydraulic system design is undergoing one of its most significant transformations in decades. At the heart of that change is the growing adoption of variable speed drive (VSD) technology, a development increasingly reshaping how hydraulic machines are powered, controlled and optimised. For many years, traditional constantspeed hydraulic systems dominated industrial applications because of their robustness, simplicity and high-power density. But manufacturers are now under increasing pressure to improve energy efficiency, reduce operating costs, cut emissions and simplify machine architectures. In response, intelligent demand-driven hydraulic systems are moving steadily from specialist innovation to mainstream industrial strategy. According to Juraj Bittner, Product Manager, Industrial Solutions at Danfoss Power Solutions, the momentum behind VSD adoption is accelerating quickly, particularly in sectors where energy consumption has become a major operational concern. “People have become much more sensitive to energy efficiency,” Bittner explains. “Not necessarily because of the green movement, but simply for pragmatic reasons. Energy prices have become a real issue for industry.” Matching power to demand Traditional hydraulic systems typically operate at constant motor speed regardless of actual machine demand, with excess energy dissipated through throttling valves and pressure controls. Variable speed systems fundamentally change that model by dynamically adjusting motor and pump speed to deliver only the pressure and flow required during each stage of the duty cycle. The efficiency gains can be substantial. Recent product developments entering the market illustrate how quickly variable speed hydraulic technology is maturing. Danfoss, for example, has recently expanded its Vickers by Danfoss Variable Speed Drive portfolio for industrial Juraj Bittner
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