Sensorized Hydraulic Cylinders: The Core of Intelligent Hydraulic Systems

Driven by Industry 4.0 and smart manufacturing, hydraulic systems are evolving from traditional "actuators" to "intelligent terminals." Sensorized hydraulic cylinders, equipped with multi-parameter sensors and digital communication technologies, enable real-time monitoring and closed-loop control, becoming critical for enhancing equipment efficiency, safety, and predictive maintenance.

一、 The core technology of sensor Hydraulic Cylinder

1. Types of built-in sensors Displacement sensor: Using magnetostriction (such as Temposonics technology) or Hall effect principle, high-precision detection of piston position (resolution up to ± 0.01mm) is achieved for closed-loop position control. Pressure sensor: Integrate piezoresistive or piezoelectric sensors to monitor cylinder pressure (range 0~400 bar) and provide real-time feedback on load status. Temperature sensor: Detect the temperature of hydraulic oil (-40 ° C~+150 ° C) to prevent oil degradation or seal failure caused by high temperature. Vibration and impact sensors: Monitor abnormal vibrations through accelerometers to warn of mechanical wear or load displacement.

2. Data Communication and Interface IO-Link： Support point-to-point communication, transmit sensor data (such as position and pressure) to PLC, and achieve dynamic parameter adjustment. CANopen/PROFINET： Suitable for complex hydraulic systems, supporting synchronous control and status monitoring of multiple oil cylinders. Wireless transmission (emerging direction): Upload data through Bluetooth or Industrial Internet of Things (IIoT) protocols (such as NB IoT) to reduce wiring costs.

二、 Application scenarios of sensor hydraulic cylinders

1. Heavy industry equipment Metallurgical continuous casting machine: Real time control of crystallizer vibration through displacement sensors to ensure surface quality of castings. Hydraulic press and compressor: Pressure sensor feedback closed-loop control, precise adjustment of pressing force (such as automotive stamping lines).

2. Mobile machinery Excavators and loaders: Integrating angle sensors and pressure feedback to optimize the coordination of working arm movements and reduce energy consumption. Agricultural machinery: By controlling the seeding depth through the displacement of the oil cylinder, precise operations can be achieved.

3. Intelligent manufacturing numerical control machine: Sensor cylinder driven fixture, real-time monitoring of clamping force to prevent workpiece deformation. Robot collaboration system: The force controlled hydraulic cylinder, combined with sensor data, achieves smooth grasping and obstacle avoidance functions.

Conclusion