Get Your “Smart” Cylinder Fixed Today!
With over 30 years of experience repairing hydraulic and pneumatic sensor cylinders, we provide cost-effective solutions with quick turnarounds to get your equipment up to speed.
- Cylinders, Inc
- Types of Cylinders
Sensor Cylinders
While embedding position and linear transducer sensing into hydraulic systems is a newer technology, Cylinders, Inc. has experience and expertise in repairing smart cylinders to readily meet original performance requirements.
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What Are “Smart” Position Sensing Cylinders and What’s Good About Them?
Electronic position sensing hydraulic and pneumatic cylinders can have internal or external data acquisition methods. They can be referred to as position sensing, intelligent cylinders, smart cylinders, or sensor cylinders and have extra internal parts, seals, and electronic port connections. The benefits of determining the position of the cylinder and reporting the data to a centralized control system include:
- Position sensors enable safety interlocks to limit equipment movement under certain conditions
- Intelligent cylinders allow recording the productivity of the equipment, system or operator
- Many electronic position-sensing sensors are solid state with no moving parts and report precise position reliability using magnetostrictive linear position sensors
- Electro-hydraulic control aids in optimizing hydraulic and pneumatic system performance
Pros and cons
What’s the Problem with Internal Sensor Cylinders and Why May You Want to Have Them Repaired?
Electric smart cylinders are designed and modified for direct stroke measurement resulting in new replacement costs that can be significantly higher. The components of the sensor systems often require additional seals, isolated signal wire chambers and electronic ports. Just like any other hydraulic and pneumatic cylinder, the seals and components are subject to heat, vibration and high stress during heavy use. The most common problems our clients have faced include:
- Often during equipment servicing the electronic ports are damaged
- Sensor failure
- Seal failure that allows hydraulic to enter the wiring chamber, causing erratic readings
- Wire harness damage
Cylinders
What Type of Position Sensor Does Your Cylinder Have?
Do you have an electronic, smart sensor cylinder?
Generally, if your cylinder has an electronic plug or port connection, position sensing is in the cylinder. Different OEM and equipment manufactures have proprietary systems, however common systems include:
What Type of Position Sensor Does Your Cylinder Have?
Do you have an electronic, smart sensor cylinder?
Generally, if your cylinder has an electronic plug or port connection, position sensing is in the cylinder. Different OEM and equipment manufactures have proprietary systems, however common systems include:
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Magnetostrictive Sensors
The magnetostrictive sensor is a non-contact transducer designed to detect the position of a magnet in hydraulic and pneumatic cylinders. The sensor’s greatest advantage is that it provides absolute position information and, if there’s a loss of power, does not need to be re-installed.
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Resistive Sensors and Potentiometers
Resistive sensors and potentiometers measure positions in hydraulic and pneumatic cylinders using electrical resistance and are best-known for their ability to function even in hostile environments.
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Limit Switches
Limit switches for hydraulic and pneumatic cylinders are great at detecting the presence or absence of an object and operate using the physical force that said object applies to them. Limit switches can handle high current values, which can handle more diverse control systems than proximity sensors.
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Draw Wire Sensors
An enclosed draw wire sensor is a cable-actuated position transducer that measures linear position in hydraulic and pneumatic cylinders. These sensors are often chosen for limited space due to their compact size and flexibility.
We Serve Your Industry
You depend on pneumatic hydraulic cylinders to keep your business going to deliver essential goods and services to your customers. Damaged or leaking cylinders translate into equipment downtime that you can’t afford. When you need hydraulic or pneumatic cylinder repair, count on Cylinders Inc. We have a track record of high-quality repairs, reliable service and effective solutions.
Process
How We Repair Position Sensing Cylinders
Inspection
After receiving a cylinder, technicians will carefully inspect the cylinder and determine the sensor technology attached to the hydraulic or pneumatic cylinder. Additional information concerning the control system and the signal type may be needed if the sensor is malfunctioning. For more common electronic cylinders, Cylinders has developed workbench interfaces to read the cylinder sensor signals and determine operation. If we observe a problem with the sensor function, we contract the client to discuss the repair options.
Once the sensor is removed from the cylinder, our regular process for disassembly, cleaning, polishing and resealing proceeds.
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Repair
Our experienced hydraulic cylinder repair mechanics and technicians possess the knowledge and experience to repair and rebuild your hydraulic and pneumatic cylinders and equipment. The first step in the process is to clean and disassemble the cylinder to evaluate the repairs needed to restore cylinder performance to 100% . The inspection processes will determine:
• Check the rod and tube for straightness and in a condition to reuse.
• If the seals are damaged, installed correctly and the correct type?
• Inspect the piston, head gland for corrosion and damage. Sandblast if necessary to clean seal grooves and remove rust.
• Examine the end, clevis, trunnion or bearing mounts for wear
• Record sensor operation
Testing
Following the resealing and repair process, the hydraulic or pneumatic cylinder is tested for operation and confirmation there are no leaks. Testing is done using one of our 3 hydraulic testing benches or compressed air for pneumatic cylinders. For sensor cylinders, during the operation testing for seal performance, we verify the sensor reports the correct signal for data control.
Following successful testing, the ports are sealed and the cylinder is ready to be returned to service.
Ram Hydraulic Cylinder Repair FAQ
How much is it to repair a position sensing cylinder?
In most cases repairing an intelligent position sensing cylinder will cost significantly less than purchasing a new cylinder. For these types of cylinders, and because the cylinder is connected to a OEM specified computer operating system unique to a manufacturer, options for an economical new replacement are very limited.
Why is repairing an electronic cylinder with sensor data reporting better than getting a new cylinder?
This is a more cost effective solution. We test sensor cylinders before disassembly; if the cylinder tests as functioning normally, other diagnostics of the control system can proceed. If other faults are identified, getting a new cylinder can be entirely avoided.
How long will a smart cylinder last after a repair?
In most cases the refurbished hydraulic or pneumatic cylinder will last as long as a new cylinder. Cylinders Inc. provides a 1 year warranty on the service work we perform and the parts we replace.