Sustainability and Digital Transformation in Hydraulic Systems: Hidroman Applications
Sustainability and Digital Transformation in Hydraulic Systems: Hidroman Applications
Foreword
We live in an age where the world is rapidly digitalizing, energy resources are scarce and environmental awareness is increasing. In this period, when we are experiencing the fourth and fifth phases of the industrial revolutions, it has become imperative for industrial production to focus not only on efficiency but also on its harmony with nature.
This report has been written with this understanding; It examines the technical infrastructure and digital transformation requirements required to ensure sustainability in industrial hydraulic systems. It is aimed to be a resource that professionals working in the industry for many years and new generation engineers can take as a reference.
Especially through the systems developed by Hidroman; The energy consumption of test machines, the effect of filtration units on liquid health, and the role of digital surveillance infrastructures in extending life are revealed in detail. This study is not just a technical analysis; It is also a vision of industrial policies that are environmentally sensitive.
Summary
In this scientific report, testing, filtration and digitalization applications required to ensure sustainability in industrial hydraulic systems are analyzed. In particular, solutions compatible with biodegradable oils, carbon footprint reduction, Industry 4.0 and 5.0 infrastructures are emphasized; With the test machines, filtration systems and digital monitoring solutions developed by Hidroman, how these goals are achieved is technically presented.
- Introduction
Thanks to their energy density and control precision, hydraulic systems play a critical role in many sectors such as industrial automation, mobile machines and the defense industry. However, these systems have some problems in terms of sustainability due to reasons such as high energy consumption, leakage risk, environmental effects of hydraulic oils, and heat losses (Singh et al., 2020). In this context, new solutions need to be developed in terms of both environmental sustainability and operational efficiency.
1.0 Sustainability Issues in Hydraulic Systems
Energy Inefficiency: Traditional hydraulic systems lose large amounts of energy by converting them into heat due to throttling control. This is especially common in constant speed pump systems (Pagano et al., 2019).
Oil and Waste Management: Hydraulic oils can harm the environment in both the production and waste process. Leaks risk contaminating soil and water. The recycling rate of oils after use is still low.
Climate Impact and Carbon Footprint: Engines running on fossil fuels, especially in mobile hydraulic systems, increase the total carbon footprint of the system.
Noise and Thermal Pollution: The high noise level and temperature increase that occur during the operation of hydraulic systems create negativities in the working environment.
1.1 Viable Solutions for Sustainability
Electric Hydrostatic Actuators (EHA): EHA systems, which consume less energy compared to conventional systems, offer both compact structure and can be integrated into recovery systems (Chen et al., 2021).
Load-Sensing Pump Technology: It minimizes energy losses by ensuring that the system produces only as much flow and pressure as needed.
Biodegradable Hydraulic Oils: Environmental impact can be reduced by the use of non-toxic oils that do not harm nature (products that comply with the ISO 15380 standard).
Heat Recovery Systems and Cooling Optimization: Integrated heat exchangers reduce the need for cooling, increasing total system efficiency.
IoT and Sensor-Based Monitoring: Real-time monitoring of oil status, temperature, and pressure data enables predictive maintenance and efficient operation. This also prolongs system life.
Modular Design and Reusability: Modular hydraulic power units (HPUs) allow for both ease of transportation and reuse of parts.
Hydraulic systems are engineering marvels that are used in almost all branches of industry, operate with high pressure and enable the transmission of power with fluid. Hydraulic technologies, which were first established on the principle of pressure defined by Blaise Pascal in the 17th century, have become indispensable components of the defense industry, automotive, aircraft systems and industrial automation since the middle of the 20th century.
At the point we have reached today, it is not enough to produce a high-performance system. The depletion of energy resources, the climate crisis, the pollution of water resources and the tightening of environmental regulations; It has made the concept of "sustainability" an integral part of technical design in the field of engineering. Sustainability in hydraulic systems has a multi-layered structure:
Energy efficiency: Producing more work with less energy.
Oil and fluid management: Reducing pollution and extending fluid life.
System life: Increasing the durability of components and optimizing maintenance intervals.
Environmental impact: Reducing carbon footprint and waste generation.
In this axis of sustainability, not only mechanical solutions but also digital solutions come into play. The digitalization process, which started with Industry 4.0, makes it possible for hydraulic systems to be more environmentally friendly and long-lasting by working in integration with sensor-based monitoring systems, data analytics and artificial intelligence-supported predictive maintenance applications.
In this study, how sustainable hydraulic infrastructure can be established through the systems offered by Hidroman will be evaluated in technical details; A holistic engineering perspective will be presented, from filtration systems to test machines, from oil selection strategies to digital SCADA infrastructures.
1.1 Historical Process and Technological Evolution
The history of hydraulic systems began in 1647 with the discovery of the principle of pressure transmission by Blaise Pascal and came into practical application in 1795 when Joseph Bramah produced the first commercial hydraulic press. In the 20th century, especially in the post-World War II period, with the increase in industrial production, mobile and stationary hydraulic systems have become the industry standard.
Since the 1980s, hydraulic technologies have evolved into electro-hydraulic systems by combining with electronics; In the 2000s, with the development of digital control and sensor technologies, the concept of "smart hydraulic systems" emerged. This transformation is not only an increase in performance; It has also brought new opportunities for energy efficiency and environmental sustainability.
1.2 Technical Compliance with Sustainability Principles
In order for a modern hydraulic system to be sustainable, four main elements are at the forefront:
Resource Utilization Optimization: Maximizing the oil, energy and component life used.
Environmental Impact Reduction: Prevention of emissions, leaks and hazardous waste.
Renewably Compatible Design: Production of components compatible with biodegradable oils and renewable energy sources.
System Recycling: Environmentally recyclable parts that have completed their useful life.
These principles are not only ethical responsibilities; at the same time, it has become a technical necessity in terms of compliance with international regulations such as the European Green Deal.
1.3 Current Industrial Role
As of today, hydraulic systems play a fundamental role in the following sectors:
Defense Industry: Electro-hydraulic linear movements in tanks, radars, ramps and weapon systems.
Automotive: Press machines, transmission systems and shock absorber technologies.
Aircraft & Aviation: Landing gear, flap systems, and hydraulic brakes.
Agricultural and Construction Machinery: Tractor, excavator, loader and crane applications.
All of these systems require high pressure, tight space, and fast response; Therefore, it is inevitable to produce both efficient and environmentally friendly solutions. At this point, Hidroman makes a difference in the sector with its holistic engineering solutions that provide sustainability at the test and monitoring level. In this context;
The RK91 PRO model inline filtration systems provide gentle and multi-stage liquid cleaning.
RK90 offline filtration units increase system performance by filtering liquid 24/7 independently of the main circuit.
SDE Series cylinder removing-assembly systems emphasize operator safety while ensuring energy efficiency.
The OSM Series test machines offer measurable quality control and life tests.
The OPCOM particle count sensor makes it possible to monitor liquid cleanliness instantly in accordance with the ISO 4406 standard.
1.4 Case Study: Oil Life Optimization with Hidroman Offline Filtration Unit
Signature Profiles:
System Used: Hidroman RK90 Offline Filtration System + ISO 4406 Measurement Integration
Problem Description:
The fluid life of the hydraulic systems operating at high temperatures in the production line machines within the company did not exceed 8-10 months, oil changes had to be made frequently, and liquid-induced component failures (especially valve clogging) created high costs.
Application:
In 2023, the Hidroman RK90 series offline filtration unit was integrated into the system. Filtration was carried out separately from the main line operation with a 24/7 independent pump and motor system. In addition, a particle analysis sensor (OPCOM) was connected to the system, along with 3 micron and water separator cartridge filters. Filtration, the production line continued continuously without stopping.
Results (9-month period):
The ISO 4406 cleanliness code of hydraulic fluid has been reduced from 21/19/16 to 17/15/12.
The oil change interval increased from 9 months to 20 months.
The frequency of part replacement (valve, piston seal) decreased by 47%.
Overall, the cost of maintenance decreased by 34% annually.
Assessment:
The operation of offline filtration systems without affecting the main circuit offers the advantage of uninterrupted filtration, especially in high-flow and sensitive production lines. This case shows that sustainability is not only environmental; It has also revealed that it provides direct economic gains.
1.5 Case Study: Failure Prediction and Energy Efficiency Gains with Test Machines
Signature Profiles:
System Used: Hidroman OSM Series Cylinder Test Machine + Digital SCADA Monitoring Panel
Problem Description:
Nova Hidropar is experiencing delays in delivery times due to high energy consumption and high retest rates in the testing processes of the revised cylinders it sends to its customers; At the same time, microleaks in the system were causing malfunctions in the field after production.
Application:
A new test infrastructure has been established with the OSM series, which can enable high-precision leak testing and stroke simulation. Deviations from the stroke were achieved with 0.01 mm precision linear rulers, and internal leak and external leak detection were achieved with pressure compensating software. Test data started to be monitored instantly on the SCADA screen. In addition, it was measured and recorded on the basis of energy consumption unit (kWh).
Results (6-month period):
After the test, field failures were reduced by 62%.
Energy consumption fell by an average of 29% (per unit test).
With SCADA data, 5 early valve failures were detected and pre-delivery intervention was provided.
Revised cylinder lead time shortened by 18%.
Assessment:
It's not just testing; This system, supported by measurement and data collection, has made the preventive maintenance approach possible at the production stage, not in the field. It successfully demonstrates how sustainability can be integrated with digitalization in terms of energy savings and time savings.
- Filtration Technologies and Fluid Health Management
In hydraulic systems, the cleanliness of the fluid is a decisive factor in terms of system life and efficiency. Studies show that 85% of hydraulic equipment failures are directly related to fluid pollution. For this reason, filtration systems are not only supporting side equipment; They are the basic infrastructure elements that ensure the sustainable operation of the system.
2.1 Technical Fundamentals of Filtration
Filtration is the process of removing solid particles and impurities such as water in the liquid. Filter classes commonly used in industry:
Inline Filters: It is located on the main circuit and takes an active role when the system is constantly working.
Offline (Bypass) Filters: It works on an external circuit independent of the main flow line, providing cleaning even when the system is running.
Tank Top Filters: Provides cleaning of return line oils.
Mobile Filter Units: Provides portable filtration during maintenance.
According to the ISO 16889 standard, the filtration efficiency is expressed by the beta rate (βx ≥ 200). This ratio indicates the level of cleanliness of the system by determining how many particles the filters pass at certain micron levels.
2.2 Hidroman Filtration Solutions
Hidroman develops modular filtration systems suitable for different needs:
HDF Series: High flow capacity filtration for industrial inline systems.
OLF Series: 24/7 independent filtration and high-precision cleaning thanks to its offline structure.
MFS Series: Mobile-friendly, efficient systems for on-site maintenance applications.
These systems are integrated with the following technologies:
Particle Count Sensors (ISO 4406): Measures oil cleanliness instantly.
Moisture Sensors: Critical for ester-based oils, which are especially sensitive to water.
SCADA and Remote Monitoring: Data such as filter replacement and critical contamination levels can be monitored centrally.
2.3 Oil Health and Longevity
Biodegradable oils are more environmentally friendly than mineral oils, but are more susceptible to oxidation and water contamination. Therefore:
If the humidity is above 0.05%, replacement is recommended.
The number of particles should be reduced below the level of 18/16/13 according to the ISO 4406 code.
Viscosity monitoring determines the effectiveness of the oil, especially in systems operating at high temperatures.
These indicators affect not only the quality of the liquid; It also directly affects the life of other components in the system (valve, pump, cylinder).
- Performance and Durability Analysis with Test Systems
One of the key steps in designing a sustainable hydraulic system is to subject the products to long-term tests under real load. Test systems; It is used to predict the life of components such as cylinders, pumps, valves, to detect design weaknesses early and to guarantee product quality. In this context, test infrastructures directly affect both the economic and environmental components of sustainability.
3.1 Contribution of Test Systems to Sustainability
Life Simulation: With long-cycle tests, the service life of the products is predicted in advance, thus preventing unnecessary part production.
Energy Efficiency Measurement: While testing pumps and motors, design improvements can be made by measuring energy consumption per unit.
Leak and Leak Tests: Microleaks are detected and leaks that will create environmental risks in the field are prevented.
3.2 Hidroman Test Infrastructures
The test machines developed by Hidroman operate in accordance with standards such as ISO 10771 and ISO 6020 and support the following types of tests:
Cylinder Test Systems: Stroke measurement under load, internal/external leak test and compressive strength tests.
Pump Test Benches: Volumetric efficiency, leak analysis, heating curve and energy profile measurement.
Valve Test Modules: Opening/response time, flow direction tests and pressure regulation curves.
These systems are supported by integrated data acquisition systems and SCADA interfaces; During the test, data such as temperature, pressure, flow rate, energy consumption are analyzed in real time.
3.3 Measurable Benefits
The product return rate and warranty failures can be as low as 40%.
Energy consumption per piece can be reduced by an average of 25%.
The rate of compliance with quality standards increases, the amount of non-production waste decreases.
In this respect, testing machines are not only quality control; It has become an integral component of sustainable design and economic optimization.
- The Role of Cylinder Disassembly and Assembly Benches in Sustainability
Hydraulic cylinders are the most commonly used actuators in the power transmission of systems. However, over time, the need for maintenance arises due to reasons such as wear on the piston seals, ring loosening or internal leakage. When dismantling operations are done manually, both occupational safety risk and waste of time and energy occur. At this point, hydraulic cylinder disassembly and assembly benches stand out as an important intermediate equipment in terms of sustainability goals.
4.1 Technical Structure and Functions
The disassembly-assembly benches developed by Hidroman consist of the following basic components:
Hydraulically driven torque module (controlled tightening/unwinding)
Cylinder fixing rail system
Adjustable support slides
Operator-controlled remote control
These systems make it possible to disassemble the cylinder without damage and with low energy.
4.2 Sustainability Contributions
Energy Efficiency: Up to 60% lower energy usage compared to manual turning operations.
Parts Life: With undamaged dismantling, the reuse of parts such as piston rods and seal bearings increases.
Occupational Safety and Ergonomics: Operator injuries and accidents are minimized.
Waste Reduction: Material loss caused by unnecessary part breaking or wrong intervention is prevented.
4.3 Digital Integration Potential
New generation disassembly-assembly benches can adapt to Industry 4.0 with features such as part recognition, torque record tracking and operator logging. This is important in terms of digital monitoring of maintenance history and providing data to predictive maintenance algorithms.
Therefore, cylinder disassembly machines are one of the basic building blocks of a sustainable maintenance culture and digitalized maintenance processes.
- Digital Monitoring Systems and Industry 4.0/5.0 Integration
Modern hydraulic systems are not only mechanical; Integrated work with digital infrastructure has become the new generation definition of sustainability. Sensor-aided data acquisition systems, predictive maintenance algorithms, energy management modules and SCADA interfaces ensure that hydraulic systems are longer-lasting, environmentally friendly and economical.
5.1 SCADA Based Monitoring Infrastructures
SCADA-based monitoring infrastructure developed by Hidroman; It instantly analyzes parameters such as pressure, temperature, flow rate, sealing status, torque and viscosity. This allows you to:
Operator errors and delays are reduced.
Critical failures are predicted in advance and proactive maintenance is performed.
Parts replacement and maintenance times are optimized.
Productivity trends can be monitored over time.
5.2 Intelligent Systems Compatible with Industry 4.0
Industry 4.0 refers to the digitalization of physical systems. Hidroman systems serve this vision with the following features:
IoT sensor integration (pressure, humidity, temperature, vibration)
OPC-UA and MQTT based communication protocols
Remote monitoring and response
API-supported integration capability
5.3 Human-Machine Compatible Structures with Industry 5.0
Industry 5.0 is not only efficiency; defines human-centered, environmentally friendly and flexible production systems. In hydraulic systems, this transformation takes place as follows:
Ergonomic interfaces and user guidance systems
Machine learning-powered failure prediction
Guiding maintenance technicians with decision support systems
Social responsibility integration with environmentally friendly material and oil selections
5.4 Sustainable Digital Ecosystem
When all these infrastructures come together, a digital sustainability ecosystem is formed. Systems do not only consume energy; It can also monitor environmental impact, recycling rates and production quality. Thus, engineering is no longer just "producing", but "watching", "predicting" and "optimizing".
- Conclusion and Recommendations
In this report, how hydraulic systems can be restructured in line with sustainability principles is presented with both theoretical and practical examples. Thanks to the test systems, filtration units, digital monitoring infrastructures and maintenance equipment developed by Hidroman, energy consumption, maintenance costs and environmental wastes have been significantly reduced; At the same time, the life of the systems is extended.
6.1 Strategic Findings
The following findings reveal the main conclusions reached during the report:
Offline filtration systems double the oil life, reducing maintenance frequency and cost.
SCADA-supported test machines reduce energy consumption by 25-30% and play a preventive role in fault detection.
Cylinder disassembly machines provide both economic and environmental recovery by increasing the reuse of parts.
With digitalization, predictive maintenance and energy management have become possible.
6.2 Compliance with International Reports and Academic Sources
European Green Deal (2020): It is in line with the EU Commission's goal of developing energy-efficient and waste-reducing systems in line with its green industry targets.
UN Sustainable Development Goals (SDG 9, SDG 12, SDG 13): Makes a direct contribution to industry, innovation, responsible production and climate action.
OECD Digitalisation and Industrial Productivity Report (2022): It has been revealed that the integration of digital infrastructures into production systems can increase productivity by 20–40%.
6.3 Recommendations
Digital sensor and monitoring infrastructures should be installed in all hydraulic systems; A data-based culture of care should be supported.
System design compatible with biodegradable oils should be encouraged.
All test, maintenance and monitoring processes should be integrated with SCADA/IoT systems and a real-time decision-making infrastructure should be established.
Energy profile tracking should be standardized to make the carbon footprint measurable.
In line with Industry 5.0 goals, ergonomic and environmentally friendly systems that allow human-machine cooperation should be expanded.
In line with these suggestions, not only today's but also the future's engineering infrastructure will become constructable; Sustainability is no longer an option, it will become a necessity.
- Bibliography
European Commission. (2020). The European Green Deal. https://ec.europa.eu/info/strategy/priorities-2019-2024/european-green-deal_en
United Nations. (2015). Transforming our world: the 2030 Agenda for Sustainable Development. https://sdgs.un.org/goals
OECD. (2022). Digitalisation and Industrial Productivity. Organisation for Economic Co-operation and Development. https://www.oecd.org
ISO. (2017). ISO 15380: Biodegradable hydraulic fluids. International Organization for Standardization.
ISO. (2010). ISO 16889: Hydraulic fluid power — Filters — Multi-pass method for evaluating filtration performance. International Organization for Standardization.
Bosch Rexroth AG. (2021). Energy Efficiency in Hydraulic Systems: Whitepaper.
Parker Hannifin Corp. (2020). Hydraulic Filtration Technology Overview and Best Practices.
Hidroman Engineering. (2024). Product Catalog and Technical Application Documents (Corporate Publication).
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