The manufacturer’s truck-mounted loader cranes feature high-tensile steel construction, reliable seals and protective covers that resist weather and impact. The cranes undergo a punishing series of lab and field trials to meet a range of different demands, including air-transportability, climate/terrain conditions or specialised installations.
A common denominator among the variants of truck-mounted loader crane produced by the manufacturer is the need for reliable, yet low-weight hydraulic steel tubing and fittings. With any vehicle, weight has a direct influence on fuel economy.
When it began to experience one or two field failures of its standard hydraulic tubing due to incumbent pressure levels and mechanical stresses, the manufacturer spotted an opportunity to make simultaneous improvements in two areas: weight and strength.
The primary objective was to reduce weight across the loader crane; less weight means less load and less fuel consumption for users. It was essential to achieve this project goal in unison with delivering extra reliability to prevent tubes from cracking or bursting. Unfortunately, the side-load function of the loader crane exacerbates the potential for this unwanted outcome by imparting high mechanical stress on the tubing.
In the first instance, higher strength E355 grade tubing with thinner wall thickness replaced standard E235 tubing on the loader cranes. E355 seamless cold-drawn tubing offers higher tensile strength than standard tubing, but at a lower net weight. The elevated strength of E355 allows users to achieve similar operating pressure for thinner tubing. In this case the manufacturer was able to switch from 16mm diameter, 2 mm thick E235 tubing, to 16 mm diameter, 1.5 mm thick E355 tubing. The 0.5 mm difference in wall thickness reduces the weight from 0.69 to 0.54 kg/m (a 22% saving).
With the material identified, thoughts turned to assembly and Eaton’s series of Walterscheid fittings, connectors and tube-forming technologies. Although Eaton and the manufacturer enjoy a close working relationship that extends back a number of years, there was a clear need to avoid underestimating the importance of tube forming and fittings in this application.
“The loader crane is very demanding in terms of operating pressure and dynamic pulsation, while strong axial and radial forces also place additional stress on the tube assembly,” outlines Eaton Hydraulics Spain sales engineer Juan Moreno.
Eaton’s Walterscheid WALFORMplus-SR system is suitable for thin-wall tubing such as the 16x1.5 mm product identified for this application. An additional support ring (SR) located behind the formed tube increases resistance to vibration and bending stress. Using WALFORMplus-SR, it was possible to undertake tests that would help draw comparisons against the previous tubing solution.
WALFORMplus-SR is a positive-locking, cold-forming tube-fitting system for increased safety, even under extreme loads. The mechanically reshaped tube-end screws together using an additional support ring, as well as a conventional DIN/lSO stud and a DIN/lSO union nut. Moreover, the only possible leakage path is sealed-off in two ways: first by the WALFORMplus soft seal, and second by means of the metal-to-metal seal between the WALFORMplus shoulder and the fitting stud. Thanks to the positive-locking connection and additional support ring, WALFORMplus-SR ensures secure retention and greater resistance to dynamic loads, Eaton says. This was backed up in simulated pressure impulse and bending stress tests in the Eaton Walterscheid laboratory, and then again in the field.
In addition, the manufacturer also uses Walterscheid Guardian Seal plating, a zinc-based surface treatment applied by electroplating. The 11-15 µm thick zinc guarantees exceptionally high levels of durable protection against corrosion and meets DIN EN ISO 9227 standards.
Today, WALFORM machines located on the manufacturer’s production lines across Europe are delivering repeatable steel tube assemblies for the company and its customers. Automating the process is the best way to ensure excellent tube-fitting performance. For this reason, Eaton manufactures its own bespoke assembly machines to optimise the production of Walterscheid systems. The company produces around 80 such machines in-house every year, alongside the associated tooling.
For WALFORM (6-42 mm diameter), Eaton offers the reliable M-WF385Xplus, which suits demanding tube-forming applications in steel and stainless steel. Tools are colour-coded to avoid mistakes in the forming process.
Ultimately, the WALFORM machines are delivering repeatable assembly, reducing any potential for misalignment of fittings and, in turn, creating less opportunity for hydraulic fluid leakage. With reduced weight and reliable strength, this sector-leading manufacturer of load-handling equipment has received a notable lift in the number of USPs it can now offer to customers.