Design-Related Hydraulic Failure And Repair
Posted on: 21 July 2015
Hydraulic cylinders are as common as motors and pumps combined. If your company uses hydraulic equipment, it's very likely that repair expenses are a significant item in your budget. According to various studies, up to ¼ of mechanical equipment failures are design-related. If that percentage is applied to hydraulic cylinders, 25% of all cylinders aren't designed for the applications in which they are used. Using hydraulic equipment for purposes other than those for which it's intended can shorten the life of components. If your equipment isn't lasting as long as it should, your repair team may need to address one or all of these issues.
Bent Rods
Bent cylinder rods are often caused by too-small rod diameters, or by weak materials, improper mounting or a combination of the three factors. Once a rod is bent, a heavy load is placed on the seal, increasing leakage and resulting in eventual seal failure. Use the Euler formula to check the acceptable load for cylinders in existing applications.
Finish
The surface of a cylinder rod has a substantial effect on the life of rod seals. If the surface of the rod is too smooth, seal lifespan declines because of poor lubrication. If the rod's surface is too rough, contaminants can get into the system and leakage can result. To extend the life of hydraulic cylinders, think of the rod surface as needing lubrication and being prone to wear—and treat it properly.
In some industrial applications, the use of alternative treatments such as nickel chrome plating can increase the lifespan of seals and rods. In some cases, shroud or bellows installation can protect seals and rods from damage by contamination and impact.
Tube Ballooning
Cylinder tube ballooning is often caused by thin walls and insufficient material strength for the operating pressure of the cylinder. Once a tube has ballooned, tolerance between the wall and the piston is lost and fluid can get around the seal. As seals erode and localized heating reduces their life, the seal has a higher likelihood of failure. Lack of Bearing Area
If the area of the wear bands on pistons and in glands isn't enough to support the thrust going through the cylinder, high loads are put onto the rods and seals. Such loads can result in seal deformation and premature component failure.
Not all hydraulic components are created equally. If your company suffers from premature and recurring failure of hydraulic cylinders and other components, it's highly likely that design changes are necessary to break the cycle of repair and breakdown. Contact a local machine shop, such as Certified Products Co, for further assistance.
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