Shaoyang Victor Hydraulic Co., Ltd.
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Fully Welded Hydropower Hydraulic Cylinder with 16-45MPa Working Pressure
Features:
1. High-strength alloy steel cylinder material (e.g. 27SiMn or CrMo steel) with quenching-tempering treatment achieves tensile strength ≥900MPa, meeting heavy-duty requirements in hydropower and conservancy projects.
2. Laser cladding combined with hard chromium plating (0.05-0.1mm thickness) on piston rod surface meets ISO 6158 Class C for wear/corrosion resistance.
3. Multi-stage sealing system (PTFE guide ring + PU U-seal + wiper) ensures leakage ≤0.1ml/min@35MPa.
4. Integrated displacement sensor interface (magnetostrictive/LVDT) with 0.01mm resolution complies with IEC 61508 SIL2 safety level.
5. Topology-optimized cylinder head design with stress concentration factor ≤1.2 passes ISO 6402 million-cycle fatigue test.
6. Three-stage cushioning system (adjustable throttle + tapered plunger + elastic accumulator) achieves ≥85% end-speed attenuation.
7. Fully welded structure (welding inspection per EN 17636) with 16-45MPa working pressure and burst pressure ≥2.5×rated.
8. Autocompensation surface hardening (HVOF WC-Co coating) with ≥1100HV hardness for silt-laden water conditions.
9. SAE flange ports (4-bolt/2500psi) with shock-absorbing connectors achieve ≥30% pulsation attenuation.
10. Environmental adaptability (-40℃~+80℃) with cryogenic fluorocarbon seals per ASTM D2000 M4EE.
Technical data:
| Parameter Category | Technical Parameter | Technical Specifications |
| Basic Parameters | Bore Diameter | Φ200-Φ2500mm (H8 tolerance grade) |
| Stroke | Max. single-stage stroke 24m (straightness ≤0.05mm/m) | |
| Working Pressure | 16-45MPa (rated), instantaneous pressure ≥1.5×rated | |
| Material & Manufacturing | Cylinder Body Material | Forged 27SiMn/34CrMo4 steel (Tensile strength ≥900MPa, Yield strength ≥750MPa) |
| Piston Rod Surface Treatment | Laser Cladding + Hard Chrome Plating (Thickness 0.05-0.1mm, Hardness ≥900HV) | |
| Cylinder Bore Finishing | Precision honing (Ra ≤0.2μm, Cylindricity ≤IT7 grade) | |
| Sealing & Leakage | Primary Sealing System | PTFE Guide Rings + PU U-Seals + Dust Wipers (Leakage ≤0.1ml/min @35MPa) |
| Redundant Static Seals | Dual O-Rings + Backup Rings (Redundancy ≥200%) | |
| Cushioning & Motion Control | Cushioning Mechanism | 3-Stage Hydraulic Cushioning (Tapered throttling + Elastic accumulators, ≥85% speed attenuation) |
| Position Sensor Accuracy | Magnetostrictive/LVDT type (Resolution 0.01mm, Linearity ±0.05%FS) | |
| Environmental Adaptability | Operating Temperature Range | -40°C to +80°C (Fluorocarbon seals compliant with ASTM D2000 M4EE) |
| Corrosion Resistance | C5-M Corrosion Resistance (HVOF WC-Co coating, ≥2000 hours salt spray test) | |
| Smart Monitoring | Pressure Monitoring | Piezoresistive sensor (Accuracy ±0.5%FS, Range 0-50MPa) |
| Temperature Monitoring | PT1000 sensor (Range -50°C to +150°C, Accuracy ±0.5°C) | |
| Vibration Analysis | Triaxial accelerometer (Frequency response 0-10kHz, Sampling rate ≥10kHz) | |
| Safety & Reliability | Burst Pressure | ≥2.5×Rated Pressure (Cylinder deformation ≤0.1% of total length) |
| Fatigue Life | 2 million cycles per ISO 6402 (No cracks/permanent deformation) | |
| Emergency Manual Operation | Integrated G3/8" manual pump port (≥3 full stroke operations) | |
| Installation & Maintenance | Mounting Surface Flatness | ≤0.05mm/m mounting base flatness |
| Maintenance Interval | Seal replacement cycle ≥5 years/100k cycles (MTTR ≤4 hours) | |
| Energy Efficiency & Eco-Friendly | Hydraulic Fluid Compatibility | Compatible with mineral oils & HETG bio-oils (Seals certified per DIN 51524) |
| Energy Optimization | Differential Circuit Design (≥30% energy reduction in return stroke) |
Specifications:
| Cylinder Type | Mill type, Head Bolted, Base Welded |
| Bore Diameter | Up to 2500mm |
| Rod Diameter | Up to 2000mm |
| Stroke Length | Up to 24,000mm |
| Piston Rod Material | AISI 1045, AISI 4140, AISI 4340, 20MnV6 |
| Rod Surface Treatment | Hard chrome plated, Chrome/Nickel plated, Ceramic coated |
| Tube Material | Carbon steel AISI1045 or ST52.3, Alloy steel AISI4140, Stainless steel 2Cr13 or 1Cr17Ni2 |
| Tube Surface Painting | Colors according to RAL and thickness according to customer needs |
| Mounting Type | Clevis, Cross tube, Flange, Trunnion, Tang, Thread |
| Design Pressure | Up to 40Mpa |
| Seal Kits Type | PARKER, MERKEL, HALLITE, NOK, TRELLEBORG |
| Quality Assurance | 1 year |
| Certificate | SGS, BV, ABS ,GL, DNV etc. |
| Application | Heavy industry, steel mill, Hydraulic press, etc. |
Applications:
Competitive Advantage:
1. Ultra-High Load Capacity: Conservancy hydraulic cylinders utilize multi-layer reinforced barrels (wall ≥40mm) with topology optimization, sustaining ≥10,000kN axial force. Nitrided piston rods (≥55HRC) with TiN coating (50μm) achieve μ=0.08 for Three Gorges-scale gate stability.
2. Extreme Environment Adaptability: Hydropower hydraulic cylinder Wide-temperature seals (-50℃~+120℃) combine FKM/AU materials, maintaining ≤0.05ml/min leakage in Tibet (-40℃) and tropics (RH≥95%). Dual heating/cooling modules provide ±1.5℃ compensation.
3. Precision Motion Control: Conservancy hydraulic cylinder Magnetostrictive sensors (0.001mm) and servo valves (≤15ms) achieve 0.01° guide vane control. Multi-physics algorithms compensate thermal/pressure drift for ±0.2% pumped-storage power accuracy.
4. Sediment Abrasion Resistance: Hydropower hydraulic cylinder Laser-clad WC-12Co coating (≥1,200HV) triples lifespan in Yellow River sediment (50kg/m³). Centrifugal boron steel liners (0.003% B) improve wear resistance by 60%.
5. Intelligent Health Monitoring: Conservancy hydraulic cylinder Oil particle sensors (NAS 1638 Class 6) and vibration analyzers (0-10kHz) predict seal/bearing failure. Digital twins estimate RUL (±5%), cutting downtime by 40%.
The Analysis For Hydropower Hydraulic Cylinder Common Breakdown:
1. Hydraulic cylinder seal failure occurs when Y-ring lip wear (≥0.5mm) causes >5ml/min leakage under 45MPa. Surface roughness Ra>0.8μm accelerates degradation. FKM seals (-40~200℃) with polished grooves are recommended.
2. Hydraulic cylinder piston rod scoring (>50μm depth) caused by 0.1mm quartz particles requires WC-10Co-4Cr cladding (≥1200HV) and magnetic filtration (β≥200).
3. Multi-cylinder synchronization error (>2mm/20m) from oil temperature drift (ΔT≥15℃) demands ±0.5℃ thermal compensation valves and CANopen control (<1ms latency).
4. Hydraulic cylinder end-stop collisions (>150kJ kinetic energy) require multi-stage PU accumulators (≥85% absorption) and 10% stroke pre-deceleration zones.
5. Cavitation erosion (＞3mm pits) at <0.2MPa pressure zones is reduced 70% by flow optimization (cavitation number≥0.4) and laser-textured surfaces (Ra≤0.1μm).