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.
Manufacturing Assembly, Testing and Cleaning Devices
Hose Turntable
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.
Manufacturing Assembly, Testing and Cleaning Devices
Hydraulic Hose Cutting Machine
Cutting Machine: This Machine can be foot/hand operated or automatic feeding. 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 provided that they are used with Coolant 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.
“V” channel with adjustable stop device is recommended to determine length in hose measurement for Cutting Machines. This will ensure that the hose is held properly for accurate measurement and that 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.
Manufacturing Assembly, Testing and Cleaning Devices
Hydraulic Hose Peeling Machine
O Hose peeling machine: The peeling process can be done with a hand-held apparatus 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 peeling cannot be done properly. Also, machines with sharp edges and rotating knives 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.
Manufacturing Assembly, Testing and Cleaning Devices
Hose Internal and External Peeling Molds
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.
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.
Manufacturing Assembly, Testing and Cleaning Devices
Hose Stripping length: Hose stripping lengths for the section where the hose fitting will be installed are given in the Hydroman 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 stripping length is also very important for the proper installation of hose fittings. Hose stripping performed differently than the recommended values may cause the operating time of the hoses with fittings to be significantly shortened.
Manufacturing Assembly, Testing and Cleaning Devices
Hose Fitting Assembly Machine
O Fitting assembly machine: It is used to properly attach the hose fittings to the hoses and to prevent the hose reinforcement wires from being 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.
Manufacturing Assembly, Testing and Cleaning Devices
Hydraulic Hose Crimping Machine
O Pressing machine: Pressing machines should be able to press the desired dimensions within + 0.1mm 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 may cause conicities and ovalities during the pressing process. This may cause pressing at inappropriate dimensions and may therefore shorten the working life of the fitting hoses, cause oil leaks and explosions.
Manufacturing Assembly, Testing and Cleaning Devices
Hydraulic Hose Pressing Dimensions
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.
Manufacturing Assembly, Testing and Cleaning Devices
Hydraulic Hose Press Molds
Pressing dies: The size and structure of the pressing dies 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 dies: Pressing dies must be long enough to cover the length of the sockets to be pressed. (Including special sockets and internally locking sockets, etc.)
If the socket is pressed by two or more pressing operations (for example, pressing the front part of the socket first and then the remaining part), the working life of the fitting hose will be shortened. Many machine manufacturers produce longer pressing die sets than standard sizes.
Manufacturing Assembly, Testing and Cleaning Devices
Hydraulic Hose Testing Machine
O Trial test pressure machine: Trial test is the procedure of checking whether the fitting hose is made in accordance with the procedures and dimensions after the fitting process is completed and whether there are possible non-conformities in the material that cannot be seen with the naked eye. Performing a trial test is not a requirement, but it is recommended.
Trial test pressure treatment 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.
Manufacturing Assembly, Testing and Cleaning Devices
Inside Hose Cleaning Sponge
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.
Angle Adjustment of Hose Fittings
O Adjusting the angles of the hose fittings: A reliable system must be used to adjust the angles of the hose fittings relative to each other. This process can be done with the help of specially prepared apparatus or a calibrated protractor ruler.
Adjusting the angles of the fittings relative to each other using wall charts and other visual methods may cause sprains and undesirable rotations after the fitting of the hose with fittings, and in this case, the fitting of the hoses cannot be installed properly, shortening their working life, causing oil leaks and explosions.
O Tolerances in the angles of hose fittings relative to each other: As stated in SAEJ517 standards, the acceptable tolerance in the angles of hose fittings relative to each other is + 3 degrees for hoses with fittings up to 610 mm in length, and + 5 degrees for hoses longer than 610 mm.
Hydraulic Hose Manufacturing Procedures
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 internal fitting size change procedures in the Hydroman pressing tables in fitting hose manufacturing.
Storage of Hydraulic Hoses
Storage of hoses and hose fittings: Hoses should be stored on shelves so that they do not come into contact with the ground and preferably to protect them from any impact or damage.
Hose ends should be closed so that no contamination can enter.
Storage conditions should be dark, moisture-free and protected from electrical current. (Otherwise, ozone effect will occur in the hoses.)
Hose fittings should be stored in a moisture-free environment and preferably in cardboard boxes, free of dust, dirt, etc.
The lids of the boxes should be kept closed so that the materials do not enter and the o-ring material that may be on the fittings is protected from the effect of ozone.
Hydraulic Hose Manufacturing Training
Training system: It is recommended that new personnel coming to an organization that performs hose fitting assembly go through 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 faulty, produced incorrectly, and not manufactured in accordance with the standards and desired 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.