As one of the core actuators in the hydraulic system, the hydraulic cylinder is widely used in various types of mechanical equipment. Its main function is to convert energy into mechanical energy through hydraulic pressure, thereby completing operations such as pushing, pulling, and lifting. The load capacity of the hydraulic cylinder is directly related to the working performance and production efficiency of the equipment. When the load capacity of the hydraulic cylinder decreases, it will have a serious impact on the normal operation of the mechanical equipment. Therefore, understanding the reasons for the decrease in the load capacity of the hydraulic cylinder will help to take effective measures in time to prevent equipment failure.
During the operation of the hydraulic cylinder, the decrease in load capacity is a common phenomenon, and its reasons are relatively complex, which may involve the design, manufacturing, use environment, maintenance and other aspects of the hydraulic system itself. This article will analyze the reasons for the decrease in the load capacity of the hydraulic cylinder from several main aspects and propose corresponding solutions.
1. Hydraulic oil contamination
Hydraulic oil is an indispensable and important part of the hydraulic system, and it undertakes multiple functions such as energy transmission, lubrication, and sealing. However, impurities in the hydraulic oil (such as dust, iron filings, moisture, air, etc.) will directly affect the performance of the hydraulic cylinder. Oil contamination can cause valves, pumps, pipelines and other components in the hydraulic system to be blocked and worn, and even cause the seal of the hydraulic cylinder to fail.
Contaminants in the hydraulic oil increase friction, which intensifies wear inside the hydraulic cylinder and causes scratches or wear on the contact surface between the piston rod and the cylinder body. As friction increases, the working efficiency of the hydraulic cylinder decreases and the load capacity decreases. In addition, contaminants may also cause changes in the viscosity of the hydraulic oil, further affecting the stability of the hydraulic system.
Solution:
Regularly check and replace the hydraulic oil to ensure that the cleanliness of the oil meets the specified standards.
Install a hydraulic oil filter and regularly clean or replace the filter element.
Strictly control the storage environment of the hydraulic oil to avoid contact with moisture, air or other contaminants.
2. Aging or damage of seals
The sealing system of the hydraulic cylinder is used to prevent hydraulic oil leakage and prevent external impurities from entering the hydraulic system. The materials of the seals are generally rubber, polyurethane, polytetrafluoroethylene, etc. With long-term work, the seals will age, harden, wear or damage. This change will lead to poor sealing, hydraulic oil leakage, and even cavitation, resulting in a decrease in the working pressure of the hydraulic cylinder, thereby affecting the load capacity.
Aging and damage of seals are usually related to high temperature, hydraulic oil contamination, long-term use, and the harshness of the operating environment. Damage to the seal may cause hydraulic oil leakage, resulting in loss of system pressure, affecting the movement performance and load capacity of the hydraulic cylinder.
Solution:
Check the status of the seal regularly, and replace the aged or damaged seal in time.
Avoid hydraulic oil contamination to extend the service life of the seal.
Select seals of suitable materials according to the working environment to ensure that they can adapt to different temperature and pressure environments.
3. Increased friction in the hydraulic cylinder
During the operation of the hydraulic cylinder, there is a certain friction between the piston rod and the cylinder body. Under normal circumstances, the lubrication of hydraulic oil can effectively reduce friction and ensure the smooth operation of the hydraulic cylinder. However, if the hydraulic oil is contaminated, the lubrication is insufficient, or the viscosity of the hydraulic oil is too high, the friction inside the hydraulic cylinder will increase.
The increase in friction will not only increase the energy consumption of the hydraulic cylinder, but also cause the hydraulic cylinder to work unsteadily and even cause jamming. As the friction increases, the movement efficiency of the hydraulic cylinder decreases and the load capacity gradually decreases. Especially under high-load and high-frequency working conditions, excessive friction may aggravate the wear of the internal components of the hydraulic cylinder and accelerate the performance decline of the hydraulic cylinder.
Solution:
Use appropriate hydraulic oil to ensure that it has good lubrication performance.
Check the lubrication condition of the hydraulic cylinder regularly and add lubricating oil when necessary.
Ensure that the working environment of the hydraulic cylinder is kept clean to prevent dust and impurities from entering the hydraulic cylinder.
4. Fatigue and wear of hydraulic cylinder materials
The materials of the internal components of the hydraulic cylinder will be subjected to continuous load during long-term operation, resulting in fatigue. Especially under high pressure and heavy load, the piston, piston rod and cylinder body of the hydraulic cylinder are prone to micro cracks and wear. These wears not only affect the working efficiency of the hydraulic cylinder, but also cause problems such as poor sealing and oil leakage, further reducing the load capacity.
Material fatigue of hydraulic cylinders is often manifested as surface scratches, pits or cracks. If these problems are not handled in time, they will affect the movement accuracy and load capacity of the hydraulic cylinder. In particular, improper surface treatment of the piston rod and cylinder body can easily lead to increased wear.
Solution:
Choose high-strength and wear-resistant materials to manufacture hydraulic cylinders to improve their durability.
Check the piston and piston rod in the hydraulic cylinder regularly and replace them in time if they are worn or damaged.
Surface treatment of key components of hydraulic cylinders, such as chrome plating and hardening, is performed to improve wear resistance.
5. Abnormal hydraulic system pressure
The load capacity of hydraulic cylinders is closely related to the pressure of hydraulic systems. If the working pressure of the hydraulic system is too low, the hydraulic cylinder will not be able to generate enough thrust to push the load, resulting in a decrease in load capacity. There may be many reasons for abnormal pressure in hydraulic systems, including hydraulic pump failure, pressure regulating valve failure, pipeline leakage, etc.
The performance decline of the hydraulic pump or the unreasonable setting of the pressure regulating valve will cause the system pressure to be unable to be maintained within the appropriate range, thereby affecting the working effect of the hydraulic cylinder. When the pressure is too low, the output force of the hydraulic cylinder is insufficient; while excessive pressure may cause overload of the hydraulic cylinder or even damage.
Solution:
Regularly check the various pressure indicators of the hydraulic system to ensure that the system works within the normal pressure range.
Check the status of components such as hydraulic pumps, pressure valves, and pipelines to ensure their normal operation.
Perform pressure calibration on the hydraulic system to ensure that the pressure control of each component is accurate and effective.
6. Overload operation of hydraulic cylinders
The load capacity of hydraulic cylinders is related to their design and manufacturing capabilities. When the hydraulic cylinder is overloaded, it exceeds its design load range, which will cause deformation or damage to the internal components. Long-term overload operation may also shorten the fatigue life of the hydraulic cylinder, thereby gradually reducing the load capacity.
During the use of the hydraulic cylinder, overload operation is often caused by improper operation or improper system adjustment. For example, the pressure of the hydraulic system is set too high, or the load itself exceeds the load capacity of the hydraulic cylinder.
Solution:
Follow the design load requirements of the hydraulic cylinder to avoid overload operation.
Regularly check the use of the hydraulic cylinder to ensure that its working load is within the safe range.
Perform necessary load tests on the hydraulic cylinder to ensure that it meets the actual work requirements.
As an important part of the hydraulic system, the reduction of the load capacity of the hydraulic cylinder is one of the common faults of many industrial equipment. By understanding the reasons for the reduction of the load capacity of the hydraulic cylinder and taking effective preventive and maintenance measures, the service life of the hydraulic cylinder can be effectively extended and the normal operation of the equipment can be ensured. In the design, selection, installation and maintenance of the hydraulic cylinder, the above factors must be taken into account to ensure that the hydraulic cylinder operates in the best condition and improve production efficiency and equipment reliability.
www.toringcylinder.com
Ningbo Toring Machinery Manufacturing Co., Ltd.
