Ordering Custom Hydraulic Cylinders

Key Considerations

By Sebastien Lajoie, Cylinder Engineering Manager, Bailey International

The heart of hydraulic systems lies in their ability to efficiently transfer power through the movement of fluids. This capability depends on the quality and precision of system components. Among these, custom hydraulic cylinders stand out for their ability to significantly enhance system reliability.

In the diverse world of hydraulics, adopting a one-size-fits-all approach falls short. While standard cylinders might suffice for general applications, custom hydraulic cylinders tackle specific challenges head-on and elevate system performance. By opting for custom solutions, you guarantee your hydraulic system is perfectly aligned with the unique demands of your application. This allows for improved efficiency, an extended lifespan, and lower maintenance costs.

Custom hydraulic cylinders are engineered to cater to unique operational loads and specific usage cycles, designed to thrive under challenging environmental conditions. In scenarios where installation space is at a premium, a custom cylinder can be ingeniously designed to perfectly fit the confinement. Conversely, for applications that demand high-pressure functionality, custom cylinders can be developed using robust materials and designs capable of withstanding the most rigorous conditions. These cylinders can be equipped with special seals, coatings, or other modifications to improve durability in extreme temperatures, corrosive environments, or other harsh operational conditions.

The process of designing and manufacturing custom cylinders involves close collaboration between the client and the manufacturer. A partnership ensures that every aspect of the cylinder, from its dimensions and material selection to its sealing and mounting configurations, is optimized for the application at hand. By considering a project’s specific requirements and constraints, manufacturers can deliver custom hydraulic cylinders that meet and exceed expectations, providing a competitive edge in efficiency and reliability.

Options and Selections

Selecting the right material significantly impacts a cylinder’s durability, resistance to environmental factors, and performance in various applications. Among the common materials used are steel, stainless steel, and aluminum. Each offers distinct benefits and presenting certain limitations.

Steel stands out for its exceptional strength and durability, making it an excellent choice for hydraulic cylinders in heavy-duty industrial applications. A steel cylinder can withstand high pressures and harsh operational conditions. However, steel’s susceptibility to corrosion is a notable drawback. This issue can be addressed through the application of protective coatings or by opting for stainless steel in environments where corrosion is a concern.

Stainless steel is renowned for its superior corrosion resistance, an attribute that makes it particularly well-suited for use in environments that are either very moist or where the cylinder might be exposed to corrosive chemicals. Stainless steel also maintains an elevated level of strength and durability. Nevertheless, these advantages come at a cost, as stainless steel is more expensive than its standard steel counterpart. This cost factor may influence the material selection process, depending on budget constraints and specific application requirements.

Aluminum, with its lighter weight, presents an advantageous option for applications that prioritize reducing weight without significantly compromising the cylinder’s integrity. Its inherent corrosion resistance further enhances its appeal, particularly in applications where environmental exposure could degrade other materials. Although aluminum may not match the sheer strength and durability offered by steel and stainless steel, its performance is more than adequate for many applications, especially those where weight considerations are paramount.

The cylinder and bore size are critical factors that must be defined to ensure the cylinder’s efficacy in generating the requisite force and movement. These parameters play a pivotal role in the functionality of the cylinder in its specific application. The bore size of a cylinder directly impacts the amount of force the cylinder can exert. A larger bore size allows greater force generation, making it particularly essential in heavy-duty applications where substantial force is required. This is due to the area of the piston being larger. According to the basic principle of Force = Pressure × Area, a larger area yields a higher force output for the same pressure.

Likewise, the stroke length of a cylinder determines the distance the piston can travel from its fully retracted position to its fully extended position. Be sure to consider the space constraints of the system to avoid choosing a stroke length too long, which could lead to an inability to install the cylinder or cause mechanical interference within the system. Moreover, accurate measurements and detailed specifications can help you avoid complications such as insufficient force generation, which could render the cylinder ineffective for its intended use, or inadequate movement range, which could limit the functionality of the system.

Considerations

Of course, customization extends beyond size and material. The following factors can enhance the performance and integration of the cylinder with your system:

Mounting Options: Different applications might require specific mounting configurations, such as flange, trunnion, or clevis mounts. Custom mounting guarantees ease of installation and optimal alignment with other system components.

Seals and Bearings: The choice of seals and bearings affects the cylinder’s performance, especially in high-pressure or high-temperature environments. Customizing these components can enhance durability and reduce the risk of leaks or failures.

Port Configurations: Custom port configurations can simplify hydraulic system plumbing, reducing potential leak points and optimizing fluid flow.

For Procurement Managers, aligning the ordering process with strategic goals is vital to ensure timely and cost-effective delivery. It’s vital to establish clear communication channels with manufacturers to share detailed specifications and timelines. Working with a reputable supplier can streamline this process.

Future Trends in Hydraulic System Design

The field of hydraulic systems is continuously evolving, with advancements aimed at improving efficiency, sustainability, and performance. Staying on top of these trends can help engineers and designers make informed decisions when ordering custom hydraulic cylinders.

Smart Hydraulics: Integration of sensors and IoT technology in hydraulic cylinders is becoming more prevalent. These smart cylinders can provide real-time performance data, helping during predictive maintenance and when reducing downtime.

Eco-Friendly Materials: There’s a growing emphasis on sustainable materials and manufacturing processes. Opting for eco-friendly materials without compromising performance is an emerging trend.

Advanced Coatings: Coatings that enhance corrosion resistance and reduce friction are advancing, contributing to longer lasting and more efficient cylinders.

Ordering custom hydraulic cylinders requires a thorough understanding of specific application needs and factors that influence cylinder performance. By focusing on material selection, size, customization options, and aligning procurement strategies, it’s a guarantee that the custom cylinders chosen will optimize system reliability.