Views: 251 Author: Site Editor Publish Time: 2025-10-01 Origin: Site
Performance Mismatch: For example, the metallurgical industry requires hydraulic systems that can withstand high temperatures and high pressures. However, the seals and hydraulic oil of standardized products often fail to meet the requirements of extreme working conditions, leading to faults such as leakage and component wear;
High Energy Consumption: The flow and pressure parameters of general-purpose systems are "averagely designed" and cannot be dynamically adjusted according to the actual working conditions of the equipment. This results in serious energy waste during no-load operation, leading to high operating costs for enterprises in the long run;
Space Adaptation Difficulties: Some automated production lines or special equipment have strict requirements for installation space. The volume and pipeline layout of standardized systems are difficult to integrate into the existing equipment structure, requiring additional modifications and increasing time and cost inputs.
Working Condition Parameters: Including the maximum pressure (common range of 0-31.5MPa) that the system needs to withstand, flow demand (L/min), operating temperature (conventional working conditions of -20℃-80℃, and up to 120℃ or higher in special scenarios), operation cycle, and continuous working hours;
Functional Goals: Such as whether precise pressure closed-loop control, synchronous action of multiple actuators, emergency shutdown protection, or linkage with PLC automation systems is required;
Compliance Requirements: Whether it meets industry standards such as the ISO 4413 General Standard for Hydraulic Systems, CE certification (for export to the EU market), and explosion-proof certification (for hazardous environments such as chemical industry and mining).
Pipeline Layout: Shorten the length of invalid pipelines to reduce pressure loss while considering the convenience of later maintenance;
Component Matching: Select suitable core components such as hydraulic pumps (gear pumps, piston pumps, vane pumps), hydraulic valves (directional valves, pressure valves, flow valves), and oil cylinders/motors according to pressure and flow requirements. Well-known brands such as Bosch Rexroth, Parker, and Yuken are preferred to ensure reliability;
Energy-Saving Design: Integrate variable displacement pumps and energy-saving valve groups to achieve "on-demand oil supply", which can reduce energy consumption by 20%-40% compared with fixed-displacement pump systems.
Component Procurement: Purchase components from formal authorized channels to ensure original genuine products and avoid system faults caused by inferior components;
Assembly Process: Strictly implement the hydraulic system cleanliness standard (NAS 8 level or higher). After pipeline welding, pickling and passivation treatment are carried out to prevent impurities from contaminating the hydraulic oil. After assembly, a 48-hour no-load test run and a 24-hour load test are conducted to verify whether key indicators such as system pressure, flow, and leakage meet the standards.
Precise pressure and flow control can reduce equipment processing errors. For example, in metal forging scenarios, controlling the pressure fluctuation of the hydraulic system within ±0.5MPa can significantly improve the forming precision of forgings;
The synchronous action design of multiple actuators (such as the synchronous lifting of double oil cylinders) can shorten the production cycle. For example, the efficiency of the assembly line can be increased by 15%-30%.
Energy Conservation: The energy-saving design of "on-demand oil supply" can significantly reduce electricity expenses in long-term use. Taking a 15kW hydraulic pump as an example, working 8 hours a day can save about 12,000 yuan in electricity costs per year (calculated based on an industrial electricity price of 1 yuan/kWh);
Extend Service Life: The precise matching of components to working conditions reduces excessive wear. The average mean time between failures (MTBF) of the system can reach more than 8,000 hours, which is 50% longer than that of standardized systems;
Convenient Maintenance: The pipeline layout and component positions of customized systems are more in line with the enterprise's maintenance habits. At the same time, detailed operation manuals and fault diagnosis guides are provided to reduce maintenance difficulty.
Customized systems can reserve interfaces. If the enterprise expands its production scale in the later stage, it can conveniently add actuators or upgrade the control system without replacing the entire system;
Protective designs for special working conditions (such as low temperature, dust, and corrosive environments) (such as the use of low-temperature hydraulic oil, dust-proof seals, and stainless steel components) ensure the stable operation of the equipment in harsh environments.
Technical Strength: Whether it has an engineer team with more than 10 years of hydraulic design experience, and whether it has customized cases for complex working conditions (such as deep-sea operations and high-temperature metallurgy);
Service Capability: Whether it provides full-process services of "design - production - installation - commissioning", whether the after-sales response time is within 24 hours (on-site service), and whether it provides regular inspection and maintenance training;
Case Reputation: Check whether the service provider has successful cases in the same industry (such as automobile manufacturing, construction machinery, new energy, etc.), and understand the stable operation of the system and after-sales service quality from cooperative enterprises.
