Shaoyang Victor Hydraulic Co., Ltd.
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Water Conservancy Hydraulic Cylinder 150T Capacity Stainless Floodgate Operation
Features:
1. Ultrasonic cleaning + vacuum filling achieves ≤18/15/12 particle count, exceeding ISO 4406 16/14/11
2. Vibration analysis port (BNC connector) enables FFT monitoring (0-10kHz) for condition assessment
3. Piston rod surface roughness Ra≤0.1μm (DIN 4768) keeps dynamic seal friction ≤5% of rated force
4. TRIZ-based contradiction matrix design enhances stiffness (≥5GN/m) while reducing weight by 15%
5. Digital twin system (ISO 13374 compliant) provides ≥90% accuracy in remaining life prediction
6. Ultra-clean assembly: Ultrasonic cleaning and vacuum filling achieve cleaner-than-ISO 4406 16/14/11 levels.
7. Vibration monitoring: BNC port enables FFT analysis (0-10kHz) for condition-based maintenance.
8. Low-friction seals: Ra≤0.1μm piston rod surface reduces dynamic seal friction to ≤5% of rated force.
9. Lightweight yet rigid: Optimized design achieves ≥5GN/m stiffness with 15% weight reduction.
10. Digital twin integration: Lifecycle modeling predicts remaining service life with ≥90% accuracy for predictive maintenance.
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. Cavitation-Resistant Flow Design: CFD-optimized ports with helical flow guides and divergent cones reduce cavitation index <0.3, doubling seal lifespan through stabilized fluid dynamics.
2. Heavy-Duty Spherical Bearings: Self-lubricating spherical bearings accommodate ±8° articulation and 8,000kN radial loads, compensating for ±2° installation misalignments and foundation settlements.
3. Anti-Rotation Guiding Mechanism: Four orthogonal polymer guide bands with keyway anti-rotation control limit rod twist to ±0.5°, ensuring sensor accuracy and uniform seal wear patterns.
4. Custom Corrosion Protection: pH-adaptive coatings: 3PE (500-800μm) for acidic water or epoxy-ceramic for alkaline conditions. Achieves ISO 2409 Class 0 adhesion with 15+ year service life.
The Analysis For Hydropower Hydraulic Cylinder Common Breakdown:
1. The uneven flow distribution of the multi-cylinder parallel system leads to action deviation, which is common in the ship lock thrust system. When the servo valve response difference exceeds 5%, it will cause structural distortion. Use a closed-loop control algorithm with cross sensor feedback and adjust the equal-section flow divider and collector valve. Regularly check the displacement synchronization accuracy of each cylinder to ensure that the error is less than ±1.5mm.
2. Frictional resistance fluctuations during low-speed operation cause discontinuous motion, which is common in guide vane adjustment mechanisms. Stick-slip effects occur when the difference in static and dynamic friction coefficients exceeds 0.02. Countermeasures include step seals with solid lubricants, increasing the oil viscosity index to VG68, and preload elimination devices. Acceleration sensors can capture abnormal fluctuations of 0.01m/s².
3. Continuous high temperature (>80℃) accelerates seal aging, and cooler blockage or system overload are the main reasons. Install an infrared thermal imager to monitor the cylinder temperature field, and start auxiliary heat dissipation when the oil temperature exceeds 65℃. Use high-temperature resistant fluororubber seals instead, optimize the pipeline layout to reduce pressure loss. The heat balance calculation should ensure that the heat dissipation power is greater than 120% of the system heat generation rate.