HYDRAULICS 24 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk IoT-enabled hydraulic flow monitors expedite development of leading-edge farm machinery Kuhn North America (Kuhn), a leading manufacturer of agricultural and industrial equipment, is leveraging the benefits of Webtec CTA series hydraulic system flow monitors to expedite the development journey and time-to-market of its latest three-head Merger. Thanks to the adoption of three IoT-enabled CTA units on each prototype, Kuhn is able to identify potential issues remotely. Several prototype Mergers are currently undergoing real-world tests at pilot customers across the USA ahead of production. Kuhn, headquartered in Brodhead, Wisconsin, specialises in machinery that enhances the efficiency and productivity of farming operations. The latest development project at the 500-employee Midwest Distribution Centre and Manufacturing Facility of Kuhn in Brodhead is a new three-head Merger that aims to maximise hay harvesting efficiency. With user-friendly controls and robust construction, the Merger will offer an ideal solution for farmers seeking to enhance productivity and achieve consistent, high-quality results. The need to continue innovating, even in a sector that extends back to dawn of civilisation, is paramount. Kuhn faces a range of strategic and operational challenges driven by shifts in technology, global markets, sustainability demands, and workforce dynamics. These challenges are both sector-specific and company-specific. For example, the current trend of farm expansion is leading to higher capacity demands, meaning Kuhn must design equipment with greater efficiency and durability. Farmers also increasingly expect smart, connected technologies without compromising ease-of-use. Skilled labour shortages, meanwhile, ensure Kuhn must offer more manpower-saving automation. And of course, sustainability and compliance with environmental regulations hold further influence over newly developed solutions. To remain cost-competitive, it is essential that Kuhn maintains its strong investment in innovation without inflating costs, an ethos applied effectively to its new Merger. A carefully managed prototype phase is essential in any new product development process, which is why the company turned to Webtec for assistance in its latest project. A customer of Webtec since 2010, Kuhn invested in multiple sets of Webtec CTA heavy-duty hydraulic flow monitors in December 2024. The units were acquired in two sizes (16 and 40 gpm) to suit different machines from Webtec’s authorised regional distributor FSC (Fluid System Components in WI). By February 2025, three CTA flow monitors were fitted to each prototype of the 42 ft wide Merger, which is driven by a triple 12 gpm hydraulic gear pump running at up to 3500 psi. The Webtec CTA units, which have a very high protection against dust, moisture and vibration (to IP6K9K and SAE J1455 standards), monitor hydraulic pressure line flows as the prototypes undertake real harvesting processes for a whole season at pilot customers across the USA. With the CTA compact turbine flow monitors in place, Kuhn engineers are able to identify any potential issues and make design adjustments prior to production. Key here is the CTA’s SAE J1939 CANbus interface for monitoring and transmitting oil flow and temperature data (a 4-20 mA analogue output is also now available for flow reporting). The industry standardised J1939 communication protocol for heavy-duty vehicles provides a common language for electronic control units (ECUs) to communicate with one another. For this project Webtec provided assistance in reprogramming PGN’s (Parameter Group Numbers) where multiple monitors were installed on the same BUS. J1939 messages are identified by 18-bit Parameter Group Numbers (PGNs), so reprogramming was necessary to assign a different PGN to each of the three CTA’s used in a set. If required, customers can also reprogramme CTA units in the field using an off-the-shelf tool. Remote monitoring With Webtec’s CTA units now connected to the CAN-BUS, the Kuhn team can monitor its Merger prototypes wherever Kuhn North America is using Webtec CTA IoT-enabled hydraulic flow monitors to accelerate the development of its new three-head Merger. By capturing real-time flow and temperature data during field trials, engineers can identify issues remotely, reduce travel, shorten development cycles and deliver more efficient, reliable farm machinery to customers.
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