In the hydraulic industry, there is growing demand for increasingly precise and interconnected systems. Today, in addition to power and reliability, smart hydraulic cylinders must be able to communicate with the user and provide detailed information on their operating status.

With this in mind, Conforti Oleodinamica has embarked on an intensive programme of development and testing of new solutions to integrate position and movement detection devices directly into its intelligent hydraulic cylinders. The company's main objective is to offer cylinders capable of communicating with control systems, transmitting piston positioning data in real time and allowing precise stroke management.

Thanks to Conforti's applied sensor technology, it is possible not only to know the absolute positions, but also to continuously monitor every single millimetre of movement. The result is a smart hydraulic cylinder capable of providing immediate feedback to the control system, improving operational efficiency, reducing downtime and increasing process reliability. This approach represents a decisive step towards the integration of traditional hydraulics with Industry 4.0 logic.

MP COMPACT CYLINDERS: VERSATILITY AND PROMPT DELIVERY

Conforti's MP series stands out for its versatility and fast delivery. Their compact and lightweight structure makes them ideal for applications where weight reduction or space optimisation is required. These cylinders are equipped with a magnetic piston, which allows for the application of various types of sensors with different functions:

• Reed or magnetoresistive sensors, which can be placed at any point along the stroke to detect the passage of the piston;
• new IO-LINK electronic sensors, capable of detecting the piston throughout the entire stroke of the compact cylinder, providing a continuous position reading or an ON/OFF signal on 8 programmable reading points.

An important feature of the new sensors is their full backward compatibility with the entire range of short-stroke MP cylinders manufactured by Conforti.

The company has conducted numerous tests to ensure that the installation of the devices does not require structural modifications. This solution allows companies to easily upgrade existing cylinders, transforming them into digitally monitorable components without having to replace the entire system. This is a concrete advantage in terms of sustainability, costs and implementation times.

MAGNETIC SENSORS ON ISO 6020/2 HYDRAULIC CYLINDERS

Another option for motion control is represented by ISO 6020/2 tie-rod cylinders in magnetic version, in which two or more positions can be identified along the stroke. In this case, magnetic sensors are installed outside the stainless steel jacket and allow even intermediate points to be detected with precision, improving the management of complex movements.

END-OF-STROKE PROXIMITY SWITCHES

For limit switch control, the company offers the option of integrating proximity sensors on the cylinder heads. This configuration is compatible with the entire Conforti range, both with ISO 6020/2 models (with tie rods or counterflanges) and with ISO 6022 cylinders, ensuring great flexibility of adaptation.

MAGNETOSTICTIVE TRANSDUCERS: MAXIMUM PRECISION

The most advanced solution for stroke monitoring is the integration of magnetostrictive transducers in the TD/TK series servocylinders, which allow the position of the piston to be known at all times throughout the entire stroke. This type of sensor ensures continuous measurement, offering maximum precision even in harsh working conditions. Thanks to this technology, the operator or control system can dynamically adjust the position of the cylinder, ensuring smooth and repetitive movements. Constant feedback also allows for optimised work cycles, reduced errors and increased operational safety. The transducers are available with different types of output signals — analogue (4–20 mA and 0–10 V) and digital (SSI, PROFINET, EtherNet/IP™, EtherCAT® and many others) — for integration into the most advanced automated systems.

COMPETITIVE ADVANTAGES OF HYDRAULIC CYLINDERS WITH SENSORS

The introduction of sensors in hydraulic cylinders brings numerous benefits:

• Total control of movement, with the ability to know position and speed in real time.
• Reduced maintenance, thanks to constant monitoring of the component's status.
• Greater safety, as the system can intervene automatically in the event of anomalies.
• Easy integration into automated processes, even on existing systems.

These features make Conforti's smart hydraulic cylinders a strategic choice for those seeking reliability and precision without compromising on ease of installation.

FIELDS OF APPLICATION

Intelligent hydraulic cylinders are used in numerous industrial contexts where precision and control are essential. In industrial automation, they optimise production cycles and reduce machine downtime thanks to continuous position monitoring. In machine tool , they guarantee repeatability and precision in high-speed mechanical machining processes. In steel mills, they operate under harsh conditions with constant control even in high-temperature environments. Finally, in industrial presses and lifting equipment, millimetric stroke control increases safety and operational efficiency.

TOWARDS DIGITAL HYDRAULICS

The journey undertaken by Conforti Oleodinamica responds to the growing need to digitise even traditional mechanical components, transforming them into active elements of the production system. The goal is not only to improve the performance of individual cylinders, but to offer a new level of interaction between man, machine and data. The technological evolution of hydraulic cylinders, therefore, no longer concerns only materials or operating pressures, but the ability to collect and transmit information useful for optimising the entire process. Thanks to the combination of mechanical robustness and digital intelligence, modern hydraulics becomes an integral part of the most advanced automation architectures.