Modern Electromagnet Solutions for Mobile Hydraulics

The function of electromagnets in mobile hydraulics is based on the generation of an electromagnetic field. The magnetic field then generates mechanical work, which results in a linear movement.

When the electromagnet is used in a hydraulic application, it is used to control moving components. The moving component to be controlled is usually a valve. The armature in the solenoid generates the movement and controls the valve.

There are different types of solenoids that can be used in mobile hydraulics. Some of them are:
 

• Switching solenoids: Switching solenoids are used to open or close a valve. They are simple in design and can be easily integrated into existing hydraulic systems.
• Proportional solenoids : Proportional solenoids are able to control the movement of a valve in proportion to the applied current. They offer greater accuracy than switching solenoids and are therefore more suitable for applications that require precise control.

The selection of the correct solenoid type depends on the specific application and should be carefully considered to ensure that the requirements are met.

The advantages include above all the robust design and low sensitivity to all types of emissions (dirt, temperature, vibrations, etc.). Another advantage is their controllability. They can achieve precise, fast movements with high dynamics, which makes them ideal for mobile hydraulics applications. Furthermore, electromagnets can reach very high forces, which is required in mobile hydraulics in, for example, cranes and excavators. Other advantages:
 

• Low technical complexity compared to an electromotive solution
• Simple electrical control
• Wide operating temperature range
• Few moving parts
• Long service life and no maintenance required
• High protection classes and explosion-proof products

Electromagnets play an important role in hydraulics, primarily at the interface between the electrical control system and the power medium for the operation of a wide range of machines. They are therefore used in many mobile hydraulics applications to enable the movement and control of hydraulic systems. Here are a few examples:
 

• Excavators and cranes: Electromagnets are used in excavators and cranes to control the hydraulic grabs and buckets. Solenoids can also be used to control the support legs and other moving parts.
• Agriculture and forestry: Electromagnets are used in agricultural machinery such as tractors and combine harvesters to control the movement of attachments such as ploughs and mowers. They can also be used to control hydraulic trailers and other moving parts.
• Construction machinery: Electromagnets are also used in various types of construction machinery to control the movement of hydraulic cylinders, slides and valves. They can also be used to control hydraulic brakes and clutches.
• Commercial vehicles: In commercial vehicles such as lorries and buses, solenoids are used to control hydraulic systems such as steering, brakes and clutches. They can also be used to control hydraulic trailers and other moving parts.

Overall, electromagnets play an important role in mobile hydraulics as they provide a precise and efficient way to control the movement and steering of hydraulic systems.

Clear development trends have also emerged in the field of mobile hydraulics in recent years. Building on the established strengths of solenoids - precise valve control, high dynamics and robustness - new technological and market-driven trends are influencing the requirements placed on hydraulic systems. Digitalisation and increased efficiency are seen as key drivers, while sustainability and energy saving are often increasingly coming into focus at the same time. Below, we provide a brief overview of the most relevant trends that characterise the use of electromagnets in mobile hydraulics.

• Cross-industry: Electrification, emissions standards and sustainability
  The increasing electrification of mobile work machines in construction, agriculture or logistics requires rethinking the design of hydraulic control components. Electromagnets must often integrate seamlessly into battery-electric systems and help reduce energy consumption. Moreover, stricter emissions regulations, such as EU Off‑Highway directives or ESG requirements, call for a sustainable systems-wide approach. Electromagnets with long service life, maintenance-free operation and environmentally friendly materials help improve ecological performance – not only in operation but throughout the lifecycle.
• Greater integration, miniaturisation and expanded functionality
  Available installation space in modern mobile machines is often limited. Compact designs with high power density become key requirements. Electromagnets combining multiple functions in one component – for example position sensing and valve control – significantly aid system integration. Demand is also rising for proportional technology enabling smooth, precise movements. Intelligent control systems with feedback interfaces (e.g. CAN, IO‑Link) turn valve magnets into mechatronic systems with independent diagnostics and control logic. Hybrid solutions with electronic pre‑control are increasingly implemented.
• Increasing Demands on Functionality and Robustness of Electromagnets: Despite all technological advances, classic requirements still apply: high switching force, long service life, and maximum robustness against vibrations, moisture, and temperature. Electromagnets used in mobile hydraulics must reliably fulfil these properties even in a compact design. Particularly in demand are solutions offering high protection ratings (e.g. IP69K), ATEX conformity, or E1 approvals. For manufacturers of mobile machines, it is therefore worthwhile to rely on high-performance partners with comprehensive development expertise. Highly specialised components — tailor‑made on request and with state‑of‑the‑art magnet and coil technology — often open up completely new scope for designing efficient and sustainable hydraulic systems.