Installation and debugging of Manifold block hydraulic components
When installing hydraulic components, the components must be subjected to pressure and sealing tests.
The hydraulic pump and its transmission must have a high degree of concentricity, even if the flexible joint should be concentric as far as possible.
The valve installed with flange, the screw can not be screwed too tight, should be determined according to the specific requirements of the product, because too tight sometimes will cause the interface sealing or single side pressure phenomenon; The installation of the hydraulic cylinder should consider the influence of thermal expansion. When the stroke is large and the temperature is high, one end of the cylinder must be ensured to float. At the same time, the sealing ring of the hydraulic cylinder should not be installed too tight, especially the U-shaped sealing ring, so as not to cause too much working resistance.
Hydraulic pump in the test should consider the stability of the shaft and shaft concentricity. The former is checked by manual pump shaft. If the operation is not stable, it should be checked from the assembly concentricity, shell pressing force, single side pressing, etc., to find out the reason and react to make the operation stable; The concentricity of the shaft should be considered and overcome in the assembly.
In addition, the following tests should be carried out: determine the P port of each pipe – hydraulic cylinder control pipe, P line pressure test; Accumulator filled with nitrogen, pressure leakage test; Confirm whether the valve, instrument type oil leakage; Servo valve, proportional valve unit debugging, electrical implementation; Manually adjust the operation to confirm whether there is any blockage or collision between the machines. Complete polarity detection of servo valve; PT polarity detection; Sensor detection and signal adjustment.
After the equipment is installed and tested qualified, it is necessary to carry out operation and debugging, and make some adjustments to the equipment, so that the equipment can achieve technical performance and meet the requirements of the production process for the equipment. The main contents of operation and debugging are no-load operation and load operation.
The no-load operation of the equipment is to comprehensively check the various hydraulic components, all kinds of auxiliary devices are normal and reliable work, work cycle or all kinds of automatic transfer of the action is in line with the requirements, in order to prepare for load operation. Specific steps can be carried out according to the following:
Whether the unloading pressure of the hydraulic pump is within the allowable value, and whether the sound is normal.
Whether there is air foam on the surface of the liquid level in the tank, and whether the oil level height is within the specified range.
In the test, the relief valve should be fully opened and then the hydraulic pump should be started. After running for more than 10 minutes, there is no abnormal phenomenon, and the pressure can be slowly adjusted to the specified value to prevent the hydraulic pump from being damaged.
Control the reversing valve by hand to make the working cylinder make several reciprocating movements at the maximum stroke or make the motor turn at a certain speed. Its purpose is to remove accumulated air from the hydraulic system.
Check the correctness and reliability of all pressure regulating elements such as pressure valves and pressure relays. The method is to push the moving parts on the rigid block or in other ways to make the moving parts stop moving, with a pressure gauge test.
Check whether the hydraulic cylinder moves normally under large stroke and high speed.
Check whether the components and pipes in the system have external leakage; Internal leakage. Whether the value is within the permissible range. As the oil enters the pipeline and the hydraulic cylinder, the oil level in the tank decreases, and the oil should be replenished to the specified height range.
All parts in the condition of no load according to the predetermined automatic working cycle or work in order to test the movement, check whether the coordination of each action is reliable, whether the movement of the rhythm is correct, the hydraulic transmission mechanism work stroke and action time is correct.
Check whether the starting, reversing and speed changing motion of each working part is stable and reliable, and whether there is creep, impact and jump phenomenon. Whether the automatic lubrication is normal, whether the interlocking safety device is coordinated and reliable, whether the sensitive performance of the action meets the specified technical requirements.
On the whole length of the linear reciprocating motion of the hydraulic cylinder, the assembly, adjustment and manufacturing quality of the relevant parts of the equipment are checked by observing the pointer of the pressure gauge.
After the hydraulic system has been running for a period of time without load, check the temperature rise of the working oil, and the value should not exceed the specified value.
Load operation is the hydraulic system according to the actual work requirements or according to the design of predetermined load to work. Check content mainly has the following aspects: hydraulic system can achieve force and speed and other basic parameters requirements. The smoothness of working parts movement, reversing and speed changing is not allowed
There are crawling, jumping and impact phenomena.
Whether the noise and vibration are within the allowable range, and the leakage condition inside and outside the components and pipelines. Power loss of hydraulic system and temperature rise after running for a certain time.
At the later stage of installation and commissioning, the engineering technical management personnel should sort out the following technical data: hydraulic system construction records; System flushing record; Pressure test record; Debug record; All kinds of inspection reports, including weld flaw inspection report, cleanliness inspection report, all kinds of automatic control instruments (such as pressure gauge, thermometer, sensor, etc.) verification certificate; Product qualification certificate.