HYDRAULIC CYLINDER &
PISTON MANUFACTURING TURKEY
With this blogpost we will share some insight on industrial cylinder and piston manufacturing in Turkey and methods for manufacturing.
One of the four essential parts of a hydraulic pump is a hydraulic cylinder. There are several uses for hydraulic cylinders when a lot of force is required. At OGGO Tech, we provide hydraulic cylinders for a variety of industries, including forestry, load management, mining, and agricultural.
They come in a vast variety of sizes, designs, and materials, and include a wide number of components, making hydraulic cylinders rather complex machines. However, because the basic structure never changes, hydraulic cylinders are also relatively straightforward. When the designing process is initiated, the biggest difference among cylinders and their various varieties is encountered.
The complexity of hydraulic systems makes it difficult for design engineers to specify cylinders since each design parameter affects one or more of the numerous other design considerations required for the application. A group of design engineers creates the cylinder while considering its intended purpose as well as the surroundings in which it will be used. Materials, coatings, seals, and other specialized parts are determined by this.
The piston rod, seals, and cylinder body make up most hydraulic cylinders. Dimensional constraints, surface roughness, form, and position tolerances may all vary for hydraulic and sealing components. The design parameters are impacted by the numerous variations in working conditions for hydraulic cylinders.
The methodical design approach includes choosing the appropriate materials. The proper steel material must be chosen. Hydraulic cylinders are typically made of one of three materials: Steel types include #20, #45, and Cr40. The softest steel, # 20, is typically used in low-pressure hydraulic cylinders, such as those found in excavators, whereas # 45 steel and Cr40 are typically used in high-pressure hydraulic cylinders, which have a 10000 psi rated working capacity.
Our engineering group begins developing the more detailed production plans once the layout and materials have been approved. Our engineering team ensures that our manufacturing is equipped with all necessary tools. For instance, we must ensure that we are equipped with the appropriate tools and knowledge. Our manufacturing needs to understand precisely how the new products must be produced. The production flow and timing for each product are also designed by our engineering department. They make certain that the new items move through our manufacturing process properly. The order desk handles the production scheduling. They guarantee that the required capacity exists and plan the production process in accordance with that.
Hydraulic cylinders, as was already noted, are made up of a variety of sections and components. Visit this blog post explaining what a hydraulic cylinder is if you want to learn more about how it is constructed.
It’s time to begin the real production process after meticulous preparation. The process begins with raw materials that are lathed into components that are ready for use. At OGGO Tech , we perform some of the item machining in-house at our facility. For instance, in some circumstances, manufacturing the components internally is more cost-effective and customer-friendly than outsourcing their purchasing. The raw – materials part is turned into the proper shape during the machining process. Our machining workshop in Turkey provides best manufacturing methods and solutions. The machining is handled by our highly qualified and experienced employees. Milling as a task calls for careful management and aptitude.
Welding can begin when the components have been prepared, examined, and carefully rinsed. Tube ends and rod eyes are joined by welding.
At OGGO Tech, several cylinder models also have friction welding. The most economical way to manufacture large volumes of high quality piston rod assemblies is reportedly friction welding. More information about our contact welding procedure is available here.
When all of the components have been completed, all of the parts have been retrieved from the storage, and everything has inspected, it is time to start the assembly process. Before assembly, each component is carefully protected and cleaned. The degree of purity of each component is checked. Samples of the washed sections and the washing outcomes are examined for cleanliness each day. The chemistry and purity of the washing fluid in OGGO Tech dryers are regularly examined. A cleaner with ultrasonic technology is used to clean fragile and small parts.
After all the components have been inspected and their cleanliness has been checked, the actual assembly process starts. First the seals are put in place (for piston, cylinder head etc.) along with bearing and snap ring.
The piston is to the rod.
The seals are oiled around the piston and cylinder head.
After the rod is assembled with every component, the whole package is ready to be installed to the tube.
During every step, the cleanliness is the top priority and at every point of the assembly, the surfaces are kept clean and properly wiped if necessary.
The tube is also inspected visually and after that the tube is attached horizontally to an installation bench, a bearing is installed and the tube is oiled properly from inside.
The rod is carefully slid inside the tube with the piston end first.
The torque is set according to customer requirements.
After the actual assembly of tube and rod is ready, the bearings and grease nipples are installed.
The tubing is also given a visual inspection before being positioned on a bench horizontally, having a bearing put in, and receiving sufficient internal lubrication.
The piston end of the rod is inserted into the tube carefully first.
The torque is adjusted in accordance with the needs of the customer.
The bearings with grease nipples are put in place after the physical assembly of the tube and rod is complete.
The cylinder is prepared for proof testing after it has been put together. The testing, often referred to as a proof test, is done to make sure that the cylinders are safe and functioning. To make sure that all the connections the welds in the cylinders can withstand the pressure, the proof test is carried out at a pressure that is higher than the pressure that will actually be used at the finished machine. The computer can then be used to determine the internal leakage.
After the proof test, the valves are frequently fitted on the cylinder. This is due to the fact that following construction, cylinders are “dry” and contain air. If indeed the valves are still in position, all of the air inside the cylinder may not be allowed to escape however during proof test when the cylinder is loaded with pressured oil.
It poses a huge security concern and could result in a serious accident if compressed oil is injected inside of an air-filled cylinder. While not always true, certain valves can be utilized during proof test.
All testing documentation are filled up following the proof test. These comprise both the documents owned by OGGO Tech and those of the clients. The cylinders are now prepared for painting, and the tester additionally secures a protective layer before painting.
Following testing, the paint, coating and finishing is done. An undercoat, middle coat, and final coat of paint are applied to every cylinder. To maintain the cylinder’s body waterproof and stop it from rusting, paint is sprayed upon it. Painting as well as other surface coating are always carried out in accordance with customer needs, just like everything else.
In accordance with the needs and orders of the customer, the cylinders are then packaged and dispatched. Some of the cylinders are shipped to our clients’ warehouses as spare parts, while others are sent directly to their assembly lines.
Manufacturing hydraulic cylinders using automation is a relatively new and unexplored field. We wish to disprove this notion and demonstrate that hydraulic cylinder production can also be automated.
The new line provides our clients with improved service capabilities and a more efficient manufacturing system. With the help of our new manufacturing line, we can respond to customer requests more quickly and be more flexible. Of course, this approach isn’t the only way to do anything, but we constantly look for ways to work even more effectively.
Massive training in product knowledge, production processes, robot programming, and system management has been provided to all of our staff. When compared to conventional welding and machining activities, the routines of the automation line are very different. Additionally, this offers the employees a career path from the perspective of the organization. Despite being unusual, the defined work profile is based on the conventional manufacture of tubes and rods. The labor demands are expanded significantly as the welder and machinist operate the robots.
Where We Serve?
Sectors we serve
Over the years of expansion we have built up a great deal of experience and know-how in the roller manufacturing industry. Our experts in the business always provide the closest assistance and betterment for your requirements And we are proud to serve a wide variety of EU and international customers in the following industries:
Industries Our Cylinders Are Used
»»Oil and Gas
Design & Planning
First contact with OGGO Tech will be a throughout communication to reach the perfect processes. Our expert designers and engineers will provide the assistance and details.
Production & Finishing
A confirmed project will enter our manufacturing lines, supervised by the production managers and under constant improvement.
Delivery & Feedback
After the project is finished and delivered, our assessment team will rapport a total, top-down and bottom-up process, so that we know we are happy.