Super Hercules series high pressure and long life for winding hoses in construction machinery
1、 Technical core: Dual breakthrough of high pressure and long lifespan
The working environment of construction machinery is complex, and strict requirements are placed on the pressure resistance, flexibility, and service life of hydraulic hoses. The Super Hercules series winding hose achieves a dual breakthrough in pressure bearing and service life through material innovation and structural optimization.
（1） High pressure bearing technology
Enhancement layer material and structure
High strength steel wire: Galvanized steel wire with a tensile strength of ≥ 2200MPa and a diameter range of 0.25-0.5mm is used. Through a four layer cross winding process, the hose can maintain structural stability under a pressure of 100MPa. For example, a certain type of hose can withstand a pressure of up to 300MPa during a burst test, far exceeding the industry average.
Aramid fiber composite reinforcement: Kevlar aramid fibers are embedded between the steel wire layers to enhance the fatigue resistance of the hose. The breaking strength of aramid fiber is ≥ 28cN/dtex, and its weight is only 1/5 of that of steel wire. It is suitable for weight sensitive construction machinery (such as high-altitude work platforms).
Adaptability to pressure fluctuations
The hydraulic system of construction machinery is often accompanied by pressure pulses (such as pressure fluctuations of ± 20% when the excavator boom extends and retracts). The Super Hercules series optimizes the wire winding angle (usually 54.74 °), allowing the hose to cycle 500000 times without leakage at 1.5 times the working pressure, extending its lifespan by three times compared to traditional hoses.
（2） Long life design
The inner adhesive layer is wear-resistant and corrosion-resistant
Polyurethane (PU) internal adhesive: Shore hardness 90 ± 2 degrees, tensile strength ≥ 40MPa, friction coefficient as low as 0.15 in sand containing hydraulic oil (sand particle diameter ≤ 50 μ m), wear resistance improved by 60% compared to nitrile rubber (NBR). For example, after 2000 hours of continuous operation in a concrete pump truck, the inner wall wear depth of a certain type of hose is ≤ 0.1mm.
Fluororubber (FKM) coating: For high temperature conditions (such as the hydraulic system temperature of a roller reaching 120 ℃), a 0.1mm thick FKM coating is applied to the surface of the inner rubber layer. The oil aging resistance time is extended to 2000 hours, and the tensile strength retention rate is ≥ 85%.
The outer adhesive layer is weather resistant and tear resistant
Chlorosulfonated polyethylene (CSM) outer adhesive: UV aging resistance time ≥ 1500 hours, tear strength ≥ 25kN/m, and flexibility maintained within the temperature range of -40 ℃ to 150 ℃. For example, the hose of an excavator in a northern mine can still bend normally in low temperature environments during winter without any brittle cracking.
Anti static and flame retardant design: conductive carbon black is added to the outer layer, with a surface resistance of ≤ 10 ⁶ Ω, to prevent static electricity from causing fires; Passed UL94 V-0 flame retardant certification, self extinguishing after exposure to 800 ℃ flame for 30 seconds.
2、 Product series and typical application scenarios
The Super Hercules series is divided into multiple models based on the type and working conditions of construction machinery, covering mainstream equipment such as excavators, loaders, and cranes.
（1） Excavator specific hose
Model: Hercules X100
Parameters: Inner diameter 6-51mm, working pressure 42MPa, burst pressure 168MPa, small bending radius 5 times the outer diameter.
Application: Suitable for hydraulic systems of the boom and boom of large excavators such as Komatsu PC360 and Caterpillar 336. In a certain open-pit coal mine project, the X100 hose only needs to replace some of its joints after 18 months of continuous high load operation, while the average lifespan of traditional hoses is only 6 months.
Technical highlights
Double layer steel wire cross winding: The inner layer of steel wire bears radial pressure, while the outer layer of steel wire resists axial tension, enhancing blast resistance.
Quick connector design: Using DIN 2353 standard connectors, installation time is reduced by 50% and downtime losses are minimized.
（2） Crane high-pressure hose
Model: Hercules C200
Parameters: Inner diameter 13-76mm, working pressure 70MPa, burst pressure 280MPa, temperature resistance range -40 ℃ to 120 ℃.
Application: Used for variable amplitude and telescopic oil cylinders of 1000 ton all ground cranes such as Zoomlion ZCC9800W and XCA1600. In a certain offshore wind power installation project, the C200 hose worked continuously for 2 years without leakage under salt spray corrosion and high pressure impact, ensuring construction safety.
Technical highlights
Aramid steel wire hybrid reinforcement: The aramid layer bears 30% of the load, while the steel wire layer bears 70% of the load, reducing weight by 15% while maintaining high strength.
Anti seawater corrosion coating: Nano zinc oxide coating is added to the outer layer. In the seawater immersion test, the mass loss rate after 72 hours is ≤ 0.5%.
（3） Wear resistant hose for loader
Model: Hercules L50
Parameters: Inner diameter 10-38mm, working pressure 25MPa, burst pressure 100MPa, wear resistance life ≥ 1 million cycles.
Application: Suitable for hydraulic systems of steering and working devices of wheel loaders such as LiuGong CLG888 and LongGong LG855N. At a certain sand and gravel yard, the L50 hose has a lifespan four times longer than ordinary hoses when transporting hydraulic oil containing 20% quartz sand.
Technical highlights
Ceramic particle inner adhesive layer: Aluminum oxide ceramic particles (particle size 10-30 μ m) are uniformly embedded into the PU inner adhesive layer, increasing the hardness to 95 degrees and achieving a wear resistance of 0.02g/1000 revolutions per minute according to ASTM D4060 standard.
Self lubrication design: PTFE micro powder is added to the inner rubber layer, reducing the friction coefficient to 0.1 and minimizing energy loss.
3、 Industry Trends and Manufacturers' Competitive Strategies
（1） Technological development trends
Ultra high pressure and lightweight
The hydraulic system pressure of construction machinery is developing towards 80-100MPa, and the hose needs to use carbon fiber reinforced materials. For example, the carbon fiber resin composite hose developed by a certain laboratory has a working pressure of 120MPa and weighs 40% less than steel wire hoses.
3D printing technology is used to manufacture irregular joints, reduce stress concentration, and improve the overall lifespan of hoses.
Intelligent and predictive maintenance
Integrated fiber optic sensors for real-time monitoring of pressure, temperature, and leakage. For example, a certain intelligent hose predicts its remaining lifespan through AI algorithms and provides a 30 day early warning of replacement needs to avoid unplanned downtime.
RFID chips achieve full lifecycle traceability and can be monitored throughout the entire process from production to disposal.
Environmental Protection and Sustainability
Biobased rubber (such as Eucommia ulmoides gum) and recyclable reinforcement layer materials can be used to recover 90% of the raw materials through pyrolysis after disposal.
Low VOC outer layer, compliant with EU REACH regulations, reducing environmental pollution.
（2） Changes in market demand
New energy engineering machinery drive
Electric excavators and hydrogen loaders require higher temperature resistance and electrochemical corrosion resistance for hoses. For example, a certain electric loader hose needs to withstand a temperature range of -40 ℃ to 150 ℃ and have insulation properties (breakdown voltage ≥ 50kV/mm).
Globalization and Localization Services
Construction machinery manufacturers require hose suppliers to have global supply capabilities and localized services. For example, an international brand requires suppliers to respond to overseas after-sales needs within 72 hours and provide on-site installation guidance.
（3） Manufacturer's competitive strategy
Differentiated product positioning
Small and medium-sized manufacturers focus on segmented markets, such as a company specializing in mining wear-resistant hoses, which occupies 25% of the mid to low end market share through the combination of "ceramic particle internal glue+aramid reinforcement".
Large manufacturers monopolize the high-end market through technology, such as an international brand of carbon fiber hoses that are priced 50% higher than similar products, but have extremely strong customer stickiness.
Service oriented transformation
Provide a one-stop solution of "hose assembly+installation tools+training". For example, a manufacturer customized hose installation fixtures for a crane manufacturer, which increased assembly efficiency by 60%.
Carry out the "trade in" business, recycle old hoses and remanufacture them to achieve 80% performance of new products, reducing costs by 30%.
Globalization Layout and Compliance
Establish production bases in emerging markets such as Southeast Asia and the Middle East to avoid trade barriers. For example, a domestic manufacturer has established a factory in Vietnam, with products radiating to the ten ASEAN countries, resulting in a 15% reduction in tariff costs.
Through international certifications such as ISO 3862 and SAE J517, it meets regulatory requirements in different regions.
In the future, the Super Hercules series of hoses will require continuous technological iteration to adapt to the trends of high pressure, electrification, and intelligence in construction machinery. Manufacturers need to strengthen cooperation with host manufacturers, deeply participate in hydraulic system design, and build technological barriers and cost advantages through material innovation and process optimization, in order to take the initiative in global competition.
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