Hydraulic systems with telemetry for mobile machinery

Modern construction machinery has long since ceased to consist solely of hydraulic cylinders, pumps and steel components. Electronics, decentralised control and digital monitoring are increasingly becoming central components of mobile machinery.

At the bauma in Munich, Hawe is therefore showcasing a system solution that combines classic hydraulic technology with telemetry, machine control and remote diagnostics. The focus is not on a single component, but on the interaction of several components within a machine. Particularly in mobile machinery such as truck-mounted cranes, the demands for precision, ease of use and digital connectivity are constantly growing. Today, manufacturers must not only supply high-performance hydraulic systems, but also integrate data processing, control and maintenance concepts. The solution presented illustrates this shift particularly clearly. Different control blocks handle different tasks within the same machine – tailored to ease of operation, load requirements and cost-effectiveness.

Hawe combines hydraulic control with digital machine control

The system begins with the hydraulic pump. It supplies power to the various working functions and forms the basis for all movement sequences. Connected to this are several control blocks, each with different tasks. For demanding work movements, such as those of a truck-mounted loading crane, a central control block is used. According to Hawe, the focus here is primarily on sensitivity and load-independent operability. Particularly with crane movements, the precision of the control system determines safety and ease of use. Loads must be moved in a controlled manner, often under difficult conditions or in confined spaces. In addition, there are simpler functional areas within the same machine. These include, for example, the outriggers of a crane. Here, the requirement for high-precision motion control is lower; instead, the focus is more on cost-efficiency. The system architecture therefore deliberately separates high-value work functions from less complex auxiliary functions. This division reflects a trend that is evident in many mobile machinery: not every movement requires the same level of technical complexity. Modern systems are therefore increasingly designed with a modular structure.

Decentralised modules handle individual machine functions

A central component of the solution is an electronic control unit that acts as the overarching machine control system. It coordinates the various components and processes the relevant operating data. In addition, decentralised modules are used. For the support functions, for example, there is a separate small control module that handles this area exclusively. The architecture thus distributes the tasks across several specialised units. This not only reduces the complexity of individual components but also facilitates adaptation to different machine types. Manufacturers can add or modify functions in a targeted manner without having to redevelop entire systems.

Key components of the system solution presented:

• Hydraulic pump for mobile machinery
• Central control unit for precise working functions
• decentralised modules for auxiliary functions
• electronic machine control
• telemetry module for real-time data and remote access

Telemetry enables remote access to machines worldwide

The integrated telemetry module is particularly interesting. It allows machine data to be read in real time and monitored remotely. According to Hawe, the operator can connect directly to the machine even from a distance of several hundred kilometres. This provides continuous insight into the current operating status. Speed, load conditions, motion sequences or error messages can be evaluated centrally. For operators of larger machine fleets, this opens up new possibilities in service and operational planning. An important area of application is predictive maintenance. Maintenance should no longer be carried out solely at fixed intervals, but based on real operating data. Components are monitored, wear is detected at an early stage and failures are prevented wherever possible before they actually occur. This is playing an increasingly important role, particularly in international business. Manufacturers or machine suppliers can support equipment worldwide without having to set up their own service centres everywhere. This gives small and medium-sized enterprises access to markets that were previously much more difficult to serve.

Digital hydraulics is transforming mobile machinery

The solution shown illustrates just how much traditional hydraulic technology is changing. In the past, the focus was primarily on pressure, flow rate and mechanical load capacity. Today, software, data analysis and connectivity have been added as further dimensions. This development affects almost all mobile machinery – from cranes and municipal vehicles to construction and specialist machinery. Operators expect precise control, operators require transparent operating data, and manufacturers are seeking more efficient maintenance concepts. Remote maintenance is also gaining in importance. Fault analyses can often be carried out digitally before a technician even arrives on site. This reduces downtime and simplifies service processes considerably. Hawe is thus demonstrating not just individual components, but a fundamental shift within fluid technology. Hydraulic systems are increasingly evolving into networked integrated systems in which mechanics, electronics and software work closely together. This development is likely to gain further momentum in the coming years, particularly in the field of mobile machinery.