The Process of Cylinder Repair and Servicing
Cylinders are essential pieces of hydraulic engineering equipment and if a cylinder fails, it can impact your entire business. Keeping cylinders regularly serviced and maintained can improve their lifespan and keep them working at the optimum level. If something does go wrong and you need a repair, you want to make sure it lasts. At Berendsen, we offer a full range of industrial hydraulic services, including cylinder servicing and repair, and we follow a strict process to ensure a high quality, long-lasting result. The process adopted in the repair and servicing of cylinders is detailed below.
- Assessment and Stripping
The first stage is to conduct a thorough assessment of the cylinder. The cylinder will be stripped, inspected, measured, pre-tested if required and where appropriate a failure analysis conducted where necessary.
Once stripping and assessment are completed, the cylinder may be put through one or more of our repair services, these include:
- Design Enhancement
Cylinders experiencing continuing problems or those that have suffered catastrophic failure could be the result of poor design. Our design enhancement service, through the use of the latest computer assisted design technology, will review all aspects of cylinder design and make any necessary design improvements to reduce downtime and improve the lifespan of your equipment.
- Milling and Turning
Manufacturing precision engineered cylinder parts with close tolerances requires the use of milling and turning machines. These machines can be either manually or computer operated to assist in the repair and remanufacture of threads, pistons, barrels, rods, end caps and other components.
- Barrel Honing and Reclamation
Barrel honing is a process that involves an abrasive rotating tool to remove metal from the interior surface of a cylinder barrel. The main purpose of honing is to finish the bore surface to a particular diameter with an improved surface finish. Honing in the repair of cylinder barrels is typically done to remove any internal wear or scoring evident. Honing can be accommodated for barrel bores up to 500mm and barrel lengths up to 12,000mm.
Chroming is a technique of electroplating a thin layer of chromium onto the external surface of cylinder rods. Chroming can be done to a very high standard, with chroming and grinding undertaken to obtain a thickness of 0.002” (0.05 mm) for optimum levels of durability and corrosion resistance.
A variety of welding techniques including TIG and MIG as well as specialised techniques such as the application of Aluminium Bronze and Submerged Arc overlays are used during the repair process of cylinder parts and assemblies.
- Assembly and Testing
Cylinder parts are re-assembled to achieve the original closed centre and stroke distances. Assembly of cylinders is always carried out by Berendsen’s documented assembly procedures, ensuring a consistent, high quality result every time.
To ensure that our work has been carried out according to standard, all hydraulic cylinders are tested in-house before being returned to our customers. Testing ranges from basic pressure testing to more rigorous testing that can be tailored to your particular application. Once testing is complete, all cylinders are painted and special coatings applied where necessary.
Regular service and maintenance is essential for the smooth running of your hydraulic system. Keep your cylinders working to perfection and deal with any repairs quickly and effectively with Berendsen’s in-house cylinder and repair service.
Berendsen Fluid Power also offer a comprehensive range of manufactured cylinders and customised hydraulic solutions suitable to your system needs. Contact your local Berendsen branch to see how we can assist with your cylinder repair and servicing needs.