Hydraulic hose assemblies are used in many application areas and are a part of almost all hydraulic systems. The hydraulic system is a very important component, it relies on the hose to handle the pressure and flow of the liquid-allowing hydraulic oil to be transmitted among components under controlled pressure and temperature. Hose assemblies consist of the hose and hose end fittings, essentially the driving force behind the entire hydraulic operation-without it, the system cannot run. Now, you understand the importance of hydraulic hose assemblies.
let's give you a further guide on hydraulic hose assemblies!
What is a hydraulic hose assembly?
Hoses and assemblies: for many people, they are the same thing. But technically, they are completely different.
A hydraulic hose is part of a hydraulic hose assembly. A hydraulic hose assembly actually consists of a hose and fittings. These fittings connect the hose to other components within the hydraulic system. Hydraulic hose assemblies are suitable for various applications, typically used in construction, injection molding, material handling, and agricultural markets.
Where is a hydraulic hose assembly used?
In simple terms, the hydraulic hose is used to transport hydraulic oil between two ports or hydraulic components. You can imagine, this system can have a lot of applications!
In the mining industry, there is a range of machines that use hydraulics. Notably, earthmoving equipment depends on hydraulic hoses to power its arm and lift loads. Other machines include drills, trucks, continuous miners, and bulldozers.Construction
Overlapping with mining, the construction industry also utilizes earthmoving equipment. Hydraulic hoses are used to assist machines in lifting heavy construction materials.
Manufacturing
Hydraulic hoses have multiple uses in the manufacturing process, especially on assembly lines, and with the growing prevalence of robotic technology. In manufacturing, hydraulic hoses can also be used for food production, car manufacturing, and even cheese making!
Hydraulic systems in the automotive industry are used for various components. Examples of hydraulic systems include: pumps, brakes, and engines. The application of hydraulic hoses spans from the manufacturing process to equipment used for vehicle maintenance.
Hydraulic hose assemblies are often used in crop-harvesting machinery. These machines and their associated hydraulic hose systems face harsh conditions. Hydraulic hoses used in agriculture face extreme weather conditions, daily UV radiation, and pollution from surrounding crops.
How to Make Hose Assembly - Custom Manufactured
The hydraulic hose assemblies customized by Sinopulse for your business will use hoses and construction methods designated for the type of work the assembly will endure. We use only the best materials and pressure test each assembly before sale, ensuring the quality of every hydraulic hose assembly we produce.
Production tests include:
Corrosion resistance is essentially a matter of choosing the right alloy (although we must also consider other factors). As manufacturers, the challenge we face is to develop the appropriate processes to produce the product that best satisfies the remaining three attributes (pressure, flexibility, and cost).
Pressure rating is the term used to express the ability of the hose to withstand internal pressure. The pressure rating of the hose is determined through a variety of pressure tests carried out in our product analysis laboratory. The pressure rating of our hoses is expressed in our catalog as maximum working pressure and must be adjusted as needed to compensate for temperature fluctuations or dynamics during use, such as pressure peaks or water hammers.
Flexibility refers to the ability of the hose to bend during use. However, flexibility can mean different things to different people. Some people need hoses that can bend to a small radius, while others want hoses with a high cyclic life. Still, others want hoses that are flexible and can bend easily without applying great spring force to the equipment to which the hose is connected. In most applications, Hose Master's proprietary forming process is the best way to form a hose that has all three properties. For corrugated hoses, flexibility is expressed as the minimum dynamic bending radius (MDBR), which is determined by cyclic tests in our laboratory.
At the same time, the hose assembly fittings are crimped at both ends of the hose, which will not damage the structure of the hose or create weak points. Through professional assembly units composed of high-quality components, we can ensure that your hydraulic hose assembly performs at its maximum utility.
We can manufacture and assemble any number of hose assembly you order, regardless of their style. We can also complete assembly in the shortest possible time, keeping your workplace active with the least amount of downtime.
Standard and Specification(SAE100 R1 for example)
| Hose code | Size | Dash size | ID | WD | OD | |||||
|---|---|---|---|---|---|---|---|---|---|---|
| A | AT | |||||||||
| mm | inch | min | max | min | max | min | max | max | ||
| SAE100R1-01 | 5 | 3/16 | -3 | 4.6 | 5.4 | 8.9 | 10.1 | 11.9 | 13.5 | 12.5 |
| SAE100R1-02 | 6.3 | 1/4 | -4 | 6.2 | 7.0 | 10.6 | 11.7 | 15.1 | 16.7 | 14.1 |
| SAE100R1-03 | 8 | 5/16 | -5 | 7.7 | 8.5 | 12.1 | 13.3 | 16.7 | 18.3 | 15.7 |
| SAE100R1-04 | 10 | 3/8 | -6 | 9.3 | 10.1 | 14.5 | 15.7 | 19.0 | 20.6 | 18.1 |
| SAE100R1-05 | 12.5 | 1/2 | -8 | 12.3 | 13.5 | 17.5 | 19.0 | 22.2 | 23.8 | 21.5 |
| SAE100R1-06 | 16 | 5/8 | -10 | 15.5 | 16.7 | 20.6 | 22.2 | 25.4 | 27.0 | 24.7 |
| SAE100R1-07 | 19 | 3/4 | -12 | 18.6 | 19.8 | 24.6 | 26.2 | 29.4 | 31.0 | 28.6 |
| SAE100R1-08 | 25 | 1 | -16 | 25.0 | 26.4 | 32.5 | 34.1 | 36.9 | 39.3 | 36.6 |
| SAE100R1-09 | 31.5 | 1-1/4 | -20 | 31.4 | 33.0 | 39.3 | 41.7 | 44.4 | 47.6 | 44.8 |
| SAE100R1-10 | 38 | 1-1/2 | -24 | 37.7 | 39.3 | 45.6 | 48.0 | 50.8 | 54.0 | 52.0 |
| SAE100R1-11 | 51 | 2 | -32 | 50.4 | 52.0 | 58.7 | 61.9 | 65.1 | 68.3 | |
Components of Hydraulic Hose Assembly
If special options or accessories are not needed, corrugated metal hoses have four basic components: the tube (or hose itself), braiding, braid collar, and the end fitting. Sometimes unbraid hose can also be used, but most applications require an assembly comprising these four components. Let's look at each of these components and their functions as part of the whole assembly, and how they work together to provide value.
Types of Hydraulic Hose
There are several types of hydraulic hose assemblies, designed to meet the requirements of different applications. Various factors will influence which type of hose is best suited to withstand the system's environmental conditions, but the main categories of hydraulic hose include:
This high-pressure hose is designed for temperature ranges from -40°C to 100°C, suitable for providing power for general industrial applications using petroleum or water-based fluids.
The multi-spiral hose is very suitable for heavy construction applications in industries such as mining, quarrying, petroleum, and agriculture. It has a high degree of flexibility and can be used to transport water-oil emulsion, mineral oil, and hydraulic oil.
This type of hose is usually woven from textile materials and is very suitable for light operations with low working pressure.
Stainless Steel Wire Braided Hose
This is a very heavy-duty hose, typically designed with a single or double layer of stainless steel wire braiding. This type of hose is used in harsh applications due to its durability and the ability to withstand extreme pressure and temperature.
These hoses are typically used in hydraulic lifting equipment, heavy construction, and lubrication pipelines, featuring two layers of thermoplastic material and a reinforcement layer of synthetic fiber mesh in the middle. Depending on its design, the thermoplastic hydraulic hose is wear-resistant and can work at extremely low temperatures.
components of a hydraulic hose assembly
A critical component of any hydraulic hose assembly. Hose end fittings are crucial for maintaining and directing fluid flow, preventing leakage, maintaining the prescribed pressure within the hose, and securely connecting the hose to other components in the hydraulic system (such as cylinders, valves, and pumps).
There is a wide variety of hydraulic hose fittings, with diverse thread types and styles. Whatever the fitting, its design should be compatible with the specific hose and fluid used.
Hydraulic fittings are most commonly assembled using a crimping method. The fitting assembly includes:
Crimp fitting – This part of the fitting is attached on the outside layer of the hose.
Hose fittings – The insert is directly pushed inside the tube and comes out from the hose, with appropriate end thread, flange/fitting to connect to the system.
Hydraulic hoses and their fittings must meet various specifications, with hoses typically designed to conform to EN standards or SAE standards - the latter being most common in the UK.
Manufacturing
Hose Size: Different manufacturers offer hydraulic hoses in different sizes. It is the responsibility of the technician/engineer to analyze the hose requirements and choose an appropriate hose. Inner diameter is a key factor to consider when choosing a hose. Both larger and smaller diameter hoses can impact the performance of the system. That is to say, if a hose with a larger diameter is chosen, it can reduce fluid pressure. Similarly, a hose with a smaller diameter can reduce fluid flow. Both of these points can be justified using Pascal's law.
Temperature and Pressure: The working environment of hydraulic systems can vary. Both the external temperature and internal temperature of the hose need to be considered. Hydraulic systems used in automobiles experience high external temperatures which can damage the hose cover, leading to a gradual hose leakage. Moreover, if you consider any system working continuously without oil coolers, internal temperatures can be higher and cause inner tube wear. Therefore, it is necessary to consider how much pressure a hose can withstand.
Fluid Compatibility: The choice of hydraulic fluid depends on system application. Various properties of the fluid need consideration before selection. Nonetheless, the fluid plays a critical role in extending the lifespan of the hose. Most mineral oils are compatible with common hose types. However, fluid compatibility still needs to be considered when users select hoses and fittings.
In simpler terms, it is about determining the application scope and specifications.
Temperature ranges, both mechanical and environmental
Type of fluid or gas being used
Machine or tool specifications
Pressure variances
Make to Order
Custom manufacturing of hydraulic hose assemblies is a specialized process designed to create high-performance, durable solutions tailored to meet the precise specifications and demands of various applications. This process involves the selection of suitable materials, hoses, and fittings that can withstand different pressures, temperatures, and fluid types, ensuring that each assembly performs optimally in its intended environment.
Sinopulse stands out in this regard, as a professional hydraulic hose assembly company that excels in providing made-to-order services. With a deep understanding of the complexities involved in hydraulic systems, Sinopulse leverages its expertise and state-of-the-art technology to manufacture hose assemblies that precisely fit the unique requirements of each client. Whether the need is for construction, agriculture, or industrial machinery, Sinopulse is dedicated to delivering custom solutions that enhance system efficiency and reliability, making them a trusted partner in the field of hydraulic hose assembly.
Assemble Process
Step 1: Gather Needed Tools and Materials
It's best to have everything you need in one place or nearby. This helps to reduce time and waste. Here's what you usually need,
Hydraulic hose (note to determine the inner diameter of the hose or special hose type)
Hose fittings (For assembly of hydraulic hoses, you can choose straight, 45°, 90° and other combinations of end fittings, if you are unsure of the direction of the hose, please call our office before ordering)
Lubricant
Safety equipment
Crimping machine
Caliper
Marker/Chalk
Crimping dies and collar
Tape measure
These are the things you most often need. They can help you easily complete the assembly without wasting time.
Step 2: Measure and Cut Hose
Once you have your tools and materials ready, you'll need to adjust the hydraulic hose to a specific length required.
Measure the hose and mark the specific length required on it. Then, you could use a saw or hose cutting machine to cut the hydraulic hose at the specific mark. Make sure the end of the specific cut is clean, smooth, and even. If it's not, use a file to clean the edges to make them even, this can reduce hose assembly failures.
Remember, safety is paramount and extra caution should be taken during this process. It's important that you hold the hose correctly or tighten it onto the cutting machine to prevent it from springing up due to friction. Many times these precautions are overlooked and result in injuries.
Step 3: Hose Dressing
Dressage of the hose should be done at this point (if any). This cannot be done after this as we will be sealing the end of the hose.
This is entirely dependent on the specific application, sometimes spring protectors and additional brading are necessary to protect the hose from external environmental damage. These help to prolong the lifespan of the hydraulic hose.
Step 4: End Fitting Series
Choose the series of end fittings to be assembled with the hose. This helps to connect the hose to the machine or system to be used.
You can choose from our wide range of fitting options. Whatever end fittings you need, we can meet your needs. If you need custom fittings, do not hesitate to email us.
End fittings can be complex. This depends on the machine's inlet/outlet ports/application points. You must meet the specifications for a perfect performance. You need to consider the connection method, direction, working pressure and corrosion-resistant materials.
Step 5: Connect the Fittings and the Hose
Connect the fittings to the end of the hose and prepare for crimping. You need to place the hose cover and insert the fitting into the hose. Remember the insertion depth, and the fitting should be firmly secured inside the hose before crimping.
Step 6: Crimping
Once all checks are passed, you can now start crimping the hose. We recommend checks before crimping which saves a lot of trouble. Wrong fittings, incomplete hose dressing is easier to handle before crimping.
Prepare the crimping machine, place the right dies and adjust the crimping settings. Then, feed the end of the hose through the die into the crimping machine (normally bottom loaded). The hose cover or collar needs crimping, so hold the fitting accordingly.
Wear safety equipment and turn on the machine. Push the button, the machine will compress the collar on the hose to secure the fitting as tight as possible. Do not touch while the machine is running. After compression, the machine pulls back or stops, and you can check the assembly.
Step 7: Validate Crimping
Check if the crimping has been done correctly. Always follow the crimping diameter, and check if the fittings have moved during the process. If they have, the crimping result is poor.
One of the checking methods is to make a mark at the bottom of the fitting, if the mark is still clearly visible after crimping, it means the hose or fitting has not moved.
It is very important to check if the crimping is correct. We have a full set of advanced testing facilities, which can test whether the hose fittings can withstand pressure. This helps to ensure the successful completion of the fittings and possible leaks.
Step 8: Cleanse Hose Assembly
After crimping is completed and approved, the hose assembly should always be cleaned, removing any possible residues inside the hose. You can use chemicals or blow out contaminants with compressed air.
Step 9: Cap Hose Assembly
Once the hose assembly is cleaned, make sure to cap both ends to ensure no other contaminants are introduced into the hose assembly. You can cap it to protect the threads and seal the inlets.
clean hydraulic hose assemblies
Air cleaning involves the use of compressed air to blow out any debris or contaminants inside the hose assembly. It can effectively remove any loose fragments, dust or other particles that may be present inside the hose assembly. It's fast and cost-efficient, but ineffective for removing any heavy or stubborn contaminants that might be present.
Fluid flushing involves pumping a cleaning fluid into the hose assembly to remove any contaminants that might be present inside the hose. This method is typically used when the hose assembly has been exposed to particularly dirty or contaminated hydraulic oil. Fluid flushing requires a specialized flushing device or system providing the necessary flow and pressure to remove the contaminants.
With projectile cleaning, foam particles or sponge is inserted into the hose assembly and then pushed through the hose using compressed air or fluid pressure. As the projectile travels through the hose, it scrubs the interior surfaces of the hose and removes any contaminants that may be present. This method is very effective on all kinds of hoses, but may be time-consuming and requires specialised equipment.
Selecting Hydraulic Hose Assemblies
It goes without saying that hose assemblies are at the heart of many hydraulic applications, so choosing the right hose is critical to ensuring optimal performance and safety.
If you are purchasing a new hose or a replacement hose, the best way to determine which hose your application requires is to use the STAMP method:
Size – Accurately determining the diameter your hose needs to hold the correct amount of fluid will ensure it can operate at the required operating pressure.
Temperature – The temperature of the fluid inside the hose and the temperature outside the hose must be considered to ensure the material can withstand the conditions and have a longer service life.
Application – Consider the environment in which the hose will operate, the type of equipment it will be used in, and the specifications it needs to adhere to.
Media – The hose selected must be compatible with the fluid in the tube to ensure optimal performance and prevent wear or corrosion.
Pressure – Accurately calculate the required operating pressure and select a hose with a maximum operating pressure that exceeds or matches the system operating pressure.
Replacing Hydraulic Hose Assemblies
Once a hydraulic hose is assembled, it must be properly maintained. Both internal and external factors affect the life of the hose assembly. Contaminants, pressure, temperature, corrosion, etc. are internal factors, while external factors are factors that are introduced by the technician through pulling, squeezing, kinking, etc…
Hose assembly replacement can only be done with a proper visual inspection. Listed below are some symptoms of hose assembly failure.
Leaking hose
Exposed wire (frayed)
Cracked fittings
Kinked hose
Cracked or corroded fittings
Twisted hose
Rules For Hose Safety And Installation
Always allow your hose to have some slack when first installed. This will avoid placing unwanted stress on your hose if it moves during use.
Make sure that there is no unwanted twist on the hose assembly during installation. The hose will attempt to straighten out during use which can lead to damage to your hose assembly.
Avoid excess bends when installing hose. This can lead to unwanted crimps in your hose, which may lead to catastrophic failure.
Adapters and brackets can prevent exposing your hose to environmental hazards. Keep your hose neatly secured and away from sources of heat via brackets to ensure the longest lifespan of your hose.
cost and price
Cost is a balancing factor in all purchasing decisions. Making a purchasing decision based solely on cost assumes that all products are the same except for price, which is absolutely wrong. While we must consider the cost factor, we also focus on providing value by providing products with the attributes listed above, as well as exceptional service. You can think of this value as an equation: Value = Quality + Service - Cost. While there may be lower-priced metal hoses on the market today, our value (quality and service) exceeds the cost of our products. This value, combined with the value you bring to your customers, creates a one-two punch that is hard to beat. Helping users of our products understand our definition of value can be difficult. That's why we offer courses like Hose Master University to help people understand how we bring value.
Sinopulse hydraulic hose assemblies save you time and money. Our high-quality assembly kits provide everything you need to keep your industrial hydraulic system running at peak productivity and efficiency. Our proprietary brand hydraulic hoses, Sinopulse, can be pre-assembled to meet your desired specifications. We also offer a wide range of accessories to complete your hydraulic hose assembly. These hoses and accessories are all made in-house and guaranteed to meet your specifications. Once you determine the hose size you need, as well as the end fittings, we can complete the job. Best of all, they come with protective hose packaging. Contact us to tell us what you need and help us create the best hose assembly to meet your needs. If you would like advice on your project before you buy, we have a dedicated technical support team ready to help you design a solution so you get the right parts for your application.
