High pressure hoses are flexible hoses whose main task is to supply working fluids (emulsion, gases, oil) to hydraulic systems. Good performance characteristics allow the product to withstand high pressure and not deform.
High pressure hoses are actively used in various production areas. This can be not only construction and mechanical engineering, but also agriculture, metallurgy, natural resource extraction industries and other areas.
Features of high pressure hose repair
High-pressure hoses, more often called high-pressure hoses (HHP), are designed to create or absorb working force, which is transmitted under high pressure by liquids or gases pumped into them.
High pressure hose
The main area of application of RVDs is hydraulic and pneumatic systems of various devices and mechanisms. Outside of industrial production, vehicle owners most often deal with high pressure hoses, these are power steering hoses, and those who use high-pressure pumps, for example, our most common brand, Karcher.
RVD structure
The design of the RVD is determined by the need to withstand internal pressure, which can reach several hundred atmospheres.
In addition, the inner surface of the high-pressure hose must be impervious to the effects of the transported medium. Therefore, its bottom layer is made of oil- and petrol-resistant rubber or synthetic rubber.
To make the upper, thicker layer of the high-pressure hose, wear-resistant rubber is used, which, if necessary, is supplemented with thermal protection in the form of a corrugated coating, metal or polymer.
Between the upper and lower layers of rubber, metal wire is wound in several layers, thanks to which the hose receives the necessary rigidity and strength. Layers of wire are interspersed with thin rubber films.
Depending on the method of winding the wire, there are two types of high-pressure hoses:
- Winding. When producing this type of hose, turns of wire are wound in even rows.
- Braided. In this case, the turns are wound at an angle to the axis of the hose so that the turns of the previous layer intersect with the turns of the next layer of wire. Braided hoses have greater strength and can withstand greater pressure than coiled hoses.
High pressure hose
In addition to wire, textiles can act as an internal rigid frame.
The number of layers of wire and the thickness of rubber layers are set by standards that determine the scope of application of a particular type of hose.
Do-it-yourself hose crimping machine - Metals, equipment, instructions
To manufacture hose hoses, TsPK LLC placed Finn-Power equipment in its warehouse in Moscow, and we also use Parker components.
The high pressure hose is an indispensable and one of the most important parts of the production process. It transports gases and liquids. But installation of high pressure hoses requires special equipment for reliable fastening of hoses and their strong connection.
Lines for the production of high-pressure hoses today need to be equipped with special crimping equipment. Machines and presses for crimping high-pressure hoses are available in various types and sizes and can be used both in industrial conditions and for urgent repairs anywhere (mobile presses).
Types of hose crimps
Pressure testing of high-pressure hoses is carried out using specialized equipment. The technological process is quite labor-intensive and requires care and precision. Today, mainly two methods are used for crimping:
- 1. European (longitudinal). This method is also applicable when crimping braided hose hoses. The essence of the method is as follows: the internal coupling is equipped with ring teeth, which are inserted into the sleeve braid, ensuring a reliable connection. When crimping two types of hoses - 1SN and 2SN - the outer thin layer of rubber is not removed. This allows you to make the connection even tighter.
- 2. Cross crimp. This method is considered classic and is used most often. Used in crimping high-pressure braided hoses. This process uses a tubular coupling. The process is as follows: the top layer of rubber is removed along the entire length, which holds the sleeve from the inside with transverse protrusions. The coupling is pressed tightly against the sleeve and provides fastening.
Traditional crimping is transverse. Longitudinal is most often used for crimping hose hoses with metal braiding of domestic production, produced in accordance with GOST 6286-73. Such hoses are the most economical and reliable in operation.
In hydraulic systems with high pressure, longitudinal crimping methods are mainly used. The sharp teeth on the coupling cut firmly into the metal braid, allowing you to avoid scraping off the top rubber layer.
The connection is sealed due to high pressure compressing the sleeve on the nipple.
Crimping equipment can be divided into types depending on the scope of application:
- The service press is most often used in workshops and small-scale or even single-piece production;
- a mobile press is in demand for urgent repairs, mines and replacement of high pressure hoses directly on site;
- an industrial press is used in large-scale production.
Features of the machine for the manufacture of hose hoses
The hose crimping press is part of the production line. Today on the market there are both small mobile machines and stationary ones for industry. When choosing a machine, it is necessary to take into account the initial parameters of working with the equipment: the type and diameter of the hose, the maximum size of fittings, the type and performance of the machine.
The scope of use of crimping machines is quite large:
- · production of hydraulic hoses;
- · production of auto parts;
- · production of construction equipment;
- · production of sea and railway transport;
- · production of wire, hoses, pipes and pipelines, cables.
The crimping machine has the following features:
- · works from several sources: battery, compressed air or manually;
- · crimping accuracy is always at its best;
- · the design of the machine is convenient and ergonomic, it is easy to operate;
- · quick pressure testing of hose hoses is possible due to the system for quick replacement of cams;
You can use the machine in production conditions and on site.
Selecting a crimping machine
The reliability of fastening of sleeves and hoses depends on the quality and performance characteristics of the equipment. When choosing, pay attention to the details and characteristics of machines and presses:
- 1. Crimping speed. This parameter is especially important in production. Machines with high crimping speeds are used in multi-batch production and various conveyors. In standard press models, the speed ranges from 300–2500 crimps per hour.
- 2. Mobility. In industrial conditions, mainly stationary powerful machines are installed. In the field, for urgent installation and repair, mobile portable presses will be required.
- 3. Crimping force. Varies between 3500-12000 kN.
- 4. Working diameter. The maximum permissible opening of the crimping jaws in millimeters shows the permissible size of the hose that can be crimped.
High-pressure hoses are used today both in large enterprises and in small workshops. Crimping of the hose may be required at any time. A high-quality crimping machine is a guarantee of connection reliability, long service life and strength of the connection point.
We manufacture hose hoses of any complexity and sizes up to 2.5 inches. with fittings made of galvanized and stainless steel, as well as polymer protection (plastic spiral).
Contact us by phone +7 (495) 247-87-27. We are located at: 115230, Moscow, Elektrolitny proezd, 3, 5 minutes from the Nagornaya metro station.
Manufacturing and repairs are possible in front of you and in the shortest possible time!
Business in the production of high-pressure hoses (HHP) (November 2018) - how to open from scratch, examples and a ready-made plan with calculations for beginners
Train your brain with pleasure
Start developing
High pressure hoses are a pipeline through which any gas or liquid can be distilled. They are used both in everyday life and for industrial purposes. Of course, the characteristics of these products, depending on the purpose, are different. These products also exist on the market from manufacturers from Europe and the CIS countries. Today we will look at how to set up the production of high-quality high-pressure hoses.
- What equipment to choose for the manufacture of high pressure hoses?
- RVD production technology
- Franchise business
- Step-by-step plan for starting a business
- How much can you earn
- How much money do you need to start a business?
- Which OKVED code must be specified for the production of high-pressure hoses?
- What documents are needed to open
- Which taxation system to choose for the production of high-pressure hoses
- Do I need permission to open?
This product requires certain knowledge of the technological process. It is also impossible to organize a production workshop without special equipment. It comes in different capacities and differs in other characteristics. You need to study them before purchasing. It would also be a good idea to find out reviews from industrialists who are already working on it.
What equipment to choose for the manufacture of high pressure hoses?
You can buy equipment for the production of hose hoses in the form of a finished line or each machine separately. The standard kit looks something like this:
| Machine name | Price, thousand rubles |
| Crimping press or crimping device | 200,00 |
| Cutting machine | 80,00 |
| Apparatus for stripping rubber inside and on the surface of hoses | 60,00 |
| Marking machine | 50,00 |
Additional equipment (rolls, frames) will cost another 150 thousand rubles. The prices in the table are the minimum prices. This price segment of equipment will provide an opportunity to open a small production facility.
This is enough to start a business, since it is very important to determine the channels for future sales of products.
After establishing strong partnerships with customers, you can think about increasing production capacity.
To make a high-pressure hose you will need the following equipment:
| 1 | Crimping machine or crimping press. |
| 2 | A device for removing the upper and inner layers of rubber from high-pressure hoses. |
| 3 | Equipment for marking. |
| 4 | Roll for unwinding coils. |
| 5 | Racks for presses. |
| 6 | Storage for a set of jaws. |
The technological process can be divided into several stages:
- preparatory work with material and equipment setup;
- crimping operation;
- quality control and testing of finished products.
High-pressure hoses are distinguished by the type of metal coating. They can be made by braiding or winding. I also use different materials for this process.
Fittings for high pressure hoses
To secure the hoses in place, fittings (tips) are mounted at their ends, which are of the following types:
- Screw;
- Union;
- Nipple;
- Quick connect connections.
Fittings are attached to the ends of the hose using crimp couplings, which are crimped on special machines.
Depending on the type of shank, fittings are classified into series:
- Universal. This series can be used in all hoses of high pressure hoses with the exception of coiled type hoses.
- Interlock. The series is used for coiled hoses.
When installing fittings of this type, it is necessary to remove both layers of rubber, internal and external.
Fittings for high pressure hoses
The operation of removing layers of rubber is called hose debarking.
- CS. Fittings of this series also crimp coiled hoses, but there is no need to remove the rubber of the upper and lower layers.
Failure of fittings is the most common cause of damage to high pressure hoses. This is explained by the magnitude and intensity of the loads they experience.
Range of equipment for hoses and pipes
In addition to stationary machines, we offer you to equip a mobile workshop that solves the problems of repairing high-pressure motors in remote areas. Many machines can operate on a pneumatic drive and from a 12V network. All presented equipment is manufactured in Italy, machine components are made of high-quality materials and assembled by experienced specialists, among whom there are design engineers who are engaged not only in the development of technical drawings, but also in work related to the study of ergonomics. Despite high competition, OR Srl can rightfully be called a leader among companies producing equipment for the production of rigid and flexible pipelines.
OUR ADVANTAGES:
- High-quality equipment for hoses and pipe processing;
- Wide range of machines for hoses and pipe processing;
- Multi-level quality control;
- Possibility to purchase equipment with installment payment;
- Maintenance of equipment for the manufacture of hose hoses and pipes;
- Low prices for wholesale purchases and the opportunity to become a distributor.
When purchasing equipment for hose hoses and pipes from us, you will always receive guaranteed, high-quality and professional assistance; we will teach you how to properly operate the equipment and provide full warranty and post-warranty service.
Damage to high pressure hoses
The causes of damage can be divided into the following types:
Important! In order to protect yourself as much as possible from possible damage to hose hoses, when choosing them, it is necessary to carefully check the compliance of their characteristics and parameters with operating conditions.
High pressure hoses with fittings
Manual mechanical
used for crimping car air conditioning hoses with replaceable jaws.
The jaws snap into the crimper quickly, no pins or screws required.
For ease of recognition, each holder with cams has its own color:
- #6 (5/16″) - pink, 71500-6
- #8 (13/32″) - red, 71500-8
- #10 (1/2″) - yellow, 71500-10
- #12 (5/8″) - green, 71500-12
The weak point of a car's air conditioning system is the hoses connecting the air conditioning compressor to the condenser and the low pressure side. Most often, rubbing against foreign objects or rupture of the hose due to high pressure occurs. Finding a new hose can be time consuming and costly. For services involved in refilling car air conditioners, there is inexpensive equipment that allows you to perform professional repairs.
air conditioning system hoses are a crimper.
Replacing damaged high pressure hoses
From all of the above, we can conclude that the repair of high pressure hoses consists of either replacing the damaged area or replacing fittings that have become unusable.
When replacing a damaged area, as well as when replacing fittings, you will need to crimp the couplings, that is, technologically these two actions are very similar.
High pressure hoses
The sequence of operations looks like this:
- The damaged sleeve is disconnected from the main mechanism.
- A new sleeve is cut to the size of the old one on a cutting machine. Moreover, for measurement, the distance between the ends of the nipples at its ends is taken. It is better to choose a hose pump designed for a higher pressure than that for which the old hose pump was designed.
- The markings on the sleeves will help you choose the right diameter.
The factory marking DN indicates the diameter of the internal channel of the hose.
If a non-standard connection is encountered, repairs are carried out using a repair fitting. To do this, take the head of the old fitting, to which the part to be crimped is soldered.
High-pressure hoses
This method is often used by car enthusiasts for emergency repairs of power steering hoses, as well as by owners of Kircher pumps and miniwashes.
Cleaning and testing of high pressure hoses
For those who want to be confident in the quality of manufactured hoses, we offer a unique additional service - testing of finished products. The special Uniflex test bench we use allows us not only to check the load under the most severe conditions, but also to treat the hose hose with a water-oil mixture, which has an anti-corrosion effect.
Cleaning of hose hoses is also carried out using German Uniflex equipment. Flushing of the high pressure hose is carried out both from the inside and from the outside. After washing, the sleeves are completely cleaned of microdust, burrs, etc.
Source
Repair and replacement of power steering hoses
The reason for damage to power steering hoses is most often that when the steering wheel rotates due to friction, a serious force is generated. This force causes deformation of the elastic element, which changes the size of the holes in the distribution mechanism that regulates the pressure drop in the hydraulic cylinder.
As a result, the power steering sleeve connected to the limit valve wears out. This power steering sleeve is designed for pressure, depending on the make of the car, from 70 to 130 kgf/cm2.
At such high pressure, repairing a damaged power steering hose using clamps or wire is almost impossible.
There are two options left: either replace the entire power steering tube, or replace only the damaged part of it, replacing the fittings with a new hose.
Moreover, it is better to rearrange the fittings in a special workshop.
Replacement and installation of the power steering hose is carried out as follows:
- The front of the car is raised on jacks.
- The steering wheel is turned all the way to the left.
- Using a syringe with a tube attached to a needle, fluid is pumped out of the power steering reservoir.
- After this, the hose is disconnected, and the working holes of the hydraulic system are closed with plugs.
Power steering hoses
The selection of a new hose is made with exact observance of the diameter, otherwise the performance qualities of the power steering may change.
What is a crimp coupling?
Crimp coupling (sleeve, sleeve, ring) is a compression fitting designed for mounting end fittings on a high-pressure hose (HPR). The coupling is an integral part of all types of RVD end fittings, solving several problems:
- Mechanical fixation of the end fittings on the hose, ensuring its normal functioning at high pressure;
- Protection of the end part of the hose from ruptures and deformations;
- Due to its rigidity, it protects the end parts of the hose from bending when installed with bends.
With the help of crimp couplings, a permanent connection of the hose hose with fittings is ensured; they are used in piece and serial production of high-pressure hoses (hoses) for hydraulic systems of various types and purposes.
Manual hydraulic
A manual hydraulic crimper (hose crimping device) allows you to crimp hoses, mainly for automobile air conditioners, with a thickness from 8 mm to 16 mm, both thin-walled and thick-walled.
The hydraulic crimper allows you to carry out the process of crimping the hose “overhang”, faster and with better quality, without securing the crimper in a vice.
Allows the production of hoses of all standard sizes.
Types and designs of crimp couplings
RVD end fittings - coupling and nipple with nut
Connecting a high-pressure hose with an end fitting
Structurally, all couplings are the same - it is a short steel tube (bushing), at one end of which there is a collar directed inward to rest against the end of the hose. The outer surface of the couplings is smooth; on one edge there may be markings in the form of one or more annular grooves, a narrowing of the diameter or hatching. Also, alphanumeric markings can be applied to the coupling.
Crimp couplings are divided into several types according to their applicability and the structure of the internal surface.
There are two main types of couplings:
Lightweight couplings have a small wall thickness; they are designed for mounting end fittings on hose hoses of types 1 ST/SN and 2 ST/SN (with one and two braids). Reinforced couplings are designed for use with hose hoses of types 4 SP/SH, R12 and R13 (with four and six braids) and others.
In this case, crimp couplings are divided into two groups according to the method of installation on the hose:
Stripping couplings require stripping (barking) of the outer and/or inner layer of the hose for installation; they come into direct contact with the outer wire braid. Non-stripping couplings can be mounted directly on the hose without removing the outer layer; couplings for plastic and metal-plastic pipes also belong to this type.
Selection and correct use of crimp couplings
The choice of crimp couplings must be made based on the type of high-pressure hoses, their characteristics, dimensions and purpose. For hose hoses of types 1 ST/SN and 2 ST/SN, lightweight couplings are suitable; to work with hose hoses of types 4 SP/SH, R12 and R13, it is necessary to use reinforced couplings. In most cases, it is sufficient to use universal couplings, although in the manufacture of some pipelines, end fittings with specially designed couplings may be required.
Corrugated couplings are best suited for rubber hose hoses, which ensure the most reliable installation during longitudinal crimping. Smooth couplings are used for transverse crimping, during which annular grooves are formed on the coupling. Smooth couplings are also used to work with many types of plastic pipelines.
When choosing couplings, special attention should be paid to the technology of their installation, namely, whether it requires stripping the hose or not. If the coupling is stripping, then the hose must first be prepared - remove the outer and/or inner rubber layer; if the coupling is not stripped, then installation can be performed without pre-processing the sleeve. Installation of stripping couplings on an unstripped hose is prohibited, as this reduces the reliability of the hose and end fittings. This rule is also relevant for non-stripped couplings - it is not recommended to install them on a stripped hose.
Crimping of high-pressure hoses is carried out using special presses. If the work is carried out using stripping couplings, then you also need to have a debarking machine to remove the top and/or inner layer of the hose. If crimping is performed correctly, the high-pressure hose and its end fittings will meet the requirements of GOST; such products will ensure reliable operation of hydraulic and other systems in any conditions.
Advice on choosing a machine
Manual crimper
Industrial or repair equipment has certain technical characteristics. They are the main selection criterion. Therefore, it is first necessary to study the parameters of the finished product and select a crimping machine that would correspond to them.
Basic selection options:
- crimping force, tons;
- maximum and minimum diameter of the hose. The number of braid layers is taken into account;
- for electric models – mains voltage;
- maximum cam opening value, mm;
- dimensions and weight;
Dies are important. They can be either crimping or marking
In some cases, special designs will be required for limited crimping of the product. They are made to order.
The advantage of the crimping machine is its versatility. With its help, you can not only produce high-quality hose hoses, but also crimp any products
It is important that they correspond to the parameters of the equipment
