Hydraulic cylinders under extreme conditions: Solutions for the underground deployment

Robust, precise, durable – when other systems reach their limits

Underground mining is one of the most demanding areas of application for hydraulic cylinders. Confined spaces, permanently high loads and abrasive media pose extreme challenges for components. Added challenges include high pressures, extreme temperature fluctuations and constant exposure to dust, water and salty air. In this environment, maximum reliability is essential – any failure means downtime, safety risks and high costs.

Hydraulic cylinders used in underground mining must be capable of more than standard components. Special solutions are required that are individually tailored to the specific conditions on site: corrosion-resistant materials, special sealing systems, compact designs with high power density and comprehensive ease of maintenance. Because when service is required, it has to be done quickly – every minute counts underground.

We develop and manufacture customised hydraulic cylinders for precisely these conditions. In close cooperation with our customers, we produce special cylinders that deliver what they promise – even under extreme conditions.

Custom cylinders for mining – uncompromising performance underground

A leading mining company approached us with a specific challenge: they needed a powerful and compact hydraulic cylinder that could be used in a new extraction machine. The cylinder had to perform key functions in roller adjustment and guidance under the extreme conditions of coal mining.

The requirements at a glance:

Operating pressure up to 350 bar with high pressure surges
Extremely compact design for integration into confined machine segments
Resistance to abrasive dust and salty air
Reliable operation at temperatures from -20 °C to +60 °C
Minimal maintenance intervals with maximum availability

Our task was clear: to develop a cylinder that functions reliably under extreme mechanical stress – while maintaining high dynamics and precision in movement. In close cooperation with the customer's development team and taking into account the existing machine interfaces, we developed a specially designed, double-acting hydraulic cylinder with a position measuring system.

In order to meet the spatial requirements, the cylinder housing was pierced with oil-carrying lines. These holes run along the entire length of the cylinder and were manufactured in-house. Deep holes with a diameter of 12 mm and a depth of 1200 mm are no problem for us.

The piston rod is coated with a fusion-bonded coating to minimise wear caused by carbon dust and other external influences. A multi-stage sealing system was used for sealing – optimised for the abrasive environment and the continuous movement of the machine.

Digital twins and installation prototypes in CAD enabled the cylinder to be integrated precisely into the machine layout – without additional design effort on the part of the customer. Particular attention was paid to the limited installation space within the machine. Production took place on high-precision CNC machines, with a final pressure test.

The result:
A low-maintenance special cylinder that can withstand the harsh conditions of continuous underground use – reliable, durable, precise.

Our expertise does not end with the design. It begins where it gets challenging.

Do you have a project under extreme conditions? Contact us – we will find a solution.