Key Trends in the Hydraulic Industry

The hydraulic sector is in great transition, shifting significantly beyond the conventional idea of a source of brute force. The dominant news trends focus on the convergence of power density, intelligence, and environmental sustainability.

The following are the major trends and innovations shaping the hydraulics industry today:

1. Intelligence Integration: Smart Hydraulics and IoT

The biggest trend has been digitalising hydraulic systems, more firmly establishing the industry in the trends of Industry 4.0.

Smart hydraulics: Traditional hydraulics have smart components consisting of advanced sensors and controllers. These smart components monitor important parameters such as pressure, flow, temperature, and vibration in real-time.

Predictive Maintenance (PdM): Real-time data is now captured using the Internet of Things (IoT), enabling any system to predict component failure even before that point in time. This yields, shifting maintenance from reactive or scheduling to accurate just-in-time maintenance schedules that can reduce unplanned downtime and maintenance costs significantly.

AI and Data Analytics: Machine learning algorithms are rapidly being applied to hydraulic data that intelligently assess, and then autonomously adjust hydraulic systems' performance. This enables real-time optimization of power consumption, and efficiency based on load and operating conditions.

Remote Monitoring and Control: Operators now have the ability to monitor and troubleshoot hydraulic equipment from a centralized, off-site location, thus improving safety and response times, particularly with respect to geographically dispersed assets, such as construction or mining assets.

2. Electrification and Hybrid (Electro-Hydraulic) Systems

The pursuit of higher efficiency and lower emissions is a powerful trend driving the combination of hydraulic power coupled with electric controls. 

Electro-hydraulic (EH) combines the high power density of hydraulic cylinders with electric servo drives' precision, control, and energy efficiency. EH enables power to be utilized only when needed (Power-on-Demand), eliminating wasted energy during idle time. 

Mobile equipment hybridization: The market for electro-hydraulic is rapidly growing for off-highway (excavators, construction vehicles, etc.). These hybrid systems use accumulators that store energy similar to the regenerative braking technology on electric cars, releasing the energy instantly when a power burst is needed, ultimately providing terrific fuel and energy savings. 

The power density advantage: Electric drives challenge the industry, yet hydraulics remains by far the strongest option for applications requiring high force in small spaces. Electro-hydraulic systems will maintain this advantage while gaining the "smart" benefit of electric control.

3. Sustainability and Energy Efficiency

"Green Hydraulics" are becoming essential for innovation, driven by environmental regulations and increasing energy prices.

Energy-Efficient Components:

Variable Speed Drives (VSDs) on Pumps: VSDs allow the electric motor driving the hydraulic pump to match its speed precisely to real demand, reducing energy consumption dramatically if the system is not at full load.

Regenerative Systems: Innovative circuit designs and components are being developed to recapture energy that would otherwise be lost to heat or pressure drop.

Transition to Eco-Fluids: Manufacturers are slowly transitioning to the use of biodegradable hydraulic fluids (vegetable-based or synthetic esters) that have a lower impact on the environment if spilled or leaked.

Lightweighting: Advanced materials (composites, specialty alloys) are used to develop all components for structures to reduce the weight of the machine. This decrease in weight means a loss of power is inherent to moving the equipment, which translates into a direct reduction of fuel/energy consumption.

4. Advancements in Manufacturing and Components 

The foundational components of hydraulic systems are also experiencing advancements thanks to technology.
 
Advanced materials & coatings: New internal coatings and highly-engineered seals are reducing friction - a major source of energy loss and heat. This ultimately leads to better efficiency and increases the service life of the pumps, valves, and actuators.
 
3D printing (additive manufacturing): Additive manufacturing is being used for rapid prototyping of complex hydraulic manifolds and components. It allows for highly-optimized design with complex internal flow paths which previously could not be created through traditional machining to reduce pressure drop and improve overall performance.
 
Modular and integrated designs: The trend is going towards compact, highly integrated power units and modular valve systems to install, customize, and service power units and valve systems for configurable production purposes.