The FCT45 hydraulic transformer
The hydraulic equivalent of an electric power converter
How the FCT45 converts and controls hydraulic power
The FCT45 operates as the core component in next-generation CPR-systems, converting energy with minimal loss. This transformer enables hydraulic systems to work smarter, delivering more power while consuming less fuel and generating less heat.
Efficient Floating Cup Technology
Power is transformed via a single fixed displacement device that runs on the multi-piston floating cup principle. The floating cup principle is the only principle that allows operation from standstill, without high friction losses and wear.
Three ports
The transformer features three connections:
- one linked to the high pressure CPR-line
- one linked to the low pressure CPR-line
- one linked to the load
Rotating port plate
A BLDC-motor equipped with an integrated controller adjusts the rotational angle of the port plates between 0° and 80° to regulate power conversion.
Proven Floating Cup Technology
Converting and controlling hydraulic power
Continuously variable
Extremely efficient
No problems with close to zero speed operation
Exceptional dynamic performance
Robust and reliable
FCT45 transformer
Engineered for efficient and extremely dynamic power control.
Technical specifications
The FCT45 functions effectively throughout its broad pressure operating range of up to 35 MPa (5100 PSI), maintaining reliable output even in challenging off-road environments. Its design enables pressure amplification capabilities that can exceed the supply pressure by as much as 50%.
This transformer is capable of producing flow rates as high as 200 l/min (53 GPM). Its Floating Cup principle offers distinctive advantages, enabling smooth operation at near-zero speeds under substantial load pressure.
The large number of pistons of the Floating Cup Principle effectively minimize torque, flow, and pressure fluctuations. Such reduction is critical for accurate and efficient management of hydraulic loads.
The transformer also functions in reverse mode, making it possible to recover valuable energy. The recuperated energy can be used for other loads, or stored in the hydraulic accumulator of the Common Pressure Rail.
Hydraulic transformers regulate loads directly where they are applied. These transformers connect to the Common Pressure Rail, functioning similarly to how electrical devices are plugged into an electrical power grid.
The FCT45 incorporates Floating Cup Technology as its foundational design principle. Initially created for use in pumps and motors, this technology is now utilized in Bucher Hydraulics' AX-series pumps and motors.
The transformer's high efficiency and energy recovery capability substantially decrease environmental impact while enabling smaller batteries and lower (sustainable) fuel consumption. Additionally, minimal energy losses allow for more compact cooling systems.
Available in multiple configurations to match specific application requirements. INNAS works with partners to develop solutions tailored to unique operational demands and system constraints.
What others say
About the hydraulic transformer from INNAS
Hydraulic transformers can recover energy and, most importantly, adapt the pressure level of a given flow rate without introducing throttling losses. A prototype with good energy efficiency was presented in 1997 by modifying conventional axial-piston units. Further improvements resulted in the “floating cup” principle with a much larger number of pistons. This design reduces pressure pulsations and improves low-speed performance (a crucial characteristic for direct control of actuators) while enabling accessible manufacturing costs.
These 3-port devices are connected to the high-pressure power supply, the low-pressure line, and the linear actuator (digital valves allow piston extension or retraction). Transformers can, therefore, efficiently reduce the power supply’s pressure down to the load-induced value of the actuator.
Damiano Padovani, Pavlos Dimitriou, Tatiana Minav
Guangdong Technion-Israel Institute of Technology, China Tampere University, Finland
"The HT is the core component when it works with the CPR system. It absorbs the necessary hydraulic power and delivers this power at the required pressure and flow, similar to an electric transformer that transforms voltage and current. Aiming at meeting the performance requirements of the CPR system, Holland's INNAS Corporation manufactured the first HT prototype that integrated the two hydraulic pumps or motors in 1997."
Jihai Jiang & Zhongxun Liu
Harbin Institute of Technology, China
In hydraulic systems, hydraulic transformer is a particular power conversion unit, which is not only able to reduce the pressure but also to increase the pressure. It has the potentials to propose the new hydraulic hybrid architecture [4] and improve the energy efficiency of the fluid power system [5].
Junjie Zhou, Chongbo Jing, Wei Wu
Beijing Institute of Technology, China
"Compared to valve based control, hydraulic transformers do not rely on throttling to change pressure, and pressure can be boosted as well as bucked. Moreover, power can flow in both directions to allow energy regeneration. Thus they have significant potential to improve hydraulic system efficiencies."
Sangyoon Lee & Perry Y. Li
University of Minnesota, Minneapolis, MN, USA
"And there you have it - a hydraulic transformer in all its glory! Connect a pressure source to the top port (red), and you can regulate the pressure in the outlet port (yellow) by changing the timing angle of the valve plate, and thus altering the relation between the displacements of the pressure kidney and the outlet kidney. And note that all this happens without throttling losses! Also note that the rotation of the valve plate can be performed fast, which means that such a system can actually have a decent response time!
That's the principle in a nutshell - and you can build so much on it! If it gets inside your head - I bet you won't be able to sleep tonight!"
Sergiy Sydorenko
Insane Hydraulics
In 1997, Innas designed a new type of HT, which has three-port plate on the port plate innovatively. (…) The simplified structure of IHT is made more compact with higher efficiency and faster response. The appearance of IHT leads the direction of future development. Since then, global researches on HT are mainly based on the principle of IHT.
Wei Shen, Hamid Reza Karimi & Ruihan Zhao
University of Shanghai for Science and Technology, China Zhejiang University, China Politecnico di Milano, Italy
Ready to transform
Contact INNAS today to discuss technical specifications, partnership opportunities
Questions
Find answers about the FCT45 and how it performs in real applications.
Contact INNAS directly to discuss your application requirements and technical specifications. Our team provides detailed information, performance data, and support throughout the evaluation and implementation process.
No, only if this is beneficial for loss reduction or for control reasons. In for instance an excavator, the boom cylinder and the swing are good candidates to be controlled by a transformer, but valve control might still be a good option for the bucket cylinder.
The CPR-system with transformers fundamentally alters the system. In numerous instances, the engine can be substantially reduced in size, the variable displacement pump can be substituted with a simple and considerably more efficient fixed displacement pump, and the coolers will be noticeably smaller.
Fuel savings depend on your specific application and operating conditions. The FCT45 reduces consumption significantly through advanced power management and efficient energy conversion. Contact our team for detailed performance data relevant to your equipment.
The port plate controls the torque on the internal rotor, resulting in a change of rotor speed and load pressure. This controls in the end the hydraulic power to the load.
The FCT45 is a hydraulic transformer that converts energy with minimal loss. Unlike conventional systems, it delivers more power while consuming less fuel and generating less heat. The FCT45 is the key enabling technology for the next generation of CPR-systems.