Industrial Vehicle Technology - Off-Highway Annual 2026
The modular solution for hydraulic control
2025-12-05 13:05:36
SCALABLE VALVE ARCHITECTURE COMBINES MECHANICAL MODULARITY WITH PROGRESSIVE CONTROL PLATFORMS AND INTEGRATED ELECTRICAL INTERFACES FOR EFFICIENT HYDRAULIC SYSTEMS
ByWire is a modular directional control valve system designed to simplify valve configuration and optimise hydraulic system performance – from the traditional open centre layout to advanced electronic control.
Modular structure and components
The platform includes inlet and outlet sections, sectional elements, priority inlet flow regulators, flow control elements (including recovery types), intermediate plates, interface conversion modules, end plates and tie rods. This modular breakdown makes the valve assembly fully scalable starting from the hydraulic “core”, only the required regulation, interface and diagnostic modules are added. The result is compactness, flexibility and readiness for future system evolution.
Four circuit control platforms
The ByWire family is organised into four control platforms, each covering increasing levels of integration and energy efficiency. They are compatible with both fixed- and variable-displacement pumps, depending on the configuration.
The open centre (OC) provides pressurisation of the circuit through on-off control, accepting modules of different sizes and proportional options. It is a simple, robust base – ideal when functions are limited or only essential control is required.
Load sensing (LS) introduces on-demand flow control, minimising energy losses as the pump delivers only the flow required by active functions. The LS platform can operate with variable-displacement pumps or, with suitable configurations, with fixed-displacement pumps, maintaining efficient load response.
Hybrid load sensing (HLS) combines hydraulic and electronic management to refine the LS signal for each function, optimising the dynamics of individual actuators. Modes such as stand-by, standard with restrictor, and pressure/flow boost demonstrate how HL reduces overall power consumption while ensuring responsiveness when needed. CANBus communication enables coordination and diagnostics.
With electronic load sensing (ELS), the most advanced level, control and compensation are fully electronic, offering repeatable settings, high sensitivity and fast response. The open architecture is ready for smart/IoT functionalities, supporting scalability and predictive maintenance.
Simplifying wiring and control
Technology has evolved from basic hydraulics to integrated systems, and then to smart and connected hydraulics. On the actuation side, the evolution runs from manual valves to analogue electric valves and finally to fieldbus and smart valves.
Throughout this process, the integration between hydraulic power in/out and electronic & data management has been the key – enabling bidirectional data exchange (data in/ out) that transforms the valve into an intelligent machine node.
The ByWire hub concept brings this evolution into the application field: the valve is no longer a simple hydraulic component but a module with an integrated electrical/digital interface. The aim is to shorten design and commissioning times, standardise connections and offer three integration levels – from simple centralised wiring to full ECU-based systems with bus diagnostics.
Simplified electrical wiring
In the E-Hub version, connection between the valve and the machine is streamlined via a single front electrical connector. Commands are received as on-off or PWM signals, with a reduced, neatly routed cable harness. The functional chain – machine control interface → interface connection (electric commands) → ByWire E-Hub (wiring harness) → hydraulic functions – demonstrates how E-HUB keeps systems tidy, easy to protect from external agents and quick to assemble. It is the ideal choice for machines with basic automation or as the first step towards full valve electrification.
Integrated ECU and CAN-Bus network
With I-Hub, integration moves to a higher level: the control ECU and dedicated wiring are built into the module. Communication over CAN-Bus manages not only commands but also data and diagnostics.
The structure – machine control interface → interface/network communication (CAN-Bus commands/data/diagnostics) → ByWire I-Hub (ECU standard functions) → hydraulic functions – highlights logical centralisation: fewer wiring variants, greater interoperability with third-party sensors and actuators and simplified maintenance thanks to onboard diagnostics.
Plug-and-play, reduced assembly time
The I-Hub Plus version takes the plug-and-play concept further. ECU, wiring and connectors are engineered as a single unit, with high protection ratings and optimised routing. The customer connects just one electrical link for the entire electro-hydraulic assembly. The outcome is a drastic reduction in assembly time and error risk, improved environmental shielding, and a ready platform for IoT integration – enabling data collection, updates and extended diagnostics.
Selection guidelines
When functional simplicity and cost efficiency are priorities, the OC or E-Hub platforms are recommended. For applications requiring energy efficiency with multiple functions, the LS platform is suitable; when per-function optimisation is needed, the HLS platform should be considered. Applications that demand electronic integration and diagnostics benefit from the I-Hub platform with its CANBus capabilities. The I-Hub Plus version is ideal for projects requiring pre-engineered wiring and reduced time-to-market. For machines that require digital and IoT readiness, the ELS platform combined with I-Hub or I-Hub Plus enables telemetry and remote updates.
ByWire provides a coherent platform to transition seamlessly from traditional valves to connected smart systems.The modular mechanical design of heads, sections and plates allows precise configuration of flow and function. The four control platforms offer a tailored balance between cost, efficiency and dynamic response, while the Hub system simplifies connections, standardises machine interfaces and enables digital integration.
For mobile machinery manufacturers, this means faster design cycles, more efficient systems ready for diagnostics all without compromising the robustness required in the field.
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