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When building a hydraulic power unit, components play a vital role in the units functioning and it is important that they are supplied to the right specification ensuring system reliability and efficiency.
At Hydraproducts, we recognise this, and with our ever growing stock of hydraulic components, we have decided to form a Components Division which offers a range of stock components from well-established manufacturers such as OMT, OT and Setima for which we are official UK Distributors.
We have handpicked all of our stock components we offer for their tried and tested reliability, efficiency and value, so our customers get the best components for the best prices and with our experienced team of engineers, we can guide our customers to the part they require and the exact specification needed for their hydraulic system.
For those looking to create a bespoke system, we offer a selection of bellhousings & couplings, gear pumps, accumulators, valves and more.
Below we give you more of an idea of the hydraulic components we stock and their function:
Bellhousing & Coupling – Bellhousing is a crucial component that makes the connection between the hydraulic pump and the motor. They are commonly made from the lightweight aluminium material and are available in two different configurations, single piece and composite; the latter containing a flange or distance ring for a more flexible range of pump adjuster solutions.
Like bellhousing, drive couplings are traditionally made from either aluminium or steel and work alongside the bellhousing to form a shaft connection between electric motor pumps. OMT are a world leading manufacturer of both bellhousings and couplings and as official UK distributor of these components, we have a wide selection in stock covering a range up to 132kW motors.
Gear Pumps – The main function of gear pumps is to pump hydraulic fluid through the system and they come in many different specifications dependent on the correct fluid flow needed in a given application.
Hydraproducts is an official UK distributor of OT-Oil Technology (Brevini) gear pumps, a world renowned Italian manufacturer of hydraulic pumps. These pumps offer excellent quality, strength and durability and we have been using and supplying them for a number of years now, with excellent feedback.
The OT100, 200 and 300 range of pumps, which vary in size and function are fully compliant with European Build Standards.
Accumulators – are tasked with storing hydraulic energy under pressure. In damping applications they help to lengthen the life and functioning of a system, as well as giving the benefit of noise reduction and general running cost savings.
We stock two different types of OMT accumulators, bladder accumulators and diaphragm accumulators, with the bladder version working with volumes up to 500 litres and diaphragm up to 3.5 litres.
Hydraulic Valves – When hydraulic motors and actuators are operational they need valves to help control pressure and direction together then complete a hydraulic circuit.
Valves are commonly interchangeable and at Hydraproducts we stock Cetop, directional control solenoid valves, flow and pressure relief valves and pilot operated check valves.
As well as the components above, we also stock the following:
· Manifold Blocks
So, with the new Hydraproducts Components Division you can now fully customise your hydraulic system in the knowledge that you are using a trusted, quality supplier with industry leading components.
Feel free to visit our new Components Division page here - https://www.hydraproducts.co.uk/hydraulic-components.aspx
1. UK Manufacture
Hydraproducts was founded in Gloucestershire in 2002 and we are proud to manufacture our hydraulic power units here in the UK, which we have done so since our inception.
Having UK built power units is a huge plus point as we ensure each one is hand-built with fine precision and fully tested in-house, offering you a reliable product with excellent aftersales support and service. This minimizes the risk of buying sub-standard and cheaply made mass produced products which could potentially lead to costly failures.
2. Technical Support
Our in-house engineering specialists have years of experience working with hydraulic power units and offer expert support and advice; answering any questions you may have and guiding you through the bespoke design process for specific applications.
3. In-House Product Testing
As well as the benefit of UK manufacture, Hydraproducts also has its own test facility, to fully test our power units before they are dispatched. We carry out our tests to set industry cleanliness standards and components are stress tested to ensure the units function correctly in a range of environmental conditions.
Many competitors don’t offer in-house testing and this one of the reasons Hydraproducts has built up its reputation for quality and reliability.
4. Bespoke Design Options and Extensive Product Range
Hydraproducts has a large product range and componentry division that caters for a wide range of applications. We are constantly adding to our product base to cater for the ever changing hydraulics world and offer full bespoke design solutions for those of you in need of something a little different, be it a unit for use in a hostile environment to a space restrictive application that needs a compact solution.
To aid in this design process, our expert CAD design team, which has a wealth of experience and knowledge and can create any bespoke hydraulic power unit to exact specifications; using the popular design package, Solidworks, can fully render complete units and tailor component specs and positions for use in a range of custom applications, keeping in close contact to ensure you are kept up-to-date with project progress.
We have created some unique power units for interesting applications in the past including a recent petrol driven unit to power a prop in the up-and-coming Terminator film, a bespoke unit which powered a ship caught in a storm in Alice in Wonderland 2 as well as units that were used for Formula One gearbox testing amongst others.
5. Quick Product Turn-Around
An important aspect of running a successful business nowadays is a quick turnaround of products.
At Hydraproducts, we have a large and varied customer base and have to ensure we manage our production process successfully and to tight timescales. We are constantly fine tuning our production process to ensure optimal turn-around times from the initial product query and required specifications to product completion and delivery.
We understand some customers need a quick turn-around of products to satisfy last-minute emergencies or have been let down by other suppliers and here at Hydraproducts, we fit the bill and can satisfy your needs, providing you with a quick service yet offering a quality end product.
Our latest blog looks at our in-house Test Rig which is used to test many of our larger power units before they leave our premises for delivery to customers.
We are proud to be able to re-assure our customers that we fully test our units after they are built as to ensure our end users are satisfied with their product. This gives you, the customer, peace of mind that you have bought a reliable unit that, properly maintained, will last long into the future.
Below, we have covered the common test procedures for our Power units and how they are carried out:
This is carried out to remove debris and contamination from all valve, pipework and reservoir internals. Always ensuring that sufficient flow is generated by our test rig ensures a high velocity turbulent flow (above Reynolds number 2000). This action will agitate any debris that is lodged in corners and crevices.
Guaranteeing we supply the correct flow rate is crucial to ensuring the customers application runs at the speeds expected. So Hydraproducts is able to measure the hydraulic pump flow rates using the latest digital flow meter technology up to 150lpm.
Measuring pressures throughout a hydraulic system gives a hydraulic engineer a thorough knowledge of how it is performing and enables the setting of pumps and valves. Using a fully UKAS calibrated pressure test system, we are able to certify our systems with confidence that they will perform as expected.
Measuring the power input to a system is fundamental to confirming that the system has firstly been designed correctly and secondly that the combination of the pressure and flow are being achieved within parameters set by our hydraulic design engineers.
Many of the systems we manufacture are for lifting or clamping applications, where load holding for long periods is critical to the machine performance. Over the years Hydraproducts has developed a very stringent method of checking this that far surpasses those used by component suppliers. This enables us to check a whole system is holding pressures without decay.
This test focuses on the cleanliness of the hydraulic system as any contaminants from particles and foreign bodies entering the system can greatly affect its operating ability, causing wear and even failure in vital system components. The test adheres to strict international cleanliness standards and is carried out on a regular basis.
A vital system test which focuses on the system temperature in varying operating conditions and is carried out to make sure that temperatures are within standard set tolerances and do not exceed them when increased load is added.
The test ensures that system components do not suffer damage and wear from the increased heat levels given off by the system, which could render a system inoperable and could potentially result in large repair bills.
Filtration and Particulate Cleaning
Hydraulic filters work to ensure that particulate matter doesn’t find its way into the hydraulic system. It is essential that they are inspected and cleaned regularly to ensure excess particulate isn’t clogging the filter and affecting system performance.
Environmental conditions such as dusty workshops and foundries can affect the levels of contaminants entering the filter, and in these situations the filters will have to be checked more frequently and cleaned or replaced accordingly.
Hydraproducts are one of the leading international suppliers of hydraulic power packs, with a long history of manufacturing expertise and the design and supply of bespoke products. Firstly, our in-house manufacturing capabilities for all types of hydraulic power packs means that we are able to specify, design, build and supply orders for many global customers, with no middle man and no extra distribution and supply costs. Our micro packs are world leading and in demand from across the globe, with customers as far away as New Zealand and Finland.
Secondly, we are also suppliers of Cetop valves for use in hydraulic power and thanks to our global distribution network, we can supply these parts quickly to our customers. Our experience in hydraulics allows our customers to feel safe and confident working with and ordering from us.
A third benefit is our membership of the British Fluid Power Association (BFPA), which demonstrates our commitment to hydraulic technology developments and means we have access to the latest research and design ideas, as well as keeping at the forefront of legislation that affects the use of fluid power, both at home and abroad.
Our modern facilities create a fourth plus point, allowing us to design, build and test systems or components with the latest equipment, ensuring our products are always up to scratch and will meet technical requirements. We can test electro-hydraulic equipment on site, which means we are able to maintain a leading position on electro-hydraulic technology developments and retain a good working knowledge of these systems, which are becoming more and more important for the fluid power industry as electrical systems start to replace fully hydraulic ones, in some applications.
Our fifth strength is that alongside our hydraulic power packs, we also manufacture and supply hand pumps that can be used to keep things moving in the event of a power failure, or for applications where independent handling and hoisting of materials needs to be finely controlled by a human hand. Our wide range of expertise shows our extensive capabilities and knowledge in the fluid power industry and serves to further reassure our customers that we are the right choice for hydraulic power packs and associated equipment.
At Hydraproducts we are continually striving to improve our customer service, we have had some feedback from our customers requesting an on-line platform where we can provide spares and service for many 1000’s of Hydraulic Power Packs manufactured over the last 10 years. We have set up an eBay shop just for spares and items customers can easily identify and purchase 24 hours a day. This shop gives the customer visual assistance in identifying the parts needed, but also information on how to maintain and service our products.
This shop is now live and already having an impact. We are very cautious not to replace the great customer relationship and trust we have built up over the years, with online purchasing the world is becoming more digital. We strive to adapt and stay at the forefront of hydraulic design and manufacture while offering great customer services at competitive prices.
Current products we have on the store are to only support the 12 and 24VDC HPM range of hydraulic power units, there may be further requirement to increase the range of spares to our HPS Power packs, HPR/HPU Micro hydraulic power packs and Hand Pumps. If you would like to see a bigger range of products on our shop or can offer any feedback regarding the shop, please call the sales team on 01452 523352 who would be pleased to offer there assistance.
In today’s uncertain economy it’s critical to practice proactive hydraulic system maintenance to avoid untimely failure of components and the associated cost. If you suffer from a failure, then check whether your components are still under warranty from the supplier. If they aren’t, then your maintenance budget will have to bear the cost.
Avoid component failure
For this reason, our recommendation is to put focus on the following activities to lower the risk of component failure:
· Maintenance should be proactive as opposed to reactive
· Apply the rock solid principle of using the right oil and keeping your machine dry, cool and clean
· Design your hydraulic system to deliver the results you want in terms of reliability and maintenance goals
· Apply the use of checklists to ensure regular maintenance and to determine hidden failures
However, the reality of operation is that it’s still possible for failures to occur even when all these preventative fundamentals are applied. When a component fails the first query is usually about who will cover the cost? Normally it would be the party who has been negligent. But identifying who has been negligent and then getting everybody on the same page with it, is often far easier than it sounds.
Factory Produced or Refurbished?
If the component in question was installed pretty much straight from the factory floor, then questions will be asked whether it was installed correctly and about the conditions of its operation. These questions will include how clean the oil was, how hot it was and whether the oil had the correct viscosity. Was there any wrongdoing by the operator, faults with the circuit design or incorrect operating pressure? Although it’s possible that the manufacturing plant produced a defect, it’s not common and this will usually be ruled out.
However, if the component was refurbished or rebuilt, then the quality of this in addition to the above questions will be asked.
Whatever the source of the failed component is, it’s critical that a complete and detailed analysis takes place to identify the cause. In truth, analysis of component failure is a critical task that plays into proactive and preventative maintenance of any upkeep program.
The rationale behind this is that if the reason why a component has failed is not found and rectified, then the same fate could happen to a replacement part.
Handling analysis of the component failure requires specialist expertise. There needs to be a full understanding of hydraulic circuits in addition to a good understanding of the construction of the component and their methods of failure. This will usually be taken on by the manufacturer or the rebuilder of the component. This then leaves the machine owner’s perspective out of the equation, which can cause some frustration depending on what information you may have to add.
Having witnessed and been involved in a number of warranty claims – both here and at previous companies, we have learned the following:
1. The analysis of a failed component is not always clearly determined.
2. Although a rebuilder may recognise that he has made a mistake, he is not always willing to admit to it.
3. It’s not everybody who gets involved in a warranty claim that has the expertise and experience to do so.
4. Of course contamination and cavitation can have adverse effects on components, they cannot always be used as reasons why.
In some cases, it really does make you wonder whether avoidance of taking responsibility is a strategy to avoid warranty claims.
However, it’s important to understand what has compromised the longevity of a component. Is it operational issues, storage or erroneous installation?
Component suppliers worth their weight in gold are those that advise on potential pitfalls.
In summary, if there’s one thing that needs to be applied in this industry, it’s this: Wherever you are positioned in the component cycle, manufacturer, supplier or operator, it’s your duty to take reason steps to stay outside of the warranty claim process.
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