From industrial manufacturing to robotics and steel processing, hydraulic systems have a broad range of functions and applications. They are similar to pneumatics, which use easily-compressible gas to perform tasks. However, hydraulic systems use incompressible liquids as their fluid instead of a compressible gas. As a low-cost, efficient way to create movement, repetition–hydraulic systems are preferred over other methods in the industry.
To effectively use these systems, workers should understand the risks and potential hazards associated with hydraulics. If they are not aware of its extreme fluid pressure, maintenance, and heavy workload, your employees could be in serious danger. Thankfully, various safety measures significantly reduce the risk of injury or death.
Our hydraulics safety precautions guide will go over common hazards and precautions to help you and your staff stay out of harm’s way.
How Does A Hydraulic Press Work?
In their simplest form, hydraulic press systems use a pump that pushes fluid throughout the machine to create energy. The fluid then enters a set of valves and flows to the cylinder, where hydraulic energy changes back to mechanical energy. These valves also help control the liquid’s movement and relieve pressure, when necessary.
There are several types of hydraulic press systems on the market. Depending on your application or industrial setting, you will most likely use one of the following:
- An Arbor press uses a narrow range to support the disposal, seating stamping, manufacturing, and repairing of equipment.
- An H Frame press (or four-column) is the standard in many businesses and has become popular for its renowned versatility. They are used to straighten, bend, shape, stamp, or cut metal objects.
- C Frame press systems are relatively smaller than H frames but maintain similar utility and flexibility in a light, yet compact build.
- A Custom press can be designed for a company’s personal needs and specifications.
- Press brakes were created for sheet metal and plate material. They are used to clamp and bend items in preset locations.
Although these machines make work easy and productive, they are still highly dangerous and can break down if it is not properly maintained.
Common Causes of Hydraulic System Failure
Whether you have a custom press or four-column frame, hydraulic systems can fail. After a while, presses may show wear and tear in critical areas. However, many damages can be prevented with regular maintenance checks and care.
Let’s take a look at five common reasons why hydraulic systems fail, along with electric and hydraulic tool safety practices.
1. Maintenance
In order to keep your hydraulic press at optimal performance, maintenance is critical. We recommend that you organize a six, nine, or 12-month schedule and record progressive data. This will help keep the equipment in peak condition while extending its lifespan. Here are some parts and functions to review during evaluation:
- Hoses
- Oil leaks
- Ram Speed
- Wire tightness
- Oil temperature
- Electrical Fuses
- Solenoids and relays
- Oil level and particle count
- Hydraulic fittings for tightness
- Coupling and insert for tightness
- Pressure adjustment for full range
If these functions aren’t checked regularly, presses can experience costly failures. Daily inspection and standard maintenance are recommended to preserve its service life and–most of all–keep workers safe.
2. Pinhole Leaks
Pinhole leaks can release toxic fluid at more than 600 feet per second. Although they may be hard to find at first glance, pressure switch technology will notify the user of a leak before there are any visible signs. It’s still important to check your hoses during inspection to ensure proper utility.
3. Improper Couplings
Another dangerous hazard is improper coupling of low-and high-pressure systems. You and your employees should never attach a high-pressure pump to a low-pressure system because component, hose, or fitting ruptures can occur.
4. Component Removal or Adjustment
Servicing a hydraulic system while the machine engine is running will likely cause bodily damage or death. Do not remove any components while the working units are resting on the ground, safety stands, or blocks; remember to always shut off the engine when doing so.
5. A Low & High-Pressure Alarm
Removing or adjusting components without releasing the pressure can expose workers to three kinds of hazards: burns from hot, high-pressure fluid; bruises, cuts, or abrasions from flailing hydraulic lines, and hydraulic injection of fluid into the skin.
To avoid these common errors, be sure to educate yourself on hydraulic press systems and follow instructions with caution.
Protect Your Industrial Operations With CCS
With better knowledge of hydraulic safety precautions, you and your team can increase productivity, quality, and raise employee morale. At CCS, we make an effort to deliver top-grade pressure or temperature switches, cutoff switches, and emergency shutdown switches for those in industrial hydraulics. The 604P and 6900P series pressure switches specifically work best with hydraulic applications.
For more information about hydraulics safety, check out this article about effective system management or contact us directly.