Small abnormalities in a hydraulic system can show up as changes in motor load
Hydraulic equipment is core equipment that delivers high force and precise control at many industrial sites, such as presses, injection molding machines, machine tools and forming and processing equipment.
When the condition of key components such as the hydraulic pump, motor and valves degrades, pressure and flow become unstable, which can lead to lower equipment performance and production stoppage.
Load and power signals of the hydraulic power unit motor are monitored continuously to find early signs such as leakage, cavitation and valve degradation and support stable equipment operation.
In a hydraulic system, a pump pressurizes the fluid and valves control pressure and flow to drive the actuators.
When problems such as leakage, reduced valve performance or cavitation occur, the operating state of the hydraulic unit can change to maintain the required pressure and flow, and this can appear as changes in motor load and power pattern.
If these abnormalities are not found early, they can lead not only to higher energy consumption and lower performance but also to further damage to key parts such as the pump and motor.
Key operating challenges
Hydraulic leakage
Internal or external leakage increases the pump's workload to hold the required pressure and can reduce system efficiency.
Cavitation
Poor fluid supply or unstable pressure conditions can cause cavitation, leading to lower pump performance and component damage.
Valve degradation and malfunction
Valve wear, clogging or slower response affects flow and pressure control and can make the hydraulic system unstable.
Falling energy efficiency
If abnormal pressure or flow conditions persist, the hydraulic unit can consume more energy than necessary.
Unplanned equipment stoppage
Serious faults in the hydraulic pump, motor or valves can cause a sudden stop of the whole production equipment.
Analyze hydraulic unit motor load in real time
Power and load data of the motor driving the hydraulic unit is collected continuously and compared with the normal operating state.
By analyzing how the load pattern changes with operating conditions, abnormal states inside the hydraulic system can be found early, beyond a simple ON/OFF status.
Hydraulic unit motor load monitoring
Motor power and load data is collected continuously to track changes in the operating state of the hydraulic system.
Leakage warning-sign detection
Sustained load changes that differ from normal operating conditions are analyzed to find reduced pressure-holding performance or possible leakage early.
Cavitation warning-sign detection
Load changes that accompany abnormal hydraulic pump operation are analyzed to identify possible cavitation, so you can respond before it grows into equipment damage.
Valve warning-sign detection
Load pattern changes caused by valve degradation or malfunction are analyzed to find signs of abnormality in the flow and pressure control system.
AI-based operating pattern analysis
Motor load and power characteristics are analyzed against normal operating data to identify subtle changes that people can hardly distinguish.
Real-time abnormality alerts
When an abnormal operating state is detected, maintenance staff are alerted so they can inspect quickly, preventing the problem from growing into a serious failure.
Manage hydraulic system stability and energy efficiency together
Hydraulic equipment condition diagnosis can be used not only to prevent pump and motor failures but also to keep pressure and flow stable and energy efficiency high.
Expected benefits
Early detection of hydraulic warning signs
Signs of abnormality in the hydraulic system, such as leakage, cavitation and valve degradation, can be found early.
Fewer unplanned shutdowns
Checking pump and motor degradation in advance reduces sudden equipment stoppages.
Better energy efficiency
Identifying abnormal load and unnecessary operating states reduces energy loss.
Lower maintenance cost
Planned maintenance based on actual equipment condition is possible instead of emergency repair after a failure.
Longer life of key components
Responding before abnormal conditions grow into serious damage to the pump, motor and valves extends equipment life.
Higher equipment reliability
Continuously managing changes in hydraulic system condition supports stable pressure and flow and stable operation of production equipment.
Find hydraulic problems before they become failures
Abnormalities in a hydraulic system do not show up only as sudden failures.
Problems such as leakage, cavitation and valve degradation can lead to changes in the load and operating pattern of the hydraulic unit motor.
By continuously analyzing the motor's power signal, you find these changes early and respond proactively, preventing equipment failure and raising energy efficiency and operating stability together.
Prove it on one asset first
A pilot starts with one critical asset, establishes its baseline and reviews edgeSV diagnostic results with your team.