The growing need for cybersecurity vigilance in electro-hydraulic systems

17 December, 2024

Electro-hydraulic systems represent one of the most significant advancements in industrial machinery in recent decades. They combine the power and precision of hydraulic technology with the flexibility and intelligence of electronics, enabling fine-grained control and operational efficiency in fields as diverse as construction, manufacturing, aerospace, and agriculture. However, as these systems evolve, they face a new kind of threat—cybersecurity vulnerabilities. What was once purely mechanical has now become a sophisticated blend of hardware and software, and with this convergence comes a range of security concerns that were nearly unthinkable in previous eras.

In a world increasingly interconnected through digital systems, the safety and security of electro-hydraulic systems are now pressing concerns. These systems are no longer isolated, analogue machines. Instead, they’re interconnected, often controlled remotely, and designed to share data with other systems in real time. This connectivity has led to enhanced productivity, real-time monitoring, and predictive maintenance capabilities that were previously unavailable. However, the same features that enhance these systems’ functionality also make them susceptible to cyberattacks. Security weaknesses within electro-hydraulic systems not only threaten operational reliability but also pose significant safety risks, as these systems frequently control heavy machinery or critical infrastructure.

One of the primary reasons electro-hydraulic systems are vulnerable to cyberattacks is their rapid integration into the Internet of Things (IoT) and the Industrial Internet of Things (IIoT). In order to achieve higher levels of automation and control, many electro-hydraulic systems are now equipped with sensors and communication interfaces that connect to centralised control systems or even cloud-based servers. Through these connections, operators can monitor performance, track maintenance needs, and adjust settings from remote locations. While these features bring operational efficiency, they also open doors for cyber threats. Often, the security protocols applied to these systems lag behind the pace of their technological advancement. Manufacturers and operators alike are sometimes focused on improving speed, precision, and efficiency without giving cybersecurity its due priority.

The consequences of ignoring cybersecurity within electro-hydraulic systems are far from hypothetical. In recent years, several high-profile incidents have demonstrated how vulnerable industrial machinery can be when connected to the internet without adequate security measures. In some cases, hackers have been able to gain control of critical infrastructure, including water treatment facilities, power grids, and transportation networks. These incidents serve as a wake-up call for industries that rely on connected electro-hydraulic systems. While these systems may not be the first targets of cyberattacks, they are certainly not immune to them. The risk is that, with minimal access, hackers could take control of electro-hydraulic systems to interfere with their operation, potentially causing physical damage to machinery, endangering workers, or disrupting entire supply chains.

At the heart of this issue is the fact that most electro-hydraulic systems were not designed with cybersecurity in mind. Many of these systems were developed in an era when industrial machines operated in relative isolation, with no expectation of remote access or internet connectivity. As a result, when companies integrate these systems into modern, connected infrastructures, they’re often left scrambling to retrofit cybersecurity features. This approach is not only inefficient but also creates vulnerabilities, as existing systems are seldom equipped to handle the layers of security needed to prevent cyberattacks. It’s somewhat like trying to add a lock to an open door, rather than having it built into the frame.

One major vulnerability stems from the communication protocols used in electro-hydraulic systems. Protocols such as Modbus, Ethernet/IP, and CANbus are common in industrial settings, allowing components to communicate with each other and with control systems. However, many of these protocols were developed without cybersecurity in mind, which means they often lack features like encryption and authentication that are crucial in today’s digital landscape. Consequently, a determined hacker could exploit these communication pathways to intercept data, alter commands, or even take control of machinery. For companies relying on electro-hydraulic systems to perform sensitive or hazardous tasks, the potential consequences of such an attack are considerable.

Cybersecurity vulnerabilities

Cybersecurity vulnerabilities within electro-hydraulic systems also extend beyond communication protocols. The human element—typically the weakest link in cybersecurity—plays a significant role here as well. Operators and maintenance staff may inadvertently create security gaps through practices such as using default passwords, neglecting software updates, or relying on outdated systems. Furthermore, as these systems require a blend of mechanical and software expertise, the individuals managing them may not always have specialised knowledge in cybersecurity. Training gaps can leave systems exposed to risks that could have otherwise been mitigated through better awareness and understanding.

The regulatory landscape adds another layer of complexity. Many industries that utilise electro-hydraulic systems are subject to strict regulations concerning operational safety and environmental impact, but cybersecurity standards have not always kept pace with the digital evolution of these systems. For example, safety standards governing hydraulic systems may dictate specifications for pressure limits or fail-safe mechanisms but may overlook cybersecurity requirements entirely. In the absence of mandatory cybersecurity guidelines, companies may find themselves unprepared to tackle emerging threats, especially in sectors where there’s a significant reliance on legacy systems. While newer standards, such as those from the International Electrotechnical Commission (IEC), are beginning to address cybersecurity in industrial automation, these standards are not yet universally adopted, and compliance can be inconsistent across different sectors and regions.

Addressing cybersecurity in electro-hydraulic systems will require a multifaceted approach. First, manufacturers of these systems must integrate cybersecurity measures from the design phase. Rather than treating cybersecurity as an add-on, it should be an integral part of the system architecture. This includes using secure communication protocols, building in mechanisms for regular software updates, and ensuring that authentication and encryption are core features rather than optional extras. By adopting a “security by design” approach, manufacturers can create systems that are inherently more resistant to cyberattacks.

Companies that rely on electro-hydraulic systems also have a responsibility to implement best practices for cybersecurity. This includes regular maintenance of both hardware and software, ensuring that all systems are updated with the latest security patches, and conducting routine vulnerability assessments. Additionally, companies should invest in cybersecurity training for their operators and technicians, ensuring that they are aware of the potential threats and know how to minimise risks. Just as safety training is a standard part of working with heavy machinery, cybersecurity awareness should be part of the operational culture within any company that uses connected industrial systems.

As electro-hydraulic systems continue to advance, the importance of cybersecurity cannot be overstated. These systems are transforming industries, providing unprecedented control, efficiency, and adaptability. Yet, without robust cybersecurity measures, their potential for improvement is accompanied by a corresponding risk. The integration of digital control into hydraulic systems brings significant operational benefits, but it also demands a commitment to vigilance and proactive protection against cyber threats. In an era where connectivity is both a tool and a target, the future of electro-hydraulic systems hinges not only on mechanical precision and electronic innovation but also on a strong foundation of cybersecurity