Project
Customized Hydraulic System Integration Solution for a Shandong Machinery Manufacturer (May 2023 – March 2024)
The client, a Shandong-based mechanical equipment manufacturer specializing in large cargo cranes, previously relied on domestic procurement or imported hydraulic equipment from a foreign brand for its hydraulic systems. This resulted in issues such as unstable supply, high failure rates, and frequent maintenance needs, necessitating a localized service solution to address timely delivery and cost control.
Our company provided a hydraulic pump system adapted for crane equipment, with:
● Rated pressure ≥35MPa and flow volatility ≤5%;
● A full set of hydraulic circuit solutions compatible with the crane's existing electrical control system;
● Achieved over 20% cost reduction while meeting ISO9001(2015) standards.
Solution:
1. System Structure Design
● Main Pump Selection: Independently developed swashplate axial piston pump (displacement 80cc/r, peak pressure 42MPa), adapted for closed hydraulic circuits to reduce energy loss by 26%.
● Redundancy Design: Dual-pump parallel scheme (main pump + emergency pump) with MOOG RKP series servo valve groups to achieve dynamic flow compensation.
● Intelligent Control: Integrated CAN bus communication module supporting remote diagnostics and real-time feedback of pressure/flow parameters.
2. Product Adaptation and Optimization
● For the high salt-fog environment in ports, the pump body surface uses a nickel-based alloy coating (corrosion resistance grade C5-M).
● Matched with Rexroth A2FM series motors, optimized hydraulic pipeline layout to reduce the number of 90° elbows and lower turbulence risks.
Implementation Process
1. Joint Development Phase (2023Q2)
● Dispatched an engineer team for 3 weeks of on-site work to complete mainframe structure surveying and working condition simulation tests.
● Built a hydraulic system digital twin model based on Matlab/Simulink to verify the load response characteristics of the pump unit.
2. Production and Delivery Phase (2023Q3)
● Enabled a flexible production line with a capacity of 500 units/month, achieving IT5-level precision for key components (plunger pairs, valve plates).
● Completed the first batch of 200 pump units within 48 hours.
3. Testing and Validation Phase (2024Q4)
● Passed 200-hour continuous full-load operation testing (pressure 35MPa, oil temperature 65±3℃).
● Completed 100,000 start-stop fatigue tests with leakage ≤0.1ml/min.
Results and Value
● Performance Compliance: System pressure increased to 38MPa, flow controlled at 3.8%, energy consumption reduced by 18%.
● Cost Optimization: Overall procurement costs decreased by 22%, and delivery cycles were shortened to 6 weeks (50% reduction from the original plan).
● Market Expansion: The client secured 1,200 new orders in 2025, simultaneously driving cooperation with Shandong-based affiliated manufacturers.
