Sustainability and Reliability in Hydraulic Actuators

Hydraulic actuators—the workhorses of heavy machines—have long enjoyed a reputation for their exceptional power density, precision, and durability. From large construction equipment to high-speed manufacturing lines, hydraulic actuators convert fluid pressure to mechanical force and are indispensable for industrial and mobile applications.

However, in an age with increasing emphasis on environmental responsibility, the hydraulics industry is experiencing a shift. Sustainability and reliability, two concepts that are increasingly woven together, are now a more integrated part of the design and operation of every hydraulic actuator. 

The Sustainability Challenge in Hydraulics

Historically, hydraulic systems have been heavily dependent on mineral oil-based fluids and constant-drain power consumption, leading to environmental challenges. Leaking, waste energy, and disposal at the completion of life have initiated a transition to more sustainable practices. Fortunately, innovative practices are blending the gap, as actuators evolve into components that promote a more sustainable industry.

Important Elements of Sustainable Actuators:

Biodegradable Fluids: The transition away from petroleum-based oils toward biodegradable hydraulic fluids, often plant-based, is revolutionary. If the fluids leak or spill, they will break down naturally, representing a significantly lower risk to soil and water contamination than petroleum-based fluids.

Energy Efficient: New designs are addressing the inherent inefficiency of traditional throttle systems. Technologies such as variable speed drives (VSDs), load-sensing systems and regenerative circuits allow pumps to only deliver the flow and pressure that is required, greatly reducing energy use and emissions.

Leak Prevention: Leaks are not just a costly maintenance problem, they are an environmental hazard. New sealing technologies and precision machining are enabling strong, nearly leak-free systems that save fluid and protect the environment around the system.

Material Choice: Systems are being designed with lightweight, recyclable materials such as aluminum or advanced polymers. This reduces overall weight in machines (fuel savings in mobile applications) and contributes to a circular economy at end-of-life of the component.

Reliability: The Cornerstone of Sustainability

Reliability transcends uptime - it is the essence of sustainability. A reliable actuator that lasts longer, uses less energy, and requires fewer replacements inherently reduces its environmental impact.

Reliability via Intelligent Design and Maintenance:

From Time-Based to Condition-Based Maintenance (CBM): Changing from time-based, reactive maintenance to Condition-Based Maintenance (CBM) is a crucial step.

Smart Sensors embedded in actuators inspect critical parameters such as fluid quality (contamination, temperature, and water content), pressure, and vibration in real-time.

This information enables the practice of predictive maintenance, which is to service components just prior to their failure - minimizing the potential for catastrophic failures, reducing costly downtime and reduce the environmental impact of emergency repairs and unexpected replacements.

Robust Component Design: Reliability starts with design. Engineers are focused on:

Improved Surface Technologies for piston rods to resist wear and corrosion in tough environments, ultimately extending the life of seals.

Simplicity in systems where it makes sense; for example, the use of Electro-Hydraulic Actuators (EHAs) that combine the pump, motor, and reservoir into one self-contained unit, minimizing the complexity along with points of possible leaks in a central system.

Fluid Management—Nearly 60% of hydraulic systems fail due to contaminated fluid; therefore, monitoring fluid quality and filtration efficiency is critical to actuator life and reliability. If fluid quality is maintained, internal component wear will be reduced, and system life will be prolonged. 

The future is integrated

The most successful actuator systems in the future will have sustainability and reliability integrated into the design and system operation. 

By using biodegradable fluids, energy-efficient controls, and predictive maintenance/reliability technologies, hydraulic actuators not only remain an industry’s workhorse but also define the cleaner, smarter, and reliable way for a more sustainable world. Having sustainability and reliability integrated ensures while the actuator works hard it also will work smart and green.