| Summary: | The hydraulic system is the backbone of industrial, construction, and agricultural machines. Its high-power density and efficiency execution make it the preferred choice for high-energy applications. This manuscript presents the evidence against the statement, Whenever the system runs to its full capacity, hydraulic oil heats up more as compared to partial loads.“ Our experimental study on Injection Molding Machine (IMM) hydraulic system tries to reshape the above statement by presenting the fact where we came across that lower system loading case is causing higher hydraulic oil temperatures than full loading.” The concern started when the machine at lower speeds results in frequent shutdowns due to increasing operating temperature high alarm!“ This article presents the study to resolve the stated issue completely. For the design evolution, a systematic diagnostic approach is displayed based on the six-sigma and the associated mathematical model. Our study concludes with an approach to find the self-balancing system for the case where the temperature increase is must be due to the higher rate of heat addition than the rate of heat rejection. Presented learning can be equally extended for the other fields of interest, as care should be taken to understand the passive system losses, which can result in elevated temperatures due to lower cooling capabilities.
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