Tailormade Hydraulic Solutions
Phase One
At HYDROX we pride ourselves on offering a truly bespoke service, setting us apart through our commitment to creating custom solutions that perfectly align with each customer’s unique needs. Our approach is deeply rooted in understanding the specific requirements and challenges faced by our clients.
A customer was experiencing problems with their hydraulic system not being able to produce enough pilot pressure to operate a counterbalance valve controlling a hydraulic cylinder.
Our team visited the customer’s site and conducted a system review to gather all correct technical information. After collecting all necessary information, our team then identified the customers specific requirements for the project.
Phase Two
After the initial consultation process with our customer, assessing the system, and gathering all appropriate information to support us, a plan was put in place to trial alternative counterbalance valves.
The hydraulic system was experiencing high back pressure in the rod end (retract) circuit and low system pressure on the base end (extend). As a result, there was insufficient pressure to effectively pilot the rod end counterbalance valve.
Our Technical Team were aware that using a counterbalance valve, with a higher pilot ratio, would reduce the pilot pressure needed to operate the valve, but this would compromise system stability. Since the induced load pressure varies throughout the operating cycle, maintaining good system stability is essential.
A Sun Hydraulics vented counterbalance valve was selected for in-field testing, on the rod end side of the circuit, this effectively lowers the required pilot pressure when there is back pressure and ultimately maintains the stability of a lower pilot ratio.
An ‘off-the-shelf’ manifold was fitted to test the hydraulic performance of the new valves.
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Phase Three
Following successful field trials of the valve’s hydraulic performance, work progressively began on a bespoke manifold to optimise the fit of the valves to the customers machine.
To make the fitment as easy as possible, and to minimise the number of leak points, the manifold was designed to directly mount to the cylinder, via a banjo bolt.
Our Technical Team created 3D files that were proofed to check fitment on the customer’s CAD models. This was brought to life through a 3D-printed rapid prototype, which was used to verify the physical fitment of the customer’s manifold. The 3D print was fitted with adaptors and attached to the customers machine.
This rapid prototyping enabled the fit of the manifold to be checked in days rather than weeks, and ultimately provided a cost-effective method for testing fitment.
Phase Four
The next step was to supply our production valve assemblies with the counterbalance valve pre-set, to ensure an easy fit for the customer.
Eventually, our Technical Team designed a kit to enable the complete fitment of the new valve assembly to new or existing machines.
Our commitment to this level of bespoke service not only guaranteed that our customer received solutions that were perfectly suited to their needs, but also helped strengthen our collaborative relationship built on trust and mutual success. At HYDROX, we believe that the true value of our service lies in our ability to deliver not just a product, but a tailored solution that drives real results for our customers.
