INTEGRATED SYSTEMS 26 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk Hydraulic systems have been part of automated manufacturing for as long as automation itself. But as robotics and digital control continue to reshape production lines, engineers are rethinking how hydraulics fit into systems that now depend as much on data and software as they do on pressure and flow. In many applications, hydraulics remain the best option when serious force is needed in a compact footprint. Electric actuators can’t always match that power density, especially in heavy forming, pressing, or moulding work. The focus today isn’t on replacing hydraulics with something new, but on making them work more intelligently alongside robotic control systems and automation software. As automation systems evolve, the challenge isn’t replacing hydraulics but modernising them. Engineers and system designers are now exploring how hydraulics can integrate seamlessly with robotics and control technologies to deliver the best of both worlds — force and finesse. Smarter hydraulics for smarter automation The rise of robotics and Industry 4.0 has shifted expectations around how every part of a system should communicate and adapt. Traditional hydraulic systems, once largely mechanical and manual, are now being equipped with sensors, digital controllers, and advanced feedback mechanisms. The result is a new generation of “smart hydraulics” capable of matching the responsiveness of electric drives while retaining their superior power density. Modern electro-hydraulic actuators can be controlled with remarkable precision through proportional and servo valves, allowing for fine motion control that was once considered the preserve of electric systems. When linked to programmable logic controllers (PLCs) or industrial PCs, these systems can operate as part of wider automation networks, continuously feeding back data on position, pressure, temperature, and flow. That information can then be analysed to improve performance, predict wear, and schedule maintenance before downtime occurs. This data-driven approach has been a game changer for industries that depend on hydraulic motion. For example, in metal forming or pressing operations, predictive control now allows a press to adjust its force dynamically during each stroke, improving accuracy and reducing material waste. In automated handling or robotics applications, closed-loop hydraulic control can deliver smooth, repeatable motion even under heavy loads - something electric drives can struggle to match without substantial cost or bulk. Efficiency and energy recovery Another key area of development lies in energy efficiency. Historically, hydraulic systems have been criticised for their energy use — particularly in systems that rely on constant-speed pumps. However, the introduction of variable-speed drives, efficient pump control, and energy recovery circuits has transformed the picture. By matching pump speed to system demand, energy can be saved during idle periods without compromising performance. In some advanced systems, regenerative braking or accumulatorbased recovery allows energy from deceleration to be stored and reused within the same cycle. This not only reduces energy costs but also helps manufacturers meet tightening sustainability targets. In integrated robotic environments, where multiple actuators operate in sequence, these improvements can be significant. Coordinating energy flow between actuators and controllers helps balance system load and smooth power demand across the production line. It’s an approach that mirrors the energy efficiency strategies already used in electric drives, bringing hydraulics in line with wider automation goals. Seamless integration and control A key challenge for engineers integrating hydraulics into robotic or automated systems has always been control. Early hydraulic systems often required separate control hardware and bespoke wiring. Today, however, integration is much simpler. Thanks to advances in electro-hydraulic modules and open communication standards such as EtherCAT and IO-Link, hydraulic components can now “speak the same language” as Hydraulics continue to play a vital role in automation, delivering the force and precision required for robotics. As systems become more digital and connected, engineers are integrating smart, sensor-driven hydraulics with advanced control technologies to improve efficiency, reliability, and responsiveness across automated manufacturing environments. H&P reports. The evolving role of hydraulics in automation
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