TECHNOLOGY FOCUS
Fluid Power and Handling
A roundup of recent advances in engineering technology. In this issue, a look at some of the latest innovations and advances in fluid power and handling technology.
STEER-BY-WIRE TECH
Automated steering isn’t easy to apply on off-highway equipment without significant added costs. Traditional hydro-mechanical systems rely on orbital valves, while add-on electro-hydraulic manifolds just attach onto an existing machine. And complete steer-by-wire (SbW) systems replace mechanical and hydraulic linkages entirely with electronic controls.
In February, Husco released what it’s calling a safe, simple, and scalable path to off-highway SbW. GenSteer™ is a patent-pending SbW technology that reimagines the steering control unit from the ground up. It uses the operator’s own input as a fail-functional power source, just like traditional hydraulic orbitals. If a fault occurs, the system seamlessly transitions to operator-powered control with no lag, no loss of steering, and no backup electronics required.
During normal operation, a force-feedback motor delivers real steering feel while electro-hydraulics control the wheels. During an electrical fault, GenSteer instantly becomes a generator, converting operator input into electrical power to control the hydraulic valve and maintain steering. This approach preserves trusted safety while unlocking digital control.
“The GenSteer platform is designed to start simple and scale with you. OEMs don’t need every automation feature on day one to justify the investment,” explained Ben Holter, Husco’s product director, in a press statement. “Begin with a compact, compatible steering platform, then add capabilities like lane guidance, return-to-center, and haptic feedback as your needs evolve. It’s a practical on-ramp to Steer-by-Wire—without the heavy bill.”
Photo: Husco
A CEPHALOPOD’S DELICATE GRIP
Robotic grippers don’t have quite the finesse of a human hand and typically have less luck when handling delicate objects. But a team of researchers from the Lanzhou Institute of Chemical Physics at the Chinese Academy of Sciences and Shanghai Jiao Tong University has developed a hydraulically actuated solution that draws inspiration from nature.
This octopus-inspired hydraulically actuated gripper is made from hydrogel and can handle extremely fragile objects (as soft as egg yolks and tofu) underwater without causing damage.
What makes this possible are the gripper’s material and structure. The hydrogel is engineered using cooperative hydrogen-bond networks that make it simultaneously soft and tough, surviving more than 100 load cycles without leaking. Each sucker on the gripper mimics an octopus tentacle, combining a flexible curvature membrane with a sealed negative-pressure cavity, allowing it to switch rapidly between a firm grip and a gentle release simply by adjusting water pressure. The hydraulic actuation requires less than 40 kPa, which makes it low enough to handle delicate objects without rupturing them.
It’s also fully 3D-printable using vat photopolymerization, so the design is accessible and can be readily customized.
<< A schematic illustration (left) shows the soft gripper’s design principle and hydraulic drive mechanism. A schematic diagram (center) and photo (right) of the gripper handling an egg yolk underwater. Photos: Yixian Wang et al.
RETRIEVABLE ELECTRIC GAS LIFT SYSTEM
Conventional gas lift systems work best during an oil well’s early life, when tubing pressure is high. However, as reservoir conditions change, drawdown efficiency decreases and oil output declines, which can result in over-injection or under-injection of lift gas.
Emerson and Interwell recently launched a solution: the Adaptive Gas Lift System (AGLS), which the companies are calling the world’s first retrievable electric gas lift system.
The AGLS ensures continuous oil production optimization without expensive and invasive well interventions. It works by providing real-time remote control of valve port sizes, gas injection rates, injection depths, and drawdown, without interrupting production. Since the valve closure doesn’t rely on reducing casing pressure, the AGLS also makes deeper injection possible.
A retrievable design allows for the complete replacement of entire valve assemblies using standard wireline techniques as well.
“We designed the AGLS to meet the most rigorous industry standards,” said Jan Inge Ellingsen, vice president and general manager for Roxar products at Emerson’s measurement solutions business in a press statement. “This innovative technology will help unlock the full potential of assets in the field while eliminating the need for extensive interventions, improving safety, and supporting the transition toward net-zero energy production.”
Photo: Emerson
HYBRID POWER SOURCE
Stellar Industries is bringing a first to the service truck industry with its Hybrid Power Source (HPS), a fully integrated, emission-free power system. By combining an automotive-grade lithium-ion technology with a modular hydraulic power system, the HPS offers clean, reliable energy for hydraulic tools and equipment without relying on the chassis engine.
The integrated hydraulic power unit delivers up to 12.8 kWh of output and can supply up to eight hours of operation on a single charge. At 790 pounds, it can be mounted in a truck's load bed or side pack, while integrated thermal protection and a built-in heating system ensure optimal charging temperatures in any conditions.
Recharging is automatic, either through the truck's alternator while driving between jobsites, or via a standard 120V connection. The system is compatible with both internal combustion engine and electric vehicle chassis. On ICE trucks, it draws from the engine for quick top-ups, while on EV chassis, it operates as a fully standalone power source.
The HPS also supports efficient pneumatic operation, with the standard HPS capable of running a 40P compressor.
Photo: Stellar Industries
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