SPECIAL REPORTS 40 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Hydraulic and pneumatic systems are valued for their ability to deliver force, speed and repeatable performance. Yet the very qualities that have made them so central to industrial life have also highlighted their shortcomings. Hydraulic fluid leakage, air pressure losses and uneven wear can create inefficiencies that are not always visible until they interrupt production. Traditional maintenance regimes, based on fixed intervals or reactive repairs, often lead to either wasted resources or costly downtime. It is in this space that digital monitoring of actuators has begun to demonstrate its value. The principle is straightforward. Sensors placed within or around actuators record real-time data on variables such as pressure, temperature, vibration and flow. That information can then be fed into a central control system, analysed, and used to trigger maintenance alerts before problems become critical. In some cases, it can also allow systems to adjust operating parameters dynamically, compensating for changing conditions and maintaining output quality. This shift moves actuators from being passive components to active participants in an intelligent network. The promise is not only fewer breakdowns, but also more consistent performance and lower total cost of ownership. For sectors where reliability is paramount, this development is more than a convenience. Energy generation, transport infrastructure and heavy manufacturing all face significant costs when equipment fails. A production line halted for hours can mean lost contracts, penalties and reputational damage. In energy or transport, the risks are not just financial but also safety related. Being able to predict the early stages of seal wear in a hydraulic actuator or detect unusual vibration in a pneumatic cylinder could be the difference between a planned service stop and an unplanned outage. Yet there are barriers to overcome before such systems become the norm. One of the most immediate is cost. The investment required to install sensor networks, upgrade controllers and train staff is not trivial. For large multinationals, these are capital projects that can be justified through long-term savings. For smaller firms, particularly those operating on thin margins, the equation is more difficult. If an actuator has historically been replaced every few years at modest expense, convincing a business owner to invest in a fully instrumented alternative may be challenging. Demonstrating clear, quantifiable return on investment is essential. Harsh operating environments There are also technical considerations. Harsh operating environments raise questions about the resilience of sensors and communication links. In many plants, electromagnetic interference, dust, vibration and temperature extremes are part of daily life. Monitoring systems must be robust enough to withstand those conditions without becoming another point of failure. Cybersecurity is another factor. As actuators become part of wider digital networks, they introduce potential vulnerabilities. Protecting operational technology from malicious interference will require ongoing attention, especially as remote access becomes more common. Perhaps the most subtle challenge lies in people. Engineers and maintenance The growing role of smart actuators in UK industry The discussion around actuators in hydraulics and pneumatics is increasingly shaped by automation and digital monitoring. For many companies in the UK, the question is no longer whether to adopt these technologies but how to implement them in a way that is proportionate, reliable and commercially viable. This reflects a wider industrial reality: pressure on margins, energy costs and compliance obligations is growing, and every part of the production chain is being examined for potential efficiencies. H&P reports.
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