Hydraulic Control Systems
Power units, manifolds, actuators and valving sized against the real duty cycle — not the one on the original nameplate.
Control Systems
Control Systems
Hydraulic, pneumatic and electro-mechanical control designed as one system — power, actuation, sensing and logic specified together rather than bolted together.
Control problems are rarely confined to one discipline. A slow actuator might be a hydraulic sizing error, a valve response issue, a sensor lag or a control loop tuned for different conditions — and a supplier who only owns one of those will find the fault in someone else's scope.
We take responsibility for the whole chain: power unit, actuation, valving, sensing, wiring and control logic. That means when the system does not do what it should, there is one number to call and one party accountable for finding it.
What this service covers
System design & sizing
Load, duty cycle and response requirements converted into a specified circuit — pump, cylinder, valve and accumulator sizing with the calculations shown.
Hydraulic power & circuits
Power units, manifolds, cylinders and valving specified, built and commissioned for the actual duty.
Pneumatic circuits
Air preparation, actuation and valve island design for clean, fast, low-maintenance motion.
Electro-mechanical integration
Motors, drives, sensors, limit switches and interlocks wired into a coherent, documented control scheme.
Control logic & instrumentation
PLC and microcontroller logic, sensor selection and calibration, and operator interfaces built on our software development capability.
Commissioning & handover
On-site commissioning, tuning and operator familiarisation, with as-built schematics and a maintenance schedule.
Specialist capabilities
Each of these is a discipline in its own right. Follow through for scope, deliverables and the questions clients ask most.
Pneumatic Control Systems
Fast, clean actuation with the air preparation and circuit design that keeps it repeatable through a full production shift.
Electro-Mechanical Integration
Motors, drives, sensors and interlocks brought together into one documented control scheme your maintenance team can actually work on.
How the work runs
Survey
We measure the existing system and the duty it has to meet, on site, before proposing anything.
Circuit design
The hydraulic, pneumatic and electrical schematics are produced and reviewed with your engineers.
Build
Panels, power units and assemblies are built and functionally tested before they reach the plant.
Install & commission
Installation, loop checks, tuning and safety verification against the agreed acceptance criteria.
Support
As-built documentation, spares list and a maintenance interval you can plan around.
What you receive
- Hydraulic, pneumatic and electrical schematics, as-built
- Component sizing calculations and selection rationale
- Built and tested control panels and power units
- Commissioning record with measured performance figures
- Recommended spares list with sourceable part numbers
- Preventive maintenance schedule and operator notes
Common questions
Can you retrofit controls to old machinery?
Yes, and it is a large part of this work. Mechanically sound machines with dead or unsupportable controls are usually far cheaper to retrofit than to replace, and a retrofit lets you add sensing and diagnostics the original never had.
Do you work with the PLCs already on our site?
Wherever possible we standardise on what your maintenance team already knows and stocks. Introducing a fourth brand of controller to a plant is a maintenance cost, not a feature.
Who commissions the system?
We do, on site, and we do not consider the job finished until it meets the acceptance criteria agreed at survey stage. See testing and maintenance for ongoing support once it is running.
Related
Services that pair with this one
Work rarely stops at one discipline. These are the service lines most often used alongside control systems.
Design & Development
Concept, engineering and prototyping through to a production-ready design pack.
Manufacturing Services
Precision machining, fabrication and form-fit parts made to drawing.
Testing & Maintenance
Functional testing, PCB repair and condition monitoring that catches faults early.
Sourcing & Supply Chain
Hard-to-find electronic and mechanical parts, procured and verified.
Trading Services
Import, export and distribution of technical equipment, delivered landed.
Reading
Related insights
When the OEM Part Is Gone: A Practical Guide to Reverse Engineering Spares
Copying a part is easy. Reproducing what it does in service — including the properties the original drawing never recorded — is the actual job.
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Does Condition Monitoring Actually Pay? Working Through the Arithmetic
The answer does not depend on how big your plant is. It depends on what one specific machine stopping costs you, and how much warning you would need to avoid it.
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Tell us what has stopped, or what you need built.
Send a drawing, a sample or just the symptom. We will tell you the quickest route, what it costs and how long it takes.