INTEGRATED SYSTEMS 28 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk The integration of electro-hydraulic systems depends heavily on the degree of compatibility between their electrical and hydraulic elements. Although these systems have become a common feature of modern industrial and mobile equipment, the task of ensuring that components from two distinct domains work together in a predictable manner is still one of the most significant engineering challenges. Electrical subsystems operate through signals, sensors and controllers that function within tightly defined ranges of voltage, current and frequency. Hydraulic subsystems operate through fluid power, pressure and flow, all of which are influenced by a broad set of mechanical and environmental variables. Bridging these two environments requires careful attention to the underlying physics as well as to the behaviour of the components under real operating conditions. A fundamental issue is the nature of the signals that pass between the electronic controller and the hydraulic actuator or valve. Electrical signals are precise and usually linear within their operating range, while hydraulic responses are often nonlinear and influenced by fluid compressibility, valve dynamics and load changes. If a controller is developed without acknowledging these characteristics, the response of the hydraulic component may not correspond accurately to the command. This can be seen in the simple case of a proportional valve, where the relationship between the input signal and the resulting flow or pressure is not always uniform. Without appropriate compensation, the controller may issue signals that cause overshoot, sluggish motion or oscillation. Sensor compatibility presents another layer of complexity. Modern electro-hydraulic systems rely on a range of sensors, including pressure transducers, flow meters and position encoders. Each of these produces a specific type of signal that must be interpreted correctly by the control system. If the sensor range does not match the expected input of the controller, data can be lost or distorted. Even when ranges match, differences in resolution, sampling rates or noise tolerance can introduce inaccuracies. These issues become pronounced in systems that require high levels of precision, such as those used in automated manufacturing equipment or in aerospace applications where even small errors in feedback can affect performance. Communication protocols Communication protocols also influence the level of compatibility between electrical and hydraulic components. Many controllers now use digital communication networks, such as CAN or industrial Ethernet, to transmit signals and collect feedback. Hydraulic valves and actuators may be supplied with integrated electronics that conform to one of these protocols, but not all manufacturers adopt the same standards. As a result, engineers must ensure that devices can not only exchange information but do so in a timely and reliable manner. A delay of only a few milliseconds may not matter in simple applications, Achieving true compatibility in electro-hydraulic systems Electro-hydraulic systems rely on precise interaction between electrical controls and hydraulic components. Ensuring full compatibility is essential for stable performance, accurate response and long-term reliability across varied industrial applications. H&P reports.
RkJQdWJsaXNoZXIy MjQ0NzM=