Advanced Electro-Hydraulic System Design & Integration
Electro-Hydraulic System Design
AIMRSE delivers fully integrated electro-hydraulic solutions that merge mechanical power density with precision electronic control. Whether you need a turnkey hydraulic power unit, a closed-loop motion control system, or an energy-efficient upgrade to existing equipment, our engineering team provides the complete design and validation package—from initial schematic development to final on-site commissioning.
Leveraging proprietary simulation tools and a deep portfolio of in-house manufactured components, we eliminate the guesswork from hydraulic circuit design. Our approach ensures optimal component sizing, minimized pressure losses, and robust control logic that withstands the harshest industrial duty cycles.
For legacy systems experiencing chronic leakage, we also offer specialized seal failure analysis and life prediction prior to redesign.
Share your force, speed, and control precision targets with our engineers for a feasibility assessment and preliminary hydraulic schematic.
Request Engineering ConsultationTypical response within one business day.
Core Electro-Hydraulic Engineering Capabilities
System Architecture & Simulation
Full hydraulic schematic generation with Amesim/Simulink dynamic simulation. We verify pressure transients, flow distribution, and thermal balance before a single component is ordered.
Control Logic Development
PLC and motion controller programming for position-force closed-loop control. Includes HMI interface design and safety interlock logic compliant with ISO 13849.
Manifold & Power Unit Design
Compact cartridge valve manifolds and custom hydraulic power units utilizing our premium fluid power components. 3D CAD models with integrated pressure testing ports for simplified maintenance access.
Energy Efficiency Optimization
Load-sensing and variable-speed pump control strategies to reduce heat generation. We quantify potential annual energy savings as part of the design deliverable.
Prototype Validation
Pre-shipment testing on our 350 bar (approx. 5,000 PSI) test rigs under simulated load profiles. Performance curves and step-response data are documented for your records.
On-Site Commissioning Support
Our field engineers assist with final tuning, bleeding procedures, and operator training to ensure a seamless transition to production.
Integrated Design & Validation Infrastructure
AIMRSE maintains a dedicated electro-hydraulic engineering lab equipped for both virtual prototyping and physical validation. This infrastructure enables us to de-risk complex designs and deliver systems that perform as simulated.
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1D/3D Co-Simulation Environment
Combining Siemens Amesim for hydraulic network analysis with Simulink for control algorithm development. This co-simulation validates the interaction between fluid dynamics and electronic feedback loops before hardware assembly. -
Programmable Logic Controller Test Bench
Features Siemens and Rockwell PLC hardware for code debugging and hardware-in-the-loop testing. We emulate sensor feedback and actuator loads to validate control logic under fault conditions. -
High-Fidelity Hydraulic Test Rig
Capable of continuous operation up to 5,000 PSI (350 bar) with integrated flow, pressure, and temperature sensors. Data acquisition at 10 kHz captures valve dynamics and pump ripple characteristics for performance tuning. -
3D Mechanical Design & Piping Suite
SolidWorks-based manifold and power unit design with automated BOM generation. Integrated flow simulation ensures uniform velocity distribution and minimizes manifold pressure drop.
Fig. 1. Integrated hydraulic test bench with multi-channel DAQ and PLC simulation interface.
Featured Electro‑Hydraulic System Application
Inconsistent Clamping Force and Slow Response in Automotive Stamping Press Retrofit
A Tier-1 automotive supplier needed to modernize a 1,200‑ton mechanical stamping press with a high‑speed hydraulic cushion system paired with heavy-duty hydraulic cylinders. The existing hydraulic circuit suffered from pressure oscillations during rapid die closure, leading to part thickness variation and unacceptable scrap rates. Additionally, the legacy directional valve manifold introduced a 350 ms delay between trigger signal and full clamping force, limiting production throughput.
The Solution: High‑Response Proportional Control and Optimized Accumulator Sizing
AIMRSE engineers designed a new hydraulic cushion circuit using high‑flow proportional pressure relief valves and a fast‑acting logic cartridge. A dynamic simulation model was built to optimize accumulator pre‑charge pressure and volume, reducing pressure ripple by 74%. A dedicated PLC subroutine was written to implement feed‑forward control based on ram position, eliminating response lag. The new manifold block integrated all valving into a single, leak‑free cartridge body.
Validated Cycle Time Reduction and Improved Part Consistency
32% Faster Response Time
Post‑retrofit measurements confirmed a reduction in force‑buildup delay from 350 ms to 240 ms, enabling an additional 4 strokes per minute. Clamping force variation decreased from ±8% to ±1.5%, virtually eliminating thickness‑related scrap. Annual energy savings from reduced pump idling exceeded 19,000 kWh per press.
Frequently Asked Questions — Electro‑Hydraulic Design
What types of electro‑hydraulic systems do you design?
Do you provide control logic programming and PLC integration?
Can you retrofit an existing hydraulic system for improved efficiency?
What simulation tools are used to validate the design?
Do you offer on‑site commissioning and training?
Engineer Your Electro‑Hydraulic Advantage
From a single customized manifold to a complete turnkey system with PLC integration, AIMRSE provides the engineering depth to bring your motion control concept to life. Share your performance targets with our team for a preliminary feasibility review and design consultation.
For immediate technical questions or schematic reviews, contact our electro‑hydraulic design group at info@aimrse.org.
Disclaimer: All products are for industrial B2B use only. Specifications subject to change without notice.
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