Customer Challenge: A customer in the Hydraulic Repair Industry had been experiencing ongoing issues with the performance of a 10-inch Piston Seal Assembly included in a seal kit. The existing design allowed pressure to leak past the piston seal, resulting in reduced power and diminished performance of the drill cylinder it was intended to support. This inefficiency posed significant operational challenges and increased downtime, ultimately affecting the end customer’s productivity and profitability.
Upon further inspection, it was determined that the custom seal profile was poorly designed. Specifically, the seal groove was too wide, preventing the seal from maintaining proper interference with mating surfaces and functioning as intended. This flaw highlighted the need for a comprehensive solution tailored to the application's unique requirements.
PSP Seals’ Solution: The customer reached out to PSP Seals for assistance in resolving the issue. After collecting detailed information about the problem and the operating conditions of the hydraulic system, the PSP Seals engineering team initiated a redesign of the Piston Seal Assembly.
Key enhancements included:
- Custom Design Adjustments: The engineering team developed a new custom piston seal profile optimized to fit the existing groove dimensions while ensuring effective sealing performance.
- Heavy-Duty Backups: The redesign incorporated heavy-duty backup rings to fill the axial length of the piston seal assembly. This improvement enhanced stability and prevented extrusion under high-pressure conditions.
The redesigned seal assembly was manufactured and sent to the customer for installation and testing.
Results: After installing and testing the new Piston Seal Assembly, the customer reported a complete resolution of the performance issues. The redesigned seal was able to maintain the proper engineered interferences, thus preventing pressure leakage and restoring the drill cylinder’s power and efficiency. Satisfied with the outcome, the customer requested that the new design permanently replace the previous underperforming assembly in their seal kits.
Impact:
- Improved System Performance: The redesigned seal assembly eliminated pressure leaks, significantly enhancing the drill cylinder’s functionality.
- Increased Customer Satisfaction: The end customer’s operations were stabilized, reducing downtime and improving productivity.
- Long-Term Solution: By adopting the PSP Seals redesign, the hydraulic system is now more reliable and will allow for sustained performance and fewer repairs in the future.
Conclusion: This case exemplifies PSP Seals’ commitment to delivering tailored, high-performance sealing solutions. Through engineering expertise and a collaborative approach, PSP Seals resolved a critical hydraulic performance issue, enabling the customer to achieve operational excellence. For industries seeking reliable and innovative sealing solutions, PSP Seals remains a trusted partner in performance optimization, leading always with an engineering-driven approach.
Contact PSP Seals today to discuss how we can help you optimize the performance of your hydraulic cylinders and ensure longevity and productivity in your business.
