Energy Optimization of a Hydraulic Servopump in Industry 5.0

Technological development represents one of the most important topics in the field of industrial automation. The evolution of Industry 4.0 is now well-established, and there is a gradual shift beyond traditional concepts of digitalization, paving the way for Industry 5.0. The latter aims to leverage technology to address new global challenges, focusing on the principles of environmental sustainability, customization, and social well-being. The first two points are essential to ensuring a sustainable future by minimizing energy and material waste. Social well-being is indispensable as it emphasizes enhancing human capabilities and improving workplace safety. This work aims to analyze the activities carried out during the internship at the company Trumpf. The subject of study is the TruBendCenter machine, designed to perform tangential bending of metal sheets. In line with the principles of Industry 5.0, the focus is on energy sustainability. To identify energy waste in the machine, consumption tests were conducted on all electrical axes. The hydraulic servo pump proved to be the most energy-intensive axis, accounting for 98% of consumption compared to the other electrical axes. This high consumption is caused by excessive pressure accumulation required to perform the bends. To address this issue, strategies and algorithms were developed to allow for a more precise and specific adjustment of the target pressure. This solution enables significant energy optimization, resulting in an overall reduction in machine consumption by up to 20%.