Preventing Contamination in Hydraulic Systems

Hydraulic oil is the lifeblood that powers hydraulic machinery and equipment used in a broad range of industry sectors around the world. Hydraulic fluid provides the pressure needed to hydraulic systems through hydraulic hoses and quick couplings at connection points. There are many reasons why contamination may occur in a hydraulic system, which could create minor disruptions or cause major equipment damage and extended downtime.

Contamination in Hydraulic Systems: The Aftermath

Preventing contamination in hydraulic systems should always be a top priority of equipment operators and maintenance technicians.  According to an article in Hydraulics & Pneumatics, 65% to 90% of all hydraulic system failures are caused by contamination as reported by industry experts. With numbers like that, preventing contamination in the first place is critically important to prevent costly consequences.

The aftermath of contamination in a hydraulic system can range in severity from causing intermittent malfunctions to expensive machinery damage with complete equipment downtime.  Hydraulic fluid contamination could cause:

 

●       Costly equipment repairs

●       Loss of efficiency

●       System flushing

●       Catastrophic failure

●       Equipment downtime

 From minor inefficiencies to total equipment downtime, anytime your equipment is out of service, lost productivity negatively affects profitability. Regardless of the severity of equipment damage or failure, extensive troubleshooting is required to determine the cause of the contamination and hydraulic system failure.

What Causes Contamination in Hydraulic Systems?

There are many different possible sources of contamination in hydraulic systems. It is important to know the potential sources to deal with contamination effectively. Some of the most common causes of hydraulic fluid contamination include:

During production of hydraulic fluid - while it is rare due to strict quality controls, contamination during hydraulic fluid production can occur during mixing or processing. It is a good idea to filter all hydraulic fluid entering into a hydraulic system as even fresh hydraulic fluid could be contaminated.

Contamination during hydraulic fluid storage - of course you should always keep hydraulic fluid storage containers tightly sealed at a controlled temperature. Changes in temperature can create thermal expansion or allow moisture to access the interior of storage containers. Moisture contamination is not easy to notice visually but can significantly impact performance.

Contamination during handling and fluid transfer - anytime hydraulic fluids are exposed to the air, it is exposed to moisture, dust and airborne particles. Contamination will most definitely occur if the equipment and the area where fluid transfer is taking place are not clean. Never leave the lid off of fluid any longer than you need to and do not open fluid in an area that is not clean.

Contamination of fluid during maintenance and service - hydraulic fluid naturally degrades over time, requiring regular service intervals. Seals should be checked as leaking seals can be a source of contamination. Maintenance on hydraulic equipment provides an opportunity for many errors to allow contamination to occur. The best thing that maintenance technicians can do to prevent fluid contamination during preventive or repair maintenance procedures is to follow a meticulous checklist and always be aware of the possibility of contamination.

How to Prevent Contamination in Your Hydraulic System

All components should be thoroughly cleaned during each maintenance procedure, all hoses, hydraulic fittings and adapters should be handled carefully with a clean, lint-free cloth. Use dust caps on quick couplers and cap hoses as soon as they are opened.  Do not open new filters or seals until they are ready to be used.  Remember to always flush the system before adding fresh fluid, and always filter fluid before adding to your hydraulic system.

Flat Face Quick Couplers Limit Contamination

You can additionally reduce your risk of contamination in your hydraulic circuit by using flat-face hydraulic quick couplers, which limit contamination in any hydraulic circuit and are easy to clean. Stucchi offers a wide selection of flat face hydraulic quick couplers with easy connect under pressure, no leak performance and easy cleaning features.

Stucchi’s flat face quick coupler design set the ISO 16028 industry standard.  You can find many Stucchi flat face quick couplers to meet your needs or ask a hydraulic specialist. 

Our VUZ check valves help prevent backflow and keep fluid moving in the right direction.  Stucchi’s hydraulic adapters and check valves are especially helpful in vertically structured circuits, preventing backflow from gravity if or when the pump stops. 

Stucchi offers more than 60 years of experience in providing hydraulic solutions to a wide range of demanding industries including construction, demolition, oil and gas, agricultural, mobile, aerospace ground service support and more. If you are experiencing contamination in your hydraulic system, let the hydraulic specialists at Stucchi evaluate your process for a better solution.

Stucchi excels with providing hydraulic solutions that improve your hydraulic applications and overall business operations. Preventing contamination within the circuit and eliminating hydraulic fluid spills saves time and money and maximizes equipment uptime. Contact us with any questions and speak with a specialist today to learn how to prevent contamination in your hydraulic system.

This article was previously published at:  https://www.stucchiusa.com/blog/preventing-contamination-in-hydraulic-systems/

 

 

 

Mobile Hydraulics Vs. Industrial Hydraulics

 

The main purpose of hydraulic fluid power is to transmit force.  One might think that with the same purpose, all hydraulic machinery and equipment would be similar in design and scope.  Wouldn’t the same valves, actuators and pumps achieve the same hydraulic force? Machinery and equipment is designed for the task at hand, thus mobile machinery may require similar hydraulic force as industrial machinery, although the design and engineering considerations are vastly different.

Challenges with Mobile Hydraulic Equipment

Mobile hydraulic equipment manufacturers faces design considerations to meet the needs of end users that are not factors for industrial equipment design, such as:

●       Environmental factors

 

●       Weight and size imitations

 

●       Cost constraints

●       Controls

The need to meet these considerations, or constraints, with mobile hydraulics, leads to improvements in power density. The relationship with power density and hydraulic machines is the differentiating factor with mobile vs. industrial hydraulics.

Environmental Considerations

Mobile equipment obviously operates within broad environmental conditions which are not considerations for industrial equipment.  Whether we are talking about tractors, log-splitters, forestry equipment, mulching machines, snow removal equipment or other outdoor mobile hydraulic applications, exposure to the elements must always be a design factor.  Mobile equipment must be compact and powerful, with performance not affected by things like rain, snow, ice, dirt, uneven terrain, extreme heat, or moisture.  These factors typically never affect the design or performance of industrial equipment.

Weight and Size Limitations and Power Density of Mobile Hydraulics

Weight and size are paramount considerations for mobile machinery, often considered equally as important as cost.  Reducing mass while producing equal hydraulic force is typically more expensive, rather than providing a cost savings.  Mobile equipment requires weight and strength to tackle tough jobs, although there is a better solution than adding thick plates of steel to machine design for added weight and strength. 

Lighter weight mobile machines are in demand for many reasons, agility, and load capacity as well as environmental emissions. Reducing machine mass can free up available weight for load carrying capacity, which is important when maximum vehicle weight is part of the equation. Reducing weight on mobile machinery with things like unique, lightweight materials, advanced computer design and replacing mechanical components with electrification can all contribute to increasing maximum load capacity.

Power density is the amount of power output per unit volume, or the power output capacity as a ratio of the actuator size. For example, a modern bulldozer will operate with more than 6,000 psi, typically double that of standard industrial hydraulic equipment.  When you compare a 300-hp drive motor that weighs only 300 lbs. to a 300-hp industrial electrical motor that weighs 3,000 lbs,, you realize the importance of power density.

Improvements in power density on mobile hydraulics free up mass on mobile machinery, whether that is offset with load capacity or not.  When you can make do with a 175-hp machine vs. a 200-hp machine, freeing up mass also provides environmental benefits with lower emissions.

Mobile Machinery Demands Lower Costs

Industrial hydraulic machinery design and engineering enjoy liberties that are not accessible to the mobile equipment camp, specifically with size, weight and budget. Industrial machinery and equipment design does not face the dimensional limitations of mobile equipment with floor space and typically mass is not an issue for installation (as is evident in massive automotive stamping presses).

Mobile hydraulic equipment, however, is a market that faces shallow margins with strict cost control.  Even so, some mobile equipment may cost more than a fleet of industrial presses due to advanced design and power density requirements. While the budget for industrial hydraulics is not limitless, industrial customers place value on different considerations than users of mobile hydraulics.  Industrial applications may place a higher value on things like quieter operation and efficiency, whereas purchasing decisions for equipment like a log-splitter for example, would place more value on cost and reliable operation.

Industrial Hydraulic Controls vs. Mobile Controls

One area where mobile hydraulics and industrial hydraulics differ nearly without exception is the entire control system which uses very different components, logic and circuits.  Industrial hydraulic applications are most often designed with custom manifolds or stacked valves, whereas mobile hydraulics often feature advanced valves with custom designed functionality to meet the needs of heavy-duty equipment.

One of the biggest differences in hydraulic controls is that mobile hydraulics commonly feature load sensing tactics, a control concept that measures the downstream pressure close to the actuator, comparing flow-induced pressure drop and load pressure. The load sensing signal is interpreted by the pump to provide the right flow and pressure to meet the demands of the operating valve.  Load sensing pressure drop within a few hundred psi significantly improves efficient operations. 

Stucchi Offers Solutions for Both Mobile and Industrial Hydraulics

Stucchi offers hydraulic solutions for both mobile hydraulics and industrial hydraulics, with quick couplers and hydraulic adapters designed with highly engineered, specific characteristics.  

Our quick coupling solutions for mobile applications include a wide selection of flat-face and threaded flat-face couplers, ISO 16028 and ISO A couplings in various port options, sizes and materials including stainless steel. Technologies like zinc plating and QPQ plating provide additional durability and corrosion resistance. Our hydraulic solutions keep your mobile equipment on the road with leak-free operations for improved safety and zero environmental impact from hydraulic fluid leaks.

Multi-coupling plates improve efficiency in mobile and industrial applications, with easy quick connect and quick release of multiple lines at once.  Our industrial quick coupling solutions include flat face and threaded flat-face couplings, high-pressure couplers, multi-plates and more.  We provide the hydraulic solutions that keep your equipment up and running to meet 24/7 production requirements with minimal downtime.

Stucchi differs from other hydraulic quick coupler suppliers with our staff of skilled and experienced hydraulic specialists dedicated to your overall process improvement. We ask the right questions to provide the most reliable and safe quick connect solution for your application. Contact us to learn how to improve your mobile or industrial hydraulic processes with improved quick connect safety, efficiency, and reliability.

 

This article was previously published at: https://www.stucchiusa.com/blog/mobile-hydraulics-vs-industrial-hydraulics/