Excavator Accessories - Hydraulic Scissors
Hydraulic shears (hydraulic pliers): efficiently cut steel bars, H-beams, beams, columns and other metal components with strong shear force, widely used in steel structure demolition, scrap steel treatment, bridge dismantling and other working conditions. Behind the efficiency of a 23 ton excavator swinging a hydraulic shear at a demolition site, cutting 12 steel bars per minute, lies the evolution of hydraulic shear from a "bulky tool" to an "intelligent blade" over the past decade.
1、 Material Innovation: Dual Breakthrough in Wear Resistant Alloys and Structural Design
The core combat effectiveness of hydraulic shears first depends on the material and structural design. In the early days, ordinary alloy steel was used as the cutting edge, which was prone to curling when cutting steel bars and needed to be replaced after an average of 300 hours. The new generation of hydraulic shears has achieved triple upgrades:
Blade material: Made of 60Si2MnA high-strength spring steel substrate and tungsten carbide coating (hardness ≥ 500HB), with wear resistance three times that of traditional materials. The 23 ton excavator equipped with this type of cutting blade has a lifespan of over 800 hours in scrap steel processing.
Structural reinforcement: The double cylinder articulated support design (such as Shanghai Pengcheng's patented technology) disperses shear stress through a symmetrical rib plate layout. After the application of a 15 ton excavator, the failure rate of bracket cracking decreased by 60%.
Lightweight breakthrough: Q460D high-strength steel plate replaces traditional cast steel parts, reducing the total weight of 15 ton hydraulic shear by 18% and significantly reducing energy consumption of small equipment.
2、 Technological breakthrough: from doubling power to intelligent control
Hydraulic system upgrade
Dual cylinder collaborative technology: Shanghai Pengcheng's patented "scissor arm lower bracket" achieves precise synchronization of dual oil cylinders, with a shear force deviation of ≤ 5%. After the application of a 23 ton crawler excavator, the cutting efficiency of H-beams has increased by 50%.
Adaptive flow control: The intelligent valve group dynamically adjusts the oil pressure based on the hardness of the material (such as the accumulator intervention technology of the 1000T hydraulic shear). When a 15 ton excavator cuts steel bars, it automatically increases the pressure by 30%, while switching to energy-saving mode when processing aluminum reduces fuel consumption by 22%.
Quick change and protection innovation
The 30 second quick change system enables a single 23 ton crawler excavator to quickly switch between multiple functions such as cutting and crushing, increasing equipment utilization by 40%.
The high-temperature protection system integrates an air-cooled mechanism (semi-circular frame+multi-directional air nozzle), which continuously delivers 0.3MPa compressed air to the sealing components, solving the problem of high-temperature failure of the sealing ring during steel billet shearing, and extending the fault interval by three times.
3、 Development Process: History of Three Generations of Technological Iterations
1. First generation (before 2010): single cylinder drive+welded bracket, 23 ton excavator needs multiple pressures to cut steel bars, and the failure rate of oil pipe winding exceeds 35%.
2. Integration period (2011, 2020): Modular valve groups and dual cylinder structures are popularized. The Shanhe Intelligent SWRM155W multifunctional platform enables quick switching between hydraulic shearing and belt opening attachments, making the 15 ton wheel and shoe dual-use equipment the mainstay of forest fire prevention engineering.
3. Intelligent era (2021 present): AI cutting parameter self-learning system is put into application. By optimizing the oil pressure curve based on historical data, the 23 ton excavator achieved a cutting accuracy of ± 2mm during the dismantling operation of waste vehicles.
4、 Maintenance points: Full cycle maintenance strategy
Hydraulic system management
The replacement cycle of hydraulic oil strictly follows the standard of "first 150 hours → second 300 hours → subsequent 1000 hours"; The filter element must be replaced if it is clogged by more than 20%. A steel plant suffered a loss of over 200000 yuan due to the failure of a filter element, resulting in damage to the main pump of a 15 ton excavator.
Cold region operations require the installation of oil circuit insulation covers to maintain oil temperature ≥ 60 ℃ (the failure rate has decreased by 70% in a tested environment of 30 ℃ in Heilongjiang Forest Farm).
Sealing system protection
The piston rod adopts a threaded protective sleeve+WD40 anti rust spray dual safety. The case of a steel rolling mill shows that the unprotected 23 ton excavator piston rod has a half year pulling rate of 80%, which decreases to 5% after protection.
The inventory of sealing rings is reserved at 1.5 times the replacement cycle, with priority given to high-temperature resistant models made of fluororubber material.
5、 Fragile parts management: the core of cost control
Four key component replacement standards and cost optimization plan:
1. Cutting edge: If the blade wear exceeds 3mm or the breakage exceeds 5%, it needs to be replaced. Adopting a four bladed rectangular design, it can be flipped and used 4 times, reducing the cost of single cutting by 60%.
2. Sealing components: including guide sleeve O-ring (every 500 hours) and piston rod seal (every 800 hours). The coal mining machine case shows that widening the guide sleeve design reduces oil leakage faults by 90%.
3. Oil cylinder piston rod: If the surface chromium layer falls off by more than 2cm ², it must be repaired, otherwise it may cause chain damage to the sealing ring.
4. High pressure oil pipe: If the surface crack depth is greater than 0.5mm, replace it immediately. It is recommended to increase the pressure resistance of metal braided hoses by 40%.
Typical case: After a demolition company in Fujian equipped a 23 ton crawler excavator with intelligent hydraulic shears, the efficiency of scrap steel recycling increased from 80 tons/day to 200 tons/day, and the equipment investment payback period was shortened to 5 months.
Future vision: The combination of lightweighting and intelligence
With the carbon fiber shearing arm (reduced by 30%) and hydrogen hydraulic system (8-hour endurance) entering the testing phase, hydraulic shearing is undergoing a new round of evolution. According to data from Shanhe Intelligent Laboratory, a 15 ton electric excavator equipped with AI hydraulic shears can reduce energy consumption by 40% and noise by 60%. The 5G remote cutting system enables the 23 ton crawler excavator to achieve safe operation of "human-machine separation" in hazardous waste treatment.
From wear-resistant alloys to predictive maintenance, hydraulic shears have evolved from auxiliary attachments to "profit multipliers" for 15 ton and 23 ton crawler excavators. The new generation of products that integrate dual cylinder collaboration, intelligent oil control, and wear-resistant coatings are continuously reshaping the efficiency boundary in the fields of dismantling engineering and resource recycling - and the evolution of this "steel blade" is just beginning.
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