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.