New system for monitoring hydraulic pump systems

Purpose and Objectives

The main objective of MonPuForm is to minimize the risk of critical operational issues and wear, while improving the reliability of hydraulic pump systems. The project aims to identify key parameters and develop an integrated monitoring system that supports predictive maintenance, ensuring pumps are only serviced or replaced when a potential failure is anticipated.

Background and Challenge

The shift towards a resilient, climate-neutral industry requires greater digitalization, improved resource efficiency, and strengthened resilience across the entire value chain. This is especially true in the manufacturing sector, where the need for advanced plant technology that supports these goals is on the rise. Furthermore, there is increasing demand for production support of geometrically complex components based on novel materials with tailored properties.

In forming technology, the transition is reflected in modified and new process techniques (e.g., pulsation drawing, press hardening). The broader application of advanced forming processes leads to increased strain on machine components, particularly hydraulic drive systems for forming machines. Additionally, the boundary conditions related to load cases, and therefore the stress on the hydraulic drive system, are constantly changing due to a wide product range and smaller batch sizes, which is particularly relevant for small and medium-sized enterprises (SMEs).

These conditions can lead to significant damage to pump systems, potentially causing damage to the component in continuous operation, up to and including total failure.

Solution

A promising method for reducing operational uncertainties and detecting overloads or critical wear and tear conditions at an early stage is monitoring of the hydraulic pump system. While sensor-based monitoring systems for physical variables are already available in the market, they often struggle to accurately assess the operational status of complex hydraulic systems.

Therefore, MonPuForm aims to develop a condition monitoring system that provides knowledge-based support for the operation of hydraulic pumps used in hydraulic servo presses. The foundation of the project is a sensor system integrated into the hydraulic drive system. The key to effectively monitoring machine components lies in linking sensor data with technology-specific process and machine data.

Additionally, the information and data can be used to strengthen or redefine existing business relationships between machine and component manufacturers, as well as to develop new business models using the new monitoring system.

Expected Impact

The project is anticipated to have a range of positive effects for Sweden and its competitiveness. Currently, pumps are often replaced prematurely by adhering to standard service intervals. The implementation of the MonPuForm system would enable predictive maintenance, allowing pumps to be repaired or replaced only when the monitoring system predicts a risk of failure. Hydraulic servo presses are a significantly more resource- and energy-efficient alternative to conventional servo presses. Access to a predictive monitoring system that significantly reduces pump system failures would promote the wider use of hydraulic servo presses in the manufacturing sector, ultimately helping to conserve the Earth’s resources.

The development of an advanced monitoring system positions Sweden as a technological leader in the manufacturing industry and can help Swedish industry expand its presence in multiple markets. We also anticipate that the project will promote skills development and generate new expertise in areas such as data analysis, IoT technology, and industrial automation—factors that could attract young, talented workers to the manufacturing sector.

Successful project outcomes could be applied to other types of pump systems, thereby having an even greater impact on sustainability.