Hydraulic Cylinder was Failed | We Make a New Cylinder From old Ships High Strength Pipes
We manufacture our own hydraulic cylinders, rather than simply supply those made by a third party. This gives us great flexibility over the products we offer, as well as good insight into the manufacturing and quality control processes that lead to superior performance and working life.
Here is a brief overview of the hydraulic cylinder manufacturing process we follow:
1) Design
In the design stage the customer’s specifications are transformed into technical drawings detailing the materials, tolerances and dimensions of the hydraulic cylinder. This is the most important stage of the whole process, and is why we take care to ensure that each customer is equipped with full technical drawings before we produce any components. The design takes into account the performance outcomes required by the application, the customer’s budget, size constraints and other considerations.
2) Machining
A range of high-capacity CNC lathes, milling and drilling units are available for the production of modern hydraulic cylinders. These machines are arranged in cells on a production line for efficient machining and assembly. The rods themselves are pre-manufactured from turned and hardened chrome, ready for manufacturing into cylinders of the correct size. Stainless or high-strength steel may also be used.
Modern CNC equipment gives manufacturers the flexibility to machine complex and non-standard hydraulic cylinders. During high volume production runs, quality control is carried out in the cycle through accurate measuring components mounted on the machine. Manual lathes are also sometimes employed for prototypes and low volume orders.
3) Assembly
Assembly takes place in line with the technical drawings agreed with the customer before machining. This is preceded by a quality check to minimise the amount of materials handling required during the assembly process. Assembly may involve welding, in which case every care is taken to ensure the strongest join. Welding may be automated through a CNC welding unit, or carried out manually if high-strength or irregular joints are required. Weld designs are tested in advance in a virtual environment, and weld strength is verified by destructive testing.
4) Testing
Each cylinder undergoes rigorous performance testing under power and load to confirm its specifications and durability. A quality control procedure rules out defects, and specifications are confirmed in line with customer expectations. We use coordinate measurement machines (CMMs) to verify quality standards and calibrate each cylinder before delivery.
Although testing and inspection are an integral part of the manufacturing process, visual inspection and environmental control also takes place at the machining and assembly stage. For instance, care is taken throughout the process to prevent dust accumulating on the internal surface of the cylinder – which may impede its operation.
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