Danfoss Power Solutions
Choosing the right hose for high-pressure hydraulic systems ensures machine performance

Braided Hydraulic Hose Meets High Pressure Needs of Electric Backhoe

March 27, 2024
Replacing spiral hydraulic hoses with braided hoses offered cost and weight savings for a mobile equipment manufacturer without compromising on its high-pressure requirements.

Spiral hydraulic hoses are commonly used on mobile equipment as they can manage the high pressures required by these machines. But when a major OEM was developing the next generation of its electric backhoe loader, it discovered the high-pressure fluid conveyance components it previously used did not provide the same performance.

The equipment manufacturer reached out to multiple suppliers for a hydraulic hose that would meet the 3,800 psi working pressures of its electric backhoe. In its RFQ (request for quotation), the OEM specified SAE 100R12 four-wire spiral hoses.

However, engineers at Danfoss Power Solutions saw an opportunity for the manufacturer to utilize a two-wire braided hose instead which would still meet its high-pressure requirements while offering the potential to reduce costs.

Making the Switch From Spiral to Braided Hydraulic Hoses

Traditionally, high-pressure applications have required the use of spiral hoses because they commonly have four or six layers of wire reinforcement to withstand the hydraulic pressures moving through them.

As such, the backhoe OEM specified the need for a four-wire spiral hose which would be used for the high-pressure line between the machine’s hydraulic pump and the main control valve. Although the backhoe is electric, hydraulics remain important to its functionality as many electric alternatives cannot yet match the power density needed in this type of application. Therefore, the OEM needed hydraulic hoses that could match the performance of those used in its diesel-powered machines.

During the RFQ process, Danfoss’ engineers realized there could be an opportunity to utilize the Aeroquip by Danfoss EC881 Dynamax hose. This two-braided hose has a 35% higher pressure rating than other braided hoses, suiting its use in a high-pressure hydraulic application. It is also qualified to 1 million impulse cycles, a rating that commonly requires use of a spiral construction.

These and many other features make it possible to use the EC881 hose in place of four-wire spiral hydraulic hoses in certain applications.

The Benefits of Using a Braided Hose

Utilizing a braided hose like the EC881 instead of a spiral hose can provide various cost and design benefits to OEMs.

According to Danfoss, braided hose is more flexible than spiral hose which enables the hose to be rerouted if necessary to accommodate different machine layouts. It also helps to ease installation for the OEM and maintenance for machine owners.

Braided Hydraulic Hose Offers Future Design Opportunities

While Danfoss knew the benefits possible with its EC881 braided hose, switching to a different hydraulic hose construction for the electric backhoe application did require some convincing.

“The mentality has been, if I want spiral performance, I need a spiral hose. And now we’re saying there’s this braided hose that can do the same. They’re skeptical,” said Scott Larson, senior engineer, Danfoss Power Solutions, in the company’s press release on the project.

Danfoss provided the OEM with an array of test data to demonstrate the hose’s ability to meet the application’s high-pressure requirements, such as how many impulse cycles the EC881 could withstand at specific pressures.

Based on what it saw in the test data as well as the OEM’s previous history with Danfoss, it decided to use the EC881 hose in its electric backhoe.

The equipment manufacturer was too far along in its design phase to change the hose performance specification and routing, but may consider doing so on future machines – especially those with space constraints – now that it knows about the flexibility possible when using the two-wire braided hose. This aspect can be taken into consideration earlier in the design process and therefore taken better advantage of if desired.

In addition, Danfoss said the OEM is looking at other applications in which it may be able to use the EC881 braided hose in place of four-wire spiral hoses.

“It's a breakthrough, in my opinion, because we've taken the industry norm of four-wire spiral hose – which is perceived as stronger and more durable – and come out with a product that still meets those requirements, but in a lower-cost hose construction,” concluded Travis DeBoer, senior account manager, Danfoss Power Solutions.

READ MORE - Extending Hydraulic Hose Life: Going Beyond Standard Expectations

About the Author

Sara Jensen | Technical Editor, Power & Motion

Sara Jensen is technical editor of Power & Motion, directing expanded coverage into the modern fluid power space, as well as mechatronic and smart technologies. She has over 15 years of publishing experience. Prior to Power & Motion she spent 11 years with a trade publication for engineers of heavy-duty equipment, the last 3 of which were as the editor and brand lead. Over the course of her time in the B2B industry, Sara has gained an extensive knowledge of various heavy-duty equipment industries — including construction, agriculture, mining and on-road trucks —along with the systems and market trends which impact them such as fluid power and electronic motion control technologies. 

You can follow Sara and Power & Motion via the following social media handles:

X (formerly Twitter): @TechnlgyEditor and @PowerMotionTech

LinkedIn: @SaraJensen and @Power&Motion

Facebook: @PowerMotionTech

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