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Switching to Electric Power for Hydraulic Systems: Key Considerations

Posted on by WIT Team

Switching to Electric Power for Hydraulic Systems: Key Considerations

Switching to Electric Power for Hydraulic Systems results in many benefits and some challenges. Last year, Parker Hannifin’s Hydraulic Pump and Power Systems Division hosted a webinar for OEM Off-Highway readers, detailing the conversion process from internal combustion engine (ICE)-powered hydraulic systems to electrically powered hydraulic systems. Below is a summary of the core insights and considerations discussed.

1. Increased RPM: Speed and Control Advantages

One of the most impactful changes in switching hydraulic systems from ICE to electric power is the ability of electric motors—especially permanent magnet types—to operate at significantly higher RPMs than traditional ICE-powered systems. These motors can accelerate and decelerate quickly, and can be shut off when not in use, conserving energy.

However, higher speed isn’t the only factor. The entire hydraulic component system must be evaluated, as increased speeds can lead to:

  • Cavitation risks
  • Accelerated wear
  • Maintenance challenges

Proper system matching of the electric motor, hydraulic pump, and inverter is critical. Performance under unique operating conditions must be validated through comprehensive system testing to ensure component longevity and efficiency.

2. Downsizing Potential: Smaller Hydraulic Systems

Electric systems’ ability to operate at higher speeds allows for downsizing hydraulic components, which can lead to:

  • Reduced overall system footprint
  • Weight savings
  • Simplified integration compared to larger ICE systems

3. Noise Reduction: A Hidden Challenge

When the ICE is removed, hydraulic noise becomes more noticeable. In some systems, pumps or actuators may become the loudest elements. This requires:

  • Improved acoustic engineering
  • Selection of quieter hydraulic components

4. Cost and Total Cost of Ownership (TCO)

While initial investment in electric systems is typically higher, long-term energy savings and reduced maintenance can result in a lower total cost of ownership. OEMs should weigh:

  • Upfront hardware costs
  • Energy efficiency gains
  • Projected system lifespan and ROI

5. Robustness and Lifecycle Alignment

Electrically powered systems must be designed to meet or exceed the durability expectations of their ICE predecessors. This means:

  • Careful material and component selection
  • Lifecycle testing under real-world duty cycles

6. System Complexity and Customization

Electrification introduces new layers of complexity, such as:

  • Displacement control
  • Advanced cooling loops
  • Integration with digital control systems

OEMs must ensure that system architecture is well understood and properly engineered to handle these nuances.

7. Efficiency as a Core Design Metric

In ICE systems, hydraulic efficiency has always mattered—but in battery-powered electric systems, it’s critical. Improved efficiency leads to:

  • Smaller battery requirements
  • Longer runtime per charge
  • Greater reliability in off-highway applications

Comparing Hydraulic System Architectures: ICE vs. Electric

A. ICE Centralized Architecture

Overview:
Traditional ICE hydraulic systems use a single engine and pump to drive multiple work functions.

Pros:

  • Proven, familiar technology
  • Robust and widely supported
  • Economical components

Cons:

  • High idle requirements (e.g., ~2000 RPM)
  • Combined hydraulic and engine losses
  • Poor efficiency and high emissions
  • Regulatory pressure to phase out fossil fuels

B. Electrically Powered Centralized Architecture

Overview:
A centralized electric motor replaces the ICE, still powering multiple hydraulic functions via shared valves and circuits.

Pros:

  • Easier retrofit compared to decentralized
  • Leverages existing hydraulic hardware (cylinders, hoses, valves)
  • High-speed motors (0 to 8000 RPM)
  • Potential to decouple traction and work circuits

Cons:

  • Centralized inefficiencies remain (e.g., valve and pump losses)
  • Still requires complex cooling systems

Bottom Line: A solid transitional architecture for OEMs looking to electrify without starting from scratch.

C. Electrically Powered Decentralized Architecture

Overview:
Multiple electrohydraulic units are placed at points of use, each with its own motor and pump.

Pros:

  • Maximum efficiency and energy recovery
  • Lower line and component losses
  • Optimized power usage and control
  • Enhanced battery performance and longevity
  • Shut off unused functions to increase efficiency

Cons:

  • Greater initial system design complexity
  • Requires more hardware redesign and new control logic
  • Steeper learning curve for OEMs and technicians

Bottom Line: Offers the best long-term gains in efficiency, performance, and battery optimization.

Why Decentralized Systems Are the Future of Electro-Hydraulics

Switching to a decentralized architecture unlocks significant benefits:

  • Tailored power delivery to each function
  • Reduced non-value-added energy loss
  • Regenerative energy potential
  • Improved system runtime and battery size efficiency

For electric-powered mobile equipment, this approach provides the most scalable path forward.

Watch the Full Webinar

🎥 How To Take a Calculated Leap to an Electrified System with Electro-Hydraulic Pumps – Parker.com

Contact us to discuss designing and fabricating your custom hydraulic power unit!

WIT Team