Electrified hydraulic power unit from Hydraulic Controls Inc.

The systems engineering team at Hydraulic Controls Inc. (HCI) often builds a one-of-a-kind machine as a way to showcase what they can do for customers. The team has developed an electrified hydraulic power unit (eHPU) for mobile and stationary hydraulic applications where reduced noise, zero point-of-use emissions, and controllability are desired. Far from a one-off, the eHPU will be available from HCI to customers nationwide.

“This system used to run on a gasoline engine and we electrified it,” said Happy Singh Randhawa, Systems Division manager, HCI. “It runs on batteries so it’s really quiet. Operators can adjust pressure and flow through the touchscreen interface, while the system’s control software optimizes hydraulic performance based on operating conditions. The result is a user-friendly platform that can be adapted to a wide range of applications. Flow, pressure, battery status, and system operating data are available through the display, allowing operators to monitor performance and make informed decisions in real time.

“There is a misconception around engines that more noise is going to be more powerful. There is power with the noise, yes, but there is also the loss to heat. Because battery energy is a limited resource, the system was designed with efficiency as a primary objective. Software controls help optimize hydraulic output while maximizing battery runtime.”

A top-down view into the inner workings of HCI’s eHPU. (Photo: Chad Elmore)

Battery pack expertise

A Concord, Calif.-based hydraulics, pneumatics and electronic component distributor that has been in business for more than 60 years, HCI signed with Briggs & Stratton in 2022 to handle its Vanguard lithium-ion battery packs. The new eHPU uses Vanguard’s 48-volt swappable battery packs. HCI offers three different variants with batteries from 1.5 to 7 kWh.

Work on HCI’s engine-less power unit required two years of development, an exercise that resulted in a saleable product and also helped get HCI’s engineering teams well-versed on designing electrically driven equipment. The project expanded HCI’s expertise in battery integration, software controls and advanced hydraulic system design, which it said will create new opportunities to support customers pursuing electrified equipment solutions.

Product development goals

HCI’s goal was to develop a hydraulic power unit with 5,000 psi and an 8 gpm flow rate. Those specifications limited the component selection, said Randhawa. Power from the Vanguard lithium-ion battery system drives a Hydac electric motor coupled to a Oilgear hydraulic pump package incorporating pressure control and torque-limiting features designed to protect system components and optimize performance The hydraulic reservoir is a rotomolded unit from Schroeder Industries.

HCI’s new eHPU. (Photo: Chad Elmore)

“We are seeing significant interest from customers looking to operate hydraulic tools in indoor or noise-sensitive environments where traditional engine-driven units may not be practical. The eHPU enables no exhaust emissions at the point of use while also reducing operating noise,” said Randhawa. “Where they used to be running outside the building and run hoses to the worksite, now you can run zero emissions inside the building. It can also be used as a backup unit.”

The eHPUs are designed and builtin HCI’s Stockton, Calif., location.