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Matched Hydraulic Hose Systems
There are numerous standards available that the world's hose manufacturers can comply to including; International (ISO), European (EN), and American (SAE). These standards provide the general detail the manufacturers must adhere to, to be compliant:
- Hose ID/OD
- Over wire dimension
- Cover thickness
- Working pressure
- Burst pressure
- Minimum bend radius
- Fire resistance (not all standards)
- Electrical conductivity (not all standards)
As defined by NSW Mines safety spec MDG41, A matched hose assembly is where the hose and fittings (insert/ferrule) are designed, manufactured, and routinely tested to match up to a particular manufacturer’s hose type. In this case both (hose and fitting) are assembled and crimped using the methods as specified by the designer, meet the tolerance specified by the designer, and have been tested as a hose assembly, at the maximum tolerance, to the specified standards.”
These standards provide the types of tests that need to be performed and when these tests are conducted. It also advises how long the hose shelf life should be.
What the standards don’t do, is tell the manufacturer how to make a hose that can achieve those parameters. It does not tell them anything about the rubber compound or additives needed, nor the wire thickness, type, number of braid strands, angle of weave, or strength.
Rubber Compound
The way a hose works in any given environment is determined by specific ingredients which has an effect on the hardness, pliability, UV resistance, and bend radius, etc of the rubber compound and accordingly the way it reacts when you crimp a hose tail on. For example, high-temperature hose compounds are generally softer, so achieving tail collapse is not always a good indicator of the correct crimp dimension. Sometimes, if you do go by the tail collapse theory you will more likely crush the liner to a point of cracking and leakage.
Cover Thickness
If the manufacturer makes the cover of the hose to the higher end of the allowance within the standard (a thick outer cover) and this is usually very generous, there may not be enough room between the teeth of the ferrule to allow for the dispersion of the outer cover rubber and at the same time grip onto the hose reinforcing. In this situation, the result more often leads to the hose tail blowing off regardless of the amount of tail collapse you may have achieved.
If the cover is too thin the barbs bite through the wire and may even cut the wire before achieving tail collapse. Without the correct thickness of the cover, the barbs of the ferrule may be too aggressive and even if the wire is not cut, may apply too much pressure to the liner through the wire and crush it excessively also causing failure.
The types of failures caused by the above problems do not always result in immediate failure, rather they will severely reduce the life of the hose.
Hose Tail And Shell Design
The hose tail and shell design are generally laid out in the relevant ISO standards (ISO 12151 etc), but this is limited to the dimensional requirements, for example, the overall hose tail length, drop length of 90 degrees, the thickness of the tube nut sizes, etc.
The standards do not tell the manufacturer what type of steel to use, how to heat-treat (if required) or the method to be used. These standards give no information to the manufacturer on the length or shape of the shell or even the number of teeth in the shell. This design work is all up to the manufacturer and can vary considerably from brand to brand.
Exactfit Hose assemblies and Senaxis fittings meet these tests as a matched system and as a manufacturer, we stand by our products. Buy Exactfit Hose assemblies here.