Cylinder testing

Hydraulic systems & components

2nd Quarter 2009 Hydraulic systems & components

Hytec Group invests in technology.

Hytec Engineering, a member of the Hytec Group, designed, constructed and recently commissioned a R1,5m cylinder test bench in response to customer demand for a leading edge hydraulic cylinder testing facility.

Built using expertise, hydraulic and automation equipment, and products from the entire Group, the test bench is used at the end of the assembly line. Functional testing helps to maintain safety standards and durability and in a quality-orientated manufacturing and repair environment there is a need to control the performance of manufactured and refurbished components.

The bench tests cylinders up to 450 mm bore, to a pressure of 420 bar

A family affair

According to Charlie Harrison, general manager, Hytec Engineering, the best products on the market were used from Bosch Rexroth components to Hydac filters and contamination sensors. “The Bosch Rexroth components were supplied by sister companies, Hytec, which manufactured the main power pack, while Tectra Automation supplied automation components including an Indra Motion MLC automation system, Indra Drive servo axes and a Datasensor laser. The sensor is mounted on a two-axis linear system from Rexroth with a travel of 12 m in one direction and 1,5 m in the other. Specialist filtration company Hytec Fluid Technology also supplied products.”

The control panel has several Rexroth digital display screens which can be individually configured to show all analogue and digital outputs. To ensure the protection of the operator and customers witnessing the test, the entire system is guarded by a Rexroth Eco-safe fence system with polycarbonate panels for added safety.

Operators are safely encased in a Rexroth Eco-safe fence system with polycarbonate panels

Investment rationale

Harrison notes that having a test bench of this sophistication is important to the company due to the amount of repairs that it performs and its desire to remain number one in the market place. “Hytec Engineering manufactures and repairs cylinders and is probably the leading company in sub-Sahara Africa in this regard. The majority of our repair customers come from the mining sector where quality, safety and cost-efficiency are crucial.”

Testing

The fully automated bench tests cylinders up to 450 mm bore, to a pressure of 420 bar with a maximum stroke length of 6 m and offers an accuracy of 0,1 mm.

The only manual operations needed are the loading and unloading of the cylinder onto the bench and the hydraulic connections.

Tests performed include:

* Verification of the external measurements.

* Leak test.

Closed and open measurements are taken using a laser to determine the stroke.

A full leak test is performed at 150% of design pressure. During the test the cylinder is cycled to remove all air from the system, extended and retracted. A mid-stroke bypass test is also performed.

Possible oil contamination is analysed in both cylinder chambers during the test according to ISO 4406, and oil temperature can be adjusted to suit the specific system temperature.

Once a cylinder has been tested, the system generates an automatic, tamper-proof, printed certificate that can be used for quality control by clients.

The test bench was fully commissioned in February 2009 and has been well received by customers.

For more information contact Charlie Harrison, Hytec Engineering, +27 (0)11 387 1900, [email protected], www.hyeng.co.za

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Cylinder testing

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