Project title

“To collect data on the air pressure

leakage in the grease chamber and
enclosure of the actuators and
reduce the incidence of leakage by
50% of the present value”.

Presented by
Hareesh Banagar

Guided by
Vivek R Gurjar
Introduction to Actuators:

An actuator is a mechanical device for moving or controlling a mechanism

or system. It takes energy, usually transported by air, electric current, or
liquid, and converts that into some kind of motion.

Mechanical actuators operate by conversion of rotary motion into linear

motion, or vice versa. Conversion is commonly made via a few simple types
of mechanisms

An actuator is something that converts energy into motion. It can also be

used to apply a force. An actuator typically is a mechanical device that takes
energy, usually created by air, electricity, or liquid, and converts that into
some kind of motion. That motion can be anything from blocking to
clamping to ejecting. Actuators are typically used in manufacturing or
industrial applications and may be used in things like motors, pumps,
switches, and valves.

The most common type of actuator is powered by air — the pneumatic

cylinder, also known as the air cylinders. Air cylinders are air-tight
cylinders, typically made from metal, that use the energy of compressed air
to move a piston. Air cylinders are most commonly used in manufacturing
and assembly processes. Grippers, which are used in robotics,
use actuators driven by compressed air to work much like human fingers.

Actuators can also be powered by electricity or hydraulics. Much like there

are air cylinders, there are also electric cylinders and hydraulic
cylinder where the cylinder converts electricity or hydraulics into motion.
Hydraulic cylinders are often used in certain types of vehicles.

Many actuators have more than one type of power source. Solenoid valves,
for example, can be powered by air and electricity. Electricity powers the
solenoid, and the solenoid, powered by air, actuates the valve. Alternatively,
the solenoid can be powered by hydraulics and electricity.

Actuators can create a linear motion, rotary motion, or oscillatory motion.

That is, they can create motion in one direction, in a circular motion, or in
opposite directions at regular intervals. Hydraulic and air cylinders can be
classified as single acting, meaning that the energy source causes movement
in one direction and a spring is used for the other direction. Alternatively,
these cylinders can be double acting cylinders, meaning the energy is used in
two directions.

Electric actuator on a valve in a power plant Actuator are used for the
automation of industrial valves and can be found in all kinds of technical
process plants: they are used in wastewater treatment plants, power
plants and even refineries. This is where they play a major part in
automating process control. The valves to be automated vary both in design
and dimension. The diameters of the valves range from a few inches to a few
meters.
Depending on their type of supply, the actuators may be classified as
pneumatic, hydraulic or electric actuators

Classification of actuators according to their

movement

Multi-turn actuators
Multi-turn actuators are required for the automation of multi-turn valves.
One of the major representatives of this type is the gate valve.
"A multi-turn actuator is an actuator which transmits to the valve
a torque for at least one full revolution. It is capable of withstanding thrust."
Gate valves may have a diameter of approx. 4 inches to several meters. The
torque requirement for multi-turn solutions ranges from approx. 10 N m to
30,000 N m.

Part-turn actuators

Part-turn actuators are required for the automation of part-turn valves. Major
Representatives of this type are butterfly valves and ball valves. The basic
requirements on part-turn actuators are described in the standard EN ISO
5211 as follows:
 "A part-turn actuator is an actuator which transmits a torque to the valve for
less than one full revolution. It need not be capable of withstanding thrust."
Part-turn valves diameters range from a few inches to several meters. The
torque requirement for operating the closing element has a comparable range
from approximately 10 N m to several 100,000 N m. Electric actuators are
unrivalled for large-diameter valves with high torque requirements

TYPES OF ACTUATORS

OPEN- CLOSE Model: SAR

Auma Norm Duty
Regulating Duty Model: SA

Auma OPEN- CLOSE Model: SA

Compac
t Regulating Duty Model: SAR
Actuator Auma Integral Compact
types Starter

OPEN- CLOSE Model: SA e-pac

Auma
Duty
e-pac
Regulating Duty Model: SAR e-pac

Expl.Pro OPEN- CLOSE Model: SAEx

of Norm Duty
Regulating Duty Model: SAREx
Auma FlameProof
Explosion Proof
OPEN- CLOSE Model: SACEx
Expl.Pro Duty
of
Compact Regulating Duty Model: SARCEx
Grease path test:

To know the air pressure leakage in the grease chamber and the
enclosure of the actuators a test is conducted which is known as “Grease
Path Test”

After the basic assembly of an actuator, the actuator is tested under pressure
equipment machine i.e. Leak test computer (LTC) to test the leakages which
are occurring in an actuator to ensure that grease chamber is free from
leakages.

WHY IT’S REQUIRED…

• Our actuators are installed in a site where the actuators will face
unfavorable conditions of the environment like increase in pressure,
increase in temperature, and increase in humidity or dust from the
environment. To resist these kinds of environmental conditions our
actuators should not have any leakages so Grease path test ensures
that actuators are free from leakages.

• If grease path test is not conducted we will not sure about the leakage
in the actuator where its occurring, because of this these kind of like
dust, air, moisture enters into the actuators grease chamber, which
consists of many mechanical components will be corroded and wear
out. This will affect out put of an actuator in future it may lead to
failure of an actuator.

• To avoid such kind of problems Grease path test makes very

important role in testing of an actuator during assembly.

Assembly of actuator that is ready to conduct grease path test

GPT assembly consists of two stages

• Basic assembly
• Mechanical Assembly
Basic assembly consists,

• Housing (depending on the type of actuator)

• Caution plate
• Grease plug with O-ring
• External Bearing retainer plate with O-ring
• O-ring on lever side
• Lever with circlip
• Roller pin short
• Clutch fork
• Roller pin larger
• Sub washer-spacer
• Name plate

Mechanical assembly consists,

• Worm shaft assembly
• Internal Retainer plate with oil seal
• Hollow drive shaft
1.Bearing flange with B6 circlip
2.Hollow drive shaft press with circlip
3. Oil seal
4. Worm wheel
5. Snap ring
6. O-ring

• Torque switch Drive

• Clutch ring
• Compression spring
• Circlip
• Limit Switch Drive
• Hand wheel
LOCATIONS OF LEAKAGES WHIICH CAUSES
GPT FAILURE

Lever side bolts

External bearing retainer

plate
 TSD fixing flange

LSD fixing flange

Roller pin location

Bearing retainer
plate at motor
Housing

Hand Wheel
Oil seal at bearing
flange

REASONS FOR GPT FAILURE

• There are many mating parts in the actuators assembly. If there is
slight Miss-match between these mating parts leads to GPT failure.

• Due to over size or undersize of bores of any component.

• If there is improper assembly of components.

• Missing of an O-ring in any of the mating parts.

• Usage of damaged components or O-rings for assembly.

• Wrong program selection during GPT.

• If there is improper tightening of components in the assembly.

PROCEDURE TO CONDUCT GREASE PATH
TEST

• By removing BSC plug in the housing of an actuator, Leak Test

Computer (LTC) is connected to the actuator assembly.

• The test will be conducted in 4 stages

1. Filling
2. Stabilization
3. Measuring
4. Ventilation

1. Filling: In this stage of testing LTC will fills the air with a pressure
of 1 bar to the actuator
 2. Stabilization: in this stage pressured air will allow to enter into
each corners of the actuator for some time it stabilizes that pressured
air inside the actuator.

3. Measuring: In this phase the LTC will measures the amount of

pressure drop inside the actuator provided if there is a leakage.

4. Ventilation: After the measurement of pressure LTC will empties

the air that is present inside the actuator.

HOW IT WORKS?
The test piece is filled with test air (filling pressure, filling time)
stabilization and pacification of filled air (test pressure, stabilization time)
follows. These processes are controlled continuously (tolerance is max
deviation) At the start of actual measuring time current value of the test
pressure is found and filled in the memory as reference value. At the end of
the measuring time the reference pressure is compared with last current
value the difference is the pressure difference. During ventilation time the
air is emptied from the actuator. This concludes the end of the test.
Measurement mask:

1. Program No: 1 Name of the program: SA6-

SA100

2. Set Point : 1.00 bar Actual value : 1.00

bar

3. Limit : 22pa Leak Rate : 14

pa

4. Test Piece Result: OK or NOK

Line 1: Actual program number & program name

Line 2: Required pressure (test pressure) & actual pressure (Measured

test pressure)

Line 3: Limit required value & actual value

Line 4: Test result & comment

 Each program consists of individual settings which are used to test
different types of the actuators.

Program 1: GPT SA3-SA15

Program 2: GPT SA25-SA60
Program 3: GPT SA100
Program 4: PT SA3-SA15 norm
Program 5: PT SA3-SA15 E pac
Program 6: PT SA25-SA60 norm
Program 7: PT SA25-SA60 E pac
Program 8: PT SA100 norm
Program 9: PT SA100 E pac

Data collection sheet:

This sheet will give clear idea about the actuator leaking,
• That is, number of quantities which are tested.
• Which part of the actuator is leaking?
• In what rate they are leaking.
• Effectiveness of the actuator that is OK or NOK.
 Data collection sheet for grease path test
Date of observation:23-08-2010 to 10-09-2010
Product:SA3 & SA6
Defective places

Handwheel

Lever side
commission no Leak rate

Result
Hollow

LSD

TSD
Internal External drive
retainer retainer shaft and Grease
plate plate oil seal plug
101381001-01 Major leak 1 NOK
101381001-03 Major leak 1 NOK
101381001-04 Major leak 1 NOK
1088310004-02 63pa 1 NOK
1018610001 52pa 1 NOK
107891002 85pa 1 NOK
1074210002 127pa 1 NOK
1013010001 662pa 1 NOK
1041510003-04 29pa 1 NOK
1041510001 Major leak 1 NOK
108571002-01 36pa 1 NOK
3 1 7 11
Total Quantity inspected=40 ok=29 NOK=11

X axis-defects Y axis-Quantity
 Data collection sheet for grease path test
Date of observation:23-08-2010 to 10-09-2010
Product: SA15
Defective places

Handwheel

Lever side

Result
commission no Leak rate Hollow

LSD

TSD
Internal External drive
retainer retainer shaft and Grease
plate plate oil seal plug
1033710001-28 1601pa 1 1
1033710001-35 281pa 1
1033710001-37 771pa 1
1033710001-38 251pa 1
1033710001-40 261pa 1
1033710001-42 111pa 1
1033710001-43 33pa 1
1033710001-44 139pa 1
1033710001-49 143pa 1
1074510001-03 149pa 1
1012510005-01 Major leak 1
1012510005-02 139pa 1
1 3 9
Total Quantity inspected=30 ok=18 NOK=12

X axis-defects Y axis-Quantity
 Data collection sheet for grease path test
Date of observation:23-08-2010 to 10-09-2010
Product:SA12
Defective places

Handwheel

Lever side

Result
commission no Leak rate Hollow

LSD

TSD
Internal External drive
retainer retainer shaft and Grease
plate plate oil seal plug
1008210002-01 249pa 1 NOK
1106810001 149pa 1 NOK
1051510001 54pa 1 NOK
1051510001 28pa 1 1 NOK
102310003 58pa 1 NOK
1069510002-01 139pa 1 NOK
1069510002-02 128pa 1 NOK
1069510003-02 240pa 1 NOK
1069510003-03 139pa 1 NOK
1069510003-08 Major leak 1 NOK
1069510003-04 Major leak 1 1 NOK
1069510003-10 Major leak 1 1 NOK
1073610002 229pa 1 NOK
7 1 8 NOK
Total Quantity inspected=40 ok=25 NOK=16
X axis-defects Y axis-Quantity
 Data collection sheet for grease path test
Date of observation:23-08-2010 to 10-09-2010
Product: SA25
Defective places

Handwheel

Lever side

Result
commission no Leak rate Hollow

LSD

TSD
Internal External drive
retainer retainer shaft and Grease
plate plate oil seal plug
1014810001-02 63pa 1 NOK
1014810001-01 48pa 1 NOK
1074510002 96pa 1 NOK
101810001-08 45pa 1 NOK
101810001-09 63pa 1 NOK
101810001-10 48pa 1 NOK
101810001-06 major leak 1 NOK
1074610002-01 196pa 1 NOK
1074610002-02 87pa 1 NOK
10658510003-08 major leak 1 NOK
1080110003-03 256pa 1 NOK
11 NOK
Total Quantity inspected=39 ok=28 NOK=11
X axis-defects Y axis-Quantity

From the data collected above with pareto diagrams we called for
brainstorming session from each department of the organization to collect
the no of possible causes for the leakages in an actuator.
In that we selected major issues by considering major leakages that is,
1. Oil seal leakage in SA3,SA6 and SA15,SA12.
2. Hand wheel leakage in the SA25 and SA30.
Brainstorming

Brainstorming is a group creativity technique designed to generate a large

number of ideas for the solution of a problem.
brainstorming does not increase the productivity of groups (as measured by
the number of ideas generated), it may still provide benefits, such as
boosting morale, enhancing work enjoyment, and improving team work.
Thus, numerous attempts have been made to improve brainstorming or use
more effective variations of the basic technique.
Rules to be followed in brain storming

There are four basic rules in brainstorming. These are intended to reduce
social inhibitions among group members, stimulate idea generation, and
increase overall creativity of the group.

• Focus on quantity:
Focus only on the quantity of possible causes not on the
quality. Quantity makes important role than the quality.

• Withhold criticism:

In brainstorming, criticism of ideas generated should be put 'on

hold'. Instead, participants should focus on extending or adding
to ideas, reserving criticism for a later 'critical stage' of the
process. By suspending judgment, participants will feel free to
generate unusual ideas.

• Welcome unusual ideas:

To get a good and long list of ideas, unusual ideas are

welcomed. Looking from new perspectives and suspending
assumptions can generate them. These new ways of thinking
may provide better solutions.

• Hitch hacking (Combine and improve ideas):

Good ideas may be combined to form a single better good idea,

as suggested by the slogan "1+1=3". It is believed to stimulate
the building of ideas by a process of association.

In that brain storming session we collected no of possible causes which are

listed below. and also these are helpful to draw the cause and effect
Diagram(Ishikawa diagram).
Possible Causes for SA6, SA12, SA15 oil seal leakage

• Surface finish of the Hollow drive shaft

• Tolerance specified NOK
• Bearing flange ID oversize
• Hollow drive OD & ID NOK
• Assembly procedure NOK
• Oil seal quality
• Oil seal OD oversize
• Excessive air pressure
• Improper pressing of the oil seal during assembly
• Circularity of oil seal
• Compression between bearing OD and oil seal ID
• Insufficient holding area between Hollow drive shaft and oil seal.
• Oil seal blown out problem for not using fixture for testing.

Possible Causes for SA25 Hand Wheel leakage

• Improper pressing of hand wheel

• Improper assembly
• Hand wheel adopter oversize
• Improper fitness
• Poor surface finish
• O-ring quality
• Quad ring quality
• Testing method
• Dust in quad ring
• Dust in quad ring groove
• Blow holes in hand wheel
• Seating dimension of hand wheel NOK
• Damage to the quad rings
• Non repeatability of measuring equipment
• Cross section of the Quad ring
 • Improper pressing of blazer bush
• Uneven Chamfer.
• Proper training.
From the major issues and no of possible causes for those major issues will
help me to draw Cause and effect Diagram.(oil seal)

OIL SEAL
MEHTOD

Rubber

Material
Improper pressing
of oil seal Ovality of oil seal
Hydraulic press
or manual press Soft Hard
Missing of the spring
in oil seal Wrong placement of
Compression oil seal
between oil seal
OD and HDS ID

Bend spring
used in oil seal Dimension of oil seal(ID or
OD) according to the drawing
OIL
SEAL
LEAKA
GE
Method of
measurement wrong
Pre-stage testing
Not fixing fixture

Insufficient holding area

Excessive air pressure
between HDS and oil seal
HDS ID and
OD

MEASUREMENT
 Cause and effect diagram for SA25 Hand wheel leakage

MEN QUAD RING

Hard

Rubber used in material

Quantity and used in quad ring
material used

Skilled Soft
External damage

Semiskilled OD

Compression
Cross section of set
Improper pressing of
quad ring
hand wheel
ID

HAND
WHEEL
LEAKAGE

Equipment (ID) dust in quad

repeatability for OK ring groove Wrong
and NOK actuators measurement

Wrong program
selection in test ring
O-ring groove Pre-stage
(OD) measurement

EQUIPMENT ENVIRONMENT MEASUREMENT

 Testing and Measurement:
Below table gives the percentage of defects, which occurs, in the grease
chamber of the actuator.

Type of External
the Oil seal Hand wheel retainer OK NOK Total tested
actuator plate

SA6 7 3 1 29 11 40
SA12 8 7 1 25 15 40
SA15 9 0 3 18 12 30
SA25 0 11 0 28 11 39

DEFECTS IN PERCENTAGE

Type of External
the Oil seal Hand wheel retainer OK NOK Total tested
actuator plate

SA6 17.50% 7.50% 2.50% 72.50% 27.50% 40

SA12 20% 17.50% 2.50% 62.50% 37.50% 40
SA15 30% 0 10% 60% 40% 30
SA25 0 28.20% 0 72% 28.20% 39
 Oil seal Material

 As the material point of view the oil seal material what we are using is
Nitril Butadine Rubber, which has shore hardness of 75 and temp
range of –30 to 120 which has good resistance to most of the oils and
grease. So according to this oil seal material will not cause any
leakages is confirmed.

Oil Seal Leakage

 While testing an actuator I observed leakage through oil seal due to
under size of the oil seal. As oil seal suppliers are green channel
suppliers we are not inspecting those oil seals. Due to this problem as
mentioned above they’re about 2% defects. So by changing the oil
seal we can eliminate this problem.

Oil seal blown out due to pressure

 There are many cases of oil seal blown out while testing causing GPT
failure.
If we analyze this,
Ref article:
STD radial shafts seal performs best and last longest if the
pressure on both sides of the seal is same. The slightest amount of
pressure increase on the inside of the seal will cause sealing lip to be
pressed against the counter face, widening the path it traces. Friction
will increase in the contact and heat will be generated. The rise in
temp will cause the seal to wear rapidly. An extreme pressure in the
housing can even force the seal out of the bore.
 Permissible speeds under pressure are given below

Differential Shaft speed in

pressure in bar rpm
0.2 bar 3000

0.35 bar 2000

0.5 1000

From the above table we can notice that 0.5 bar pressures is enough to
test a seals which are sealed to shafts rotating at 1000 rpm

But in our case actuators are tested for 1 bar of pressure with
stationary shaft.

Special radial shafts (currently using) seals are usually

required. If there is a considerable differential pressure across the seal.
Standard seals can normally withstand Differential pressure of 0.7 bar
is maximum at relatively lower speed of shaft.
As we standardized the testing pressure of 1 bar we cannot
change that pressure.

Solutions to avoid oil seal leakages in the Grease

path chamber

Quality: Proposed actions

• Inspection to be made for oil seals in that we have to check Inner
diameter and Outer diameter of the seal. If there is dimensional
error we can reject those oil seals so that leakage can be avoided
during assembly.
Assembly: Proposed actions
• While conducting GPT, before filling air, an actuator should be
fixed with Fixture at bearing flange as shown in the picture. So that
oil seal blown out problem can be avoided.

• While pressing oil seal at the bearing flange make sure that the
inner and outer slip of the oil seal should be counter faced exactly.
Error in counter facing leads to leak at the oil seal.

• Displaying the assembly process charts with pictures at assembles

sections we can avoid problem which is mentioned in the above
point.

Result Data Sheet:

After following the above-mentioned actions its possible to see a better

results in the GPT for SA3, SA6, SA12 and SA15.
 Type of the
commission no Leak rate Effctiveness
Actuator
SA12 1137310004 6pa OK
SA12 1149210001-01 7pa OK
SA12 1149210001-02 13pa OK
SA3.5 1136710036 16pa OK
SA6 1136710025 3pa OK
SA6 1137310003-01 8pa OK
SA6 1137310003-02 19pa OK
SA12 1130910001 64pa NOK
SA3 1108610002-01 20pa OK
SA3 1108610002-02 21pa OK
SA3 1108610002-03 17pa OK
SA3 1108610002-04 13pa OK
SA6 1063410001-03 2pa OK
SA3 1094410002 13pa OK
SA12 1033110001 14pa OK
SA12 1029810001-06 5pa OK
SA6 107501000-01 6pa OK
SAR12 1033110001 47pa NOK
SA6 1125110001-07 2pa OK
SA6 1125110001-08 3pa OK
SA6 1125110001-11 52pa NOK
SA6 1125110001-12 2pa OK

Total tested=21 OK=18 NOK=3

% of leakage=14%

Analysis of the hand wheel leakage:

Type of corrective action
commission leak
actuato no Defects observed and preventive effectiveness
rate action
r Measurement

SA12 1097810001-02 Hand wheel tight 54 pa Changed the hand test ok 2pa
wheel

SA12 1097810024-06 Hand wheel rusted 568pa Applied rust spray 12 test ok 12pa

SA30 1054410051 Hand wheel lekage due to blow hole 1239pa Hand wheel changed test ok 6pa

Dust present in the

quad ring and quad
SA30 1054410052 Hand wheel leakage Major leak test ok 14pa
ring groove, cleaned
and retested
Dust present in the
quad ring and quad
Hand wheel leakage 200pa test ok 3pa
ring groove, cleaned
SA30 1054410052 and retested
Dust present in the
quad ring and quad
Hand wheel leakage Major leak test ok 6pa
ring groove, cleaned
SA12 1097810025-12 and retested
Dust present in the
quad ring and quad
adopter leakage 671pa test ok 23pa
ring groove, cleaned
SA60 1096810001 and retested
oil seal leakage due to undersize Major leak oil seal changed test ok 11pa
SA60 1054410061-02
Dust present in the
quad ring and quad
Hand wheel leakage 1239pa test ok 18pa
ring groove, cleaned
SA30 1041010003 and retested
teflon tape applied
lever side leakage 668pa test ok 22pa
SA30 1104010003-02 and retested
SA25 1075610003 Hand wheel leakage Major leak Hand wheel changed test ok 23pa
Dust present in the
quad ring and quad
Hand wheel leakage 2539pa test ok 22pa
ring groove, cleaned
SA25 1103310004 and retested
Dust present in the
quad ring and quad
Hand wheel leakage 966pa test ok 23pa
ring groove, cleaned
SA25 1103310002 and retested
oil seal damaged near internal retainer
Major leak oil seal changed test ok 7pa
SA12 1088410005-12 plate
absence of compression spring in the oil
Major leak oil seal changed test ok 10pa
SA12 1088410005-03 seal
Dust present in the
quad ring and quad
Hand wheel leakage 643pa test ok 20pa
ring groove, cleaned
SA25 1097810020-03 and retested
 pareto diagram for hand wheel leaka ge

9
8
7
6
y
ti
t5
n
a4
u
Q
3
2
1
0
SA25&30 SA12
type of actuator
SA60

As we can observe from the above graph that there may be

leakage in the actuators due to the presence of the dust which is present in
the Quad ring and Quad ring groove, if we use cleaned one we can avoid
such leakages in the grease path chamber. The defect and result of that we
can notice it in the above table.

Proposed actions for SA25 Hand wheel leakages:

• Process sheet for the Hand wheel sub assembly.

 Instructions to be followed for Hand wheel sub-Assembly
Ensure that, the quad
ring and O-ring which
are used for hand wheel
should not have any
external damages

Before inserting Quad

ring or O-ring, remove
the
dust particles that are
present on the Quad ring
and Quad ring groove as
shown in the picture

Use cleaned Quad ring and

O-ring.

Finally ensure that, Hand

wheels that are going for
assembly cell should not
have any kind of demerits as
mentioned above.
 Apart from this still we notice the leakages in the hand
wheel, where quad ring is situated. The below table gives
the details about leakages.

Type of
the commissi Defectiv Leak Effectiven
actuator on no e area rate ess

1052010005 Quad ring Major

SA30 -01 area leak NOK
1052010004 Quad ring
SA25 -02 area 568pa NOK
1052010004 Quad ring
SA25 -03 area 220pa NOK
1052010004 Quad ring
SA25 -04 area 96pa NOK
Quad ring
SA25 1118210018 area 30pa NOK
Quad ring
SA25 1110510002 area 35pa NOK
1118210017 Quad ring
SA30 -01 area 1239pa NOK
1128410004 Quad ring
SA30 -04 area 1311pa NOK
1128410004 Quad ring Major
SA30 -05 area leak NOK
1128410004 Quad ring
SA30 -06 area 440pa NOK
1105210002 Quad ring
SA25 -19 area 220pa NOK

Total
tested=29 OK=18 NOK=11
 This is due to the error in the fitment of the quad ring with
hollow drive shaft this can be analyzed by below table.

Fitment analysis for Hand Wheel leakage:

SA6 SA12 SA25

Min Max Min Max Min Max
Handwheel Slot dia 41.200 41.300 54.150 54.250 74.300 74.400

Quad Ring OD 41.580 41.580 55.850 55.850 73.520 73.520

Fit between HW & 0.380 0.280 1.700 1.600 0.780 0.880

QR OD*

Hollow shaft OD 34.950 34.975 44.950 44.975 64.940 64.970

Quad Ring ID 34.370 34.670 44.950 45.450 62.835 62.885

Fit between HS & 0.580 0.305 0.000 0.475 2.105 2.085

QR ID*

Handwheel slot 4.00 4.20 6.00 6.10 6.00 6.20

width
Quad Ring width 3.53 3.63 5.20 5.46 5.20 5.46

Fit between HW slot 0.470 0.570 0.800 0.640 0.800 0.740

& QR width
From the above table, if we see the fitment between Hollow drive shaft and
Quad ring ID for SA6 and SA12 where normally we are not getting the
leakages from quad ring area that fitment corresponds to 0.1 to 0.5.
But if we see the fitment between Hollow drive shaft and Quad
ring ID for SA25 where we got maximum no of leakages corresponds to 2.0
to 2.5

It has been observed in the above graph that the fitment increased in SA25
that corresponds to 2.2. so the fitment where we are not getting the leakages
ie, for SA6 and SA12 the fitment corresponds to 0.2 to 0.4.

So therefore, if we reduce the fitment between Hollow drive shaft

and the Quad ring ID that is from 2.2 to 0.8 -1.2 so finally we concluded to
change the dimensions the Quad ring. Why because changing of the Hollow
drive shaft OD is not possible.
The dimensions of that Quad ring and the fitment are mentioned in
the below table.
 Current Required
value value
MIN MAX MIN MAX
Hollow drive
shaft OD 64.94 64.97 64.94 64.97
Quad ring ID 62.61 63.11 63.95 64.45
FIT between
HDS &QID 2.33 1.86 0.99 0.52

Actual Dimension of the QUAD ring

INNER DIAMETER =62.86, ±0.25

WIDTH =5.33 ,±0.13

Required Dimension of the QUAD ring

INNER DIAMETER =64.2, ±0.25

WIDTH =4.75 ,±0.13

As we ordered the Quad ring with required dimensions and awaiting for the
test results.