Shaoyang Victor Hydraulic Co., Ltd.
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200T Load Capacity Hydropower Plant Hydraulic Cylinder for Dam Gate Control Systems
Features:
1. High-strength cylinder material: Forged alloy steel barrel with quenching-tempering treatment achieves tensile strength ≥900MPa, suitable for heavy-duty hydropower and consevancy applications.
2. Wear-resistant piston rod: Laser cladding combined with hard chromium plating (0.05-0.1mm) enhances corrosion and abrasion resistance.
3. Multi-stage sealing: PTFE guide rings, PU U-seals, and wipers maintain leakage ≤0.1ml/min at 35MPa.
4. Precision displacement monitoring: Magnetostrictive sensors provide 0.01mm resolution for closed-loop control.
5. Fatigue-resistant design: Topology-optimized cylinder head reduces stress concentration to ≤1.2, validated by million-cycle tests.
6. Three-stage cushioning: Adjustable throttle, tapered plunger, and accumulator achieve ≥85% speed attenuation.
7. Fully welded pressure structure: Non-destructive weld testing ensures burst pressure ≥2.5×rated pressure (16-45MPa range).
8. Silt-resistant coating: WC-Co coating via HVOF process provides ≥1100HV hardness for abrasive water conditions.
9. Anti-vibration ports: SAE flanges with shock-absorbing connectors reduce pulsation by ≥30%.
10. Wide-temperature seals: Fluorocarbon seals maintain performance from -40℃ to +80℃.
Technical data:
| Parameter Category | Technical Parameter | Technical Specification |
| Structural Parameters | Cylinder Bore (D) | Standard range Φ200-1400mm, customizable up to Φ2500mm+ with tolerance grade IT7 |
| Piston Rod Diameter (d) | Designed based on load calculation, standard range Φ80-500mm, surface hardness ≥HRC55, straightness ≤0.05mm/m | |
| Stroke Length (L) | Maximum stroke 24m, segmented cylinder splicing error ≤0.1mm/m | |
| Performance Parameters | Rated Working Pressure | Standard grades: 16/25/31.5/42/45MPa, test pressure = 1.25-1.5×rated pressure (≥16MPa: 1.25×) |
| Synchronization Accuracy | Multi-cylinder synchronization error ≤0.5% (closed-loop control), displacement resolution ±0.1mm | |
| Minimum Stable Speed | No creeping under full load, speed range 0.01-0.5m/s (with servo regulation) | |
| Material Parameters | Cylinder Material | High-strength alloy steel (e.g., 42CrMo/SAE4140), tensile strength ≥800MPa, yield strength ≥650MPa |
| Piston Rod Material | Surface high-frequency quenched or HVOF-coated, base material 42CrMo/30CrNiMo, hardness HRC55-65 | |
| Sealing & Buffering | Main Sealing System | V-type composite seals + dust wipers + guide bands, leakage rate ≤0.1mL/h (42MPa condition) |
| Buffering Device | Adjustable multi-stage buffer (mechanical/hydraulic hybrid), impact attenuation rate ≥85% | |
| Environmental Adaptability | Corrosion Resistance | Passes 3000-hour neutral salt spray test, applicable to seawater depth of 300m (special coating version) |
| Temperature Range | Operating temperature -40℃~+120℃, cold-start heating power ≥500W, high-temperature heat dissipation area ≥2.5m²/MPa | |
| Installation & Maintenance | Mounting Types | Flange type (MF3/MF4), eye type (MP3/MP5), trunnion type (MT4), etc. (8 standard interfaces) |
| Maintenance Interval | ≥5-year maintenance-free under normal conditions (IP68 protection), seal replacement time ≤30min (modular design) |
Specifications:
| Application industry | water conservancy, mechanical/marine/mining equipment, oil industry, vehicles, energy and port facilities |
| Stroke length | 50 to 16,000mm |
| Tube inner diameter | 80 to 1,200mm |
| Piston rod diameter | 45 to 600mm |
| plate | Ni/Cr/ceramic |
| Working pressure | 70 to 700 bars |
| Seal type | common stand or in accordance with client's requirement |
| valves | parker/rexroth/atos/hydcom |
| Certification | DNV, ABS, Lloyds, BV, SGS, GL, and CCS |
| Material | carbon steel, alloy, stainless steel |
Applications:
Competitive Advantage:
1. Integral Forged Cylinder Body with High-Strength Alloy Steel: Manufactured through multi-directional die forging per ASTM A182 standards, the cylinder body features uniform grain flow lines and ultimate tensile strength ≥900 MPa. This design withstands alternating impact loads from frequent gate hoist operations, achieving >2 million fatigue cycles while eliminating weld joint failure risks inherent in traditional welded cylinders.
2. Multi-Stage Composite Sealing System: Incorporates a triple-stage axial sealing architecture combining polyurethane U-cups with PTFE wear rings as primary seals, HNBR step-type seals as secondary protection, and integrated guide bands with wipers. This pressure-gradient configuration maintains leakage <0.1 ml/min at 35 MPa operating pressure for long-term gate holding applications.
3. Corrosion-Resistant Surface Treatment Technology: Piston rods receive HVOF-sprayed WC-10Co-4Cr cermet coatings (80μm thickness, HV1200 hardness) with electrochemical passivation, achieving >3,000-hour salt spray resistance. Specifically engineered for chloride-rich hydropower environments. accuracy.
4. Intelligent Displacement Feedback System: Equipped with temperature-compensated magnetostrictive linear displacement sensors (±0.05% FS accuracy) featuring CAN bus interfaces. Delivers 4-20mA outputs for PLC-controlled gate positioning (±0.5mm precision), supporting Modbus RTU/Profinet protocols.
The Analysis For Hydropower Hydraulic Cylinder Common Breakdown:
1. Aging or wear of hydraulic cylinder seals can lead to pressure leakage, which is common in gate control systems that operate under long-term high loads. Rubber materials are prone to cracking under high temperature and high pressure, and metal sealing rings may fail due to scratches from impurities. Failures manifest as accelerated pressure drop and slow actuator action. It is recommended to replace sealing components regularly and use high temperature resistant materials, and clean the sealing groove before installation.
2. Wear of the guide sleeve or external impact loads can cause deformation of the piston rod, which is common in turbine speed control systems. Rod bending exceeding 0.1mm/m will cause eccentric wear of the seal and increase sliding resistance. Use a laser alignment instrument to check straightness and, if necessary, use high-frequency quenching to enhance the strength of the rod. Installing an anti-collision device can prevent mechanical impact damage.
3. The increase in the clearance leads to internal leakage between the cylinder barrel and the piston, which is common in over-running 100 thousands time of the gate hoist. Wear particles enter the oil to form a grinding effect, which aggravates the expansion of the gap. Online oil particle size detection can warn of faults. Repair requires honing the cylinder and matching a larger piston. Maintain oil cleanliness NAS 7 Level and above is the key.