In industrial equipment and fluid systems, are there short-term bulges in hydraulic system hoses, serious internal wear on the hoses transporting powder, and sudden bursts of pneumatic pipelines under pressure fluctuations? Rubber hoses are not single-function connectors. Hydraulic, pneumatic, and material handling are common requirements for industrial rubber hoses, and pressure adaptation and media compatibility are the selection dimensions. Failure to meet the scene selection may lead to equipment system failure and production safety accidents. By analyzing the core differentiated requirements of rubber hoses in pressure resistance, medium compatibility, and structural design, the customized scheme is combined with the scene raw surface.
1. Pressure and medium are the core of custom hoses
In industrial scenarios, the core function of rubber hoses is to safely transport fluids, gases, and solid materials, and the pressure and medium directly determine the service life and safety:
Risk of pressure mismatch: Lower pressure will cause burst leakage, higher pressure will cause cost waste, and may also affect installation flexibility due to excessive hose thickness;
Media incompatibility hazards: different oils, chemicals, gases, particulate materials and other media will react chemically with the rubber material, resulting in swelling, cracking, and even pollution of the transmitted materials;
Customized core value: Standardized hoses cannot adapt to complex working conditions of high temperature, high pressure and strong corrosive media, and can be customized according to specific pressure, medium and installation environment, accurately matching material, structure and performance parameters to achieve accurate and adaptable safe transmission.
2. Differentiated analysis of different hoses and core parameters of the medium
The differences in application scenarios of hydraulic, pneumatic, and material handling hoses determine the core differences in pressure levels and media compatibility under working conditions:
Hydraulic rubber hose: High pressure resistance is the core, and oil resistance compatibility is the key
Hydraulic hoses are mainly used in hydraulic systems of construction machinery, machine tools, and hydraulic equipment to transmit hydraulic oil, lubricating oil and other fluids, and the core requirement is to bear high pressure and oil resistance adaptation.
Pressure Demand Differentiation:
≤10MPa low-pressure working conditions: small hydraulic equipment, auxiliary pipelines, customized single-layer braided reinforcement structure, taking into account cost and flexibility;
10-31.5MPa medium pressure working conditions: mainstream scenarios such as excavators and hydraulic machine tools require double-layer weaving or winding reinforcement structure to ensure pressure stability;
≥31.5MPa high-pressure working conditions: heavy machinery and aerospace equipment need to be reinforced by winding more than four layers of steel wire, and the blasting pressure needs to be greater than 4 times the working pressure.
Media compatibility and material customization:
Core compatible media: mineral oil-based hydraulic fluids, synthetic phosphates, hydroethylene glycol hydraulic fluids;
Customized material selection: basic selection of mineral oil resistant NBR, high-temperature hydraulic oil scene upgrade to HNBR, strong corrosive medium selection of FKM.
Core requirements:
Extremely high pressure resistance and pulse resistance: The hydraulic system usually works at tens to hundreds of bars, or even higher, and is accompanied by frequent pressure shocks and fluctuations. Hoses require a strong layer or more of wire reinforcement to withstand high pressures and provide excellent fatigue resistance.
Superior media compatibility: The inner adhesive layer must resist the erosion, swelling, and hardening of hydraulic fluids, lubricants, emulsions, and other media. Commonly used adhesive materials such as NBR are preferred due to their excellent oil resistance.
Strict dimensional stability: At high pressure, the expansion rate of the hose must be extremely low to ensure precise and efficient transmission.
Customized focus: determination of the safety factor of working pressure and burst pressure.
Pulse life test requirements.
Compatibility testing with specific types of hydraulic fluids.
Pneumatic rubber hose: stable low pressure, airtightness and anti-aging requirements
Pneumatic hoses are used in automated production lines, pneumatic tools, compressed air transmission pneumatic systems, core transmission of compressed air, inert gas, and demand-focused low-pressure seals are compatible with gas.
Pressure Demand Differentiation:
≤1.6MPa Conventional working conditions: most equipment such as cylinders and pneumatic wrenches, customized single-layer or double-layer fiber reinforcement to ensure flexibility;
1.6-4.0MPa high-pressure pneumatic working conditions: special equipment such as high-pressure pneumatic valves need to be reinforced with three-layer fiber weaving to optimize the sealing structure to prevent leakage;
Negative pressure vacuum working conditions: For vacuum adsorption equipment, it is necessary to choose materials with strong airtightness to avoid air penetration and hose collapse.
Media compatibility and material customization:
Core compatible media: compressed air, nitrogen, oxygen, carbon dioxide and other inert gases;
Customized material selection: EPDM and SBR are mainly selected with good gas permeability resistance, and oxygen transmission needs to be customized flame-retardant CR to avoid electrostatic ignition.
Core requirements:
Good flexibility and bending properties: Pneumatic tools and equipment need to be moved frequently, so the hose must be very soft for easy wiring and handling. Fiber braided threads or textiles are often used as reinforcements.
Efficient sealing: Despite the low pressure, the hose must ensure that the compressed air does not leak and maintain stable system pressure.
Abrasion and external environment resistance: Pneumatic hoses are often exposed to factory environments, requiring good wear resistance, ozone resistance, and weathering resistance. Materials such as PVC and PU are widely used due to their flexibility, wear resistance, and lightweight.
Customization Focus:
Operating pressure range, usually lower than hydraulics.
Maintains flexibility in extreme temperatures.
Color, abrasion grade and flame retardant requirements for the outer adhesive.
Material conveying rubber hose: dual adaptation of medium diversification and pressure wear resistance
Material conveying hoses are used in chemical, food, mining, building materials and other industries to transfer chemicals, food raw materials, granular materials, slurry, etc., the core requirements are medium compatibility, wear resistance, corrosion resistance and adaptation material transmission pressure.
Pressure Demand Differentiation:
≤0.6MPa low-pressure materials: food raw materials, liquid chemicals are transported, and lightweight reinforced structures are selected to ensure smooth material flow;
0.6-2.5MPa medium-pressure materials: granular materials and slurry transportation need to be reinforced with multiple layers of fabric or steel wire to resist the impact pressure of the material;
Negative pressure material (vacuum feeding): Choose a structure with thin walls but strong air tightness to avoid hose collapse.
Media compatibility and material adaptation:
Chemical acid, alkali, solvent media: customized FKM or poly PTFE lining, strong corrosion resistance;
Food-grade edible oil, beverage, pharmaceutical raw material medium: customized food-grade SR or NBR, in line with FDA, GB 4806 standards, no odor, no migration of harmful substances;
Granules, sand, pulverized coal, ore abrasive materials: customized NR or SBR outer lining, plus wear-resistant rubber layer to extend the service life;
Asphalt, high-temperature syrup and high-temperature materials: customized high-temperature resistant silicone rubber or fluoroelastomers, withstand temperature - 50°C~250°C.
Core requirements:
Extreme wear resistance: When conveying materials such as sand and gravel, grain, plastic particles, etc., the wear and tear on the inner walls is devastating. Ultra-high molecular weight polyethylene UHMWPE lining or such as SBR wear-resistant rubber is required as the inner layer.
Specific media compatibility and cleanliness:
Food grade: Conveying food and pharmaceutical raw materials requires platinum vulcanized silicone tubes or rubber that meets FDA standards to ensure non-toxic and odorless.
Anti-static: When transporting flammable dust, the hose must have a static conductive function to prevent sparks from detonating.
Corrosion resistance: When transporting chemical slurry or wastewater, the inner rubber needs to be able to resist acid and alkali corrosion, such as EPDM has excellent acid and alkali resistance.
Flexible bending and anti-blocking design: Some applications require the hose to be supported by a certain amount of spiral wire to prevent it from being pumped out and to keep the bend open.
Customization Focus:
The properties of the conveyed material abrasiveness, particle size, and temperature.
Sanitary grade FDA, USP Class VI, EC1935 and other requirements.
Whether conductive, antistatic, or food-grade certifications are required.
3. Customized hose core requirements
Clarify the core parameters of working conditions
Pressure parameters: provide working pressure, peak pressure, whether negative pressure, customized according to peak pressure or customized according to working pressure;
Media details: clarify the medium name, concentration, and temperature, and provide chemical properties for special media to facilitate matching materials;
Installation and use environment: whether it needs to be weather-resistant outdoors, whether it needs to be highly flexible for frequent bending, whether it is exposed to oil stains, and whether it needs to be protected by outer lining for chemicals.
Clarify the priority selection of media compatibility
Priority 1: The first principle is media compatibility, PTFE lining is preferred for strong acid media, and FDA certified materials are preferred for food grade;
Priority 2: Pressure adaptation, according to the pressure level, select the number of layers of fiber braided and wire wound reinforcement layers;
Priority 3: Additional properties such as wear resistance, high and low temperature resistance, flame retardant, anti-static.
The structure and size are customized to meet the needs of installation and transmission
Inner diameter size: calculated according to the flow rate of materials and fluids, to avoid pressure loss caused by too fine, and difficult installation caused by too large diameter;
Reinforced layer structure: low-pressure fiber weaving, medium and high pressure steel wire winding, granular material plus wear-resistant outer lining;
Connector customization: Customized according to the type of equipment interface to ensure that the seal is leak-free and avoid pressure loss or media leakage caused by mismatched connectors.
4. Precise adaptation of pressure, medium and scene
The customized core of hydraulic, pneumatic, and material conveying rubber hoses has differentiated adaptation, such as hydraulic hoses that are heavy and high pressure oil resistant, pneumatic hoses that are heavy and low pressure and airtight, and material that convey hoses that are compatible with heavy media and wear resistance. Only by clearly understanding the core parameters such as working pressure, medium type, and installation environment can we issue accurate customized plans.
Pneumatic Hose