Intelligent hydraulic cylinders: the evolution of control in hydraulic motion

In the fluid power sector, demand is growing for increasingly precise and interconnected systems. Today, beyond power and reliability, smart hydraulic cylinders must be capable of communicating with the end user and providing detailed information about their operational status.

In this context, Conforti Oleodinamica has undertaken an intensive programme of development and testing of new solutions to integrate position and motion sensing devices directly into its intelligent hydraulic cylinders. The company’s primary objective is to offer cylinders capable of interfacing with control systems, transmitting piston position data in real time and enabling precise stroke management.

Thanks to Conforti’s applied sensor technology, it is possible not only to determine absolute positions, but also to continuously monitor every millimetre of displacement. The result is a smart hydraulic cylinder capable of providing immediate feedback to the command system, improving operational efficiency, reducing downtime and increasing process reliability. This approach represents a decisive step towards the integration of traditional hydraulics with Industry 4.0 logic.

MP COMPACT CYLINDERS: VERSATILITY AND RAPID DELIVERY

Conforti's MP series stands out for its versatility and rapid delivery times. Its compact and lightweight construction makes it ideal for applications requiring reduced moving masses or optimised envelope dimensions. These cylinders are equipped with a magnetic piston, enabling the application of various sensor types with different functionalities:

• Reed or magnetoresistive sensors, which can be positioned at any point along the stroke to detect piston passage.
• New IO-LINK electronic sensors, capable of detecting the piston along the entire stroke of the compact cylinder, providing either continuous position readout or an ON/OFF signal at up to 8 programmable switching points.

A significant aspect of the development work for the new sensors is full compatibility with the entire Conforti short-stroke MP cylinder range.

The company has conducted extensive testing to ensure that device installation requires no structural modifications. This solution allows companies to easily upgrade existing cylinders, converting them into digitally monitorable components without replacing the entire system — a tangible benefit in terms of sustainability, cost and implementation time.

MD ISO 6020/2 HYDRAULIC CYLINDERS WITH MAGNETIC SWITCHES

A further option for motion control is provided by ISO 6020/2 tie-rod cylinders in magnetic version, which allow two or more positions along the stroke to be identified. In this case, magnetic sensors are installed on the outside of the stainless steel barrel and enable precise detection of intermediate positions, improving the management of complex motion sequences.

END-OF-STROKE PROXIMITY SWITCHES

For end-of-stroke detection, the company offers the option of integrating proximity sensors into the cylinder end caps. This configuration is compatible with the entire Conforti range, including ISO 6020/2 models (both tie-rods and counterflanges versions) and with ISO 6022 cylinders, guaranteeing a high degree of adaptability.

MAGNETOSTICTIVE TRANSDUCERS: MAXIMUM PRECISION

The most advanced solution for stroke monitoring is the integration of magnetostrictive transducers into the TD/TK series servocylinders, which provide instantaneous piston position data across the full stroke at all times. This sensor type delivers continuous measurement with maximum accuracy even under demanding operating conditions. Thanks to this technology, the operator or control system can dynamically adjust the cylinder position, ensuring smooth and repeatable motion. The constant feedback also enables optimisation of duty cycles, reduction of positioning errors and enhanced operational safety.

The transducers are available with multiple output signal types — analogue (4–20 mA and 0–10 V) and digital (SSI, PROFINET, EtherNet/IP™, EtherCAT® and many others) — for seamless integration into the most advanced automated systems.

KEY ADVANTAGES OF HYDRAULIC CYLINDERS WITH SENSORS

The integration of sensors into hydraulic cylinders delivers numerous benefits:

• Total motion control, with the ability to monitor position and velocity in real time.
• Reduced maintenance interventions, thanks to continuous condition monitoring of the component.
• Enhanced safety, as the system can intervene automatically in the event of anomalies.
• Easy integration into automated processes, including on existing installations.

These features make Conforti’s smart hydraulic cylinders a strategic choice for those seeking reliability and precision without sacrificing ease of installation.

FIELDS OF APPLICATION

Smart hydraulic cylinders find application in numerous industrial contexts where precision and control are paramount. In industrial automation, they enable production cycles to be optimised and machine downtime to be reduced through continuous position monitoring. In the machine tool sector, they ensure repeatability and precision in high-speed machining processes. In steelworks, they operate under severe conditions with constant control even in high-temperature environments. Finally, in industrial presses and lifting systems, millimetre-accurate stroke control increases both safety and operational efficiency.

TOWARDS DIGITAL HYDRAULICS

The path taken by Conforti Oleodinamica responds to the growing need to digitalise traditional mechanical components, transforming them into active elements within the production system. The objective is not merely to improve the performance of the individual cylinder, but to offer a new level of interaction between operator, machine and data.

The technological evolution of hydraulic cylinders therefore no longer concerns only materials or operating pressures, but the ability to collect and transmit useful information to optimise the entire process. Thanks to the combination of mechanical robustness and digital intelligence, modern hydraulics becomes an integral part of the most advanced automation architectures.