Unique Test Bench Ensures Quality

Hytec Engineering has completed the in-house design, construction and commissioning of a highly sophisticated cylinder test bench.

The bench was built in response to customer demand for a leading edge testing facility, and according to specifications and standards from a long standing customer in the mining industry.

This test bench is used at the end of the assembly line for testing different types of hydraulic cylinders with the aim of helping to maintain safety standards and durability. This is especially important in a quality-orientated manufacturing and repairs environment where there is a need to control manufactured and refurbished components.

The test bench is valued at over R1, 5-million and is unique to sub-Saharan Africa. It was built using expertise, hydraulic and automation equipment, and products from the entire Hytec Group.

The best products on the market were used from Bosch Rexroth components to Hydac filters and contamination sensors.

The bench tests cylinders up to 450 mm bore, to a pressure of 420 bar with a maximum stroke length of 6m and offers an accuracy of 0.1mm. The bench is able to perform two tests and is fully automated. The first test includes verification of the external measurements using a laser. This includes measurement in closed and open position to determine the stroke.

The second test is a full leak test with the pressure set at 150% of design pressure. The test pressure is always considerably higher than the operating pressure to give a margin of safety. In this instance, the cylinder is cycled to remove all air from the system, extended and retracted. A mid-stroke bypass test at various points is also performed. The only manual operations needed are the loading and unloading of the cylinder onto the bench and the hydraulic connections.

Possible oil contamination is analysed in both cylinder chambers during the test according to ISO 4406, and oil temperature can be adjusted to suit the specific system temperature.

Once a cylinder has been tested, the system generates an automatic, tamper-proof, printed certificate that can be used for quality control by clients. This certificate is stored in the computer and will be e-mailed to the customer after testing to advise on the status of the cylinder.