www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2025 27 other automation devices. A proportional valve or digital pump controller can be connected directly to a machine’s central PLC, with real-time data exchanged across the same industrial network that handles robotic motion or quality control sensors. This interoperability has opened new design possibilities. For example, compact self-contained hydraulic actuators can now be deployed as plug-and-play units, complete with integrated sensors, controllers, and communication ports. They can be mounted directly on robotic frames or mobile machinery without the need for a central hydraulic power unit or extensive pipework. This modularity makes it easier to incorporate hydraulic motion where high forces are needed without compromising system flexibility or ease of installation. Maintenance and skills As systems become more integrated, the skills needed to maintain them are changing. Where once a hydraulic engineer might have focused primarily on fluid dynamics and mechanical service, today’s technicians need to understand software parameters, network communication, and diagnostic interfaces. This shift has prompted a wave of new training initiatives and collaboration between manufacturers, automation specialists, and training providers. Service tools are also evolving. Portable diagnostic devices and mobile apps now allow maintenance teams to visualise hydraulic performance in real time, compare it to baseline data, and identify issues before they escalate. The move towards predictive maintenance — supported by embedded sensors and cloud-based monitoring — has also reduced the need for reactive repairs. Instead of waiting for pressure drops or leaks to signal a problem, systems can automatically flag when filters need replacing or when pump efficiency begins to fall. For manufacturers operating round-theclock automation lines, that can make the difference between planned downtime and an expensive production halt. Balancing hydraulics and electrics One of the most interesting developments in recent years has been the shift towards hybrid actuation — systems that combine hydraulic and electric technologies to deliver the most appropriate performance for each task. In a robotic press, for instance, hydraulics might handle the high-force stage of a cycle, while electric drives manage positioning and light-load movements. This hybrid approach delivers efficiency, control, and compactness, while ensuring the system remains costeffective and durable. Hydraulic manufacturers are responding by developing electro-hydraulic servo drives that provide the control and feedback of electric systems with the muscle of hydraulics. These drives are increasingly used in mobile robotics, automated construction machinery, and even collaborative robots for heavyduty industrial use. The end goal isn’t to replace one technology with another but to design systems that exploit each technology’s strengths in harmony. A practical path forward The evolution of hydraulics within automation isn’t about revolution but adaptation. The underlying principles of fluid power remain the same, but the way they are controlled, monitored, and maintained continues to advance. The focus for most manufacturers now is integration — ensuring that hydraulic systems operate as part of an intelligent, interconnected network rather than as isolated components. The path forward is pragmatic. It’s about understanding where hydraulics add unique value and then using modern control technologies to unlock that potential. With the right mix of digital integration, training, and system design, hydraulics can continue to underpin automation with the reliability and power they’ve always offered — now enhanced by precision, efficiency, and connectivity. As robotics become more capable and automation more widespread, the demand for hydraulic systems that can work in harmony with digital control will only grow. Those companies that bridge the gap between traditional engineering and modern automation will be best placed to deliver the adaptable, efficient, and data-driven systems that industry increasingly depends on.
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