When designing or upgrading a pneumatic application, the devil is in the details. It is essential to specify the right components for each function of the application, in order to optimise both performance and safety. Essentially, a well-chosen pneumatic setup gives you a more efficient, reliable, and compliant application aligned with customer-specific requirements.
Continue reading “How to Choose the Right Pneumatic Components for Your Application”
When a critical fault develops within a hydraulic-powered system, the consequences can be dire, including unexpected downtime, loss of revenue, and safety hazards. Detecting issues at an early stage is the key to keeping your hydraulic application running smoothly and efficiently, but not all issues are of equal urgency. Some latent minor issues can wait till your next maintenance cycle, while others need immediate attention. It is these that we will look at in this article.
A sudden, unexpected drop in system performance, such as difficulty lifting a load within its safe working limits, noticeably slow operation, or failure to start at all, can indicate an underlying problem.
Solution: power down the system, and when safe, check for any pressure irregularities in your hydraulic pump. Power loss often stems from an internal leak, worn components, or contaminated hydraulic fluid. You should also inspect your hoses, fittings, and valves for obvious leaks or damage, and make sure the fluid level and quality meet the manufacturer’s recommendations.
If a hydraulic cylinder is moving jerkily or inconsistently during operation, it may point to fluid contamination, air bubbles in the system, or piston seal failure. Unaddressed, these issues could trigger catastrophic failure and cause your application to shutdown.
Solution: inspect the cylinder rod and seals for any damage or contamination, then bleed air from the system to remove any air locks. You may also need to clean or replace any dirty filters to keep your hydraulic fluid clean.
Ideally, hydraulic fluid should be clear, with an odour and colour specified in the manufacturer’s instructions. Any variation from this norm could indicate contamination by water, dirt, or air. Cloudy or milky looking hydraulic fluid is an especially likely candidate for contamination.
Solution: contamination is a serious issue in hydraulic systems, so if you suspect contaminated fluid, we recommend that you drain the hydraulic reservoir immediately and replace with new, clean fluid. You should also flush the system to remove any residual impurities. The most common cause of contamination is a blocked or dirty filter, so regularly replace all filters to minimise this issue in future.
Many hydraulic-powered machines vibrate at a base level, but you should take careful note of any excessive vibrations or pulsating movements, and anything that doesn’t ‘feel right’ compared to how your application normally operates. These can indicate loose components, irregular pressure waves, or a fault with your pump.
Solution: inspect all fasteners and mounting components to rule out looseness causing the vibrations. Then, check your hydraulic pump and motor for the correct alignment – many unusual vibrations arise from out of balance pump and motor systems. Use an accumulator, if required, to minimise system pulsation.
Finally, many hydraulic applications now include sensors that trigger alarms or specific diagnostic codes when system temperature, vibrations, and other parameters stray outside the normal range. An alarm of this kind shouldn’t be ignored, as it may indicate imminent component failure, even if there are no visible symptoms yet.
Solution: immediately check your error code or alarm type against your manufacturer’s diagnostic manual and follow the appropriate troubleshooting steps. If in doubt, or if the alarms persist, contact a manufacturer-qualified engineer for an expert opinion.
Get in touch with Hydrastar today if you’d like to find out more about system maintenance and how to maximise efficiency in your fluid power applications.
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Fluid power systems, while eminently useful, have never had a reputation for being particularly quiet. Unfortunately, excessive noise has the potential not only to compromise worker comfort but can also pose long-term health risks such as hearing loss and tinnitus. This situation, however, is changing, with a new generation of pneumatic applications being better optimised to tackle the workplace challenges associated with noise pollution and safety risks.
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Hydraulic applications are the backbone of machinery and production lines in a wide range of industries, from agriculture to manufacturing and construction. In recent years, hydraulic applications have become ever more sophisticated and complex, responding to the needs of modern industry.
Continue reading “The Importance of Hydraulic Hose Protection: Enhancing Durability and Safety”
Reliable hydraulic hoses are the unsung heroes of many industrial operations. By focusing on routine visual inspections, professional installation, correct storage, and proactive replacements, operators can significantly reduce their downtime and minimise safety risks. Let’s take a closer look at these proactive best practices for safety and longevity:
Many of the commonest faults with hydraulic hoses can be spotted through simple visual checks. For example, signs of surface degradation caused by cuts, cracks, and abrasions can be easily diagnosed, as are bulges on the outer layer of the material. Inspecting the fitting connections can also diagnose fluid leaks and seepage, and allow rapid resolution of the issue often by simply tightening the connection. Above this, structural concerns can sometimes be identified by testing the flexibility of the hose. Stiffness or kinks in the hose, or simply a reduced level of flexibility, could indicate internal degradation or damage. Metal couplings and connectors should also be inspected for rust and pitting. When to carry out these inspections? Little and often works best. Many operators find that short visual checks at the end of each shift suffice for regularly used applications, while lighter duty systems may only need weekly or monthly checks.
Time spent on professional installation is time invested in the longevity and safety of your hydraulic system. Simply put, correctly installing hydraulic hoses can reduce unnecessary strain over time, and minimise the risk of premature failure. ‘Professional installation’ involves following the manufacturer guidelines when routing your hoses, making sure that the hose adheres to the specified bend radii. This can vary from application to application. Avoid twisting and stretching when installing a hydraulic hose if possible, as this can weaken the internal structure. And finally, it’s important to avoid any contact with sharp or abrasive surfaces – use protective sleeves or clamps when in doubt.
Good hydraulic hose management practices start at the warehouse. Storing your spare hoses properly while awaiting use can prevent premature failure and degradation. The most important factor at play is to store your hoses in a dry and cool environment away from direct sunlight and high temperatures, because UV exposure and excessive heat can weaken the rubber and polymers used in many hydraulic hoses. Hoses can also be damaged by being flattened by heavy equipment, boxes, and materials being stacked on top of them. It’s also worth storing your hoses away from electric motors and other ozone-producing machinery, as this can damage the integrity of some rubber compounds.
It’s always easier to replace your hoses proactively at the appropriate intervals than to wait for them to fail. All hydraulic hoses have a finite lifespan, influenced by their working intensity, material, and manufacturer recommendations, and unexpected failure is always a risk no matter how diligent your team are in their visual inspections and maintenance schedule. Following the service life recommendations provided by the hose vendor – even in the absence of visible damage – will help avoid unplanned downtime and damage to your system.
For more information about hydraulic hose management and how to extend the longevity and safety of your fluid power applications, please contact one of the experienced team at Hydrastar today by clicking here, or by calling 01353 721704.
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The international hydraulic cylinder industry is experiencing an interesting period of diversification and growth, driven by a variety of technological and market changes. The UK, in particular, is strongly positioned to leverage this growth due to the strong focus of many sectors on renewable energy, innovation, and infrastructure investment.
The Labour government’s Green Prosperity Plan, which includes the ambitious goal to ‘make Britain a clean energy superpower’, could provide opportunities for businesses reliant on hydraulic technologies due to its focus on clean energy and decarbonisation. This builds on the £12 billion earmarked for the sector by the previous Tory administration as part of their 10 Point Plan For A Green Industrial Revolution in 2020.
In this article, we’ll look at the main drivers and challenges affecting the outlook of the global fluid power industry.
The transition from human and animal powered farming to mechanised farming, something we take for granted in the modern West, is now accelerating across the world, driven by the need to meet rising food demands. Hydraulic cylinders and fluid power systems are integral to agricultural machinery including combine harvesters, precision planters, and tractors, powering critical functions like steering, lifting, and operating attachments.
The demand for cheap, high-quality, and energy-efficient hydraulic systems is driving an explosion of demand in the agricultural sector and beyond. The development of smart farming technologies also aligns with this trend. For example, hydraulic actuators integrated with IOT platforms allow British farmers to monitor and adjust the performance of some agricultural plant (e.g. sprinkler and irrigation systems) remotely, with potential benefits to crop yields. These innovations in precision, materials, and control systems could, in the coming years, help to offset the challenge of high manufacturing costs associated with many current hydraulic cylinders and other fluid power components.
The global boom in commercial and residential construction is one of the main factors driving demand for fluid power systems. Construction machinery relies heavily on modern hydraulic power systems to perform their heavy lifting and precision tasks in infrastructure and building projects. In the UK, the construction sector provides plenty of opportunities for an expansion of fluid power systems. Large-scale infrastructure projects such as the Thames Tideway Tunnel and offshore windfarm expansions in the North Sea have increased the reliance of many applications on hydraulic-powered machinery. In residential construction, meanwhile, the offsite/onsite hybrid ‘modular construction method’ is driving further innovations in hydraulic design, with a crossover between the way hydraulic systems are used in manufacturing and construction settings.
Renewable energy systems – especially wind and solar power plants – are a rapidly growing market for hydraulic systems. From China and India to the Irish Sea, wind turbines depend on hydraulic mechanisms for their blade pitch control, which improves efficiency by allowing the turbine to micro adjust their blade angles in response to wind conditions. In a similar way, solar plants use hydraulic systems linked to tracking mechanisms to align panels with the direction of the sun throughout the day for maximum energy capture. Wind energy is big news here in the UK, with enormous offshore installations such as the Dogger Bank Wind Farm forecast to generate up to 5% of the nation’s electricity demand by 2026.
Get in touch with HydraStar today to find out about our innovative approach to hydraulic design and how we can support you to make your applications leaner, greener, and more efficient.
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Two of the most popular hydraulic couplings from our supply partner Gates are the MegaCrimp and GlobalSpiral. In this article, we’ll look at the comparative benefits of both components and the recommended applications to help you make the right choice.
MegaCrimp couplings are compatible with a variety of hydraulic hose types, including wire hoses and braided hoses. This makes them a versatile choice for varying pressure applications, and those with moderate performance requirements. One of the things we like most about the MegaCrimp is the coupling’s ‘C’ insert, which allows uniform crimping and a secure connection around the full 360° of the hose. This improves sealing efficiency and reduces the risk of leaks.
Both the MegaCrimp and GlobalSpiral couplings are plated with the patented Gates TuffCoatTM plating, providing superior corrosion/rust protection compared to many standard zinc-plated couplings. This is a bonus in applications used in outdoor or corrosive environments.
The main difference between the GlobalSpiral and the MegaCrimp is the design intent. GlobalSpiral couplings are engineered for heavy duty, high pressure hydraulic applications, subjected to demanding loads and temperature cycles. As a result, GlobalSpiral couplings are built for strength, resilience, and reliability – delivering exceptional performance under pressure.
Similar to the MegaCrimp, GlobalSpiral uses a ‘no skive’ design, which avoids the need to remove the hose cover for fitting assembly. This saves time during installation and helps to preserve the integrity of your hoses. The GlobalSpiral can be used with four and six-wired spiral hoses and at loads up to 6000 psi, making them the coupling of choice for high-performance applications in various sectors. The interlocking ‘bite to wire’ attachment provides an exceptionally strong hold, reducing the risk of failures or blow outs even under high pressure surges.
Modern fluid power applications require precision couplings to operate at peak performance and efficiency. The Gates MegaCrimp and GlobalSpiral are the market leading components for general applications and high-pressure systems, respectively, and are each engineered for long lasting performance and minimal downtime. Investing in Gates couplings helps to deliver a safe and efficient system tailored to the needs of your application.
If you would like support choosing the best components for your application, please feel free to contact one of the experts at Hydrastar today by clicking here, or by calling 01353 721704.
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Hydraulic fluid power systems are the workhorses behind some of the most critical applications in various industries, from heavy construction equipment to manufacturing production lines. When these systems experience unscheduled downtime, therefore, the impact on output can be significant, delaying projects and driving up costs. This article will cover a selection of troubleshooting techniques and preventative practices that engineers can use to minimise the risk of disruptions and maintain operational efficiency.
Continue reading “Troubleshooting A Hydraulic System: 7 Key Considerations”
Infrastructure development is facing a huge challenge in the UK as domestic property developments, climate change, decarbonisation, and supply chain onshoring reshape the economic and social landscape. New hydraulic and pneumatic technologies are among the bold innovations that businesses and public organisations are adopting to step up to the task. In this article, we’ll take a look at the way that smart technologies, sustainability, and efficiency measures are adapting to the needs of current and future infrastructure projects.
Industrial and construction machinery often operates under demanding conditions, in which high loads, environmental conditions, and continual heavy use lead to significant wear and tear. Two of the main weak points for machinery used in these conditions are friction/overheating, and contamination. In this article, we will look at the role of diesel fuelling equipment and grease and lubrication tools in improving operational reliability and protecting your machinery assets.
