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Hydraulic hoses and fittings play a vital role in the fluid power transmission in hydraulic equipment. Construction and mining equipment will continue to be a major growth driver for this segment.

As construction and mining equipment work in extreme environments, sturdy and reliable hose and fittings are important for the proper function of a hydraulic system and the entire equipment. From selection of the right hose, to storage, installation in a machine and operation influence the life of a hose. The weakest part of hydraulic hose is the connection of the hose to the fitting, which is why proper fitting selection and installation is essential in high pressure applications.

Neglecting the hoses on a hydraulic machine can become costly for a machine. 鈥淭o transmit hydraulic power from one component to the other, hydraulic hose and fittings play a vital role. The beauty of the hose is its flexibility and it enables the machine designer to optimise the space,鈥� said a spokesperson from Gates India.

Selecting the right hose

It's not as easy to make a superior hose, it needs a complete know-how about the materials used. Quality of the hose is dependent on the design and quality of the rubber compounds, reinforcements used in the hose, fitting design and compatibility. The hoses should be able to withstand the severe pressure cycling, flexing, elevated temperatures, abrasion of the hose against the machine body or other hoses. All these have an impact on the life of the hose. Hose is typically constructed of three parts: an inner tube that conveys material, reinforcement and a protective outer cover. Cover protects the tube and reinforcement from heat, abrasion, corrosion and harsh environmental conditions. It is made of rubber, fibre braids, polymers or a combination depending on the application.

Reinforcement determines working pressure and impulse resistance. Wire reinforcement provides the hose the necessary strength to resist internal and external pressures.

Braided hose is typically made of wire or textile, with one or multiple layers and typically used for medium- to high-pressure applications.

Spiral hose, made of four or six alternating layers of high tensile steel wire handle high to extremely high pressures for longer service life on high impulse applications.

Helical hose, coil reinforcement prevents the hose from collapsing during suction transfer from reservoir to pump.

There are many types of industrial and hydraulic hoses - all designed for a particular application or several related applications. Selecting the right hose for a particular application is crucial for the smooth function of an equipment. Khanna elaborates, 'Proper hose selection is the first step in preventive maintenance. Selecting the best product for the application will allow to obtain the maximum life expectancy from the product for the most value. Various factors to be consider are: where is the hose used, what kind of machinery is used, what's the ambient temperature, what is the required bend radius: along with various external conditions. To ease out, Gates recommends to follow simple step to follow STAMPED, an acronym, which means Size, temperature, application, material to be conveyed, Pressure, Ends or couplings, Delivery (volume and velocity).'

It is critical that the hose and coupling manufacturer are the same. Khanna cautions against the practice of mix and match hose and couplings from various manufacturers. This is very important for ensuring the safe working of the assembly.

The selection process for proper hose and couplings can sometimes seem overwhelming and complicated. When in doubt it is best to contact the local hose manufacturing representative who can assist in the selection of the best hose and couplings for a particular application.

鈥淓very application demands something different or special and hoses are being developed keeping this in mind,鈥� says Venkatesh S Aiyer, Director, Uniflex.

On the basic application requirements, the spokesperson from Gates adds, 鈥淯sually in construction equipment, mining equipment and forklifts, where the relative motion among the components such as the boom, bucket and forks, vibration and pressure surges are the basic requirement of application where hose plays important role. Fittings provide the convenience of routing with different bend angles, sealing methods etc.鈥�

Tubes are made from a variety of compounds, the tube must resist damage and deterioration from conveyed material as well as the effects of temperature extremes. According to Shandar Alam, Director - Sales and Service, Vehicle and Hydraulics Businesses, India, Eaton, the technology is fast shifting towards more compact machines with higher productivity, more efficiency, and reliability and with guarantees on uptime. He says, 'OEMs are developing new generation machines and equipment with simplified designs and architecture that improve the overall efficiency. Adoption of mechatronics, i.e. integration of hydraulics with electronics is the future. Use of diagnostics and prognostics on hoses for conditioning and monitoring, smart connectors and 3D printing technology are some of the major technology trends we foresee in hose and fittings market.鈥�

Types of hose and applications

According to Gates鈥� spokesperson, in high or extremely high pressure applications spiral hose which meet the SAE 100R12, R13 & R15 or EN856 4SH & 4SP hoses are used. For medium pressure applications, wire braid family hoses which meets SAE 100R1, R2, R16, R17, R19 or EN853 1SN / 2SN or EN857 1SC / 2SC hoses are used. For low pressure application, yarn braid family hoses which meet SAE100R3 and R6 hoses are used. For suction application, helical family hose is used. SAE100R4 meets these requirements.

Hose manufacturers have been continuously working on the development of hoses and fittings with innovative features material technologies to meet the emerging demands from the user industry. For example, Gates has developed innovative MXT, Multimaster and MXG hoses which are compact and can be used for multiple applications.

Safety

Lack of awareness among customers about a hose assembly may lead to premature failure. 'The awareness of the importance of safety in hydraulic hoses has increased significantly and customers are preferring quality products.

Most of the leakages happen at the interface of hose and coupling, but some people resist to change, preferring local fittings available in market at cheaper prices over a validated coupling from the manufacturer. Gates offers a high performance and safe hose and coupling system, which we insist our customers to buy to get maximum output and to reduce down time. It is always preferable to buy fittings directly from hose manufacturers, which are manufactured and validated as per industry standards for leak-free performance.

Alam agrees as he says, 鈥淐ertainly, a lot of awareness related to safety and leakage is being created in the hydraulics industry. Nowadays OEMs are looking for more robust hoses which will not only eliminate leakage problems but also improve the overall efficiency of the system. Preference for fire-resistant hoses is increasing in critical applications like steel mills and molten metal furnaces to improve safety.鈥�

Looking ahead

The market is going through tough situations owing to the Covid-19 pandemic attack and the subsequent lockdown. However, with the economy is in the unlocking mode and more segments are opening up, the market is limping back to normalcy. Though this year will go slow on recovery, next year onwards, the market is expected to be back on track. In the new changing market scenario, there is an increased requirement of components like hose and fittings sourced locally can create a better impact in time and economy for the customers. This is possible through producing and supplying these products locally.

When the market is slowly returning to the growth path post-Covid, the new practices and approaches will definitely aid in the continued growth of the hose and fittings sector.