Smart Flow: The IoT Revolution in Hydraulic Valves

The industrial machinery industry is becoming increasingly intelligent, and hydraulic valves are no different. Traditional hydraulics are often robust, reliable, and strong as devices, but the performance data can often be treated as a black box. Internet of Things (IoT) technology is now changing hydraulic valves from static, critical components to intelligent, communicative components. IoT implementation in hydraulic valves is often referred to as "smart hydraulics" and is helping to develop an age of unprecedented efficiency, reliability, and accuracy.

What is IoT in Hydraulic Valves?

Applying IoT to hydraulic valves primarily means the valves have been equipped with sensors, a microprocessor, and ability to communicate.

Sensors: The sensors are embedded within the valve (or near) to measure variables such as pressure, temperature, flow rate, and valve spool position.

Microprocessor/Edge Device: The microprocessor is a small computer that processes the "raw" model sensor data locally on at the "edge". It can do basic analysis and filtering of the model data.

Connectivity: The data can then be transmitted wirelessly (Wi-Fi, Bluetooth, or cellular) to a central platform, cloud storage, or SCADA system for processing, advanced analysis, and visualization.

The purpose of this is allow some sort of continuous monitoring of the health and performance of hydraulic valve; for example, a valve can go from a passive component to active data source.

Advantages of Smart Hydraulic Valves 

There are clear benefits realized across a number of industries, manufacturing, construction, agriculture, mining, etc. when installing smart hydraulic valves. 

1. Predictive Maintenance (PdM) 

This is undoubtedly one of the biggest changes for the better. Rather than doing maintenance on a time-based schedule, or waiting for something to fail, IoT enabled valves will provide a condition-based reading on service. 

Early Detected Anomalies: Significant and sudden increases in temperature and pressure spikes are indicators that an issue may develop, such as wear on the seal, internal leaks, and even a sticking spool before a failure occurs. 

Reduced Downtime: Since your maintenance can be generated by the actual state, you can schedule your maintenance as needed, rather than prematurely or reactively, yielding far fewer unexpected machine failures and subsequently far less downtime. 
 
2. Performance and energy efficiency 

The data provided by smart valves can also add value by enabling systems to operate in a more efficient manner. 

Flow and Pressure Control: Data can help monitor the systems in real-time to maintain performance levels, and even make necessary adjustments remotely when optimal conditions are not being achieved. 

Energy Savings: Monitoring the flow and pressure can identify inefficiencies like excess pressure drop and overloading the pump can lead to unnecessary energy usage.

3. Enhanced Safety

Smart valves help maintain a safe working environment by continuously monitoring operational parameters. 

Overload Protection: Being notified right away for high pressure or temperature encourages the early prevention of catastrophic system failures, damage to components, and potential accidents.      

Remote Monitoring: Workers can evaluate the status and health of equipment in hazardous or remote areas, without needing to be present near the equipment or component.      

4. Improved Diagnostics and Troubleshooting

When fault is experienced, the significant quantity of historical and real-time data compiled by the IoT system increases the efficiency and quality of troubleshooting. Finding the exact failure of the electrical component or fault in operation becomes a matter of data analysis and not guesswork.     

The Future is Flowing Smartly

The IoT with hydraulic valves is more than just a new technology but is a fundamental transition to Industry 4.0. Utilizing data from these critical components allows the move from reactive maintenance to proactive asset management while unlocking higher efficiencies, greater sustainability, and competitive advantage.    

If your industrial operation uses hydraulic power, now is the time to look into how smart flow can alter your maintenance efforts and bottom line. The future of fluid power is connected, intelligent, and optimized!