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When it comes to reliability in industrial hydraulic systems, quality is not an option but an absolute necessity. 100% cylinder testing is a quality control procedure that involves verifying every single product rather than relying on sampling. The goal is operational excellence, because a hydraulic cylinder that fails during a production process can cause costly machine downtime, compromise operator safety, and damage a company's reputation. For this reason, hydraulic cylinder testing represents a critical phase of the manufacturing process.
In the industrial hydraulics sector, manufacturers do not always subject their cylinders to comprehensive verification before delivery. Testing is often limited to spot checks, with partial tests carried out only on certain batches. Conforti Oleodinamica has chosen to subject every cylinder to full testing in accordance with the international standard ISO 10100, with systematic recording of results.
The ISO 10100 Standard: the reference for cylinder testing
ISO 10100 defines international standards for acceptance and performance testing of hydraulic cylinders. This technical specification establishes rigorous procedures for verifying the structural integrity, sealing, and operational performance of every component.
Testing according to ISO 10100 involves the application of test pressures that significantly exceed nominal operating pressures: 240 bar for tie-rod cylinders ISO 6020/2 of the CD and DK series, 315 bar for HD and HK cylinders with cap flanges, and 375 bar for ISO 6022 cylinders of the DP series intended for heavy-duty applications.
These values represent exactly 1.5 times the nominal operating pressure of the cylinders.
Applying a test pressure higher than the working pressure makes it possible to verify that every component has adequate safety margins and that any latent defects emerge before the cylinder is put into service.
Pressure test to verify structural integrity
The pressure test is the most critical moment in the testing process. During this phase, each cylinder is connected to a specialised test bench that gradually brings the system up to the specified test pressure. This process enables the simultaneous verification of the structural resistance of the barrel and end caps, the integrity of the seals, and the correct tightening torque of the mechanical components.
The gradual increase in pressure allows the behaviour of the cylinder to be monitored throughout the process, detecting any anomalies before they can develop into failures. During the hold at maximum pressure, technicians verify the absence of external leaks and monitor pressure stability over time.
Particular attention is given to critical points: the connection zones between end caps and barrel, and the areas where the rod passes through the seals.
Stroke verification and dimensional tolerances
In accordance with ISO 8131, the stroke must comply with a tolerance of 0/+2 mm with respect to the nominal value requested by the customer. A cylinder with a nominal stroke of 500 mm may have an actual stroke of between 500 and 502 mm, never less than the nominal value.
During testing, it is also verified that the ground and chrome-plated rod slides smoothly within the bronze guide bushings.
Optional components: sensors and transducers under test
The complexity of testing increases significantly when cylinders are equipped with optional components such as magnetic sensors or position transducers. Cylinders with magnetic sensors of the MD series require specific verification procedures.
For HD and HK cylinders fitted with end-of-stroke sensors integrated into the end caps, manufactured in stainless steel with protection rating IP69K, testing includes verification of the correct operation of the detection system. These sensors are supplied already correctly mounted on the cylinder and tested prior to delivery. Servo-cylinders with position transducers of the TD, TK, TH, TX, and TP series are equipped with magnetostrictive linear transducers that enable precise, continuous position detection of the piston along the entire stroke.
Material quality: control from the source
The final test represents the last verification in a quality process that accompanies every cylinder from the start of production. The ground and chrome-plated rod reduces seal wear and guarantees optimal performance over time.
Bronze guide bushings offer excellent sliding properties and protection of the chrome-plated rod surface. Seal groove dimensions comply with ISO standards, ensuring easy availability of spare parts on the market. Steel end caps are inspected to ensure the absence of surface defects that could compromise seal integrity.
Systematic recording for complete traceability
Every cylinder that passes testing in accordance with ISO 10100 has its data recorded in the Conforti Oleodinamica information systems. This complete traceability makes it possible at any time to retrieve the specific characteristics of the cylinder, the test pressures applied, and the values measured during the checks.
Systematic recording constitutes a valuable knowledge base for the continuous improvement of production processes and for the analysis of performance over time. In the event that technical assistance is required, having the complete history of the cylinder enables qualified support to be provided and any issues to be identified promptly.
A cylinder tested individually offers guarantees that no sampling-based inspection can provide.
Systematic recording of results ensures complete traceability and qualified technical support even years after purchase. To explore the technical characteristics of the various cylinder series or to discuss the specific requirements of your application, the Conforti Oleodinamica technical team is available to provide personalised consultancy.