Analysis of the main directions for improving the operational reliability of hydraulic cylinders

Abstract

The article analyzes the key factors influencing the operational reliability of hydraulic cylinders, which are critical components in the hydraulic systems of mining and metallurgical machinery. The relevance of the study is due to the high share of failures in hydraulic actuators under extreme working conditions such as high pressure, dust, and vibrations. The paper emphasizes the importance of considering reliability indicators at all stages: design, manufacturing, and operation. The purpose of the research is to identify the causes of wear, assess quality indicators, and propose design improvements. Particular attention is given to the manufacturability of hydraulic cylinders, with a detailed analysis of structural indicators including reliability, functionality, and economic efficiency. Quantitative indicators for design assessment are proposed, based on technological characteristics and statistical analysis of failure rates.
The article describes the methodology for determining key reliability parameters, such as mean time to failure (MTTF), service life before overhaul, and labor intensity of repairs. It demonstrates that the critical parameter in most failures is the wear of seals, which is influenced by working pressure, material properties, surface treatment, and fluid purity. The analysis highlights the role of standardized and unified elements, and the advantages of modular and threaded construction in increasing serviceability and lowering costs. The conclusions summarize the recommended directions for improving hydraulic cylinder reliability, including the use of protector seals, improved materials and coatings, enhanced filter systems, and design modifications to simplify repairs and assembly. The study also emphasizes the importance of aesthetic and patent-related aspects for competitive product development. Particular attention is paid to the potential of implementing digital technologies for condition monitoring and predictive resource analysis, enabling a transition toward intelligent maintenance of hydraulic equipment.