At ACONA-Hydraulik, we not only repair our own hydraulic cylinders, but also those of other well-known manufacturers such as Ruhfus Systemhydraulik, Montan Hydraulik, Bosch Rexroth and Hunger Hydraulik.
As in the following case. A steelworks in the Ruhr area discovered a defect in a hydraulic cylinder from Bosch Rexroth.
The problem: the piston rod was continuously sagging under load.
As such a defect can have serious consequences during operation, the hydraulic cylinder had to be repaired quickly and thoroughly.
If it is not possible to remove the defective cylinder, we can also plan, design and supply you with a brand new custom-made hydraulic cylinder.
A hydraulic cylinder repair usually involves the following 5 steps:
1. disassembly and mounting of the cylinder:
To determine the exact cause of the problem, we first completely dismantled the hydraulic cylinder.
Each component was carefully inspected and measured in order to document the condition in detail.
We also created a 3D model of the cylinder to create a precise basis for the subsequent repair.
2. determine the condition of the cylinder:
During the initial inspection, it became apparent that the hydraulic cylinder showed considerable signs of wear:
The running surfaces of the piston rod and the cylinder tube were heavily worn.
The valve block was defective and no longer fully functional.
The bearings in the rod and base eye had reached their wear limit.
The hydraulic oil was clearly contaminated.
Both the head seal and the rod seal were worn and could no longer reliably hold the pressure.
This damage indicated that the hydraulic cylinder was not only subject to high mechanical stress, but that the hydraulic medium also played a role in the premature wear.
3. analysis and result
The detailed examination confirmed our suspicions: the damaged piston seal and the worn running surfaces were causing an internal leak.
As a result, the pressure in the chamber could no longer be kept constant - causing the piston rod to drop under load.
The heavy contamination in the hydraulic oil further accelerated the wear and contributed significantly to the damage.
For a long-term solution, it was therefore not only necessary to rectify the mechanical defects, but also to take measures to prevent future problems of this kind.
4. the repair of the hydraulic cylinder
To make the hydraulic cylinder fully functional again, we carried out a comprehensive overhaul.
This included, among other things:
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1. Reconditioning the piston rod:
The surface was renewed and given a new coating.
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2. Replacement of the cylinder housing:
As the wear was too severe, it was completely replaced.
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3. Overhaul of the valve block:
We repaired the valve block and restored its full functionality.
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4. Replacing the seals and screws:
All seals were replaced with high-quality new parts to ensure long-term tightness.
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5. Replacement of the supply lines:
New pipes were installed so that the hydraulic fluid can flow cleanly and unhindered.
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6. Installation of a new damping bush:
This improved the stability and service life of the cylinder. To restore an optimum damping effect - even at high speeds and loads.
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7. Renewal of the bearings:
Both the rod eye and the base eye were fitted with new, durable bearings.
Mit diesen Maßnahmen stellten wir sicher, dass der Hydraulikzylinder nicht nur wieder funktionierte, sondern auch zukünftigen Belastungen besser standhält.
5. extensive function test of the hydraulic cylinder
After the successful hydraulic cylinder repair, we subjected the cylinder to a comprehensive test procedure.
We tested the tightness, pressure build-up and stroke movement.
Only when all tests had been successfully passed did we release the cylinder for reuse.
Finally, it was given a fresh coat of paint - not only for its appearance, but also as additional protection against external influences.
Now it is ready for its next job: with full power and a stroke of over two metres, it can once again work reliably in the steelworks.
Our conclusion on hydraulic cylinder repair
This example clearly shows the importance of professional analysis and careful repair in order to ensure the service life and functionality of hydraulic systems in the long term.
If a defect occurs during operation, there is not only the risk of expensive downtime, but in the worst-case scenario also the risk of costly consequential damage.
This risk can be significantly reduced through targeted engineering: Weak points can be recognised as early as the planning phase and prevented by design.
This is how we at ACONA-Hydraulik prevent critical failures from occurring.
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What can we do for you?Whether hydraulic cylinder enquiry, tube machining, repair or general questions.
We will be happy to advise you.