HYDRAULICS In hydraulic engineering, pressure and flow often dominate discussion, yet thermal management plays an equally influential role in determining system efficiency and operational life. As hydraulic systems become smaller and more powerful, engineers are placing increasing emphasis on managing the heat generated during operation. Thermal load in hydraulic circuits arises from fluid friction, component inefficiencies and pressure losses. When this heat is not effectively dissipated, fluid degradation accelerates, lubrication becomes less effective and components such as seals, hoses, pumps and valves experience higher rates of wear. Even moderate increases in temperature can affect energy consumption and undermine long-term reliability, making controlled operating temperatures essential. Heat exchangers Heat exchangers provide the primary means of managing this thermal load. Air-cooled units are widely used in both mobile and industrial settings, particularly where water is unavailable or unsuitable. Their compact design and ease of installation make them a practical choice across a broad range of applications. Water-cooled heat exchangers, offering higher thermal efficiency, tend to be adopted in environments with a stable water supply and more stringent cooling requirements. Manufacturers such as Emmegi Heat Exchangers UK continue to refine exchanger design to balance durability, performance and ease of integration with increasingly complex hydraulic systems. Selecting an appropriate cooling solution requires consideration of the system’s fluid characteristics, its environmental conditions, available installation space and the desired operating temperature range. Incorrect sizing or selection can restrict performance or raise energy use, prompting many engineers to incorporate thermal planning earlier in the design process to ensure a suitable match between system and cooling equipment. The impact of appropriate thermal management is evident in operational settings. In one recent case, a customer of Emmegi using heavy-duty machinery in a high-temperature environment reported recurring hydraulic failures linked to insufficient heat dissipation. After replacing the existing unit with an Emmegi air–oil heat exchanger designed to improve airflow and fin efficiency, the operator recorded a 40% reduction in downtime and a significant increase in hydraulic fluid lifespan. This example 16 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk The importance of thermal management in hydraulic systems Thermal management is increasingly central to hydraulic system performance as higher power densities raise operating temperatures. Effective cooling safeguards component life, improves efficiency and supports reliability across demanding applications today. H&P reports. illustrates how targeted cooling solutions can address persistent reliability issues. Heat control As electrification, automation and compact system architectures continue to influence the fluid power sector, thermal management is expected to play an even more critical role. Developments in compact exchanger design, embedded sensor technologies and predictive maintenance are already shaping a more data-driven approach to heat control. Thermal management is now recognised not merely as a measure to prevent overheating, but as a determinant of hydraulic system performance, efficiency and longevity. As industry demands evolve, effective temperature control is likely to become an increasingly central component of system design and engineering practice. For further information please visit: www.emmegi.co.uk
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