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Real-Time Hydraulic Condition Monitoring: The Key to Enhancing Productivity by Reducing Downtime

Real-Time Hydraulic Condition Monitoring: The Key to Enhancing Productivity by Reducing Downtime



Real-Time Hydraulic Condition Monitoring: The Key to Enhancing Productivity by Reducing Downtime


Hydraulic systems form the heart of many machines and lines in modern industry. However, a small problem in the system—for example, an abnormal increase in fluid temperature, a drop in pressure, contamination in the oil—can affect the entire production line. Traditional maintenance methods are usually based on "planned downtime" or "intervention after failure"; This causes cost and time loss.

Benefits of the Condition Monitoring Module:

  • Early Warning: Suspicious situations are noticed before the malfunction occurs with signals such as pressure anomalies, excessive temperature, vibration.
  • Cost Savings: Unnecessary part replacements, sudden stoppages, and low-efficiency operation are eliminated.
  • Energy Efficiency: Ensuring that the system remains in ideal working condition, pumps do not operate under unnecessary load.
  • Maintenance Planning: Data-driven, proactive maintenance – predictive maintenance approach.
  • Documentation & Process Improvement: System performance is analyzed with the data collected over time, and improvements are made.

Technical Specifications and Installation Recommendations:

Parameter

Measurement

Recommended Sensor / Range

Pressure

Suitable for working pressure (e.g. 0-700 bar)

±1% accuracy

Temperature

Oil temperature

Between -20°C ... +100°C

Pollution (particle level)

Such as the ISO 4406 standard

Online particle counting

Vibration / Oscillation

In pump bearings or machine housing

In millimeters/sec or g
  • Connection / Interface: The module should work wired or wireless (Wi-Fi, LoRa, NB-IoT).
  • Data Processing & Alerts: Local display and alarm systems; dashboard + mobile notification via internet.
  • Integration: Easy to add to existing power units or valve blocks.

Application Scenarios:

  1. Industrial Press and Molding Line: Mold wear or change in system pressure is detected immediately, and product quality is preserved.
  2. Mobile Hydraulic Equipment (Excavator, Crane, etc.): Excessive temperature / vibration problems are identified faster in the field and maintenance is planned.
  3. Cooling/Oil Management Systems: Coolant/oil filter/oil pump performance is monitored, alarming when oil starts to get dirty.

Hydraulic systems are the heart of modern industry. They need to work uninterruptedly in many areas from presses to mobile construction equipment, from energy facilities to automotive production lines. However, a small pressure drop, an increase in oil temperature, or oil contamination can bring the entire production process to a halt.

The Real-Time Hydraulic Condition Monitoring Module developed by Hidroman is designed to eliminate these risks. With its smart sensor technology, it instantly measures and reports pressure, temperature, vibration and oil pollution and warns the user. Thus,  both predictive maintenance can be performed and operating costs are reduced.

Advantages of the Hydraulic Condition Monitoring Module

  • Failure-Free Operation: Potential issues are detected before they occur.
  • Cost Savings: Unplanned downtime and unnecessary part replacement are prevented.
  • Energy Efficiency: Pumps and motors operate in ideal conditions.
  • Easy Integration: Can be easily added to existing hydraulic power packs.
  • Remote Monitoring: 24/7 monitoring via mobile application and web interface.

Technical Specifications

  • Pressure Measurement: 0–700 bar, ±1% accuracy
  • Temperature Measurement: -20°C ... +100°C
  • Oil Contamination Sensor: Particle measurement in accordance with ISO 4406 standard
  • Vibration Measurement: Vibration analysis in accordance with ISO 10816 standard
  • Connectivity Options: RS485 (Modbus), CAN-Bus, Wi-Fi, LoRa, NB-IoT
  • Protection Class: IP67 – resistant to field conditions

Uses

  • Industrial Presses and Injection Molding Machines
  • Mobile Hydraulic Equipment (excavator, crane, construction equipment)
  • Power Plants and Offshore Applications
  • Steel, Cement and Automotive Sector
  • Plastic and Rubber Production Lines

Digital Transformation in Hydraulics with Hidroman

With more than 20 years of experience, Hidroman not only produces hydraulic equipment; but also  develops IoT and Industry 4.0 compatible solutions. The Real-Time Hydraulic Condition Monitoring Module helps you reduce maintenance costs while increasing the productivity of your business  .

Why This Product?

  • 30% fewer breakdowns
  • 20% lower energy consumption
  • Return on investment (ROI) in 6 months

 

Real-time monitoring significantly reduces not only fault repair costs, but also energy consumption, downtime, and maintenance labor costs. For hydromechanical systems to be more efficient, reliable, and sustainable, monitoring modules are no longer a luxury but a necessary tool for competition.

If you want to detect malfunctions in advance by making your hydraulic systems smart,  meet Hidroman's Real-Time Hydraulic Condition Monitoring Module.

For more information and offers: Hidroman Contact