Why custom hydraulic valving is no longer optional

Modern mining applications are often giants of steel and power.  They are celebrated for their ability to move literal mountains. Hydraulics are the muscle of these machines – giving unmatched power transfer and the ability to effectively do the work our modern society needs to keep our raw materials available to fuel the global economy.  

To get the fluid power to the muscles (actuators) with maximum efficiency valve systems are increasingly sophisticated, automated, and electrified.  This increasing complexity makes many standard “off the shelf” valve banks difficult to incorporate into modern machinery.  What if the standard, off-the-shelf parts we've relied on for decades are now the weakest link in the chain of these super machines?

The reality is that in mining, no two operations face the exact same set of challenges. Extreme temperatures, high-pressure environments, remote locations, and the relentless demand for 24/7 operation create a perfect storm where generic components are destined to fail. The consequence? Unplanned downtime, escalating costs, and unacceptable safety risks.

This is where hydraulic valving customized for each machine emerges not only as an improvement, but as a fundamental necessity. It's time to move beyond the catalog and recognize that tailored hydraulic solutions are driving the next wave of safety, efficiency, and durability in mining for machines of all sizes.

For any mine, but especially those in remote locations, downtime isn't just an inconvenience—it's a catastrophic financial blow. When a critical piece of equipment fails, the clock starts ticking on lost production, which can quickly run into millions of dollars. The culprit is often a seemingly minor component failure.

Standard hydraulic valves are engineered for general sets of applications to cover a broad range. They are often not engineered to withstand the specific combination of relentless vibration, corrosive materials, and extreme temperature fluctuations common in mining.

Alternatively, a custom-designed hydraulic valve system is built from the ground up with the application's unique stressors in mind. This involves:

• Material Science: Selecting alloys and seals that can withstand extreme cold without becoming brittle or extreme heat without degrading. For instance, using specialized elastomers for seals can prevent leaks in temperatures that would cause standard seals to fail.
• Durability Engineering: Reinforcing housing and internal components to resist the constant shock and vibration of drilling, crushing, or hauling on uneven terrain. This might involve thicker walls, more robust spool designs, or different mounting configurations.
• Contamination Resistance: Designing valves with improved filtration compatibility and sealing to prevent ingress of dust, dirt, and moisture—the sworn enemies of any hydraulic system.

While a custom valve might have a higher initial purchase price, the return on investment from preventing even one major downtime event is exponential and will certainly be well spent money.

Additionally, the immense power of modern mining equipment must be paired with absolute control. A momentary loss of precision in a high-pressure hydraulic system can have devastating consequences with a tool as it is working. Whether it's a drill rig, a rock breaker, or a haul truck's braking system, the operator's ability to make minute, instantaneous adjustments is critical for safety.

In some cases, standard valves can exhibit issues like pressure spikes, slow response times, or "stiction" (the tendency to stick before moving smoothly), all of which compromise an operator's precision control. In a high-pressure environment, these small flaws can lead to catastrophic failures or accidents.

Customized valving addresses this challenge by tailoring the performance characteristics to the machine's specific function. Engineers can fine-tune:

• Spool Metering: The shape and notches of the valve spool can be precisely machined to control the flow of hydraulic fluid with incredible accuracy. This ensures smooth acceleration and deceleration of hydraulic motors and cylinders, giving the operator a predictable and responsive "feel."
• Pressure Compensation: Integrating pressure-compensating elements ensures that the speed of a function remains constant even when the load changes. For a crane or an excavator, this means the boom won't suddenly drop or lurch when the load shifts.
• Load-Sensing Technology: Advanced load-sensing valves direct flow and pressure only when and where it's needed. This not only improves efficiency, but also reduces heat buildup in the system, a safety benefit that also extends component life.

By creating this level of precision, customized hydraulic solutions directly contribute to a safer work environment and help organizations meet and exceed increasingly stringent regulatory standards.

Also, in a continuous, 24/7 operation, every drop of fuel and every second of cycle time counts. The cumulative effect of minor inefficiencies can have a massive impact on the bottom line over time. Hydraulic systems are a major consumer of energy on mobile equipment, optimizing them is a key lever for reducing operational costs.

Custom hydraulic solutions, particularly integrated manifold blocks, are a highly efficient solution to this problem. Instead of a messy web of hoses, fittings, and individual valves, a custom manifold is a single, machined block that contains multiple valves and flow paths. This approach offers several advantages:

• Reduced Pressure Drop: Shorter, smoother flow paths within a manifold block minimize energy loss compared to the friction generated by long hoses and multiple fittings.
• Load-Sensing Integration: As mentioned, custom load-sensing circuits ensure the pump only produces the required flow and pressure, dramatically reducing energy consumption during idle periods or low-load functions.
• Improved Thermal Management: A more efficient system generates less waste heat, reducing the load on the hydraulic cooling system and further cutting down on energy use.

For operations focused on sustainability and cost reduction, optimizing hydraulic efficiency is now a core competitive advantage that begins with moving away from standard, piecemeal systems toward integrated, custom solutions.

The future is custom-built

The demands on the mining industry will only continue to intensify as time marches forward. Deeper mines, lower-grade ores, and a sharper focus on safety and environmental responsibility mean that equipment will need to be more reliable, efficient, and precise than ever before. Relying on off-the-shelf components designed for a generic heavy-duty application is a strategy with a rapidly approaching expiration date.

The path forward is embracing a philosophy of purpose-built design. It requires a collaborative approach between mine operators and hydraulic specialists, like those at Bailey International, who understand the intricate challenges of the field. By investing in customized hydraulic valving, mining companies fundamentally upgrade their operational capability. They are building a more resilient, safer, and more profitable future — one precisely engineered component at a time.

Matt Grussing, Director of Sales for Bailey International.