Hydraulic System Upgrades: Innovations for Performance

Machines and manufacturing processes that include hydraulics are common in today's manufacturing environment. You can find hydraulic cylinders in CNC operations, material handling equipment, robotics, and more.

For the original equipment manufacturers that designed these systems, hydraulics are one part of many that make everything work. Fine-tuning hydraulic systems for optimum performance frequently requires specialized knowledge and parts from a partner steeped in the science of hydraulics.

If you are a hydraulic cylinder OEM, third-party parts suppliers are a source for what’s new in the market and information on capabilities.

For both groups of companies, CRC Distribution is a supplier that you can rely on. 

The Quest for More Pressure

Manufacturing engineers face ever-increasing demands for faster production, more accurate processes, and cost containment. They look for innovations and upgrades to get more out of their hydraulic systems. They alter hydraulic hose configurations, switch out OEM valves for variable-flow options, and experiment with other ways to boost pressure and deliver more power.

Hydraulic Seals: Often the Final Victim

The final gatekeepers of this extra pressure are the various hydraulic seals in the system. When pressure increases, it often exceeds the piston seal or rod seal specifications. Pressure and fluid escape, resulting in inefficiencies, premature seal wear, and even system failure. The next phone call is to the system's OEM, and the conversation often starts with, “Hey! Your hydraulic system failed.”

This is when it is convenient to have a partner company like CRC Distribution that specializes in supplies for hydraulic systems for repairs and upgrades.

Need better performance out of your hydraulic seals? CRC Distribution can help. Chat with our experts today for a recommendation tailored to your sealing needs.

Innovations in Hydraulics

In any industry, manufacturing engineers look at existing systems and ask, “How can we improve this? How can we make it faster? More accurate? More efficient?” This is as true for hydraulic systems as it is for any other kind. There are recent innovations available across various components that can help boost hydraulic performance to some degree.

Hydraulic Hoses

Hoses are one of the first sources of leaks in a hydraulic system and one of the most frequently replaced components. They are an exposed part of the system, vulnerable to manufacturing floor elements, and in many applications, they are subject to the stresses of constant flexing and repetitive motions. New thermoplastics and rubber compounds, coupled with mesh materials and connecting hardware, offer increased longevity and greater capacity for hydraulic hose pressure. 

Hydraulic Fluids

Hydraulic fluids produce the pressure that’s converted to linear force. Essential traits include viscosity, lubrication, withstanding high temperatures, fire resistance, and the ability to release water (water in a hydraulic system causes contamination and corrosion). Most hydraulic fluids are synthetic-based, but biodegradable fluids are gaining popularity.

Considerations for a hydraulic fluid include: Will it compress to create enough pressure? How does it interact with other components? Some thermoplastic compounds and materials deteriorate when exposed to certain chemicals, including some found in hydraulic fluids. A new fluid reacting unfavorably with your hydraulic seals is definitely a situation you’d want to avoid, so always be sure to check for fluid compatibility.

Hydraulic Valves

Valves regulate the fluid entering or exiting the hydraulic cylinder. Not enough fluid means the system can’t create enough pressure. Too much fluid means excessive pressure and potential damage to other components. Variable pressure valves allow operators to better control hydraulic systems and increase pressure, but this increase in pressure can also impact other components in the system. These impacts should always be analyzed and evaluated. 

High-Strength Materials

New metal alloys, ceramics, and advanced plastics all offer potential for improved hydraulic cylinder performance. Using them for pistons, baseplates, rods, glands, and other hydraulic system parts can result in higher pressures, the ability to withstand higher temperatures, and extended component life.

Systems Controls

Digital controls are quickly gaining popularity in hydraulic systems. Systems are much more responsive and can be programmed to adjust to changes, even if the operator is busy otherwise. But sometimes this responsiveness puts an additional load on other components.

The Importance of Hydraulic Seals

As we mentioned earlier, the hydraulic seal is the final component of the hydraulic system. If all other safeguards and components function in the system were to fail, the hydraulic seal is the last defense against pressure loss. 

Fluid and pressure seek the path of least resistance. In the case of the hydraulic cylinder, this is the minuscule clearance between the piston and the cylinder bore or the rod and the front cap.  It’s a very tight space, but you will lose fluid and pressure without a specialized seal. These seals typically sit in a machined groove in a piston or rod called a gland. Along with guide seals, hydraulic seals also keep the piston or rod from coming into direct contact with the bore (such contact would ruin both components quickly).

How a Hydraulic Seal Works

When hydraulic fluid under pressure increases, the seal conforms to the bore, forming a barrier that keeps fluid and pressure from escaping. The seal design is complex, as there must be some flexibility as it moves up and down the cylinder bore, or the rod travels up and down through the front cap. If the seal material is too pliant, it will not form a complete seal. If the material is too unyielding, it will not allow the piston or rod to move freely, creating friction. Friction creates heat, and heat is lost energy that can place undue wear on the system when created in excess.

Seal Materials

Hydraulic seal materials include rubber, urethanes, PTFE (Teflon), and many others. These materials are often machined into various symmetrical and asymmetrical seal profiles. Advances in manufacturing and the machining of some of these materials often allows for inserts, anti-extrusion rings and even metal inserts, all integrated into a one-piece hydraulic seal.

The more critical the hydraulic cylinder operation, the tighter the clearances inside the cylinder. Seals must be machined precisely, often within a few microns, in order to function properly with other components.

Which seal do you use if you upgrade your hydraulic system? CRC Distribution can help you identify the appropriate materials and profiles for your seals.

Watch the video below to get a closer look at how custom machined seals are made at CRC Distribution.

Need help selecting the right seal to upgrade your system? Contact CRC Distribution to discover our ready-to-ship stock and custom machined solutions.

Advantages of a Hydraulic Supply Partner

When it comes to staying up to date with the latest innovations in hydraulic components, finding the right source can make a world of difference. That’s why system OEMs, integrators, and hydraulic cylinder manufacturers all partner with CRC Distribution. We offer competitive advantages for OEMs of all types in the marketplace, including the following services:

• Customized Seal Kits
• Seal Standardization
• Training
• Stocking Programs
• Engineering Support
• Seal Identification
• Inventory Optimization

For more details on how CRC Distribution supports OEMs and cylinder manufacturers with these services, visit our Services for OEMs page.

The Answer to Hydraulic System Upgrade Needs

For more than two decades, CRC Distribution has served the hydraulic industry with custom seals, an extensive selection of chrome-plated piston rods, and other quality hydraulic components. We also offer distribution expertise and engineering support in the hydraulic marketplace. 

Whether you are a hydraulic cylinder manufacturer or an OEM with hydraulics in your products, partnering with CRC Distribution allows you to focus on your core competencies, achieve seamless integration in your operations, and ensure compatibility in your hydraulic operations. Contact the professionals at CRC Distribution with your hydraulic system upgrade needs.