Improvement the Global Energy Efficiency of Hydraulic Systems of Technological Equipment

This paper investigates multi-scale power losses and global energy-efficiency optimization in process machinery hydraulic systems. Power-loss mechanisms are analyzed at three levels: micro (components), meso (circuits), and macro (system), and a quantitative model accounting for their interactions is developed. A global energy-efficiency model is established, and a collaborative control strategy based on an improved adaptive genetic algorithm (IAGA) is proposed to optimize energy consumption and dynamic performance. Simulation and experimental results confirm that hydraulic pump volumetric losses, control valve throttling losses, and circuit coupling losses account for over 75% of total power losses. The proposed strategy improves system energy efficiency by 12%–18% and reduces dynamic response overshoot by more than 60%. The results provide a theoretical and practical basis for energy-efficient hydraulic system design and control.