How to Manufacture Certified Hydraulic Hose?
How to Manufacture Certified Hydraulic Hose?
How to Manufacture Certified Hydraulic Hose?
Hidroman Certified Hose Fitting Assembly Technician Purposes
*To give the qualification of "Certified Hose Fitting Assembly Technician" to the assembly personnel of the companies that perform Hose Fitting Assembly. *To ensure that the Hoses with Fittings to be manufactured are made in accordance with the Hose Fitting Installation Procedures recommended by Hidroman. *To enable candidates to practice to ensure Hidroman Training Qualifications and to obtain the "Hose Technician & Advanced Hose Technician" certificate. *To minimize the risk of facing liabilities for the company and MRI.
Hidroman Certified Hose Fitting Installation Technician Registration
After the representative successfully completes the Survey (100% pass mark is required), the person will conditionally become a "Certified Hose Fitting Installation Technician" certificate. The Audit will be organized by a Hidroman representative (giving a temporary certificate for a period of 3 months). After a successful audit, a full "Certified Hose Fitting Installation Technician" certificate will be issued, valid for 3 years.
Machines Required for Hydraulic Hose Manufacturing
A Hose turntable or special hose feeder should be used to avoid trapping the hoses on the ground and to ensure that the hose can be fed into the cutting machine without being twisted or damaged. Measuring the hose on a bench or floor may cause damage to the hose. It may be difficult to measure the cutting length accurately because the hose cannot be kept straight during measurement.
Cutting Machine:
This Machine can be foot/hand operated or auto feed. The cutting blade must be metallic and sharp. The power of the machine and the size of the cutting blade must be sufficient for the type and size of the hose to be cut properly.
Abrasive cutting discs (Flex stone, etc.) are definitely not recommended for cutting as they will cause distortions in the cutting plane while cutting the hose and will also leave dirt on the inside of the hose. Abrasive cutting discs can only be used with Cooling Spray (which can prevent heat dissipation and deterioration), but is not recommended. Hand band saw: Not recommended for cutting. Due to the saw teeth, the cutting process will not be clean or the hose will cause distortions in the cutting plane.
Hydraulic Hose Cutting Machine
“V” channel with adjustable stop device is recommended to determine length in hose measurement for Cutting Machines. For accurate measurement of this hose
It will ensure that it is kept properly and the measurement is made precisely. Measuring the hose on a bench or floor may cause damage to the hose. It may be difficult to measure the cutting length accurately because the hose cannot be kept straight during measurement.
Hose peeling machine:
The peeling process can be done with a hand-held tool or an electric motor-driven machine. The blade and/or blades of the Peeling Apparatus or Machine allow the rubber material in the fitting mounting section of the hose to be peeled from the outside and/or inside without damaging the wire reinforcement.
Saws and knives are not recommended for stripping as they may damage the steel wire reinforcement in the hose and may not strip properly. In addition, machines with sharp edges and rotating blades are not recommended as they may damage the steel wire reinforcement during the peeling process.
Peeling with a wire brush is not recommended for peeling as it will cause high levels of pollution.
Inner and outer peeling mandrels:
The smoothness of the surface and finish planes of the inner and outer peeling mandrels will ensure a smooth and smooth outer surface after the peeling process in the hose.
If the surface and finish planes of the smooth Mandrels are not smooth, it will cause deterioration in the inner part of the hose. To avoid this situation, uneven Mandrels should be replaced before the process.
Since the stripping operations carried out with irregular mandrels will produce results that are not proper and suitable for the hose stripping technique, it will cause incorrect assembly of the hose fitting and therefore may cause oil leaks and explosions in the hydraulic hoses with fittings.
Recommended internal/external peeling length tolerances: tolerance is +0.5mm.
In case of hoses that are stripped shorter than the required size, the hose fitting may not be installed properly, which may cause oil leaks and explosions in the hose fittings.
Hose Strip length:
Hose stripping lengths for the section where the hose fitting will be installed are given in the Hidroman Fitting pressing tables. Recommended hose stripping lengths are calculated to ensure a good seal and to prevent any external moisture or foreign matter from entering the hose outer rubber surface of the union socket and the hose wire reinforcements. Hose stripper length is also very important for proper installation of hose fittings. Hose stripping performed differently than the recommended values may cause the operating time of the manufactured hoses to be significantly shortened.
Gland assembly machine:
It is used to ensure that hose fittings are properly attached to the hoses and that the hose reinforcement wires are not damaged during this assembly. Hitting the hose fitting with materials such as wood or metal during the installation of the hose fitting to the hose will cause the hose fitting nut, flange surface or male threads to deteriorate and this is not recommended. Hoses that are stripped longer than the required size will cause the hose wire reinforcement parts to remain exposed after the installation of the hose fitting, and in this case, the life of the fitting hose will be greatly shortened.
Hydraulic Hose Press
Pressing machines should be able to press the desired dimensions within + 0.1 mm tolerances according to the central axis of the hose after the fitting pressing process. The pressing calibration accuracy of the pressing machine is monitored with the frequently used statistical production control method. Pressing machines whose gland pressing accuracy is not constantly monitored may lose their ability to press in accordance with the measurements over time. Pressing die bearings may wear out over time depending on use, and tapers and ovals may occur during the pressing process. This may result in improper pressing, which may shorten the working life of the fitting hoses, cause oil leaks and explosions.
Hydraulic Hose Pressing dimensions
Recommended pressing dimensions are in the "Hidroman Pressing Table". When pressing the sockets, conditions in accordance with the fitting pressing procedures and recommended dimensions must be provided. Application other than recommended measurements and procedures is not allowed.
Hydraulic Hose Press Molds
The size and structure of the pressing molds must be such that they only provide the necessary dimensions after pressing in the sockets. Pressing molds must be clean and their surfaces must not show rapid deformation. If the size and structure of the pressing molds cause the sockets to change shape more than the required dimensions after pressing, cracks will occur in the sockets. The crack in the socket may not occur during the manufacturing of the fitting hose, but may occur under conditions where the fitting hose is exposed to pressure. This situation can cause injuries and even deaths to people, as well as machine breakage and environmental pollution. Pressing molds that have dimensional errors, are broken, or have dirty surfaces will prevent the sockets from being pressed in appropriate sizes and in accordance with the procedures. This may result in improper pressing, which may shorten the working life of the fitting hoses, cause oil leaks and explosions.
Pressing molds must be long enough to cover the length of the sockets to be pressed. (Including special sockets and internal locking sockets, etc.) The pressing process of the socket requires two or more pressing operations (for example, pressing the front part of the socket first and then the remaining part). If applied, the working life of the fitting hose will be shortened. Many machine manufacturers produce longer pressing die sets than standard sizes.
Hydraulic Hose Testing Machine
Trial test is the procedure of checking whether the fitting hose is made in accordance with the procedures and dimensions, and whether there are possible non-conformities in the material that cannot be seen with the naked eye, after the fitting process is completed. Performing a trial test is not a requirement, but it is recommended.
Hydraulic Hose Testing procedures:
Trial test procedures are included in the Hydrostatic test list for rubber, plastic hoses and fitting hoses in the ISO 1402 standard. Working pressure, test pressure, bursting pressure ratios are specified in ISO7751 standards for rubber, plastic hoses and fitting hoses. O Trial test is not mandatory in cases where compliance with international standards is not required and there is no special customer request. Calibration of measuring clocks in trial-tested machines must always be complete; otherwise, the accuracy of the measured pressure will be questionable and in this case, customer demands or legal obligations will not be met.
In-hose cleaning equipment:
Cleaning the inside of the hose is a necessity and is done to clean the dirt that will occur due to cutting, peeling and pressing processes inside the hose during the production of the hose with fittings. Cleaning equipment inside the hose is carried out by passing sponges and similar materials through the hose with the help of a gun or by flushing with fluid. Passing compressed air through the hose is not recommended as it will not effectively remove pollution.
Fitting hose manufacturing procedures:
It is mandatory to comply with all necessary fitting hose manufacturing procedures during manufacturing. Hidroman trainings provide the correct procedures to be followed in the manufacturing of hose fittings. You can find the fitting size change procedures in the fitting hose manufacturing in the Hidroman pressing tables.
Education system:
It is recommended that new personnel coming to an organization that performs hose fitting assembly undergo the specified training system. This training should be given to personnel who manufacture unionized hoses and perform assembly and disassembly of unionized hoses. Documents, technical drawings and specification control: It must be ensured that the relevant personnel works with the latest and valid documents, technical drawings and that manufacturing is carried out in accordance with quality control procedures.
Rejection of faulty products:
Products that are suspected to be defective, manufactured incorrectly and not manufactured in accordance with the standards and required specifications should be put into the Rejection procedure before being sent to the end user and should not be delivered to the customer. In order to detect non-conforming products, the output quality control procedure must be applied to the products.