Durable hydraulic hose | 2 Simple Data predict the service life of the hose.

Way Liu
3 Companies Founder: 11 Years Hydraulic Hose Assembly & International Trade Operate(B2B) & . Also an Honest Partner For Your China Sourcing.
The life prediction of hose assembly has always been a difficult problem that can not be solved in the hose industry. due to different application environments and conditions, even the life of the same hose assembly on the same platform is completely different. as a result, most of the prediction of hose life is based on empirical guess and mathematical modeling calculation.
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Hydraulic smart control system

Industry data observation for durable hydraulic hose

From the industry point of view, in oil field development, mining, metallurgy, and other industries, the loss caused by the shutdown caused by the sudden failure of parts is huge. For example, the loss caused by the shutdown of offshore oil platforms is as high as more than 500,000 US dollars per day; the loss caused by the shutdown of steel mills is more than 400,000 US dollars; the loss caused by the sudden stoppage of roadheader underground is as high as tens of thousands of US dollars; at the same time, the sudden failure of the system will also give rise to major personal, environmental, safety and other major problems.

In terms of cost, the loss caused by the shutdown is far greater than the value of a rubber hose. In response to these workplaces with high reliability and security, SHOTON can give play to its unique advantages to help customers prevent these situations more effectively.

SHOTON technology can monitor the internal condition of the hose in real-time. If the hose assembly is about to fail, the detection system will send a signal to remind the machine operator to arrange a time to replace the hose that is about to fail. Compared with the ordinary prediction method, its characteristic is that it does not rely on traditional mathematical modeling and calculation to predict when the hose will fail but to judge whether the hose is about to fail by detecting the changes in the internal structure of the hose. This method is more reliable than the traditional method of relying on mathematical modeling.

durable hydraulic hose

Hydraulic hose assembly

Formula prediction calculation

When it is used to analyze the service life of a durable hydraulic hose in a certain part of an application platform, there are many factors to be considered, such as the hydraulic hose of the excavator bucket, according to the soil quality, soil load, bucket size and other working conditions, the pressure of each action is different.

Assuming that the working temperature is constant, a rubber hose will basically bear P1, P2, P3 in the work. Pn et al. N kinds of pressure pulses with different peak values; withstand P1, P2, P3 under the condition of constant temperature. Under Pn pressure, the life span is N1, N2, N3, and Nn respectively, assuming that after working for a period of time, the number of pressure pulses is N1, N2, n3 respectively. Nn times, the remaining life of the hose is:

Remaining life of hose=1-(N1/n1+N2/n2+N3/n3+… … …+Nn/nn)

However, the difficulty of this method is how to determine the corresponding N value of each pressure value under fixed working conditions, because the damage caused by the same pressure pulse to the rubber hose is different under different temperatures. The purpose of the pulse test in the design is to determine how many pulses can be withstood at 100 degrees Celsius and 1.33 times the working pressure, in which the temperature and pressure are fixed, so it is necessary to get the fixed working conditions and temperatures.

The N value corresponding to each pressure P not only requires a large number of experiments and consumes a lot of financial and material resources, but also does not take into account the effects of temperature increase, ozone, surface wear, bending, and other factors in practical application, so this method is very unreliable in practical application.

Analysis of technological advantages

From a new point of view, the key point is not put on the analysis of external factors such as pressure, temperature, and environment, but on the changes of the internal structure of the hose to predict the life of the hose. Eaton designers found after a long time of research, no matter how the external environment and pressure changes, will eventually be reflected in the hose inner structure changes, and before the hose failure, the internal structure always has the same change.

After the change of the internal structure of the hose, the corresponding resistivity changes accordingly, and the current of the whole monitoring system changes accordingly. Therefore, the structure of the hose and hose joint used is different from the general structure. In the whole system, the hose and joint are used not only as fluid connectors but also as conductors to form a detection circuit.

The detection circuit formed inside the hose continuously sends electrical signals to the monitor to ensure that the hose is always in a controlled state for 24 hours, and the operator can know whether the hose is working normally at any time.

If the hose is about to fail-about 10% of the overall life is about 15%, the monitor detects a change in current and sends a warning signal to remind the operator to replace the hydraulic hose to avoid sudden failure. Regardless of the length of the hose, the circuit formed by the system always detects the whole hose, and the structural change of any part of the hose will be detected.

In addition, after continuous improvement, the system has successfully introduced the wireless function, that is, the operator can not see the monitor, the electrical signal will still be sent through the monitor to the receiving terminal-mobile phone/computer or another receiver. According to the user’s feedback, the old type of monitoring sleeve is insufficient in preventing Rain Water leakage and other aspects such as preventing sundries from affecting the circuit, so it is improved to a new type of sleeve, and the interior of the new sleeve is sealed with an O-ring. Nylon 66 material is used to ensure reliability and a more beautiful appearance. According to practical experience, in the hydraulic system, compared with high-pressure four-layer and six-layer hose, two-layer steel wire braided hose is the most prone to failure.

At present, SHOTON rubber hose can achieve the working performance of two layers of steel wire braided hose (SAE100R2AT Type S, EN8532SN, ISO 1436-1 Type 2SN). At present, it can provide a hose with common specifications such as-8gammer 12ram 16 and American thread 37-degree cone seal form-8gamma 12ram 16 hose joint, etc. At present, it can achieve the working performance of two layers of wire braided hose (SAE100R2AT Type S, EN8532SN, ISO 1436-1 hose).

Please believe that we will have an expected performance in high-end fields such as offshore oil exploitation, onshore oil exploitation, mining, metallurgy, engineering machinery, automobile manufacturing, and so on.

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Durable hydraulic hose | 2 Simple Data predict the service life of the hose.

The life prediction of hose assembly has always been a difficult problem that can not be solved in the hose industry. due to different application environments and conditions, even the life of the same hose assembly on the same platform is completely different. as a result, most of the prediction of hose life is based on empirical guess and mathematical modeling calculation.

阅读更多 »
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