Is test point adaptor necessary for hydraulic system?

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Is test point adaptor necessary for hydraulic system?

The hydraulic system is very complicated.

During the flow of hydraulic oil, the erratic flow direction and flow rate of the liquid are difficult to predict, especially for the long distance. For such a complex hydraulic system, the system is difficult to debug and maintenance is inconvenient.

Therefore, this feature should be fully considered in the design process, and various possible means should be used as much as possible to improve and enhance the performance of the system.

The application of pressure test point in the hydraulic system is helpful to the debugging of the system. And it can improve the working performance of the system.

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1. The application of pressure test point is helpful for system fault diagnosis

The hydraulic system inevitably has various faults during the working process, and the reasons for the faults are often very complicated. The abnormal working of the hydraulic motor is one of these complicated faults.

The reason for the abnormal working operation of the hydraulic motor is complicated. It can be caused by the blockage of the hydraulic or hydraulic pipeline, or it may be caused by the failure of the load or the hydraulic motor itself.

Once a failure occurs, quickly identifying the cause of the failure is the key to troubleshooting.

Install a pressure test point at the oil inlet of the hydraulic motor, it will help judge the possible cause by testing the pressure of the oil inlet of the hydraulic motor.

It will be very beneficial to find out the cause of the fault and even quickly eliminate the fault.

2. The application of pressure test point is helpful to the adjustment of system pressure.

 In the conventional design, the oil pump outlet of the hydraulic system is equipped with a pressure gauge.

The pressure gauge is not only a measuring tool for adjusting the maximum working pressure of the oil pump outlet, but also a monitoring tool for the working pressure of the hydraulic system.

 Due to the special characteristics of the hydraulic pipeline system such as long oil flow distance, liquid flow direction and flow rate change in the middle, the actual working pressure of the hydraulic motor and the outlet pressure of the oil pump may be far apart.

Through the oil pump outlet pressure gauge it is difficult to debug the actual working pressure of the hydraulic motor and the detection of the working pressure of the hydraulic motor, so the pressure adjustment when the hydraulic motor is working becomes very difficult.

And at the same time, it is impossible to make the hydraulic motor work under the appropriate pressure, which will inevitably affect the working performance of the hydraulic system  and the working state of the hydraulic motor.

 If a pressure gauge is installed directly at the oil inlet of the hydraulic motor, although the working pressure of the hydraulic motor can be measured, it will increase the cost of the hydraulic system. Moreover, the choice of the installation position of the pressure gauge, as well as the working environment and service life are all difficult to guarantee. If a pressure test point is installed at the oil inlet of a hydraulic motor, the situation is different.

Since the pressure test point is very close to the hydraulic motor, the pressure measured basically reflects the working pressure of the hydraulic motor, which will help the accurate adjustment of the working pressure of the hydraulic motor. At the same time, the cost of the pressure test point is relatively low, the installation location is easy to choose, it is not restricted by the working environment, and the service life is long.It can completely avoid the various problems of installing the pressure gauge at the oil inlet of the hydraulic motor.

3. The application of pressure test point helps to improve the working performance of the system

Hydraulic shock is inevitable in the process of hydraulic work, and hydraulic shock is very harmful to the normal operation of the hydraulic system. Avoiding or reducing hydraulic shock as much as possible is a problem that must be considered in the hydraulic system design process.

There are many reasons for the hydraulic shock, including the sudden change of the liquid flow direction and the mixing of air bubbles in the hydraulic oil. Then we can fix the pipe by using the hydraulic pipe clamp to avoid severe vibration, and set the air bubble filter metal mesh in the oil tank. And by extending the distance of the liquid flowing in the tank to make the bubbles gradually seep out, try to avoid the sudden change of the liquid flow direction.

Therefore, it is a good choice to install a pressure test point in the hydraulic pipeline. The pressure test point can be used to release the gas gathered in the higher part of the hydraulic pipeline, so as to compensate for the low rate of bubble leakage in the oil tank and reduce hydraulic shock. It is very beneficial to improve the working performance of the system.

In summary, the proper application of pressure test point in hydraulic systems generally has more advantages than disadvantages. It is very useful for fault diagnosis, debugging and performance improvement of hydraulic systems.

What is the function of test point in hydraulic system?

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What is the function of test point in hydraulic system?

In order to simplify machinery structure design, the driving systems of modern machines commonly are driven by full hydraulic systems. 、

The features of full hydraulic system include reasonable overall layout, simple structure design, convenient system operation, reliable quality, strong driving power and convenient maintenance and commission. It becomes more and more popular among users. 

In order to understand the working situations of full hydraulic system comprehensively, the pressure testing points are set in the design of full hydraulic system, and pressure taps are equipped as well in the pressure testing points to measure whether the pressure in the oil way is within normal range or not, so as that the pressure can be measured quickly for troubleshooting.    

I. The working principle and application of pressure test point

1. There is a self-sealing valve in the pressure test point. Due to the function of spring, it would be closed when used separately.

And it would be opened when it is connected with the measuring hose tube or pressure test point with same thimble to take samples and system pressure testing in the high-pressure or low-pressure fluid system.

The working pressure can reach 63Mpa, and pressure of BP can reach 250Mpa.

the video shows how our hydraulic test point works

2. The pressure test point is mainly used in the full hydraulic tubing system for pressure supervision detection, gas discharging, samples taking in the high-pressure and low-pressure systems.

It is widely used in the engineering machinery, agricultural machinery, hydraulic system, testing equipment and so on.

IKIN FLUID pressure test point

For example, the hydraulic system and operating of hydraulic excavator are complicated, but how to judge hydraulic failures?

Shown as the below picture, pressure test point is needed now to measure the hydraulic pressure of testing point so as to find the root of the problem.

 

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The pressure tap can bear pressure testing in the hydraulic system, which is critical significant for stable hydraulic equipment and reliable operation.

Therefore, pressure test point is widely used as standard configuration in current hydraulic systems.

II. The necessity of setting Hydraulic testings

The whole moving system driven by hydraulic system is integrated by hydraulic motor, hydraulic action component, hydraulic valve, oil pipes and others. It is very complicated.

The pipe line from oil pump to hydraulic action components is long, as well as the hydraulic flowing distance. It is hard to predict press loss as fluid flowing direction and flowing speed changes.

 

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It is difficult for system commission and inconvenient for maintenance. As a result, the features of full hydraulic system should be taken into full consideration in the design. Pressure testing points should be set and hydraulic testing should be equipped.

Meanwhile, the cost of hydraulic testing is low, installation location is flexible, and it is not limited by working environment with long usage life. It is benefit for hydraulic system commission and working performance of hydraulic system could be improved.

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III. Convenient for failures diagnosis in full hydraulic system

The full hydraulic system is complicated, and number of hydraulic motors and integrated valve blocks are many, leading the probability of failures is high. Once failures happen, finding the reasons of failures quickly is the key in troubleshooting.

Installing hydraulic testing in full hydraulic system can analyze the reasons that may happen through pressure testing in all pressure points.

With the help of hydraulic testing to analyze potential reasons for failures in full hydraulic system, it is very good at troubleshooting and finding out reasons for failures.

IKIN hydraulic pressure test point

IV. Improve the working performance of full hydraulic system​

The number of pumps and motors in full hydraulic system is many, and flow capacity of oil is high. Due to the limitation of machinery structure, the flowing distance of hydraulic oil in the oil box is short, bubble exudation rate is low, and huge amounts of bubbles would be brought into pipeline again.

Hydraulic test point installed in hydraulic pipeline can be used to release gas in higher parts that are gathered in the hydraulic pipeline so as to make compensation for the shortage of low bubble exudation, which is very beneficial for decreasing hydraulic impacts and improving working performance of system.

IKIN FLUID pressure test coupling

V. Conclusion

The number of hydraulic components and action parts is many in the full hydraulic system, and system is complicated.

Machinery structure, working environment, special demands and various issues that may happen should be taken into full account when design full hydraulic system equipment.

It is very necessary to adopt various methods comprehensively to improve working performance and maintainability.

Generally speaking, in the improving the reliability of quality, the advantages of proper adapting hydraulic testing in full hydraulic system equipment are more than disadvantages, which are also very beneficial for commission and performance improvement in full hydraulic system.

 
 
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What is the common leakage problems and possible causes of Hydraulic Testings?

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What is the common leakage problems and possible causes of Hydraulic Testings?

As an important tool for pressure testing and sampling in hydraulic systems, hydraulic test point are widely used.

However, establishing a reliable and leak-free connection should be the primary goal of any hydraulic system.

There are many different kinds of hydraulic testings on the market can be selected. No matter which type , it will bring inconvenience and trouble to the entire system when leaked.

Common leakage problems and possible causes of hydraulic testings:

1. When the oil leaks from the inlet end, possible reasons for this region leaks as follows:

①O-ring/sealing ring is damaged or missing (For O-ring joint / seal ring)

The unreasonable design of the sealing ring and the sealing groove will cause the compression of the sealing ring to be too large or too small; if it is frequently disassembled, the surface of the sealing ring may be worn, slag and not pressed tightly.

When the use time is too long to exceed the shelf life, the ring loses its sealing, elasticity, deformation and cracks, etc., so it is easy to leak.

② The size of the connecting thread of the joint body is poor

The connecting thread of hydraulic testings is selected according to the thread of the oil port end.

The external thread connection length of hydraulic testings should be less than the full thread depth of the internal thread of the oil port end. Otherwise, the thread of the column end will not be screwed to the bottom, resulting in leakage of the threaded end.

③ The oil port end is damaged

Scratches on the sealing surface of the O-ring at the port end will prevent the O-ring from effectively sealing, resulting in leakage; the edge of the O-ring sealing surface is too sharp or burrs, and it is easy to cut the O-ring during installation and cause leakage;

④ Improper torque / improper assembly

After torque assembly, make sure that the end face of the joint seal is in full contact with the end face of the oil port. If there is a slight gap, the O-ring is likely to be squeezed out during the system’s long-term pressurization process, resulting in leakage.

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2. Leakage in the center of the spool. The possible causes of leakage in this area are as follows:

① Excessive pressure

According to the international standard ISO 15171-2, the maximum working pressure of hydraulic testings is 63Mpa (630bar). If the system pressure is too high (the maximum pressure exceeds the limit), the valve core will be damaged by a huge impact, which will cause hydraulic testings to leak.

② Damage of internal seal

When impurities enter the hydraulic system and the pressure is tested, these impurities will damage the internal seals of hydraulic testings, and will also affect the service life of the entire hydraulic system.

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3. Leakage caused by cracks. The possible reasons for leakage in this area are as follows:

① The wall thickness is too thin

When the design wall thickness of some parts of the hydraulic test point joint is too thin, and there is stress concentration, the thin-walled part will be broken or cracks will cause leakage.

② Inferior quality materials

Choosing low-quality materials may cause small cracks in the joint body, but these cracks will be difficult to find after electroplating.

Therefore, hydraulic testings body will expand and crack under the constant pressure of the system, resulting in leakage.

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Conclusion

The above is a summary of hydraulic testings in the hydraulic system application practice, and several reasons are prone to leakage.

In practice. The possible causes of leakage should be analyzed and found in combination with the actual situation, and the problem should be quickly eliminated by searching for it in an orderly manner.

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