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Technical Note

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  • Time of issue:2020-01-06 00:00:00
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  Pipeline connector is a main part playing an important role in a fluid hydraulic system. Aiming at several main parts, the detailed technical instructions are as follows::

  Pipe joint

  High-quality products start from high-quality raw materials. The company uses the forging die molding technique to manufacture parts forging dies, thereby greatly enhancing all functions (pressure resistance, corrosion resistance, etc.) of parts and making parts exquisite and nice in appearance and easy to install and use. If parts are processed by using forging bodies, the area of parts will be certainly increased, and their resistance to pressure and corrosion will be greatly weakened relative to forging dies. Before being processed, forging dies are subjected to shot-blasting treatment through shot blasting machines in order to prevent parts surfaces from being oxidized. This technique process has good effect of protecting the surfaces of forging die parts. Therefore, material processing is the primary issue of producing high-quality parts/products. Raw materials are out-purchased. Carbon steel is purchased from Shanghai Steel No.1 Factory, Shanghai Steel No.3 Factory, Hangzhou Steel or other companies; stainless steel is purchased from Shanghai Xingsente or Shanghai Steel No.5 Factory; aluminum alloy is purchased from Shanghai Metal Material Co., Ltd., Jiangsu Jiuhua Aluminum Co., Ltd. or other companies. Thus high quality of materials is ensured.

  High-quality imported ferrules are one of the necessary conditions of ensuring good use of pipe connectors. The company adopts imported ferrules, which have particularly good flexibility due to special design, materials and heat treatment process. After joint assembly, the middle part of a ferrule is slightly arched, producing elastic effect which avoids stress relaxation of metal contact sealing so as to ensure the long-term reliable work and repeated assembly/disassembly of the ferrule. Both the structure design and heat treatment of domestic ferrules are inferior to foreign technology, and domestic ferrules cannot be used well just because of deformation after being used only once. Moreover, compared with domestic ferrules, imported ferrules also have particularly good resistance to impact and vibration.

  Elastic sealing ring: Oil-resistant rubber sealing rings are adopted, such as NBR, fluororubber, PTFE, etc. Elastic sealing rings have good sealing performance. This structure not only can seal pressure fluid in pipes, but also can prevent air from entering systems under the circumstance of pressure loss in pipes.

  Nuts are also forging die parts, which makes integral pipe joints have integral assembly parts so as to ensure not only good service performance but also beautiful streamlined appearance. Nuts of the company are mainly imported for the moment.

  Functional nut: Different from traditional ferrules, a functional nut uses ferrule to connect elastic sealing ring, positioning ring and ferrule together through rubber in outer ring of positioning ring and inner threads of nuts so as to form a whole, namely functional nut, thus avoiding parts scattering during assembly and greatly improving assembly efficiency.

  Surface treatment: Under normal conditions, surface treatment is yellow zinc plating for carbon steel parts and acid pickling or shot blasting for stainless steel parts. Welded ends or welded joints of carbon steel welding-type pipe joints are subjected to blackening treatment, which is favorable for good welding between metal parts.

  Comprehensive test: The company adopts special manual ultrahigh-pressure pump device (pressure: Max. 350MPa) to do pressure measurement test. In several tests of the company for connection pipe joints at two ends of Φ12*1 stainless steel pipes, when pressure reached around 95MPa, the middle parts of steel pipes bulged and then burst immediately, but pipe joints at two ends, ferrules and nuts were unexpectedly free from damage or falling-off. In the test for Φ12*2 stainless steel pipes, when pressure reached around 150MPa, the middle part of steel pipes bulged and became deformed, but similarly, pipe joints were without any damage or falling-off. Such tests are limit tests also called destructive tests, which can fully show the high quality and excellent service performance of our products.

  Processing and inspection of pipe joints: The company uses full-performance CNC lathes to process pipe joints. Thread sealing forms are mainly metric threads (such as M12*1.5), UK-standard threads (such as G1″, Rp1″, R1″, Rc1″, etc.), US-standard threads (such as 7/16-20 UN/UNF), etc. Use correct 6g standard plug gauge, ring gauge and corresponding stop gauge to measure threads. Use slide caliper to measure the size of inner holes and other columns and planes. Use taper plug gauge as special tool and corresponding stop gauge to detect tapered parts. Parts subjected to surface treatment will undergo visual inspection and optical inspection, and stainless steel will undergo magnetic test. Precise test steps ensure high precision and high quality of parts.

  Whether pipe joints can achieve ideal using effect mainly depends on whether ferrules are correctly installed. Imported ferrules have ideal sealing performance and can be applicable to most working conditions, including high-vacuum sealing, micromolecule gas sealing and high-pressure hydraulic oil sealing. But the ideal function of ferrules needs correct assembly as a guarantee. Incorrect assembly will cause steel pipe falling-off, joint leakage, elasticity disappearance, drop in vibration resistance and other problems. Therefore, before assembly, users should carefully read assembly instructions in sample books or ask professional personnel of the company for assembly technology training and guidance.

  Installation instructions for pipe join

  Pipe joints installed carefully according to installation guidance can still maintain reliable connection still and sealing even if the pressure makes steel pipes burst. Experience proves that following safety instructions for operation can avoid falling-off, loosening and leakage of joints. Check installation steps in installation process.

  Use CONEXA pipe joints as connectors completely in the whole system as much as possible.

  Read the recommendation list of steel pipes, and non-standard materials or over-tolerance can lead to connection fail of joints

  Don’t seal 24° conical surface by using bearing steel balls, positioning pins or conical pins instead of tapered sealing connection pipes.

  The coordinated use of steel pipe ferrule and joint assembled together must be ensured; one joint can only be used once in preassembly.

  Air leakage on pipe joints is very dangerous under pipeline-pressurized condition.

  s pipeline assembly pressure causes connection fail under vibrating condition, calculate the length and bending angle of pipelines accurately and use pipe clamps to fix pipelines.

  Pipelines cannot be mutually clamped but should be clamped at proper fixing points. Flat brackets, cable connectors and general fixing elements are inapplicable. Pipelines cannot be used for fixing filters, ventilation pipes, stop valves or other components.

  Use hoses in order to prevent oscillation, pressure and internal stress.

  Excessively tightening joints during installation can reduce the capability of joints in bearing pressure and vibration load, thus shortening the service life of pipe joints and causing leakage on pipe joints.

  When equipment is disassembled, transported and reinstalled, ensure system cleanness, no damage of connection parts (threads or sealing surfaces), no loss of sealing rings and no bending or flattening of pipelines

  Check whether detached joints are installed correctly and damaged or not, and replace if necessary.

  Don’t use manual pipe cutter to cut pipes.

  Comply with given system parameters (e.g. pressure, temperature, medium compatibility, etc.) for model selection.

  Refer to corresponding technical data (e.g. GB/T, JB/ZQ, CE, ISO, BG, TUV, DIN, etc.)

  Use weldable materials to manufacture welding-type pipe joints. Joints made of other materials are unsuitable for welding.

  Handle joint products with care.

  Pipe clamp

  Pipe clamps are produced according to DIN3015 standard.

  According to the first part of DIN3015, there are different relevant series of pipe clamps for pipes different in outer diameter to meet the requirements for mechanical strength, wherein metric pipes are 6-57mm in outer diameter; UK-standard pipes are R1/8”-R2 1/2” in outer diameter; US-standard pipes are R1/4”-R2 1/2” in outer diameter. Pipe clamps are of round closed design. Welding plates, supporting guide rails, top cover plates or combined installation accessories can be chose according to different requirements.

  According to the second part of DIN3015, there are different relevant series of pipe clamps for pipes different in outer diameter to meet the requirements for mechanical strength. The suitable outer diameter of pipes is 6-42mm. Pipe clamps are of round closed design. Welding plates, supporting guide rails, top cover plates or combined installation accessories can be chose according to different requirements.

  According to the third part of DIN3015, there are different relevant series of pipe clamps for pipes different in outer diameter to meet the requirements for mechanical strength. The suitable outer diameter of pipes is 6-220mm. Pipe clamps are of round closed design. Welding plates, supporting guide rails, top cover plates or combined installation accessories can be chose according to different requirements.

  Design of pipe clamps

  According to DIN3015, the top half and bottom half of a pipe clamp are identical. Web bars in pipe clamp holes have the function of obstructing vibration and impact, and can absorb axial force acting on pipes.

  For application to hoses and cables, pipe clamps with smooth inner holes are recommended.

  Materials of pipe clamps

  Polypropylene -30℃~+90℃ blackish green

  Polyamide -40℃~+120℃ black

  Rubber -50℃~+120℃black

  Aluminum up to 300℃

  Discuss separately for special materials as required

  Accessory materials

  Bolts and the top cover plates adopt carbon steel or galvanizing.

  Stress bearing capability

  Our pipe clamps have the outstanding characteristics of ideal elastic recovery capability, high tensile strength, high vibration resistance and ideal low temperature resistance

  The choice of the forms and materials of pipe clamps depends on different requirements of working conditions for machinery and temperature.

  nstallation of pipe clamps

  Installation instructions

  Installation of welded plates

  Weld the metal welding plate of a pipe clamp to a machine body, press the lower plate body of the pipe clamp into the welding plate, insert the steel pipe needing to be fixed, put the upper half part of the pipe clamp on, and then screw up by using bolts.

  Caution: Plastic pipe clamps must be taken down when welded! When lengthened welding plates are used, the lengthened parts can be fixed on machine body through bolts.

  After a pipe clamp is assembled and screwed up, the top and bottom halves of the pipe clamp mustn't have contact.

  Installation of guide rails

  The delivery length of guide rails is 1 or 2 meters. You can use welding or screws to fix a guide rail to installation surface. Insert fixation nut into the guide rail and rotate the nut to the end, press the bottom half of pipe clamp into the fixation nut, put the steel pipe needing to be fixed on, put the top half of the pipe clamp on, and then screw up by using bolts.

  aution: After a pipe clamp is assembled and screwed up, the top and bottom halves of the pipe clamp mustn't have contact.

  Stack-up installation

  Stack-up installation bolts and locking plates are needed. Weld welding plate or guide rail to a machine body, press the bottom half of pipe clamp into the welding plate or fixation nut, put down steel pipe, put the top half of the pipe clamp on, press and screw up the stack-up bolt (bolt head should protrude from the surface of the pipe clamp), put one locking plate on the pipe clamp to make the bolt incapable of rotating, and then install the second pipe clamp which should be installed by using common fixating bolts without locking plates

  Recommended size of installation interval of pipe clamps

  The recommended size of installation interval is in the table below, applicable to the static load condition.

  Used for the installation of pipe clamps for bent pipes.

  Pipe clamps should be installed near elbows as far as possible.

  Quick joint

  Main components and characteristics of quick joint are as follows:

  Locking casing: Change the relative position of steel ball in cavity through simple axial movement so as to realize locking after connection and separation during disconnection;

  Casing spring: Can ensure immediate elastic reset of casing and effectively realize the locking effect of steel ball;

  Steel ball cavity: Can flexibly guide the locking steel ball, have reliable axial locking torque and allow certain rotation between plug and socket in order to prevent the distortion of hoses before pressurization;

  O-shaped sealing ring: Ensure enough sealing effect and no leakage between plug and socket after plug is inserted in socket;

  Extrusion-proof ring: Extrusion-proof ring in appropriate shape has plastic deformation for O-shaped sealing ring during connection and disconnection;

  Valve: Valve equipped with static sealing element ensures loop closure and immediate sealing at the moment of disconnection through its automatic axial movement; both the structure and shape of the valve can ensure that it can completely and safely withstand high pressure even in critical situation; its internal reasonable structure ensures full opening after connection to reach the standard flow corresponding to nominal diameter;

  Valve spring: In the disconnect state, valve spring gives valve enough axial thrust to ensure the effective cooperation of valve and base, thereby ensuring good sealing property even in case of low-pressure disconnection. Under special circumstances, appropriately increasing the calibration tension of valve spring can avoid the trouble caused by high vibration, vacuum resistance, etc;

  Check ring: Check ring, in axial arrangement, is capable of keeping the relatively fixed position of internal structure, and plays a role in mechanical brake of the opened valve so as to ensure balanced opening regardless of flow direction.

  Use of quick joint In general, one end of quick joint is connected with a rubber pipe, and the other end of quick joint is connected with oil cylinder, air cylinder or other equipment or is equipped with a transition joint so as to be connected with pneumatic/hydraulic elements having various standard threads, and can also be connected with nut and connection pipe and be welded to steel pipe through connection pipe. After two ends are appropriately connected with respective pipelines, the operational connection of quick joint can be carried out. Move the casing shaft backwards to leave radial space for the locking steel ball, insert plug into socket, and then release the casing; the casing will be automatically reset through the action of the casing spring; the locking steel ball is forced to lock the plug. Thus connection is completed.

  Application notes for quick joint:

  1. Fluid passing through the quick joint should be filtered so as to prevent impurities in fluid affecting the opening/closing and sealing performance of the quick joint valve and causing leakage;

  2. Two ends of the quick joint mustn't be directly welded to other pipeline parts or pipes in order to avoid burning out steel ball, sealing ring and other parts and causing parts deformation and leakage;

  3. For safety purpose, fluid pressure in pipelines should be eliminated in general when the quick joint is assembled or disassembled;div>

  4. When pipelines are in assembly or use, using hammers to beat or using weights to press the quick joints is forbidden;

  5. When used on pipelines of vibration (pneumatic) impact tools of compressed air, quick joints should not be directly installed on the interfaces of vibration tools;

  6. After quick joints are disassembled in the occasions with much dust and sand, plugs and sockets should be provided with dustproof plugs and dustproof caps respectively in order to prevent dust from entering quick joints.

  The company produces pipeline connectors and professional parts in strict accordance with the following standards: national GB/T and JB/ZQ standards, international ISO 8434 standard, and German DIN2353 and DIN3015 standards. The professional German manufacturer of pipeline connectors, with strong advanced technical experience, guarantees the security of our products even in severe working condition of machinery, physics and chemistry.

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No. 1077, Nanyuan West Road, Qidong City, Jiangsu Province





Time of issue:2020-01-06 00:00:00
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