What if you could prevent hydraulic leakages from happening, and preserve the hydraulic connections on your heavy industrial and agricultural machinery?
In the world of heavy machinery and equipment manufacturing, hydraulic systems play a vital role in powering and controlling various functions. These systems are found in construction equipment, agricultural machinery, and industrial vehicles, among others. However, hydraulic leakage remains a persistent problem, leading to reduced efficiency, increased maintenance costs, and potential safety risks.
Understanding the Problem
Hydraulic systems are essential for the smooth operation of heavy machinery and consist of various components like hoses, fittings, seals, and connectors that must work in perfect harmony to ensure the system's efficiency and safety. Unfortunately, hydraulic leakage can occur at any point in this complex network, resulting in a range of negative consequences that impact customer loyalty and the brand.
Reduced Efficiency:
Even minor hydraulic leaks can significantly decrease the overall efficiency of heavy machinery. A slow leak can reduce the pressure and flow rate in the hydraulic system, leading to slower operation and decreased power output.
Increased Maintenance Costs:
Hydraulic leakage necessitates frequent maintenance and repairs. The cost of replacing damaged components, refilling hydraulic fluid, and labor-intensive repairs can quickly add up, increasing the operational costs of heavy machinery.
Safety Hazards:
Leaking hydraulic fluid can pose significant safety risks. It can create slippery surfaces, increasing the likelihood of accidents. In addition, exposure to hydraulic fluid can be harmful to the environment and the health of operators.
Environmental Impact
Beyond the immediate operational and safety concerns, hydraulic leakages can have adverse environmental effects. Hydraulic fluid, often oil based, can be harmful to the environment when it leaks and contaminates soil and water sources. The repercussions of such contamination can be long-lasting and detrimental to the ecosystem.
Increased Maintenance Costs:
Hydraulic leakage necessitates frequent maintenance and repairs. The cost of replacing damaged components, refilling hydraulic fluid, and labor-intensive repairs can quickly add up, increasing the operational costs of heavy machinery.
How to solve the problem: The role of correct tightening
Correct tightening of hydraulic connections is a fundamental step in preventing leakage. Over-tightening or under-tightening connections can cause damage to seals, fittings, and hoses, leading to leaks.
Quality Assurance:
Implementing quality control measures in the manufacturing process is crucial. The implementation of smart tools and solutions ensures the fastening is done correctly with direct feedback for the operator and data collection for analytical purposes.
The Importance of Error-Proofing:
Error-proofing, also known as Poka-Yoke, is a methodology that focuses on preventing errors in the production process. In the context of hydraulic systems, error-proofing techniques can significantly reduce the likelihood of leaks by addressing human error and inconsistencies in manufacturing.
Read more about our scalable error proofing solution SQS3 here
Training and Education:
Operators and maintenance personnel should receive proper training on the correct techniques for tightening hydraulic connections. This knowledge helps ensure that connections are tightened to the manufacturer's specifications, reducing the risk of leaks.
Standardized Processes:
Developing standardized procedures for assembling and connecting hydraulic components can help minimize errors. Each step should be clearly defined, and operators should follow a checklist to ensure compliance.
Design Improvements:
Implementing design changes that make it physically impossible to assemble components incorrectly can be an effective form of error-proofing. Components with unique shapes or orientations can only fit together correctly, reducing the risk of leakage
How to solve the problem: The role of the operator
Operators of heavy machinery play a critical role in preventing hydraulic leakage. They are on the front lines and are often the first to detect issues. Operator guidance is essential for keeping hydraulic systems in optimal condition.
Regular Inspections:
Operators should conduct routine visual inspections of hydraulic connections, hoses, and fittings. Any signs of leaks, wear, or damage should be reported promptly.
Reporting Mechanisms:
Create a system for operators to report issues or concerns related to hydraulic systems. This feedback loop can help identify and address problems early, preventing costly downtime and repairs.
Atlas Copco has a variety tools and solutions that can support the operators in this endeavour, such as our Mechatronic Wrench MWR. Helping the operators to utilize the torque and angle measurement to detect rehits or missing components in the joint and fix quality problems right before they leave the Station. Read more about the MWR here.
A real-life example
In this video we highlight a US manufacturer of industrial and agricultural equipment with sales operations in over 60 countries. Their customers rely on their products to keep their businesses efficiently moving forward. However, due to poor tightening processes, hydraulic leakages were something that was inevitable, which was proving to be extremely expensive for the manufacturer.
The warranty costs from their dealers and customers were losing them millions of dollars every year. The situation was that the company was leaking money, their brand was taking a beating, and the environment was contaminated with leaking oil.
In cooperation with Atlas Copco, the decision was made to implement Atlas Copco Mechatronic Wrench tightening systems. With help from the Atlas Copco Scalable Quality Solution (SQS), the tightening of the hydraulic connections and the quality of their products started to tighten up. After implementing the Atlas Copco Mechatronic Wrench tightening systems, this customer reported savings of nearly $2 million per year.
Conclusion
Hydraulic leakage in heavy machinery and equipment manufacturing is a persistent problem with significant repercussions for efficiency, cost, and safety. Correct tightening, error-proofing, and operator guidance are critical components of the solution that is needed to solve this issue.
Let Atlas Copco be a partner in your manufacturing ensuring that hydraulic connections are properly tightened, implementing error-proofing techniques in manufacturing, and empowering operators to play an active role in maintenance, the industry can make significant strides in reducing hydraulic leakage and its associated challenges. In doing so, heavy machinery manufacturers can deliver more reliable and safer equipment to their customers, benefiting both the industry and the end-users.
To learn more about our products and solutions for Heavy Machinery and Equipment and how we can help, get in touch with us today!