Hydraulic hoses are constructed of three main components; Tube, Reinforcement and Cover.
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The inner most part of the hydraulic hose is the tube, wrapped up by reinforcement, which is encapsulated with a cover.
The tube is the inner most lining of a hydraulic hose and comes into contact with the fluid being conveyed. The tube and fluid compatibility is most critical.
As described above, the inner part of a hose is the tube; its function is to contain and convey the service fluid. Furthermore, it also protects the outer elements of the hose from possible aggression of the conveyed fluid. Additional caution must be exercised in hose selection for gaseous applications where premeation my occur. Premeation of effusion is seepage through the hose pores resulting in loss of fluid. This may occur when a hose is used with fluids such as but not limited to; liquid and gas fuels, refrigerants, helium, fuel oil & natural gas. The material of the tube is chosen among a great number of synthetic rubbers. The chemical composition of the compounds should be selected to meet the requirements of the application.
The tube itself cannot withstand the pressure of the conveyed fluid; in fact, as mentioned above, the design of the tube considers only its compatibility with the fluid to contain, while the very wide range of pressures presents in hydraulic applications must be analyzed otherwise.
The reinforcement material is the “Muscle/Strength” to resist internal or external pressures. The three basic types of reinforcement are Spiral, Braid and Helical.
Spiral reinforcement is typically steel wire (Textile for Lower Pressure) and has four or six overlapping layers of reinforcement. Spiral wire hose can handle move severe applications with longer service impulse cycle life at extremely high pressures.
Braid reinforcement can be steel wire or textile, and can have single or multiple layers. Braided hose can handle low to high pressure impulse applications.
Helical coil monofilament reinforcement keeps the hose from collapsing in on itself when used in suction line applications. Helical hose can be rated to a full vacuum rating of 30Hzg.
The pressure resistance of the hose must be higher than the working pressure. The safety factor is defined as the ratio between the burst pressure and the maximum working pressure; for the hydraulic applications the safety factor is set to 4:1 by International Standards, some special static applications a water cleaning for example (ISO ) have a 2.5:1 safety factor. For low pressure applications (up to psi for example), textile reinforcements may be used. So nylon, rayon or polyester fabrics are woven, braided or wrapped around the tube. When the pressure gets higher stronger materials are needed and steel wire spirals or braids are used.
Wire braided hoses bear generally one or two layers of reinforcement (in some cases even three) while spiral ones commonly four or six spirals (layers). The application of braids and spirals can also be mixed depending on the most appropriate design. Between each layer of braids or spirals an interlayer or friction layer is installed to create a bonding effect and to prevent friction wear between wires.
In general, spiral hose constructions are better suited to high impulse heavy duty applications, which involve flexing and large pressure spikes. However, there are specialized braided hoses available from various manufacturers that can achieve significant impulse cycle life in a flexing application with a tight bend radius. Helical coil monofilament reinforcement hose is found primarily in suction line applications and low pressure return line applications. Please consult HoseandFittings.com if there are multiple constructions required to meet your application needs.
Environment, machines and operators themselves can damage the reinforcement. The cover, outermost element of the hose, is used to protect it. There are several types of cover, each designed depending on specific requirements: economy, safety, abrasion resistance, chemical resistance, etc.; even aesthetic are features linked to the choice of the cover (e.g. color). Rubber cover can have a wrapped finish: instead of the smooth finish a wet nylon tape is used around the hose during the vulcanization; at last the nylon tape is removed and leaves the hose bearing its imprint. Free steam vulcanization is also used: the hose is directly vulcanized without any wrapping or shaping method. The vapor steam at high temperature is directly in contact with the outer rubber cover of the hose. This allows saving some steps of the entire manufacturing cycle saving time and materials. Particular attention must be paid to maintain the tolerances and to avoid local defects on the cover. Cover finish is smooth. Also fabric braided covers are still used: the cover is braided fabric, often impregnated with rubber adhesive. This is the best solution when minimum weight and heat dissipation are required. This solution is usually used on low or medium pressure hoses due to its relative weakness (e.g. R5 hose type). Coverless type is usually only used for stainless steel braided hoses, mostly PTFE hoses.
© Copyright by the Assocation for Hose & Accessories Distribution, Inc. (NAHAD)
Selecting the correct hose for an application has to take into account several variables about your application. There is an acronym named STAMPED that is useful for guiding you to look at all those variables when selecting a hose. If you Google STAMPED, you’ll find a lot of companies giving you the word each letter comes from; Size, Temperature, Application, Media, Pressure, Ends and Delivery. We have used the NAHAD explanation for each letter to better guide you through your selection process.
Medium Pressure, Single Textile Briad Reinforced Hydraulic Hose
(According to ISO type 1 / DIN EN 854 type 1TE / SAE J517 type SAE 100R6)
Suction & Delivery Hydraulic Hose
(According to SAE J517 type SAE 100R4)
High pressure, single steel braid reinforced hydraulic hose
(According to ISO / DIN EN 853 type 1SN / SAE J517 type SAE 100R1 AT)
Higher pressure, double steel braid reinforced hydraulic hose
(According to ISO / DIN EN 853 type 2SN / SAE J517 type SAE 100R2 AT)
Higher pressure, double steel braid reinforced hydraulic hose
(According to ISO / DIN EN 853 type 2SN)
High Pressure, Double Steel Wire Braid Reinforced Hydraulic Hose
(According to SAE J517 Norm Type / SAE 100R16 / ISO -1 Norm type R16)
High Pressure, Single or Double Steel Braid Reinforced Hydraulic Hose
(According to SAE J517 Norm type / SAE 100R17 / ISO -1 Norm type R17)
High Pressure, Four Steel Wire Spirals Reinforced Hydraulic Hose
(According to ISO / EN 856 type R12 / SAE J517 type SAE 100R12)
High Pressure, Very Flexible, Four Steel Wire Spirals Reinforced Hydraulic Hose
(According to ISO / EN 856 type R12 ? SAE J517 type SAE 100R12)
Very High Pressure, Four Steel Wire Spirals Reinforced Hydraulic Hose
(According to ISO / EN 856 type 4SH)
Very High Pressure, Four or Six Steel Wire Spirals Reinforced Hydraulic Hose
(According to ISO / EN 856 type R13 / SAE J517 type R13)
Very High Pressure, Four or Six Steel Wire Spirals Reinforced Hydraulic Hose
(According to ISO / EN 856 type R15 / SAE J517 type R15)
High Pressure, Synthetic Polyester Braid Reinforced Thermoplastic Hydraulic Hose
(According to ISO / EN 855 Type R7 / SAE J517 type SAE 100R7)
High Pressure, Synthetic Polyester Braid Reinforced Thermoplastic Non-Conductive Hydraulic Hose
(According to ISO / EN 855 Type R7 / SAE J517 type SAE 100R7)
Contact us to discuss your requirements of sae 100r2. Our experienced sales team can help you identify the options that best suit your needs.
Very High Pressure, Aramid Braid Reinforced Thermoplastic Hydraulic Hose
(According to ISO / EN 855 type R8 / SAE J517 type SAE 100R8)
Very High Pressure, Aramid Braid Reinforced Thermoplastic Hydraulic Hose
(According to ISO / EN 855 type R8 / SAE J517 type SAE 100R8)
Hydraulic hoses play a critical role in the smooth functioning of hydraulic systems, which are widely used in industries like construction, agriculture, and manufacturing. Selecting the right hydraulic hose is essential for optimizing performance, ensuring safety, and preventing costly downtime.
Choosing the right hydraulic hose for your system is vital because it directly affects the efficiency, durability, and safety of your equipment. A poorly selected hose can lead to:
Premature wear and tear
Leaks or bursts under pressure
Increased maintenance costs
Equipment failure and downtime
The right hydraulic hose, on the other hand, ensures optimal performance, minimizes breakdowns, and extends the service life of your hydraulic system.
1. Hose Type
There are several types of hydraulic hoses, each designed for different pressures and applications. The most common types include:
Low-pressure hoses: Ideal for low-pressure applications like return lines.
Medium-pressure hoses: Used in systems with moderate pressure, such as construction equipment.
High-pressure hoses: These are designed for heavy-duty applications, such as those in mining or heavy machinery.
Always ensure the hose type you select matches the pressure requirements of your application to avoid failure.
2. Material
Hydraulic hoses are typically made from rubber, thermoplastics, or metal. The material you choose should be based on the operating environment and the type of fluid being transferred.
Rubber hoses: Flexible and durable, ideal for most industrial applications.
Thermoplastic hoses: Resistant to abrasion and chemicals, great for outdoor or harsh environments.
Metal hoses: Best for high-temperature environments or applications involving corrosive fluids.
3. Temperature Range
Hydraulic systems can operate in a wide range of temperatures. Be sure to choose a hose with a temperature rating that fits the conditions of your application. Some hoses are specifically designed for extreme cold or heat, so understanding the operating environment is crucial.
4. Hose Size and Length
Hydraulic hoses come in various diameters and lengths. The internal diameter (ID) of the hose affects the flow rate, while the length impacts pressure drop. It’s essential to select the correct hose size to ensure efficient fluid transfer and minimize system losses.
5. Pressure Rating
The pressure rating of a hose must match or exceed the maximum operating pressure of the hydraulic system. Look for hoses that are rated for higher pressures to account for spikes or surges in the system. A hose with an inadequate pressure rating can fail under stress, causing dangerous leaks or bursts.
6. Bend Radius
Hoses that need to be bent around corners or curves should have a bend radius rating. Selecting a hose with a bend radius that fits your application is crucial to avoid kinks or breaks, which can disrupt fluid flow and reduce system efficiency.
7. Compatibility with Fluids
Hydraulic hoses must be compatible with the fluids they carry. Certain hoses are specifically designed to resist specific types of hydraulic fluids, whether it’s petroleum-based, synthetic, or water-based fluids. Choosing the wrong hose can result in degradation, leaks, or system contamination.
8. Fittings and Connectors
Selecting the right fittings and connectors is as important as choosing the hose itself. Ensure that the hose’s fittings are compatible with your hydraulic system to avoid leaks and ensure smooth operation. Choose corrosion-resistant fittings for longer-lasting performance in harsh environments.
9. Durability and Longevity
Durability is a key consideration, especially if the hose will be exposed to tough conditions like abrasion, vibration, or extreme temperatures. Selecting a hose with protective covers or reinforcements, such as steel wire braiding or textile layers, can greatly extend its lifespan.
Hydraulic hoses are used in a variety of industries and applications. Some of the most common include:
Construction machinery: Excavators, loaders, and cranes require durable, high-pressure hoses.
Agriculture equipment: Tractors and harvesters use medium-pressure hoses for fluid power systems.
Manufacturing equipment: High-pressure hoses are crucial for robotic arms and assembly line machinery.
Mining: Heavy-duty hoses are essential in the mining industry, where equipment must operate under extreme conditions.
Hydraulic hose selection involves considering various factors such as pressure rating, material, temperature range, and compatibility with fluids. Making the right choice will enhance your system’s performance, improve safety, and reduce downtime. Always consult with a hydraulic hose expert or supplier if you're unsure about the best option for your application.
By taking the time to carefully select the right hydraulic hose, you can significantly improve the efficiency and reliability of your hydraulic system, ensuring long-term success in your operations.
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