Analysis of several major causes of hydraulic hose failure
1 Corrosion of inner rubber layer
Corrosion of hydraulic hoses often leads to external leakage. Corrosion of the inner rubber layer is usually caused by concentrated high-speed fluid or by fine particles in the fluid.
In order to avoid corrosion of the inner rubber layer, determine the appropriate hose size according to the recommended larger flow rate. In addition, it should be ensured that the hose assembly does not produce excessively tight bends and that the fluid medium does not cause excessive abrasion of the inner rubber layer of the hose. During the hose assembly process, it is very important to comply with the larger bending radius and diameter requirements specified in the engineering specifications of each hose.
2 Fluid compatibility
Incompatible fluids will cause deterioration, swelling and delamination of the inner rubber layer of the hose assembly. In some cases, the inner rubber layer may also be partially destroyed.
The hose must be compatible with the fluid being transferred. Make sure that the fluid is not only compatible with the inner rubber layer, but also with the outer rubber layer, joints and even O-rings.
3 Dry air/stale air
The inner rubber layer of the hose may have many tiny cracks due to old or dry air. Sometimes, this type of failure is difficult to detect because the hose can still remain flexible, but there will be signs of external leakage.
To avoid dry or stale air problems, you should confirm whether your hose rating is suitable for extremely dry air. For these applications, try to choose a hose with EPDM inner rubber material. If possible, the dew point of the air should be increased.
4Small bending radius
If the smaller bending radius is not met, the hose assembly may fail relatively quickly.
In vacuum or suction applications, if the bend radius is exceeded, the hose may become flat in the bend area. This will hinder or restrict the flow of media. If the bend is too severe, the hose may become kinked. In order to prevent hose failures with smaller bend radii, the recommended bend radius should be carefully checked.
5 Insertion depth
When the hose assembly is not properly crimped, it may cause a very dangerous situation. The connector must be pushed completely onto the hose in order to meet the recommended insertion depth requirements. The grip of the next round on the connector housing is very important for the hose to maintain strength.
In order to find the proper insertion depth, a precise production process was developed, which will ensure that the hose is pushed to the position that meets the correct insertion specifications.
6 Incorrect assembly
For hydraulic hose assemblies, contamination can cause a variety of problems. When cutting the hose, metal particles and debris may be deposited in the hose if it is not properly flushed. The abrasive left in the hose will contaminate the hydraulic system. In addition, it may also cause small cracks in the inner tube of the hose assembly, which may lead to leakage.
In order to prevent hose failure due to contamination, the hose must be properly cleaned before being inserted into the connector. The inner tube should be 'very clean' before inserting the joint. After the assembly is crimped, make sure to install the dust cap to keep the hose clean and avoid secondary pollution during transportation.
7 Heat aging
Overheating of the hose assembly can also cause hose failure. Overheating will cause the hose to become very hard. The inner hose will harden and begin to crack because the plasticizer in the elastomer will begin to decompose or harden at high temperatures. In some cases, the cover layer may show signs of excessive drying. After the hose assembly is removed, it may retain the shape it was installed in. If it is bent, a cracking sound will be heard.
In order to prevent the hydraulic hose assembly from overheating, it should be confirmed that the rated temperature of the hose meets the temperature requirements of the application. In addition, lowering the ambient temperature or using protective covers and shielding layers will protect the hose from nearby high-temperature areas.
Hydraulic hoses need to experience harsh environments every day, and the impact will be revealed on the hoses. If the inspection is not carried out regularly, wear and tear may cause the hose assembly to rupture and leak. If the hose is excessively rubbed against an external object or even another hose, the coating layer on the hose will be worn away and the strengthening layer will eventually be worn.
Hose correctly assembled and installed will have a longer life, thereby reducing downtime and maintenance costs. If you need more information on how to extend the life of the hose assembly, or if you need help determining the correct hose assembly for your application, please contact us.
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