SEAMLESS VS. WELDED TUBING
p .6
MANIFOLD DESIGN MISTAKES
p .10
PROPER HOSE CRIMPING p.18
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September 2026
CONSTRUCTION
MACHINERY TRENDS page 22
Where performance meets protection Protec Nylon Hose Sleeve
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FLUIDLINES Mary C. Gannon • Editor-in-Chief
Putting the people first in fluid power I’VE JUST RETURNED FROM TWO INTENSIVE DAYS at the Danfoss Distributor Meet-
ing, where I had the opportunity to learn what Danfoss Power Solutions is homing in on with its distribution customer base. And while it was interesting and informative to learn about the company’s updated products and solutions, I was hit with a stronger feeling unrelated to technology. Fluid power will forever be a people industry, and no amount of AI or automation will change that. As I wrote last month, it is refreshing to hear how many OEMs are focusing less on automating machinery completely, and more on how they can use this technology to enable operators to do their jobs more safely and reliably. This was a theme with Danfoss, too, as it shared how it is updating and streamlining its product lines — but in the end, these changes keep people at the center of the machine operation. This industry is special. Hydraulics’ power density is amazing. The snappy controllability provided by pneumatics is really cool. But what really makes me love writing about these technologies are the people designing, building, and using them. I’ve felt this way for a long time. But hearing it over and over again how important the relationships Danfoss has between its people and its distribution base hit home with me. Likewise, in my corporate profile on page 14, Alkon’s new CEO Rahul Deshmukh, also reiterates repeat-
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edly what sets the company apart are the people who ARE the company. AI and automation will never replace that, he said. At the close of the general Danfoss sessions, they recognized an employee who has been with the company for 40 years, the entirety of his professional career. That doesn’t happen too often anymore in the modern work world, but it does in fluid power. Meeting professionals in this industry who have been working for the same company or at least within hydraulics for two, three, or even five decades is not unheard of. At breakfast, I sat down with three gentlemen from two different distributors in my hometown of Cleveland. It turned out, one of them I had met already, years before. Between them, they had a full lifetime of experience. As one of them said, this industry just sucks you in. It’s interesting work and even better people. Over the years, I’ve built relationships — and eventually friendships — digitally with so many folks in this industry. I’ve worked with contributors, company leaders, marketing professionals, and engineers. Sooner or later, we have a chance to shake hands or more often than not, a hug on a show floor or in a conference room. I’ve bumped into people in elevators or at a lunch table. They are often subscribers who have just received my enewsletter or they follow me on LinkedIn.
We realize we know each other in the online world, and now it’s in real life. These relationships last, mostly because we all are passionate about this industry and come together regularly. I’ve never regretted attending any event in this industry, even if it turned out to have weaker content or not as many exhibitors as I’d have expected. Because in the end, if even one connection was made, that travel was well worth it. I enjoy learning about new technology, planning technical submissions, or talking about the challenges of a machine’s design. But what is most fulfilling about getting out there at industry meetings, trade shows, and conferences are the friendly exchanges and relationships built. I’ve worked in this industry more than two decades myself — a wild thought to me. I’ve got a few years left until I can retire, but I do hope that no matter when that time comes, I can say it was all time well spent in and around this special industry. FPW
Mary C. Gannon • Editor-in-Chief mgannon@arrowfly.com linkedin.com/in/marygannonramsak
SEPTEMBER 2026 • FLUID POWER WORLD
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SEPTEMBER 2026
C ONTE NTS | V O L . 1 4 N O . 8
FluidPowerWorld.com
SEPTEMBER 2026
F E AT U R E S 12 PROFILES IN FLUID POWER Rahul Deshmukh steers Alkon into the future For the first time in its history, Alkon has tapped an outsider to lead the company.
18 HYDRAULIC HOSES Why proper hose crimping is critical to uptime, repeatability, and traceability Improperly crimped hose assemblies can lead to unexpected downtime, hazardous leaks and safety risks to employees.
22 MOBILE HYDRAULICS Construction machinery trends: advancing digitalization and connectivity Connected systems combining sensors, controllers, software, displays and telematics are helping advanced hydraulics provide precise motion, control and energy management.
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FLUID POWER WORLD • SEPTEMBER 2026
HEAVYTECH
D E PA R T M E N T S 1
FluidLines
4
Perspectives
5
Safety
6
Component Focus
7
Energy Efficiency
8
Design Notes
10
Fundamentals
ON THE COVER
The future of hydraulics is digital and connected, as sensors, controllers, software, displays and telematics work to ensure precise motion, control, and energy management. BOSCH REXROTH
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September 2026 • vol 14 no 8 • www.fluidpowerworld.com
EDITORIAL
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SEPTEMBER 2026 • FLUID POWER WORLD
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PERSPECTIVES Josh Cosford • Contributing Editor
Yet another reason hydraulics is superior
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FLUID POWER WORLD • SEPTEMBER 2026
Today, nearly all passenger cars use electric assist. It eliminates the parasitic energy loss caused by hydraulic pumps and operates only when steering input is sensed at the steering wheel, relegating steering to an "ondemand" system. However, hydraulic steering is, in fact, so superior at transmitting road feel and precision that a few manufacturers refuse to switch to electric assist just to save a fraction of an MPG. And if hydraulic assist is still good enough for Lotus, McLaren and Bugatti, it’s good enough for me. FPW
Josh Cosford • Contributing Editor jcosford@higginson.ca linkedin.com/in/joshcosford ADOBE STOCK
IF YOU’RE TIRED OF MY MISSIVES about EXAMPLE OF A HYDRAULIC cars, this is your chance to click away. ConSTEERING RACK USED IN MOTOR VEHICLES versely, if you enjoyed my article on enshittification (see our October issue and live link here), this example will make you pine for the good old days of automotive technology. “But Josh, what does hydraulics have to do with cars? The only thing hydraulic are the brakes!” Sadly, you’re mostly right. However, until the past decade, the steering assist system on vehicles was hydraulic. The belt-driven, engine-powered hydraulic pump was as common as windshields, and despite disparities in execution, even the worst systems had benefits over today's Novocain-numbed electric power-assist systems. Let’s explore the differences between hydraulic and electric assist to elucidate why we find ourselves in a (nearly) hydraulics-free automotive climate. Steering a car is difficult without assist, especially at low speed. The static scrub friction between tires and asphalt rack itself. Above the pinion gear is a rotary increases the effort to pivot the wheels, but as valve that directs power steering fluid to the vehicle speed increases, the rolling tire resets power steering piston, applying pressure to its contact patch continuously to realign the assist the rack's movement. slip angle, easing up steering. Because hydraulic actuators are essentially Car steering systems are not hydrostatic like just as stiff as mechanical systems, vibrations, those in a tractor, but rather hydraulic assist resistance, feedback, and road texture are that aids an entirely mechanical system, allow- transmitted through the steering cylinder and ing steering to persist despite a stalled engine hydraulic hoses. The self-aligning torque from or a failed pump. The mechanical portion is the suspension caster angle is also transmiteither rack-and-pinion or recirculating ball, and ted through the steering wheel, resulting in if you’re familiar with both, you’re just as baf- the sensation that the steering wheel becomes fled as I am that rack-and-pinion is the newer harder to turn under hard cornering load. technology, but that’s neither here nor there. When manufacturers began to switch to When you rotate the steering wheel, the electric-assist power steering, they installed the steering shaft drives a gear set that provides electric motor to run in parallel with the rack the mechanical advantage needed to over- via a gearbox. The electric motor has its own come the massive tire friction. Without this rotational inertia that must be overcome to advantage, it would be impossible to transmit "power" the rack and is often slow to respond. enough force through the tie rods and into As well, the many gears and/or worm drives the steering knuckle. Hydraulic power steer- contain gaps, backlash, and play that eliminate ing systems add a double-rod cylinder to the the "solid column" feel with mechanical and mix, which is an embedded component of the hydraulic assist.
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SAFETY By Mary C. Gannon • Editor-in-Chief
NAHAD expands safety initiatives to the whole month of September
OVER THE LAST FEW YEARS, NAHAD has
NAHAD
celebrated Hose Safety Awareness Week, but this year, the association for industrial and hydraulic hose distribution and manufacturing has expanded the initiative to the entire month of September. NAHAD leadership said the change is intended to expand its reach and provide more resources, practical safety tips and best practices to the industry. Hose safety is critical in the industry, as hose-related incidents can result in some of the most dangerous and life-threatening injuries in industrial operations. In the U.S., OSHA reports that approximately 600 hose injection injuries occur every year. In its Accident Investigation Search, OSHA also documents hose-whip and other injuries attributed to hose failures each year. In a video introduction, Scott Bauman, chair of the NAHAD Hose Safety Institute (HSI) Committee, and Rubber Hydraulics Hose & Fittings product manager and product application engineering manager at Danfoss Power Solutions, invited industry members to participate in the month-long activities to promote safety and reduce risks. “No matter where you fit into the industry, whether in manufacturing, distribution, fabrication, installation, inspection, or using a hose assembly, we all share the
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same goal: go home safe at the end of the day by using the correct products and processes for the application,” Bauman said. “Safety doesn't always require big changes. Sometimes it's as simple as taking a closer look during an inspection, asking one more question, or sharing what you've learned with a coworker.” Bauman encouraged members to use the safety resources the HSI offers, including upcoming webinars. NAHAD also encourages companies to take the NAHAD Safety Commitment. Two safety webinars highlighted by NAHAD include: • More than Just Hose: Protecting What’s Inside! (This webinar can be viewed online, as the live date has passed.) Selecting the right hose is about more than the hose itself; it's about protecting the products flowing through it. In this webinar, presenters explored key considerations for food and
beverage hose use, including manufacturing compliance, proper hose selection, and more. • Thursday, September 24, 2-3 p.m. — Industrial Hose Inspections (End User Sites) This seminar will showcase how NAHAD member manufacturers and distributors can develop and deliver End User Inspection Programs that help end users — and maintenance and safety personnel — determine whether their industrial hose assemblies are safe, functioning properly, and more. This is all leading up to the annual HSI Handson Training in Cleveland, October 20-21. This program was designed to promote an understanding and adoption of HSI guidelines and best practices in hose design and fabrication. Attendees participate in a series of interactive presentations, visit distributor locations for hands-on exercises, and tour a manufacturer’s warehouse. On-site visits will be of Shamrock Hose & Fittings and ContiTech. A complete schedule is available on the NAHAD website. Learn more, download HSI resources and more at nahad.org/hose-safety-awarenessmonth. FPW
Coming soon! FPW launches Hose Safety Resource
Hose Safety
Resource
September 2026
We at Fluid Power World understand and value the importance of designing, building and maintaining safe hydraulic systems, so we compiled a selection of our articles dedicated to hydraulic and pneumatic hose safety. Visit our Design Guide page at fluidpowerworld.com/category/ design-guides/ to download our newest resource for tips on designing safe systems, maintaining them, and special tools and accessories that keep your hose assemblies secure and reliable.
SEPTEMBER 2026 • FLUID POWER WORLD
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COMPONENT FOCUS Josh Cosford • Contributing Editor
What’s the difference between seamless and welded hydraulic tubing? THERE ARE TWO MAJOR PLAYERS in the
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FLUID POWER WORLD • SEPTEMBER 2026
TUBE MILLING PROCESS
sively shape the steel into a tubular shape this long, but should you require something lon(which doesn’t necessarily have to be circu- ger than what can be made with a seamless lar). Once the final shape is achieved, it passes extruder, you know where to look. through the welder, where the ends are joined, A hybrid tube type is both welded and drawn. sealing the tube. Similar to seamless tube, the This tube is suitable for moderate-pressure welded tube also visits the heat treatment and hydraulic applications. It uses electric resisstraightening stations, and in many cases, you tance welding before being drawn over a mancan’t tell the difference between each tube type drel to improve accuracy while removing the by looking at the outside. interior weld bead. One of the benefits of welded tube is the If you ever have the opportunity to visit possible length that can be manufactured. a tube mill, I highly recommend you attend. Depending on the thickness of the steel coil, Although we often work in short lengths, you’d mills can manufacture coils in excess of a mile. be shocked by the scope of work involved in It’s unlikely anyone could ever use a single tube making these fluid power commodities. FPW
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hydraulic tubing game, and depending on who you ask, there might be two and a half, but I’ll get to that later. If you’re like me, you’ve heard of both seamless and welded tubes yet had no idea what made them different. Hopefully, this article can shed some light on those differences to clarify things. The primary difference is in how they are manufactured. Neither method is easy, as both require heavy-duty machinery installed inside an expansive manufacturing facility. One method is more expensive but yields a stronger end product, while the other is more economical with reduced performance, at least as far as a fluid medium for hydraulics is concerned. Seamless hydraulic tube is the stronger of the two, which is suitable for high-pressure hydraulic applications. It’s manufactured by forcing heated steel billets through an extruder, which is a series of drives, dies and a mandrel. The short, thick billet is formed into a longer, reduced-diameter tube, which then proceeds to downstream processes such as heat treating, quenching, straightening and resizing. Seamless tube (SAE J524 and ASTM A519) is most frequently used in fluid power applications, especially those with high-pressure requirements. Its superior strength, smooth internal surface, and uniform shape are perfect for reducing flow-related pressure drop, while its ductility makes it easy to bend and flare. Welded tube is still used as hydraulic tubing, and despite its lower pressure capacity and more economical production method, it’s still produced by large, impressive machinery. The factory starts by sourcing coiled steel of appropriate width for the circumference required for the finished tube diameter. Large tube manufacturers, especially, have the luxury of their own coil processing equipment to create the desired widths for the end customer’s tube size. The coil is fed from an uncoiler directly into the tube mill, where a series of dies progres-
ENERGY EFFICIENCY Ron Marshall • Contributing Editor
Plant engineer learns why compressed air drying matters FRED HAD BEEN THE PLANT ENGINEER at
RON MARSHALL/AI GENERATED
at very low demand. Because dryers are the packaging facility for usually sized for the nearly ten years, and he hottest and most humid thought he understood his day of the year, they compressed air system well. spend much of their The compressors ran, the life oversized for actual machines worked most of the operating conditions. time, and whenever there was Fred immediately a moisture problem someone thought about weekends usually changed a filter or at his plant, when drained a receiver tank. But production slowed but lately things were getting the dryers continued worse. running almost nonstop. Pneumatic cylinders That led him to were sticking. Solenoid investigate energyvalves were failing early. efficient dryer controls. Operators complained He learned that about inconsistent machine cycling refrigerated TO KEEP THE AIR FREE OF WATER IT MUST BE DRIED. THERE ARE VARIOUS CHOICES OF DRYERS, operation during colder dryers reduce power SOME BETTER THAN OTHERS. CHOOSE YOUR TYPE WISELY TO SAVE ENERGY. weather. One morning Fred consumption during light even found a rusty brown air dryers are designed to remove moisture loads, while advanced liquid dripping from an air line feeding a before it reaches production equipment. desiccant dryers use dew point controls critical packaging machine. “That can’t be Fred learned there are two common types of or moisture sensors to avoid unnecessary good,” he thought. dryers used in industry. regeneration cycles. During a Compressed Air Challenge The first was the refrigerated dryer After reviewing his system, Fred training seminar, Fred finally learned what already installed in his plant. These dryers discovered his old non-cycling dryer was was really happening inside his system. cool compressed air close to the freezing operating inefficiently for thousands of The instructor explained that air behaves point of water so moisture condenses and hours every year. By upgrading controls and much like a sponge. Warm atmospheric air can be removed. They typically produce reducing pressure differential across fouled naturally absorbs moisture. When an air dew points around 35° to 40° F, which is filters, the plant significantly reduced wasted compressor squeezes that air, the moisture acceptable for many industrial applications. energy while improving air quality and must go somewhere. As the compressed air The second type was the desiccant reliability. cools downstream, water condenses inside dryer. These systems use special moistureFor Fred, the biggest lesson was simple: the piping system. absorbing material to strip water vapor from compressed air drying is not just about And that water does not travel alone. It the air stream and can produce extremely removing water. It is about protecting mixes with dust, pipe scale, rust particles dry air with dew points as low as –40° F. Fred equipment, maintaining product quality, and compressor lubricant residue to form a learned these were often used in plants reducing maintenance headaches, and dirty soup that can contaminate equipment where moisture could ruin products or freeze controlling operating costs. And once again, throughout the plant. Suddenly, Fred in outdoor piping. the compressed air system proved something understood why his maintenance team kept But what really caught Fred’s attention Fred was learning more every year — the fighting the same problems over and over was the energy discussion. The instructor real savings are often hidden in the details again. explained that most dryers consume nearly nobody notices. The seminar explained that compressed full power even when the plant is operating FPW
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SEPTEMBER 2026 • FLUID POWER WORLD
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DESIGN NOTES By Mary C. Gannon • Editor-in-Chief
HEAVYTECH’S OPERATOR CAB COMBINES HIGH VISIBILITY WITH AN INTUITIVE DIGITAL CONTROL INTERFACE DESIGNED AROUND OPERATOR AWARENESS, COMFORT AND FUNCTIONALITY.
WHAT HAPPENS WHEN YOU GET a couple thrown out all preconceptions,” Johnson said. motor unit. That earlier work provided valuable of serial entrepreneurs together? They set out “Everything that we're putting together is out of experience in electrifying hydraulic systems, to disrupt and reshape the mobile machinery our own designs, and it's all designed around but HeavyTech is not using the HydraPulse or industry. That’s what co-founders Mike Terzo, this electrification premise of diesel hybrid or Terzo Power Systems technology. HeavyTech’s Andrew Johnson, Ryan Twiss, Nick Darrah and hybridization. architecture represents the next generation of Davide DeSilvio are doing with HeavyTech Inc. “Starting from scratch is going to give us Terzo’s work in electrohydraulics, developed as they build completely reimagined construc- long-term, real advantages. We'll be auton- independently as a complete, machine-level tion machines from the ground up. omy-ready. We’ve completely rethought the powertrain rather than as an individual elecBuilt on a hybrid platform, HeavyTech’s hydraulic system. We’re using power-on- trohydraulic pump unit. HeavyTech’s powerprototype compact track loader will have three demand electrohydraulic technology on the on-demand electrohydraulic powertrain is key features that its founders see as critical: powertrain side that is going to give us a lot of designed to provide efficiency, precision and right to repair and simple maintenance, high advantages," Johnson continued. "If we're suc- performance. Dedicated electric motors indefuel efficiency, and operator comfort. cessful, we could sell a cutting-edge compact pendently drive multiple work function pumps, As they began to build the machine in North- track loader or excavator for the same price as which eliminates energy losses and complexity east Indiana, they wanted to start with a clean most industry leaders, like Kubota or Bobcat.” associated with traditional hydraulic systems slate. “The big difference is we're starting from Terzo has been developing electrohydraulic that rely on directional and pressure control scratch. The leaders of the industry are really power-on-demand technologies for years. At valves. This valveless digital control architecnot incentivized to throw out all their existing Terzo Power Systems, he developed the Hydra- ture enables real-time high-resolution control designs and try something brand new. We've Pulse, an integrated electrohydraulic pump- of every vehicle function with instantaneous
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FLUID POWER WORLD • SEPTEMBER 2026
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HEAVYTECH (4)
HeavyTech redesigns construction machinery from the ground up
DESIGN NOTES
ABOVE: DIESEL ENGINE/GENERATOR UNIT. RIGHT: PROTOTYPE CTL UNDERCARRIAGE. INSET: PROTOTYPE VEHICLE WITH SINGLE SIDE BOOM-ARM DESIGN.
power delivery, greatly improving productivity, responsiveness and operational versatility. “The electrohydraulic architecture is a core part of what differentiates us. It’s a key breakthrough, particularly the valveless, digitally controlled system and independent electric pump drives,” Terzo said. “My earlier work at the component level helped shape how I think about electrohydraulic power-on-demand, but what we’re building at HeavyTech is a fully integrated, next-generation powertrain developed specifically for this platform.” HeavyTech is currently completing the build and integration of its first prototype compact track loader, including the cab, electrical systems, wiring harnesses and other vehicle-level components. The team has been testing and validating individual systems and subsystems throughout development, with full-vehicle testing planned to begin in the coming months as the prototype moves into its next phase of development. He noted that they went with a diesel-electric hybrid design because it offers the best of both worlds. “We've all seen the total electric solutions kind of play out. Duty cycles are an issue. Where do you charge it? It’s all the same things the automotive market struggled with. There’s no infrastructure,” he said. “An automotive comparison would be like we're kind of gunning towards the Toyota Prius. It’ll offer a good return on your investment, low maintenance, simple and easy to use, and intuitive.” Terzo added, “This analogy works from a simplicity standpoint, but we’d frame it more
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around performance improve- ency for owners and operators, while still mainments, jobsite practicality and taining appropriate safeguards around safetyduty-cycle efficiency — delivering critical systems,” Terzo said. “It will not be fully the benefits of hybridization/elec- ‘open-source’ across everything, but far more trification without the limitations accessible than current industry norms.” of charging infrastructure.” Johnson noted that this approach allows the Serviceability is key, Johnson said. Every machine to be diagnosed and repaired while component — whether mechanical, electrical maintaining safety. “There’s a tricky kind of balor hydraulic — is laid out for easy access, sim- ance, so there must be some interface for the plifying maintenance and repair tasks in the farmer to be able to work on and diagnose it field or in the shop. From removable panels in the field. That's a big goal for us. If we get and swing-out service doors to clearly labeled that accomplished, then the machines will be wiring and modular subsystems, the design is practical, and that's what we're thinking about intended to reduce the frustration of cramped — safety, practicality, total cost of ownership, spaces and buried components. and performance. Then emissions and carbon “We need to sell it at the same price as cur- footprint are icing on the cake.” rent machines. We can't be three, four times Terzo emphasized that HeavyTech is built the cost of a standard excavator. We must show to be as effective as other machines operating a much-reduced total cost of ownership, espe- in the field, and the goal is to be better overcially with repair costs,” he said. “We’re doing all. “This is an active engineering program with this by having a modular design, with less parts defined architecture and near-term execution, and universal parts across all our machines.” not just a conceptual effort,” Terzo said. “We’re The vehicles are being designed with open redefining what efficiency means in compact diagnostics and detailed service documenta- equipment. Our advanced hybrid and batterytion, allowing operators, fleet mechanics, and electric powertrains are designed to deliver independent shops to maintain and repair significant fuel savings and lower total cost equipment without needing proprietary tools of ownership— without sacrificing power or or restrictive software. By eliminating unnec- performance. Whether you're on the job site essary complexity and embracing transparency, or managing a fleet, our machines are built they are reducing downtime, lowering own- to keep operating costs low and productivity ership costs, and putting control back in the high.” hands of the machine owners and operators. “As for right to repair, our goal is to provide HeavyTech Inc. open diagnostics, serviceability and transpar- heavytech.ai FPW
SEPTEMBER 2026 • FLUID POWER WORLD
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FUNDAMENTALS By Josh Cosford • Contributing Editor
Common mistakes in manifold design folds, despite being a polysemy with manifolds used to join plumbing. Hydraulic manifolds are the most varied and unique possible valve combinations to suit specific machine needs. But with so many creative ways to execute them, the opportunity for mistakes is as plentiful as the people designing them. To help me illustrate the common mistakes in manifold design, I employed my friend Lisa DeBenedetto from GS Global Resources. With nearly four decades of fluid power experience, much of it spent directly overseeing manifold design, I couldn’t think of a better person to impart her wisdom. Many of the mistakes she’s observed revolve around the physical constraints of valves and their potential to obstruct one another or nearby ports. For example, limiting access to the valve's wrench flats could prevent correct installation or servicing. The same goes for manually operated valves or those with knobs, which must be allowed to rotate through their full range of motion without interference from valve coils, valve stems, or even other manual valves. DeBenedetto makes a good point regarding manual valves requiring 180 degrees of motion, so a 4/3 double-coil valve anywhere within the lever's arc "… is a problem." The same goes for a cartridge handpump, which is sometimes installed to provide auxiliary pump capacity in the absence of power. These hand pumps require space to operate, so designers must leave room for the handle, which must be inserted before pumping. DeBenedetto finished off the list of physical errors with, "Gloved hands to turn needle valve knobs — make sure there is clearance for a man’s hands with gloves to be able to grab and turn.” Of course, spacing errors aren't always related to the movement of levers, knobs, and screws. No manifold is complete without ports for attaching plumbing; designers must avoid mistakes when installing adapters and hose ends. DeBenedetto points out something that
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FLUID POWER WORLD • SEPTEMBER 2026
BECAUSE THEY CAN BE DESIGNED IN COUNTLESS WAYS, COMBINATION VALVES OR MANIFOLDS REQUIRE CAREFUL PLANNING.
is not always obvious: “If you need a 90-degree Although not something I would have conelbow, you need to make sure another fitting, sidered myself, DeBenedetto brings up a great port or valve is not in the way. You also need point regarding high velocity fluid. “If you have wrench clearance for the fittings.” an unloading cartridge acting as the poor man's “Countersinking valves is sometimes allowed load sense, the velocity and amount of oil that to make better cross-port connections, but then comes out that unloading valve will hit the side you need to make sure a socket can fit in the of the aluminum manifold and could eventually counterbore to tighten the valve,” DeBenedetto "worm hole" or eat away at the aluminum. So, added regarding the creative use of machin- wall thickness and whether that oil is expected ing. Indeed, if you can’t get a deep socket over to make a 90-degree bend out of the unloader a long valve, how is a technician supposed to need to be considered.” She would prefer install or replace it? to see high-flow manifolds (30 gpm and up),
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THIS ARTICLE IS ABOUT COMBINATION VALVES, which I personally refer to as mani-
machined in Durabar rather than aluminum. She continued regarding the best practices of internal porting. “A good rule of thumb when using cartridge solenoid directional valves is that port-1 should always be considered as the tank port whenever possible.” She then added, “Flow forces work against areas, and the nose of the cartridge usually has more area due to the end of the spool. Using port-1 as an inlet on solenoid directional valves could cause premature opening of the valve due to flow forces.” Regarding the internal design, DeBenedetto expertly added, “Make the port drillings as large as the cavity detail allows. If a drilling into a 10-2 cavity at port-2 is 0.406 in., then make it as close to 0.406 in. as possible where it makes sense. You can also do double drilling into a cavity port to lower pressure drops and add efficiency.” Sometimes a customer requires just one manifold, while others are shipped thousands.
Regardless of quantity, she made a good point “Over-torquing the long valves into their cavregarding mistakes in prototyping. "When ities, and over-torquing coil nuts is the numdesigning a prototype, always add test ports ber one problem I have seen with manifold for pressure transducers or gauges, and options assemblies. Watch the torque specs to avoid for orifices as needed. The prototype is always these problems. Over-torquing the long valve more expensive for the one-off, so why not put could cause the valve to bottom out, and the all the bells and whistles into it,” she said. “Then, cage can twist, causing the spool inside to bind,” validation testing can remove the items not she concluded. “Over-torquing the coil nuts needed for production to reduce costs … you stretches the tubes and causes the pole piece cannot usually add an orifice or test port after to not move smoothly in the tube assembly.” the block is drilled.” I’m humble enough to admit that I was Some of the mistakes in manifold design previously unaware of some of these wisdom increase setup and machining cost before bombs, so thanks to Lisa DeBenedetto for sharthe customer ever sees it. "The more sides a ing her vast knowledge on the subject. Indeed, designer can use on the manifold for valves, the there are many common mistakes in manifold more efficient the assembly will be,” DeBene- design, so be sure to avoid these in your next detto pointed out. “If all valves need to be on application. the top surface, the spaghetti of drillings will decrease efficiency and add pressure drop.” Finally, DeBenedetto pointed out the errors made during the assembly process.
From the original STAUFF Pipe Clamps to our Metric Tube Fittings and Quick Release Couplings, STAUFF offers port-to-port hydraulic solutions, components, and accessories for hydraulic systems and applications. STAUFF is your trusted source for industrial and mobile fluid power components and solutions worldwide.
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FPW
PROFILES IN FLUID POWER
ALKON CEO RAHUL DESHMUKH SPEAKS WITH BRYAN HARVEY, A MEMBER OF THE MACHINING TEAM, ON THE PRODUCTION FLOOR.
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PROFILES IN FLUID POWER
Rahul Deshmukh steers Alkon into the future For the first time in its history, Alkon has tapped an outsider to lead the company.
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LUID POWER WORLD’S MARY GANNON sat down with Alkon’s new CEO Rahul Deshmukh, to see where he will be focusing as he takes the helm at the company. Known for its pneumatic fittings, tubing, cylinders, and valves — for mobile and industrial markets — Alkon will concentrate on being a full-system solution provider while keeping its core tenets of skilled, customer-driven employees. Deshmukh succeeds Mark L. Winter, who served as President from 1996 to 2018, prior to serving as CEO and Chairman of the Board. Under Winter's leadership, Alkon has grown from a fifteen-person operation into a company with three state-ofthe-art manufacturing facilities and 300 employees in North America.
ALKON
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PROFILES IN FLUID POWER
ALKON TEAM MEMBER JESUS TORRES ASSEMBLES AIRBOSS PNEUMATIC CONTROL COMPONENTS.
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tinue to be a more complete, full-system solutions provider and an even better partner for our customers. Mary Gannon: That’s where the industry seems to be going — toward being a fullsystem provider. Can you talk a little bit about some of the key products that you see playing into that system-integration part for Alkon? You're known for a variety of technologies, including fittings and valves, but where do you think you’re going to take this in the future? Rahul Deshmukh: We have a fairly broad product portfolio of pneumatic components. The industry is moving toward solutions and, broadly speaking, fluid power solutions. We have such a strong foundation of a trusted brand. We offer best-in-class cus-
tomer service. Our customers trust our products. We have deep technical knowledge and expertise. In today’s environment, more importantly, we have a supply chain and manufacturing in North America. All of those things make us very unique in our ability to continue to grow beyond components into full systems or solutions. Mary Gannon: How do you preserve the legacy of those components that Alkon has always been known for while becoming the system integrator of the future? How do you maintain that reputation as you evolve the company? Rahul Deshmukh: The way we do that is really based on the foundation that we have. I think the nearly 75 years of trust that we have built with our customers is a strong foundation. Then you overlay on
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ALKON
Mary Gannon: You have a history growing industrial businesses. What attracted you to Alkon, and where do you see it moving forward as you take the helm? Rahul Deshmukh: I’ve been involved with private equity-held businesses since 2015, and so I’m fully familiar with engineered product applications and the B2B space. Alkon is such a strong, trusted brand in the markets that we serve. We have a history of nearly 75 years of working very closely with and delighting our fluid power customers. We have great people, innovative products and great service, with a focus on the customer. We serve some very marquee OEMs and channel partners. All of these were highly attractive because they are strong foundations to build on. Our focus now is to build on these strengths, expand our fluid power solutions and con-
PROFILES IN FLUID POWER
top of that our deep expertise in applications and engineering, and our ability to be highly innovative and hear the customers, to listen to the customers’ needs and wants, and be able to innovate quickly and bring those solutions to our customers and continue to delight them. It is really building on the strong foundation, but leveraging some of our strengths around innovation, North American manufacturing and rapidly scaling the business. Mary Gannon: Can you talk about some of the newer products that have been coming to the market recently as this evolution moves forward? Rahul Deshmukh: From an Alkon perspective, there are two specific products that I would like to talk about as we have transi-
tioned from being a component manufacturer to a full-system solutions provider. The first is the Alkon AirBOSS Control Box. It brings our DOT-compliant valves, controls, and fittings together in a centralized, durable enclosure. This gives the customer ease and speed of installation, fewer potential leak paths and a rugged, factorytested solution. The other innovative system that we have launched over the past couple of years is called the Alkon DuraLink, which includes our push-to-connect fittings and tubing. These are examples where we listened to our customers, got the voice of the customer into the business, and our engineers rapidly innovated with systems that helped customers reduce their operating costs, improve their uptime and give them peace of mind. Mary Gannon: I think that leads into thoughts about where the industry is headed — electrification, automation and digital. We’re seeing a lot of things shake up the industry. Sometimes people think that things like fittings or valves are commodity products, but there’s a lot that can be done to engineer them to fit into a greater, more
ALKON (3)
ALKON DURALINK DOT FITTINGS AND TUBING AND THE ALKON AIRBOSS CONTROL BOX DEMONSTRATE ALKON’S FULL-SYSTEM APPROACH TO PNEUMATIC SOLUTIONS.
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modern system. How do you see Alkon fitting into that new sphere? Rahul Deshmukh: While there is a growing need for these fluid power solutions, keeping them simple, reliable and durable is always critical. That is built into any kind of solution or system that we provide to our customers. As equipment becomes more sophisticated and as the needs of customers change, they are looking for systems that are reliable, easy to integrate and can be part of a much larger system. That means integrating fluid power technologies with smarter controls, sensing and automation. In mobile and transportation markets, the focus on reliability, safety and regulatory compliance continues to grow. As you are aware, these are continued areas of focus for our customers. During CVSA’s 2025 International Roadcheck, brake-related issues accounted for more than 40% of all vehicle out-of-service violations. That’s a big number, and this illustrates that a small control within a mission-critical system, such as a brake system, a DOT-compliant pushto-connect fitting, could have a significant impact on safety, uptime and our customers’ reputation, all of which are areas of focus for us. So, for Alkon, the opportunity is to bring together these reliable components that we are known for, leverage our application knowledge and our system-level expertise, and continue to meet our customers’ needs as their trusted full-system fluid power partner. Mary Gannon: Can you give me more details about Alkon’s manufacturing operations throughout North America? And how do you see things like AI in production or more modern manufacturing changing the way you do things over there? Rahul Deshmukh: We have continued to invest in our manufacturing capabilities.
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Mary Gannon: You talked a little bit about the culture, and Alkon has been led by the Winter family for decades. You’re the first outside person to lead this company in a while. How do you preserve that legacy and reputation while steering it into something new and exciting? Rahul Deshmukh: Yes, for the first time, the Winter family has brought in somebody from the outside to lead the business into its next phase of growth. But honoring the Winter family’s legacy really means preserving the two priorities that have been at the heart of Alkon: number one, putting customers first, and number two, supporting the people and investing in and developing the people at Alkon. The Winter family has built a company that has earned customers’ trust by investing in its people. My responsibility and my leadership responsibility is to build on that solid foundation, bring new experiences, new perspectives, new tools and
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RAHUL DESHMUKH TALKS WITH MACHINING TEAM MEMBERS RAY ROBERTS AND STEVE CHAMBERLAIN ABOUT ALKON PRODUCTS AND MANUFACTURING.
new systems while building on our existing strengths, and help the company scale rapidly. It is going to be absolutely critical to maintain the culture which is unique to Alkon. I always say it is easy to copy competitors’ products. It is easy to replicate processes and systems and implement systems and tools. But one thing that continues to differentiate companies like Alkon in the heartland of America is the unique culture that we have. And that is precious. Mary Gannon: You talked a little bit about some of the past products that have been updated in the systems. Where do you see new developments coming as you move with the systems approach? Where do you see the technologies evolving, and what are you going to be focusing on for the market? Rahul Deshmukh: Alkon’s biggest opportunity is going to be around our mission of being the trusted specialty fluid power partner. And we will do that by expanding our capabilities as a complete fluid power solutions provider and a systems integrator. We will be focused on broadening our product portfolio and strengthening our engineering and innovation capabilities. These are areas that we will continue to invest in. While we continue to look at new products, I would say there are two levers. One is around homegrown, new-to-the-business products that will continue to build on our differentiation and expand our capabilities. But the other that we are also going to embark on is acquiring products and businesses that would enhance our position
and continue to differentiate us as a trusted fluid power partner to our customers. Alkon has made several key acquisitions over the past couple of years. We have acquired Allenair. We have acquired AIRman in Michigan, and we are looking at additional acquisitions in this space. That’s part of our strategy, and the Winter family has committed equity to make that happen. Mary Gannon: Is there anything else that you’d like to share with the Fluid Power World audience that you think they need to know as you step into this role for Alkon? Rahul Deshmukh: I came into this role with the goal of helping Alkon scale rapidly and to continue to work toward its mission of being a trusted fluid power partner. Alkon has nearly 75 years of customer trust to build on. We have significant opportunity to organically and inorganically grow and be a trusted partner in the Americas and beyond. Our history gives us tremendous credibility in bringing new products to market and credibility around acquiring businesses and integrating them. But our future is going to be defined by how well we help our customers succeed. Having that fanatical focus on customers and using all the technology available today that we did not have decades ago to continue to get to our mission is going to be important. That is what excites me most about this role here at Alkon. FPW
Alkon Corporation alkoncorp.com
ALKON
We have manufacturing operations in Fremont, Ohio. We also have manufacturing in Brighton, Michigan. And we also have manufacturing operations in Mexico City. We are very uniquely positioned to serve our customers through these three centers of excellence from a manufacturing, engineering and design perspective. We have continued to make significant investments in our operations across these three facilities. We are continuing to drive significant operational and commercial improvements across the business. All of this is going to be led by the highly talented team at Alkon. That is something that I definitely want to talk about because automation, digital tools and AI will play a role, but they will not replace people. They will only make them more productive and efficient. As leaders, we will use these tools to manage the business and enhance the customer experience. It is going to be not just operations or manufacturing; it will be across the business. Some of these tools, such as AI, can also help us gain better insights into industry trends and customer needs, all of which help us be more effective, help us differentiate Alkon and be a true preferred partner to our customers.
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Fluid Power World’s Design Guide library features a variety of downloadable resources to help educate you on fundamental hydraulic and pneumatic technologies and components.
Design Guide: Preventing Failure in Your Fluid Power Systems Failure is a term that no engineer or technician wants to hear. Reliable uptime is crucial for every system and machine. In this design guide, we highlight key system prime movers as well as accessories that fail. Here, you will learn to recognize some of the signs of systems that are at risk of failing, how to diagnose them, and how to prevent them from failing in advance. Design Guide on Symbology Building Blocks Hydraulic symbology is a standardized system of symbols used to represent the components and functions of hydraulic systems. These symbols provide a clear and universal way to communicate the design, operation, and flow of hydraulic circuits. Here, we build upon basic elements and shapes to discuss the most common components in a hydraulic system.
Design Guide on Pneumatic Cylinders Pneumatic cylinders use compressed air to produce linear motion. They consist of a cylindrical chamber, a piston, and a rod, and convert energy from compressed air into mechanical force. Learn about the many types, including single-acting, double-acting, and rotary cylinders, that are used in industrial automation and motion control applications.
Design Guide on Metric Fittings Many different standards of fittings exist throughout the world — JIC, O-ring face seal, BSP, JIS, and more. Metric hydraulic fittings hydraulic hoses, tubes, and pipes to pumps, valves, and other hydraulic components. Learn where they’re used and how to specify them.
Design Guide on Hydraulic Filtration Filtration quality is the single most important measure of hydraulic machine health. More hydraulic failures are a result of particle contamination than any other cause. To effectively apply filtration, it is important to know to size, location and quality. Learn more on this critical system technology.
Visit www.fluidpowerworld.com/category/design-guides/ to learn more and download these helpful resources now!
HYDRAULIC HOSES
IMAGE HIGHLIGHTS THE MOVE FROM ANALOG TO DIGITAL IN HOSE CRIMPING.
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HYDRAULIC HOSES
Why PROPER HOSE CRIMPING is critical to UPTIME, REPEATABILITY and TRACEABILITY By Chad Peters, Product Manager for Equipment & Hydraulic Fittings at Continental
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CONTINENTAL
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OR HOSE DISTRIBUTORS, hose assembly shops and hose service operators, crimping is more than a routine production step. It is the process that joins the hose and fitting so the finished assembly can perform as intended. When the crimp is done correctly, it supports uptime, consistency and confidence in the finished assembly. When it is done incorrectly, the consequences can be detrimental and include unexpected downtime, hazardous leaks and safety risks to employees. Proper hose crimping is important for everyone involved in hose assembly operations, from the people managing the business to the operators using the equipment every day. The process needs to be accurate, repeatable and easy to follow. In many shops, the expectation is simple: the equipment must work, and the operator needs to be able to complete the task with minimal effort. That need for ease of use is increasingly shaping how crimping equipment is designed. Hose assembly has historically relied on more analog processes, including manual measurements and operator precision. As more industrial processes become digital, hose crimping has moved in the same direction.
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PROPER HOSE CRIMPING NEEDS TO BE ACCURATE, REPEATABLE AND EASY TO FOLLOW.
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operator approaches the process differently, or if settings are difficult to interpret, the chance of mistakes increases. A more guided process, through digital tools, helps reduce guesswork and supports more consistent results.
MAKING OPERATORS MORE EFFECTIVE Many hose assembly shops face workforce challenges, including high turnover in operator roles. That makes training, ease of use and process consistency especially important. A crimping process that depends too heavily on tribal knowledge or manual interpretation can create unnecessary risk when new or less-experienced operators are performing the work. The operator continues to be one of the most important components in the crimping process. Hose crimping is not fully robotic, and the process is still manual,
but smarter equipment can help operators make better decisions and get up to speed faster. The goal is to provide clear guidance, accurate specifications and a process that helps the operator complete the job correctly. That does not remove the need for skill. Instead, it supports the operator with a process that is more straightforward, less dependent on memory and less vulnerable to potentially avoidable errors. When the operator has the right specifications and an interface that clearly directs the work, the shop is better positioned to reduce mistakes.
FROM ANALOG SETTINGS TO DIGITAL GUIDANCE While the approach is slightly different with digital crimpers, the core function of the crimper continues to be to join the hose and fitting properly. The operator still inter-
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CONTINENTAL
WHY THE CRIMP MATTERS In hose assembly, the hose and fitting must be properly joined so the components work together as a finished product. The crimping equipment performs that critical function. Even when a shop uses high-quality hose and fittings, the assembly can still fail if the components are not put together correctly. The risks are not limited to product quality. If a hose and fitting are not assembled properly, there could be a fluid leak, an operator injury or a pressurized assembly failure. A fitting that is not properly secured can also become a projectile, posing an extreme safety hazard. The crimping process affects productivity and, most importantly, safety. This is one reason repeatability is so important. Hose assembly work involves doing the same task again and again. If each
HYDRAULIC HOSES
acts with the equipment and accesses the information needed to complete the crimp, but an easy-to-use, digital interface puts the necessary settings directly in front of the user, reducing the need to look up information or rely on manual adjustments. This makes the process more intuitive and consistent. In a guided workflow, the operator can select the required hose information, review the specifications and complete the crimp with fewer steps. This kind of interface can be especially useful in environments where training time is limited or where multiple operators use the same equipment. If the crimper equipment can guide the user through the process, it can help reduce variability from one operator to another. Continental’s new PC125i is one example of how crimping equipment is becoming more digital and connected. The equipment focuses on a three-tap-to-crimp operation, making it easier for the user to select the correct options. It uses ContiTech’s CrimpIQ Pro Mode technology, which provides overthe-air updates and streamlined crimp specification selection to help users achieve consistent, repeatable results. The equipment’s compact design improves portability without compromising performance. The crimper is compatible with ContiTech’s traceability solutions, including its CrimpCloud hose labeling technology. These labels help distributors and end users simplify after-sales service, support product authentication, and enable assembly fabricator branding using QR-code-based digital connectivity for fast identification and quick replacements. The PC125i is designed to support hose assembly in multiple environments, including service trucks, field repair, maintenance shops, distributor locations and mobile hose assembly, among others. For operators, the value is in making the crimping process easier to follow. For businesses, the value is in supporting consistency, traceability and confidence across different locations and use cases. CONTINENTAL
TRACEABILITY AND THE BIGGER PICTURE Shops and service operators are under increasing pressure to understand what
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was assembled, how it was assembled and whether the right process was followed. When crimping is treated as a digital, guided process, it becomes easier to support documentation, consistency and traceability. This is important for service, resale and life cycle value. A hose assembly does not exist only at the moment it is made. It may be used, serviced, replaced or reviewed later. Built-in traceability support can help connect the assembly process to the broader life cycle of the product and the equipment it supports.
Proper crimping is a technical process, and the benefits of digital crimping solutions are plentiful: fewer mistakes, better repeatability, improved traceability and less risk of downtime. As hose assembly operations continue to modernize, crimping equipment is doing more than applying force. It is helping operators make the right crimp, the right way, every time. FPW
Continental continental.com
REDUCING DOWNTIME AND AVOIDING REWORK Hose distributors, assembly shops and service operators cannot afford unnecessary downtime or assembly failures. A crimping mistake can create rework inside the shop, but it can also create problems if an assembly does not perform as expected. Smarter equipment can help mitigate these issues by making the process easier for operators, reducing guesswork and supporting more consistent results. When the process is clear and repeatable, through digital technology, shops are better positioned to avoid mistakes that lead to downtime or safety risks.
CONTITECH’S PC125I HOSE CRIMPER FOCUSES ON A THREE-TAP-TOCRIMP OPERATION, MAKING IT EASIER FOR THE USER TO SELECT THE CORRECT OPTIONS. IT USES CONTITECH’S CRIMPIQ PRO MODE TECHNOLOGY, WHICH PROVIDES OVERTHE-AIR UPDATES AND STREAMLINED CRIMP SPECIFICATION SELECTION TO HELP USERS ACHIEVE CONSISTENT, REPEATABLE RESULTS.
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MOBILE HYDRAULICS
Construction machinery trends: advancing digitalization and connectivity Connected systems combining sensors, controllers, software, displays and telematics are helping advanced hydraulics provide precise motion, control and energy management. By Rahul Das, Software Engineer IoT - Bosch Rexroth
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BOSCH REXROTH
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S DIGITALIZATION AND TECHNOLOGY advancements continue to change the construction industry, hydraulic components remain key players in connected mobile machines. Only a few years ago, the construction industry was considered one of the least digitized sectors and characterized as slow to innovate and adopt new technology. This is changing as the industry moves away from stand-alone mechanical and hydraulic functions and toward connected systems that combine sensors, electronic controllers, software, displays and telematics.
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MOBILE HYDRAULICS
WHEN OPERATORS REVIEW DATA ON MACHINE FAULTS, MAINTENANCE NEEDS, UTILIZATION, AND OVERALL MACHINE HEALTH, THEY CAN HELP SAVE MONEY AND KEEP PROJECTS ON TRACK BY REDUCING DOWNTIME.
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MOBILE HYDRAULICS
Reduced downtime, streamlined operations, improved safety and higher productivity rates among off-highway machinery are key drivers for this connectivity shift. On-demand access to machine information such as fuel consumption and component health helps strengthen machine operation to achieve these goals. Additionally, electronically controlled pumps, valves, sensors and more are forging a digitally connected path at the system level to enable more precise motion, control and energy management through closed-loop systems.
BENEFITS OF MOBILE MACHINE CONNECTIVITY Connected machines provide useful information to operators about faults, maintenance needs, utilization and machine health. This data is critical, as uptime is essential to maintaining a productive fleet. If operators are not managing data correctly, unplanned downtime can be incred-
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ibly costly, in both money and time, escalating to thousands of dollars a day from idle labor and missed project milestones. Remote access to machine data through digital integration can help service teams diagnose issues remotely, while integrated controls and assistance functions allow operations to become more intuitive and consistent. Connected hydraulics and ondemand access to machine information let operators make quick, informed decisions in real time. In turn, remote access to predictive maintenance helps forecast when a component may fail, allowing service teams to make preemptive decisions and limit downtime. In practice, this might look like a pump showing early signs of wear, prompting the digitally integrated display to alert the operator. This can also be identified remotely, so that off-site leaders can see machine status when systems are fully connected.
Another significant advantage of connectivity is the ability to continuously improve machine functionality after delivery. Historically, introducing new features often required hardware modifications or service visits. Today, connected platforms enable OEMs to deploy software enhancements, performance optimizations and diagnostic improvements remotely. This shortens development cycles, improves customer responsiveness and allows machines to evolve alongside changing operational requirements throughout their service life. Working in concert with predictive maintenance, over-the-air software updates can move the needle on machine availability and productivity by addressing machine needs. This allows teams to review fault information, operating signals and software status remotely and deliver an update without a separate site visit. This reduces troubleshooting delays and service effort while
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BOSCH REXROTH
ADOPTION OF SOFTWARE AND CONNECTED COMPONENTS IN HEAVY MACHINERY CAN IMPROVE MACHINE UPTIME AND MEET INDUSTRY DEMAND.
MOBILE HYDRAULICS
OFF-HIGHWAY APPLICATIONS LIKE EXCAVATORS, WHEEL LOADERS AND MORE CAN BENEFIT FROM DIGITALIZATION THROUGH IMPROVED PAYLOAD ESTIMATION AND STABILITY SUPPORT.
improving machine availability. Ultimately, digitalization helps OEMs develop and update functions more efficiently, while giving operators and service teams better visibility into machine condition, utilization and faults. This gives OEMs a practical way to respond to customer needs while supporting machine uptime and long-term value.
OPERATORS CAN MAKE REAL-TIME DECISIONS USING ON-DEMAND MACHINE INFORMATION FROM CONNECTED SYSTEMS.
BOSCH REXROTH
POPULAR MOBILE APPLICATIONS Excavators, wheel loaders, telehandlers, cranes and compact construction machines can all benefit from digitalizing or automating tasks. Common operational areas that can be improved with digitalization include payload estimation, collision avoidance, return-to-position, automated motion, stability support and fleet visibility. As applications are digitized, they increasingly depend on electronic hardware that is more powerful, rugged, connected and scalable. This advancement consists of the integration of
hardware, software, cybersecurity, diagnostics and lifecycle support into a single modular system. In this context, more powerful hardware allows for the processing of significantly more machine data while operating reliably in demanding construction environments. Modern controllers and connectivity devices must support advanced algorithms, high-speed communication, sensor fusion and real-time decision-making, all while withstanding vibration, dust, moisture and extreme temperatures commonly found on construction sites. Advanced control platforms can provide the computing foundation for increasingly complex machine functions, including operator-assistance systems, automated work
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HERE, CONNECTED MACHINES CAN LEVERAGE COLLISION-AVOIDANCE SYSTEMS TO DETECT POTENTIAL DANGER ZONES AND ALERT OR DIVERT THE OPERATOR. BELOW, RIGHT: SENSORS CAN ENABLE REAL-TIME DECISION-MAKING TO AVOID COLLISIONS AND PROVIDE MORE PRECISE MOTION CONTROL. BELOW, LEFT: VISUAL CONNECTED DISPLAYS CAN SHOW CRITICAL MACHINE INFORMATION SUCH AS FUEL CONSUMPTION AND COMPONENT HEALTH.
cycles, payload estimation, collision avoidance and machine safety features. Combined with ruggedized sensors for richer feedback, displays with more intuitive operator interaction, and connectivity units that can link the vehicle with service tools, these systems enable machines to process more information locally while maintaining communication with remote service and fleetmanagement platforms. This system-level approach benefits operators directly, who can maneuver mobile machinery more strategically thanks to better access to critical machine information.
MOVING THE INDUSTRY FORWARD Over the next 3-5 years, adoption of digitized components and solutions will increase, especially as younger generations enter the workforce. Construction equipment will become more software-centered, updatable and automated, all of which the younger generation grew up with and can
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understand quickly as digital natives. In turn, technicians and operators will read data and respond to potential problems more quickly to limit downtime. These connected machines will help combat the growing labor shortage and resulting project delays that have impacted 45% of contractors, which underscores importance of becoming an expert in digitalized machinery. In 2026, the industry will need to add around 500,000 new workers to meet current demand, making uptime and machine productivity more important than ever for projects to remain on track. Additionally, more realtime processing will occur directly within the machine, while cloud platforms will support fleet-level analysis and decision-making. As more machines become con-
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nected, the focus shifts from simply collecting data to managing it securely, efficiently and responsibly. This is where open architectures, cybersecurity, access control and responsible data ownership will become increasingly important. Open architectures allow OEMs, fleet owners and service providers to integrate equipment into broader digital ecosystems rather than being restricted to a single proprietary solution. This flexibility helps data from machines, service tools and fleet-management systems work together more efficiently, enabling fleet owners to derive more value from connected assets. At the same time, cybersecurity and access control have become critical as machines increasingly exchange data, software updates and diagnostic information across public and private networks. Secure communication, role-based access management and software lifecycle controls help ensure that only authorized users and systems can access critical machine functions and data. Responsible data ownership now becomes equally important as the industry moves toward this flow of data exchange. Fleet owners need clear visibility into what machine data is collected, who can access it and how it is being used. It becomes critical to protect the machine data that often contains valuable information related to utilization, productivity, operating conditions and maintenance practices. Transparent datamanagement frameworks help maintain customer trust while enabling advanced services such as remote diagnostics, predictive maintenance and fleet optimization. Experience with connected machine scenarios shows that customers expect not
only connectivity, but also confidence that machine and fleet data remain secure, traceable and under appropriate customer control. With regulations such as the European Union's Cyber Resilience Act emphasizing security for connected products, cybersecurity and responsible data governance are becoming fundamental requirements rather than optional features. Additionally, connectivity will increasingly support diagnostics, fleet health, configuration and software lifecycle management. This will be critical for leaders whose biggest concern is downtime and machine health, delivering cost and energy savings through improved uptime. Adoption will be incremental, beginning with practical use cases such as remote diagnostics, fleet visibility, over-the-air updates and operatorassistance functions before expanding into more advanced automation capabilities.
CRITICAL LEADERSHIP DECISIONS It is important for leaders to assess their current operations and what changes are needed. Digitalization of construction equipment should solve a real operator, service or business problem rather than simply adding technology for its own sake. Because construction machines work in harsh environments and may have limited network coverage, solutions must be robust, secure and able to operate reliably offline, factors that should be weighted carefully before making decisions to upgrade equipment. The best starting point is identifying a clear problem that needs to be solved, such as reducing repetitive work, improving accuracy, preventing overload or simplifying operation. Researching the types of technology and connected frameworks in the marketplace is essential when upgrading mobile machinery. Machine connectivity is worth the time and investment as the industry continues to advance and technology evolves, but leaders should approach the process strategically to avoid costly delays and downtime. FPW
Bosch Rexroth boschrexroth.com/en/us
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