How automation is transforming fluid power

24 October, 2024

Integrating fluid power systems with automation technologies, while promising, brings its own set of challenges. Industry experts are now navigating the complexities of marrying the mechanical advantages of fluid power with the digital capabilities of automation. The results can be remarkable, but the journey from traditional systems to fully automated operations is far from straightforward.

At its core, fluid power has always been about harnessing the strength of pressurised fluids—whether air or hydraulic oil—to generate movement or force. Hydraulics, known for their ability to handle high loads and offer precise control, and pneumatics, prized for their speed and simplicity, both play vital roles in modern machinery. However, in an age dominated by data, the demands placed on these systems are changing. Today, it’s not enough for a system to simply work; it must also be smart, efficient, and adaptable.

Automation, in its simplest form, is about reducing human intervention in processes, allowing machines to operate independently and with minimal oversight. While this might seem straightforward in theory, applying it to fluid power systems brings a unique set of challenges. Hydraulics and pneumatics are inherently non-linear, subject to variations in pressure, temperature, and load, making precise control difficult. Additionally, while these systems have been relied upon for their raw power and reliability, their traditional designs are not naturally equipped for the demands of modern digital integration.

Automation in fluid power

The move towards automation in fluid power is largely driven by the need for greater efficiency. Energy consumption is a significant concern, particularly in hydraulics, where systems often run continuously, wasting energy when no work is being done. Automated systems, equipped with sensors and intelligent controllers, can mitigate this issue by managing the system’s operation based on real-time needs, reducing unnecessary power usage. This is particularly important in a world increasingly focused on sustainability. Energy-efficient solutions not only reduce costs but also contribute to a company’s environmental credentials.

Another key factor in the push towards automation is precision. In manufacturing environments, the need for consistent, repeatable processes is paramount. Fluid power systems, which have traditionally been valued for their ability to provide consistent force, are now being asked to do more. Automation allows for fine-tuned control that was previously difficult to achieve. For instance, in robotics, where hydraulic systems are often employed to handle heavy lifting, automation can ensure that movements are smooth and exact, improving both the quality and speed of production.

However, despite the clear advantages, integrating automation with fluid power systems is not without its difficulties. One of the primary challenges is system complexity. Modern automation relies on a sophisticated network of sensors controllers, and communication protocols to ensure that machinery operates seamlessly. For fluid power systems, this means developing ways to integrate digital components with mechanical ones. Hydraulics, in particular, can be tricky to automate due to their sensitivity to variables such as fluid temperature and pressure fluctuations. Controlling these systems with the precision required for automation demands advanced control algorithms and responsive sensors, which must be carefully calibrated to the specific needs of each application.

Moreover, the issue of reliability is paramount. Fluid power systems, especially in harsh environments, are subject to wear and tear. Hoses can leak, valves can stick, and contamination can reduce the efficiency of the entire system. When these systems are automated, any failure can cause a significant disruption to the entire operation. Thus, ensuring that these systems are properly maintained and that automated systems are equipped to detect and respond to potential issues before they escalate is critical. Predictive maintenance, enabled by sensors that monitor system health in real-time, is one potential solution. However, this adds further complexity to an already intricate system.

Then there is the issue of cost. While automation offers long-term savings in terms of energy efficiency and productivity, the initial investment in automating a fluid power system can be substantial. Retrofitting legacy systems to accommodate sensors, PLCs, and other automation technology is often expensive and technically demanding. For smaller companies or those operating in industries with tight margins, this can be a significant barrier to adoption.

The future

Yet, despite these challenges, the future of automation in fluid power remains bright. The increasing digitalisation of industries under the banner of Industry 4.0 is pushing all sectors to embrace smarter, more connected systems. Fluid power is no exception. The rise of IoT (Internet of Things) technology offers new possibilities for integrating fluid power systems with broader automated networks. With IoT, fluid power systems can communicate with other machines, feeding data into a centralised system that can monitor, analyse, and optimise performance in real-time. This level of connectivity enables a more holistic approach to automation, where the entire production process can be controlled from a single point.

As automation continues to evolve, so too will fluid power systems. The development of more energy-efficient components, smarter control systems, and better predictive maintenance technologies will all contribute to making fluid power systems not only more reliable but also more aligned with the needs of modern industry. Furthermore, advancements in artificial intelligence and machine learning may eventually enable fluid power systems to self-optimise, learning from their environment and adjusting their performance without human intervention.

The convergence of automation and fluid power represents both a challenge and an opportunity. While there are significant technical hurdles to overcome, the potential benefits in terms of efficiency, precision, and sustainability are too great to ignore.