7 Questions to Ask Before Specifying a Hydraulic Cylinder

How do you currently specify your hydraulic cylinders? Do you base your choice off of the specific needs of your application, or do you pick an “off the shelf” model and try to make it work? If you’re the latter, then you could be missing out on the true potential of hydraulic cylinders.

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Widely used across various mobile and industrial applications, hydraulic cylinders are often the go-to power solution for enhanced performance, energy efficiencies and precision control. However, if you don’t specify the right cylinder, you could experience a number of problems, including:

• Process inefficiencies
• Performance losses
• Complete or premature failure
• Difficult installation/maintenance

Any of the above could seriously halt or harm an operation, leading to lost capital and system-wide inefficiencies.

How Do I Get the Right Hydraulic Cylinder?

Rather than suffer through the common issues with standard cylinders, it’s best to do a little leg work upfront – or let a knowledgeable hydraulics expert assist you to ensure you get the best design possible. That all starts with asking the right questions.

By talking through the key design aspects of your hydraulics, you can enable higher efficiencies, improve system performance and enhance cylinder reliability. Here are the questions to ask:

1 – What specific task does the cylinder need to do?

The number one thing that you need to know before specifying a hydraulic cylinder is what the application is. That way, you can figure out what is required of the cylinder to meet that application’s needs.

Your application will influence everything about the design of the cylinder. For instance, if you only need to push or pull in a single direction, then a single action cylinder may be right for you. If you have a more complex operation where you need to both push and pull a load, then a double action cylinder is the way to go.

Thoroughly understanding your application can mean the difference between a highly reliable and efficient cylinder, and an underperforming cylinder that fails early.

2- What are the forces involved?

Multiple forces can exist within a system, each one affecting a cylinder differently. Suppose your cylinder is not designed to properly deal with these forces at their exact magnitudes. In that case, your cylinder is likely to break down more than usual in the field, shortening the life of your design.

Common forces to keep track of include:

• Tension and compressive forces
• Forces originating from the load being moved
• Supply pressure

3 – What’s the distance the cylinder needs to travel?

How far your cylinder needs to travel affects more than just your piston rod. In order to properly size each of the individual components of your cylinder, you need to know the required stroke distance of the device.

4 – What hydraulic fluid do I need?

Different applications require different hydraulic fluids. Typically, hydraulic fluids are broken down into one of three types: petroleum, mineral-based or water-based.

Depending on the type of hydraulic fluid that you are working with, your cylinder may require additional components or a special seal package.

5 – What kind of environment will the cylinder be in?

Extreme hot or cold environments add additional demands to the design of your cylinder than if you were operating in a temperate climate. Work by the ocean or need to spray down your equipment? Your cylinder design needs to be able to handle that.

Whether it is water from a washdown or process dirt from the factory floor, foreign material and particulate can be a big problem if it gets inside your cylinder. Any particles or blockage that work their way in will impact the integrity of your cylinder and its shafting. If this might be an issue, consider adding a scraper to your design.

6 – How will the cylinder be mounted?

How you mount a cylinder matters. Cylinder mounting can affect the performance and reliability of the device, either causing the hydraulics to be a seamless part of the system or adding extra stressors every time the piston moves.

Designing a cylinder so that it easily mounts onto a system will make it easier to install the cylinder, as well as do any maintenance work later on. Your operators and technicians will thank you.

7 – What additional features do I need?

Most every application has some sort of special requirements. Maybe you need added cushioning, or some means of deceleration so that the cylinder does not impact the rest of a highly sensitive system. Or maybe you have multiple cylinders working together in a master/slave set and your cylinder needs to synchronize with other cylinders in the set. Position sensing technology or “smart” cylinders may also be an option for more precision-based applications.

In addition to the above, additional questions may arise based on your specific needs and your supplier’s experience. This is where having a supplier with experience in your industry or application can prove invaluable. A quality supplier with a history of creating innovative cylinder designs will be able to draw from their experience and further tailor a solution to your unique operation.

Columbus Hydraulics: The Leader in Hydraulic Cylinders

Here at Columbus Hydraulics, we specialize in working with our customers to guarantee that they get the right cylinder for the job. With the combination of our quality base cylinder designs, technical expertise and custom hydraulics experience, we can help you find the right solution no matter your industry or application.

You will get efficient and thoughtful service from KICAN.

That’s why we recommend working with our experts from the get-go, so that we can “own the design” of the cylinder and help streamline your experience. After analyzing your operation, we can create a custom cylinder that best fits the needs of your unique application.

Selecting the right hydraulic cylinder involves a thoughtful process to ensure it meets your specific needs. First and foremost, consider the load requirements. You’ll want to determine the maximum force the cylinder will need to exert, factoring in any potential variations or unexpected spikes. Next, assess the operating environment. Take note of factors like temperature, humidity, and potential exposure to corrosive substances, as these can impact the material and coating choices for the cylinder. Additionally, consider the stroke length, which is the distance the cylinder can extend and retract; it should comfortably accommodate the range of motion required for your application. Think about the mounting options available and how they align with your equipment. Finally, consult the manufacturer’s specifications and recommendations to ensure compatibility with your system and to guarantee a reliable and efficient performance.

Yes, they can be cushioned. A hydraulic cushion is a feature in some hydraulic cylinders that helps to reduce the impact and shock caused by the cylinder’s motion. As the name states, It’s basically like a cushion for the cylinder, absorbing the energy created by the moving piston and slowing down its motion before it reaches the end of its stroke.

Hydraulic cushions are often used in applications where a heavy load is being lifted or moved, as they can help protect the load and the hydraulic system from damage. By providing a more controlled and gradual stop to the cylinder’s motion, hydraulic cushions can help to increase the safety and efficiency of hydraulic systems.

To calculate the force generated by a hydraulic cylinder, you need to know the cylinder bore diameter, the operating pressure, and the piston rod diameter. The formula for calculating hydraulic cylinder force is:

Force (in pounds) = (Pressure (in psi) x Cylinder bore area (in square inches)) – (Pressure (in psi) x Piston rod area (in square inches))

By knowing the force generated by the hydraulic cylinder, you can select the appropriate size and capacity for your application.

Learn more about hydraulic power from the Encyclopedia Britannica.

Step 1: Gather Tools and Safety Gear Before you start, ensure you have the necessary tools and safety gear. You’ll likely need wrenches, a rubber mallet, safety glasses, and gloves.

Step 2: Depressurize the System Safety first! Release the hydraulic pressure by disconnecting any power sources and operating the cylinder to release any remaining pressure. This prevents unexpected movements during disassembly.

Step 3: Locate the Retaining Bolts Identify the bolts that hold the end cap in place. They’re typically positioned around the circumference of the end cap.

Step 4: Loosen the Bolts Using the appropriate wrench, carefully loosen the retaining bolts. Start by loosening them evenly to avoid putting stress on one side of the end cap.

Step 5: Tap the End Cap Gently tap the end cap with a rubber mallet. This helps break any seal that might have formed due to pressure and fluid.

Step 6: Remove the Bolts and End Cap Fully remove the retaining bolts and gently slide the end cap away from the cylinder body. Be prepared for a slight release of hydraulic fluid as you do this.

Step 7: Inspect and Clean With the end cap removed, inspect the interior for any signs of damage or wear. Clean the sealing surfaces and ensure no debris could affect reassembly.

Step 8: Replace or Maintain Depending on the reason for removal, this is the time to either replace a damaged part or perform any necessary maintenance.

Step 9: Reassembly When you’re ready to put everything back together, reverse the steps. Carefully position the end cap back onto the cylinder body, making sure the seal is properly aligned. Reattach and tighten the retaining bolts evenly.

Step 10: Test and Check for Leaks After reassembly, re-pressurize the system and test the cylinder’s operation. Keep an eye out for any hydraulic fluid leaks around the end cap area.

Remember, safety is paramount. If you’re unsure at any point or encounter difficulties, it’s always a good idea to consult a professional or refer to the manufacturer’s guidelines. With patience and attention to detail, you can successfully remove a hydraulic cylinder end cap and carry out necessary repairs or maintenance.

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