Every movement in industrial machinery depends on precise control. Hydraulic power packs deliver the force and motion required, ensuring smooth, reliable performance in presses, injection molding machines, machine tools, and other heavy-duty applications. For these operations, consistency and accuracy are critical to productivity and safety.
In conventional systems that rely on manual operation or relay logic, maintaining stable pressure and flow is difficult. This often results in energy inefficiencies, higher operating temperatures, component wear, and limited visibility of key parameters, ultimately reducing system reliability and uptime. To meet the demands of modern industry, hydraulic solutions must evolve with advanced automation.
Challenges in Conventional Hydraulic Power Packs
- Manual or Relay-Based Control: Leads to inefficiency, inconsistent performance, and higher energy use.
- Lack of Precise Pressure and Flow Regulation: Reduces accuracy and repeatability, affecting actuator performance.
- Increased Risk of Overheating and Component Wear: Inconsistent control causes thermal and mechanical stress, shortening system life.
- Limited Monitoring of Critical Parameters: Makes it difficult to detect issues in oil temperature, pressure, or contamination early.
No Remote Supervision or Data Logging: Restricts predictive maintenance, optimization, and integration with advanced automation
Why Use PLC Control in Hydraulic Systems
Programmable logic control enables hydraulic systems to achieve higher levels of accuracy, efficiency, and reliability.
- Real-Time Control: Pumps, valves, cylinders, and motors respond instantly to changing conditions.
- Precise Regulation: Feedback-based control ensures stable pressure and flow while reducing energy use.
- Automatic Sequencing: Simplifies coordination of multiple actuators, improving overall process efficiency.
- Enhanced Safety: Features such as level monitoring, overpressure alarms, and emergency shutdowns protect equipment and operators.
Remote Monitoring: Integration with HMI and SCADA systems supports predictive maintenance, performance tracking, and Industry 4.0 readiness.
NX-ERA Jet PLC: Advanced Control for Hydraulic Systems
Messung’s NX-ERA Jet PLC is a high-performance controller engineered for demanding industrial applications. Its modular and scalable design allows seamless integration in both compact hydraulic power packs and large installations.
High-speed I/O modules enable rapid, accurate control of pumps, valves, and cylinders, ensuring consistent actuator performance. With support for Ethernet/IP, Modbus, and CANopen, the Jet PLC provides real-time monitoring, data logging, and predictive maintenance capabilities through easy integration with SCADA systems and HMIs.
The controller supports IEC 61131-3 programming standards, offering flexibility for customization and smooth integration with existing systems. Designed for Industry 4.0, the Jet PLC empowers manufacturers to enhance energy efficiency, minimize risks, and achieve reliable, data-driven hydraulic operations.
Key Features of NX-ERA Jet PLC
| Feature | Process Enhancement |
|---|---|
| PID Control for Pressure and Flow | Ensures stable and accurate actuator performance. |
| Sensor Integration | Delivers real-time monitoring of pressure, flow, and oil condition. |
| Sequencing Logic | Automates multi-actuator coordination, streamlining complex workflows. |
| High-Speed Digital Outputs | Enables fast response for solenoid valves and hydraulic components. |
| Data Logging and Trending | Supports predictive maintenance through cycle, pressure, and temperature tracking. |
| Alarm Management | Protects systems with alerts for overpressure, low oil, or overheating. |
| Remote Access and Diagnostics | Allows monitoring, control, and troubleshooting from anywhere. |
Benefits of NX-ERA Jet PLC
- Improved Reliability and Precision: High-speed processing ensures smooth actuation for consistent pressure and flow, raising system performance.
- Enhanced Energy Efficiency: Optimized pump and valve operation reduces energy consumption.
- Reduced Downtime: Diagnostics and predictive maintenance capabilities minimize unplanned interruptions.
- Scalable Architecture: Supports up to 128 I/O modules, adapting to small or large hydraulic installations.
- Industry 4.0 Compatibility: Enables connected, data-driven operations with IoT and automation integration.
Applications
- Hydraulic Presses: Repeatable cycles with stable pressure and flow for stamping and forming.
- Injection Molding and Plastic Processing: Accurate actuation with diagnostics and high-speed I/O for reliable performance.
- Machine Tools: Precise control of clamping, positioning, and motion in CNC systems.
- Automotive Manufacturing: Modular design supports assembly lines, lifts, and material handling.
- Construction and Heavy Machinery: Robust performance with predictive maintenance and multi-actuator control.
Aerospace and Defense: Safe, repeatable, high-performance hydraulic operations with real-time monitoring.
Conclusion
Messung’s NX-ERA Jet PLC transforms hydraulic power packs into intelligent, future-ready assets. With precise control, predictive insights, and scalable architecture, it enables manufacturers to improve productivity, reduce downtime, and embrace Industry 4.0 with confidence.
Transform your hydraulic systems with Messung’s NX-ERA Jet PLC, where precision, reliability, and innovation power the future of industrial automation.