Proactive hydraulic cylinder monitoring

Proactive hydraulic cylinder maintenance saves money and boosts operational efficiency


The hydraulic cylinder plays a key role in any heavy-duty machine, converting hydraulic energy from the engine into the force and motion required for operation. In effect, it acts as the “muscle” of the equipment—essential for delivering reliable and controlled movement. Cylinders are engineered for durability and safety, built to withstand demanding conditions over time.

However, in real-world worksite environments, cylinders are subjected to extreme stress. Contaminants, harsh operating conditions, and heavy use can all contribute to unexpected failures, regardless of how robust the component is.

A sudden breakdown—whether due to leakage, structural damage, or another fault—can result in significant costs. If the cylinder becomes inoperable and operations are forced to pause, downtime costs may exceed €50,000 per hour. In cases where a full plant shutdown occurs, the financial impact can reach millions of euros per day.

Given these risks, proactive maintenance and timely repair of hydraulic cylinders are not just recommended—they are essential for maintaining operational efficiency and avoiding costly interruptions.


Hydraulic cylinders don’t need to fail


Unexpected hydraulic cylinder failures can often be avoided. With proactive condition monitoring, such as the LEO system (Lifecycle Efficiency Online), it’s possible to track the health and performance of hydraulic cylinders in real time.


LEO monitors key indicators and detects deviations from normal operation. When irregularities are identified, the system issues a warning—allowing maintenance to be planned before a failure occurs.
This approach supports continuous, uninterrupted operation of machinery, reduces the risk of unplanned downtime, and helps extend the life of critical components.


How does proactive condition monitoring work?

Proactive condition monitoring—such as the LEO system (Lifecycle Efficiency Online)—collects data from sensors installed on hydraulic cylinders and transforms it into actionable insights. LEO compares real-time usage data from the cylinder to its calculated theoretical lifespan, enabling it to predict the cylinder’s remaining service life. This means maintenance or replacement can be planned and scheduled in advance, reducing the risk of unexpected failures and costly downtime. The system also identifies which part of the cylinder is showing signs of wear or failure, making it faster and easier to locate faults and carry out repairs or replacements efficiently. In addition to monitoring condition, LEO provides insight into how the machine has been used and what kind of stress the cylinders have been exposed to. With this data, it’s possible to adjust operating practices to reduce unnecessary wear and extend component life. The visualized data for an individual machine can be accessed via a mobile app, or—if multiple machines are being monitored—through a web portal, allowing for easy analysis across fleets.
 

Why invest in proactive condition monitoring?


Proactive condition monitoring delivers clear business value. By detecting wear and potential faults before they lead to failure, it allows for timely maintenance, helping you avoid unplanned downtime and costly interruptions. With fewer unexpected breakdowns, operations remain on schedule, productivity improves, and overall profitability increases. In short, proactive monitoring isn’t just about protecting your equipment—it’s a smart move for your bottom line.


The benefits of proactive condition monitoring
Proactive condition monitoring offers a wide range of advantages that directly support both operations and business performance. You can:
Collect real-time data from your machine or equipment, including how it’s being used
Predict and plan hydraulic cylinder maintenance before issues arise
Avoid costly interruptions and unplanned downtime
Improve customer satisfaction through more reliable operations
Stay ahead of the competition with smarter maintenance strategies
Access real-time insights into pressure, movement, and stroke—valuable data for both maintenance and product development
Lower production costs through better resource planning
Use post-incident data to identify and analyze the root cause of issues, accidents, or failures
Monitor and optimize performance continuously

Solutions such as LEO can be installed on hydraulic cylinders from nearly any manufacturer, meaning you can centralize data collection and analysis across all machines on a site. Installation can be done either during cylinder manufacturing or as a retrofit during maintenance, making it a flexible solution for both new and existing equipment.

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