Following the fluid power market's latest themes and product development trends, OEM Off-Highway spoke with Paolo Patroncini, general manager of 4e Consulting, a division of ZAPI GROUP in charge of developing hybridization and electrification projects with international partners.
Patroncini holds a degree in engineering and a Ph.D. in electrification. After a decade of experience in the development and design of internal combustion engines, he founded 4e Consulting in 2010, successfully completing various innovative projects in the non-road mobility sector. In 2022, the company became part of ZAPI GROUP, providing system integration services to some of the most prestigious OEMs in the industry.
The following conversation highlights Patroncini's technical expertise that has been key in positioning the company as a leader in advanced mobility solutions, and touches on several of the industry's developing market trends.
What are the key advantages of hydraulic systems over mechanical or electrical systems in off-highway applications?
Hydraulic systems can generate substantial power from a compact size, since in off-highway applications the packaging tends to be challenging; this higher power to size ratio represents a great advantage. Traditionally, hydraulic systems can be less complex and easily controlled, but on the other hand, new electrical systems are much cleaner and scalable.
How do you determine the right type of hydraulic fluid for a specific application?
This approach is very “traditional” and is based on selecting the right matching between viscosity and expected operating range, on ensuring the fluid compatibility with system materials (including corrosion inhibitors).
What are the most common causes of hydraulic system failures in off-highway equipment?
There are three main factors affecting the reliability of a hydraulic system: fluid contamination, reduced system performance due to the stress of high temperatures, and poor fluid quality. These typical issues are obviously not present in an electrified system.
What are some of the challenges companies face right now with fluid power?
There are two main challenges: improving energy efficiency to reduce wasted energy and reducing the maintenance to improve the system durability.
What is one breakthrough technology or trend that you believe could revolutionize the off-highway industry in the next five to 10 years?
System electrification is the most transformative trend for the off-highway industry in the next decade. This shift is driven by three key factors: the need for cleaner fluid-free actuators that eliminate leaks, the advantages of more precise digital control systems embedded in machine controllers, and growing sustainability requirements. As this technology matures, electrified powertrains will fundamentally change how these machines are designed and operated.
How can predictive maintenance strategies be applied to hydraulic systems?
Typically, the hydraulic systems are purely mechanical systems and only recently have been integrated with electronic controls. Therefore, they can be remotely controlled with some adaptations. If the system is fluid-powered, instead of electrically-powered, the predictive maintenance is much more feasible because of the natural interaction with the electric components.
How is electrification impacting hydraulic systems in off-highway machinery?
Electrification has a significant impact on hydraulic systems, mainly due to its improved environmental footprint over diesel-power solutions, and its potential integration into hybrid solutions.
What are the benefits and limitations of electro-hydraulic actuators compared to traditional hydraulic cylinders?
The limitations are represented mostly by the component costs, while the great advantage is due to the precise controls and improved energy absorption/recovery.
How do hybrid hydraulic systems contribute to energy savings in construction and agricultural equipment?
Hybrid systems are “naturally” oriented to recover energy during operations typically adopted in construction equipment and agriculture, so this is a great advantage. We have recently tested a high voltage agriculture implement that can save around 30% of fuel during normal operation.
