Proper installation and commissioning, reasonable control of working parameters and standardized daily maintenance can effectively avoid common initial faults of engineering hydraulic cylinders and hydraulic rotary actuators, stabilize equipment operation, and significantly extend the service life of cylinders and complete equipment.

Engineering hydraulic cylinders are the core power components of hydraulic equipment. The smooth operation, service life and fault frequency of equipment all depend on the proper operation and maintenance of the cylinders. To ensure stable operation and reduce rework of hydraulic cylinders, three key measures shall be well implemented: proper installation and commissioning, standardized working parameter setting, and compliant daily operation. This can effectively avoid common faults and extend the service life of equipment to the greatest extent.

I. Solid Installation and Commissioning to Reduce Faults from the Source

Comprehensive inspections must be completed before installing hydraulic cylinders. First, check the cylinder model to ensure it matches the supporting equipment. Then carefully inspect the cylinder block and piston rod surface for dents, paint peeling, deformation, scratches and other defects. Meanwhile, check the integrity of small accessories such as sealing rings and gaskets. Replace any damaged or aged parts in advance instead of installing defective components. In addition, thoroughly clean the equipment installation contact surface to remove all oil stains, iron scraps and dust, preventing impurities from entering the hydraulic system and causing component wear, pipeline blockage and other failures.

Strictly control the installation accuracy during cylinder installation. The central axis of the hydraulic cylinder must be consistent with the running direction of the equipment load. Offset installation will cause unilateral wear of the piston rod and rapid abrasion of sealing parts, and in severe cases, lead to cylinder jamming and equipment shutdown. For hinged hydraulic cylinders, the tightness of the support points at both ends shall be moderate. Excessive tightness will cause inflexible rotation and uneven stress, while excessive looseness will result in shaking and offset, both of which will interfere with the normal operation of the cylinder.

Adopt matched high-pressure oil pipes for hydraulic pipeline connection, with the pipe diameter and interface size fully compatible with the cylinder. Mismatched pipelines will lead to insufficient pressure, equipment overheating and increased power loss. All pipeline joints must be tightly fastened and well sealed to prevent oil leakage. Besides, avoid air entering the pipelines during connection. Air trapped in the system will cause cylinder jitter, abnormal noise, unstable and intermittent operation.

II. Reasonably Control Working Parameters to Stabilize Equipment Operation

Overpressure operation, one of the most harmful operations for hydraulic cylinders, is strictly prohibited. Long-term overload and overpressure operation will directly cause cylinder block deformation, damage internal structures, puncture sealing parts and lead to oil leakage, greatly shortening the service life of the cylinder. The hydraulic oil flow shall be adjusted according to actual working demands. Excessively high flow will cause violent cylinder movement, resulting in impact and vibration that damage equipment; excessively low flow will reduce operation speed and construction efficiency, so targeted adjustment is required.

Keep a close eye on the hydraulic oil temperature during operation and avoid overheating. High oil temperature will accelerate the deterioration and thinning of hydraulic oil, reduce lubrication performance, and speed up the aging, hardening and cracking of sealing parts, which is a major cause of cylinder oil leakage. Turn on the cooling system in a timely manner when the oil temperature rises. In addition, avoid eccentric stress, violent impact and jacking of the cylinder during construction. Eccentric force will bend the piston rod, and instantaneous impact load will damage precision internal components of the cylinder, causing irreversible equipment damage.

III. Standardize Daily Operation to Reduce Cylinder Faults

Perform no-load trial operation before formal construction to completely exhaust air from the hydraulic system. Incomplete air discharge will cause cylinder crawling, jamming and unstable operation. During equipment operation, operators shall monitor the cylinder status in real time, check for abnormal noise, oil leakage, excessive temperature and operation offset or jamming. Stop the equipment immediately once any abnormality is found, and never resume operation until all faults are eliminated.

Fully retract the piston rod into the cylinder body after operation, and avoid long-term exposure of the piston rod. Exposed piston rods are prone to rust and dust accumulation, and will accelerate the aging and failure of dust seals. For long-term equipment shutdown, drain the hydraulic oil inside the cylinder completely, apply anti-rust oil on all metal surfaces, and store the equipment in a dry and ventilated place to prevent moisture and rust, ensuring good condition for subsequent use.