Project Information
Project Name： Hydraulic Cylinder for a Wood Splitter
Order Code：HSG80/100×45×500-25MPa
Operating Pressure：25 MPa / 250 bar
Bore Diameter：80 / 100 mm
Rod Diameter： 45 mm
Project Background & Requirements
The customer required a replacement hydraulic cylinder for an existing wood splitter. The original cylinder used an integral forged construction, which involved dedicated tooling and a complex manufacturing process. Its raised oil port flange, threaded connections and installation dimensions also needed to be carefully considered when developing a replacement.
The challenge was to optimize the cylinder’s construction without compromising its compatibility with the existing equipment or its specified operating requirements. Simply matching the external appearance would not be enough—the replacement design needed to account for the 25 MPa operating pressure, critical mounting interfaces, oil port configuration and extension direction.
AiSoar reviewed the customer’s drawings and installation photos to evaluate an alternative manufacturing approach. Our engineers proposed welded construction to simplify production and reduce tooling costs while retaining the essential dimensions and connections required by the application.
Customer’s Special Requirements
The replacement design needed to address several application-specific details:
- Small-quantity production: A manufacturing method that did not require dedicated forging tooling.
- Installation compatibility: Critical mounting dimensions had to match the existing wood splitter.
- Oil port configuration: The original oil port was located on a raised flange, requiring confirmation of its position and connection details.
- Thread compatibility: Thread sizes had to be checked against the customer’s drawing and existing connections.
- Operating direction: Cylinder orientation and extension direction needed to be verified using installation photos.
- Pressure requirement: The replacement was specified for an operating pressure of 25 MPa.
The customer also needed a clear explanation of the construction changes before approving the replacement design.
Solution & Design Description
The customer needed a replacement cylinder for an existing wood splitter. Rather than simply reproducing the original forged construction, AiSoar reviewed the drawings and installation photos to identify a manufacturing approach suited to the actual application.
Our engineers assessed the specified operating pressure, mounting dimensions, oil port arrangement and threaded connections. Based on this review, we developed a welded cylinder design that retained the critical installation interfaces while changing the construction method.
The replacement drawing clearly identified the weld locations and explained the similarities and differences between the original and proposed designs. This allowed the customer to review the construction changes alongside the dimensions needed for installation.
The value of this solution came from matching the manufacturing process to the application—reducing reliance on dedicated forging tooling while meeting the customer’s replacement requirements.
Key Design & Manufacturing Advantages
1. Application-Based Engineering
We used the customer’s drawings and installation photos to evaluate the replacement requirements and select a suitable construction method.
2. Design and Manufacturing Working Together
Our engineering review considered how the cylinder would be manufactured as well as how it would fit and operate on the wood splitter.
3. Control of Critical Interfaces
Mounting dimensions, threaded connections, oil port position and extension direction were reviewed to maintain compatibility with the existing equipment.
4. Cost Optimization Through Construction Design
Changing from integral forged construction to welded construction avoided dedicated forging tooling and provided a more economical production approach for this project.
Project Result & Application Effect
AiSoar turned the customer’s replacement requirements into a manufacturable welded cylinder design, combining application review, interface verification and production process selection.
The customer subsequently reported that the first delivered cylinder was working very well and that their customer was satisfied. This provided practical feedback on the replacement’s performance in the wood splitter application.
As the customer shared after the first delivery:
“ The cylinder they you have first delivery working very good. Customer is satisfine.”
— Customer Feedback
