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Hydraulic hoses play a vital role in industrial and mechanical equipment. They carry fluids in hydraulic systems and connect different components through flexible structures to achieve various efficient working functions. However, hydraulic hoses are at risk of bursting due to long-term exposure to high pressure, extreme temperatures, chemical corrosion, and other environments. Once a hose bursts, it will not only pose a threat to the safety of equipment and personnel, but may also lead to serious consequences such as production interruption, equipment damage, and reduced efficiency of the hydraulic system. Therefore, ensuring the stability of hydraulic hoses and avoiding hose bursts are key links in equipment maintenance and hydraulic system design.

This article will discuss in detail the causes of hydraulic hose bursts, how to prevent them, and the correct maintenance methods, to help companies improve the safety of hydraulic systems and reduce the risk of hose bursts.

1. Causes of hydraulic hose bursts

The causes of hydraulic hose bursts are usually closely related to factors such as excessive pressure, physical damage, aging, and improper use. The following are some of the main causes of bursts:

Overload pressure

Each hydraulic hose has its maximum working pressure (Burst Pressure) and rated working pressure (Rated Working Pressure). If the hydraulic hose exceeds the designed pressure range during use, the hose material will be subjected to excessive tensile force, eventually leading to rupture. Common causes include system overpressure, hydraulic pump pressure regulation failure, or pressure overshoot.

Aging and wear

As the use time increases, the hydraulic hose may age inside and outside, especially rubber and synthetic hoses. Ultraviolet radiation, moisture in the air, oil corrosion, etc. will accelerate the aging of the hose. Once the aging degree is too deep, the strength and elasticity of the hose will decrease, and the risk of bursting will be greatly increased.

Excessive bending and twisting

If the hydraulic hose is excessively bent or twisted during installation or use, the fluid flow in the hose will be hindered, the local pressure will increase sharply, and even cause the hose to burst. The minimum bending radius of the hose is determined by its design and manufacturing materials. If the bending exceeds this range, the hose will be locally subjected to pressure beyond its pressure range.

External impact and physical damage

Hydraulic hoses may encounter external impact or friction in the working environment of the equipment. For example, the hose may be pressed by sharp metal parts, rough ground or heavy objects. If the external damage is too large, the hose may be ruptured or perforated, resulting in fluid leakage and bursting.

Improper connection

The connection quality of hydraulic hoses and pipe fittings, valves, and other components directly affects the stability of the system. If the connection is not firm, it may cause leakage or breakage at the hose joint, which may cause the hose to burst. In addition, the mismatch between hoses and joints of different models and specifications will also increase the risk of bursting.

Chemical corrosion

Some liquids are highly corrosive, such as acids, alkali,s or certain solvents. When these liquids flow through the hydraulic system, if they react with the hose material, the structural strength of the hose material will be reduced, cracks and leaks will gradually appear, and eventually bursting may occur.

2. How to prevent hydraulic hose bursts?

To prevent hydraulic hose bursts, it is necessary not only to select suitable hoses and accessories but also to scientific design and regular maintenance. Here are some key anti-burst measures:

Choose the right hose material and specifications

The selection of hydraulic hoses should be based on the specific working environment and the requirements of the hydraulic system. First, the working pressure of the hose must meet the maximum pressure requirements of the hydraulic system, and the pressure fluctuation range of the system should be considered. Selecting the right hose type (such as wire braided hose, wire spiral hose, etc.) can effectively ensure stable operation under high pressure.

Secondly, the material of the hose also needs to be selected according to factors such as the type of fluid, temperature, and external environment. For example, rubber hoses are suitable for ordinary hydraulic oils and water-based liquids, while for extreme temperatures or corrosive liquids, high-temperature or corrosion-resistant hoses such as polyurethane, polytetrafluoroethylene, and other materials should be selected.

Avoid overpressure of hydraulic hoses

Exceeding the design pressure is one of the main causes of hydraulic hose bursts. Therefore, it is crucial to keep the pressure of the hydraulic system within a safe range. To avoid overpressure, this can be achieved in the following ways:

Use pressure regulators and pressure relief valves to ensure stable system pressure.

Check the pressure gauge and regulating device regularly to detect and solve the problem of excessive pressure in time.

Add pressure protection devices to the hydraulic system to prevent unexpected pressure peaks.

Follow the correct installation specifications

The installation of hydraulic hoses should avoid excessive bending, twisting, or pressure. During installation, the minimum bending radius requirements provided by the manufacturer should be followed, and ensure that the hose does not come into contact with sharp objects during operation. The connection of the hose connector should ensure tightness and no leakage while avoiding excessive stretching or loosening.

In addition, the hose should be arranged according to the shortest path, avoiding excessive bending and crossing to reduce damage caused by vibration or external impact.

Regularly check and replace hydraulic hoses

Regularly checking the working status of hydraulic hoses is an important measure to prevent hose bursts. The following points should be focused on during the inspection:

Wear and cracks: Check whether there are cracks, wear, or peeling on the surface of the hose.

Deformation and expansion: If the hose expands or deforms under high pressure, it means that the pressure bearing capacity of the hose has been affected and needs to be replaced in time.

Aging: Check whether the hose has signs of aging, hardening, or brittleness. If the elasticity of the hose decreases, it means that its strength and pressure resistance have been reduced and it should be replaced as soon as possible.

Once the problem is found, replace the damaged hose in time to ensure the safe and stable operation of the hydraulic system.

Strengthen the external protection of hydraulic hoses

Hydraulic hoses are often exposed to harsh working environments, and external protection is very important. To avoid physical damage to the hose, you can consider using protective measures such as hose protective sleeves and wire mesh to prevent the hose from contact with sharp objects or excessive friction. In addition, preventing the hose from being exposed to strong sunlight can also extend the service life of the hose.

Prevent chemical corrosion

For liquids that are susceptible to corrosion, hose materials with good corrosion resistance should be selected. The material and surface coating of the hydraulic hose can effectively prevent the erosion of the hose by liquids such as acids, alkalis, or solvents. In addition, regularly check the compatibility of the hose with the liquid to ensure that the liquid used in the system will not damage the structure of the hose.

Avoid long-term immobility

Hydraulic oil that has not flowed for a long time may cause dirt or crystallization inside the hose, increasing wear and clogging of the hose. Therefore, when the hydraulic system is out of service for a long time, the hose should be checked regularly and properly cleaned to avoid the accumulation of pollutants.

The burst of hydraulic hoses not only poses a threat to equipment safety but may also cause economic losses and production delays. Therefore, taking effective preventive measures and regularly checking and maintaining hydraulic hoses are the keys to ensuring the safe operation of hydraulic systems. By reasonably selecting hose materials, designing safe pressure control systems, complying with correct installation requirements, and performing regular maintenance and replacement, the risk of hose bursts can be greatly reduced, ensuring the long-term and stable operation of the hydraulic system.

As a professional hydraulic hose dealer, we are well aware of the importance of hydraulic hoses in industrial equipment and hydraulic systems. We not only provide a variety of high-quality hydraulic hoses that meet international standards, but also provide customers with professional selection advice and customization services to ensure that each hose can meet the needs of specific application environments.

http://www.tianyiindustry.com
Zaozhuang Tianyi Industry Co., Ltd.,

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