www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2025 29 yet it can cause difficulties in synchronised or high-speed operations. Environmental conditions further complicate compatibility. Electrical components typically require protection from moisture, vibration and temperature extremes. Hydraulic components, by contrast, are often exposed to variations in temperature and an environment where oil leakage, dust and contamination are difficult to avoid. When electrical equipment is placed near hydraulic machinery, it must be selected or protected in a way that prevents fluid ingress or thermal stress from affecting its performance. A solenoid or controller that overheats due to proximity to a hydraulic pump may produce erratic signals or fail altogether. Engineers therefore need to select housings, cable materials and connector types that maintain integrity under the expected conditions. Power level compatibility is another important consideration. Electrical components operate within defined voltage and current limits. If a valve coil or sensor is supplied with inappropriate power, its performance deteriorates or the component becomes damaged. On the hydraulic side, actuators and valves must be matched to the pressure and flow characteristics of the system. If a controller is designed to operate a particular valve but the hydraulic circuit supplies significantly higher or lower pressure than the valve is rated for, the control behaviour becomes unpredictable. It is not unusual for a component to function correctly under test conditions but behave differently once installed, due to changes in power supply stability or hydraulic transient loads that were not accounted for in the design. Software integration Software integration is also central to achieving compatibility. In modern systems, electronic control units are configured through software that interprets feedback, executes control algorithms and issues commands. The behaviour of hydraulic components must be represented accurately within this software, which often requires parameter settings that reflect the true characteristics of the hydraulic hardware. These parameters may include valve opening curves, actuator friction levels, deadband regions or response times. If the software contains incorrect assumptions, the system may respond slowly or behave inconsistently. Achieving an accurate representation usually involves collaboration between electrical and hydraulic specialists, supported by testing under real operating conditions. In some cases, compatibility issues arise not from the components themselves but from differences in engineering practice between the electrical and hydraulic disciplines. Electrical engineering often prioritises precision, modularity and adherence to strict standards. Hydraulic engineering frequently involves empirical knowledge and tolerance for variation due to the nature of fluid power. When teams from these disciplines work independently, mismatches can appear in design documentation, component selection or testing methods. A successful integration process therefore requires clear communication and joint evaluation of system requirements. The mechanical interface between hydraulic and electrical components also plays a role. Actuators may require specific mounting arrangements that determine the alignment of sensors or the routing of cables. A poorly designed interface may expose cables to abrasion or position sensors in locations where they cannot operate reliably. Moreover, the presence of vibration from hydraulic pumps or actuators can affect delicate electronic components. This requires attention during both design and installation, including the use of appropriate damping materials, secure cable routing and properly rated connectors. Long-term maintenance Another aspect of compatibility involves long-term maintenance and replacement. Electrical components can often be replaced individually, while hydraulic components may require matching sets or recalibration of the entire system when one part is changed. If the system uses proprietary electronics or hydraulic parts with unique characteristics, the availability of replacements becomes a concern. To avoid future compatibility issues, many organisations aim to standardise component choices across systems, but this is not always possible when equipment is sourced from multiple suppliers. Maintaining comprehensive documentation of the system’s electrical and hydraulic characteristics is therefore essential. Even when compatibility appears satisfactory at the time of installation, the behaviour of an electro-hydraulic system can change over time. Hydraulic fluids degrade, seals wear, and valves accumulate contamination. These changes influence response times and accuracy. Electronic components may also drift or become less stable with age. A control system that performed reliably when new may start to exhibit irregularities as the hydraulic side evolves. Engineers need to plan for periodic testing and recalibration to ensure that compatibility is maintained throughout the system’s operational life. Overall, the issue of compatibility between electrical and hydraulic components is central to achieving predictable, safe and efficient operation in electro-hydraulic systems. It requires thoughtful design, careful selection of components and ongoing collaboration between specialists in both fields. While technology has advanced to make integration more straightforward than in the past, it still demands an understanding of the distinct behaviours of electrical signals and hydraulic power, and of the ways these two domains affect one another under real working conditions.
RkJQdWJsaXNoZXIy MjQ0NzM=