DV Hydraulics designed and built a high-performance 4‑quadrant servo pump system for a 4,000‑ton hydroforming press. This installation was developed for a new production line installed alongside an existing, older line, following a specific request from Siemens. The goal was to achieve a drastic reduction in cycle time and energy consumption while significantly increasing system dynamics and efficiency. By implementing a 4‑quadrant servo pump system with extensive energy recovery, the press achieved exceptional performance improvements across all key parameters. Thanks to this advanced solution, the cycle time was reduced from 40 seconds to just 6.45 seconds, enabling a major increase in production capacity.

Key Performance Improvements:

• Cycle time reduced by 84 % from 40 s to 6.45 s

• Energy consumption per part reduced by 96% ( 5,560 kJ to 219.3 kJ )

• Average grid load reduced by 75 % from 139 kW to 34 kW.

• Pressure build-up speed increased by 150%. ( 400 bar/s to 1,000 bar/s )

• Up to 75% of the energy recovered during each cycle.

• Peak power of 304 kW.

Main Specifications of the Hydraulic System:

• Nominal operating pressure: 2,000 bar

• Design pressure: 2,500 bar

• Pressure build-up speed: 1,000 bar/s

• High-pressure medium: water

• Pilot system: hydraulic oil (250 bar)

• Power factor: Cos φ = 1

• Fully regenerative 4‑quadrant servo pump drive system

This system demonstrates how modern servo-hydraulic technology can transform existing hydroforming processes into highly efficient, dynamic, and sustainable production solutions. At DV Hydraulics, we specialize in energy-efficient hydraulic systems that deliver maximum performance with minimal energy consumption. Our servo pump solutions enable energy recovery, reduced grid loading, and extremely short cycle times. A servo pump system can be applied to many types of installations. Do you have a process where energy efficiency and performance are critical? Contact us!