液压泵严重磨损原因分析及改进

液压泵严重磨损原因分析及改进

2010-04-20 13:34:16 阅读6 评论0 字号:

译文:
1故障现象及原因分析 我厂生产的ZL04型轮式装载机,常出现空载大油门时动臂缓慢起升、重载时不动作的故障现象。该机液压系统为单泵串联回路。 我们在维修时从以下三点查找故障原因,并对系统进行了改进,现介绍如下。 (1)检查动臂油缸的内漏情况。最简单的方法是把动臂升起,看其是否有明显的自由下降。若下落明显则拆卸油缸检查,密封圈如已磨损应予更换。 (2)检查操纵阀。首先清洗安全阀,检查阀芯是否磨损,如磨损应更换。安全阀安装后若仍无变化,再检查操纵阀阀芯磨损情况,其间隙使用限度一般为0.06mm,磨损严重应更换。 (3)测量液压泵的压力。若压力偏低,则进行调整,加压力仍调不上去,则说明液压泵严重磨损。 经检查测量液压泵的压力仅为5-7MPa,明显低于液压系统的额定压力。拆卸液压泵后发现轴套已磨损,低压区泵壳内壁被齿轮严重“扫模”,侧壁也稍有磨损。由此可见,造成动臂带载不能提升的主要原因为: a.液压泵严重磨损。在低速运转时泵内泄漏严重;高速运转时,泵压力稍有提高,但由于泵的磨损及内泄,容积效率显著下降,很难达到额定压力。液压泵长时间工作又加剧了磨损,油温升高,由此造成液压元件磨损及密封件的老化、损坏,丧失密封能力,液压油变质,{zh1}导致故障发生。 b.液压元件选型不合理。动臂油缸规格为70/40非标准系列,密封件亦为非标准件,制造成本高且密封件更换不便。动臂油缸缸径小,势必使系统调定压力高。 c.液压系统设计不合理。,操纵阀与全液压转向器为单泵串联,安全阀调定压力分16MPa,而液压泵的额定工作压力也为16MPa。液压泵经常在满负载或长时间超负荷(高压)情况下工作,并且系统有液力冲击,长期不换油,液压油受污染,加剧液压泵磨损,以致液压泵泵壳炸裂(后曾发现此类故障)。 2改进及效果 (l)改进液压系统设计。经过多次论证,{zh1}采用先进的优先阀与负荷传感全液压转向器形式,见图2。新系统能够按照转向要求,优先向其分配流量,无论负载大小、方向盘转速高低均能保证供油充足,剩余部分可全部供给工作装置回路使用,从而xx了由于转向回路供油过多而造成功率损失,提高了系统效率,降低了液压泵的工作压力。 (2)优化设计动臂油缸和液压泵造型,降低系统工作压力。通过优化计算,动臂油缸采用标准系 列80/4。液压泵排量由10ml/r提高为14ml/r,系统调定压力为14MPa,满足了动臂油缸举升力和速度要求。 (3)在使用过程中还应注意装载机的正确使用与维护,定期添加或更换液压油,保持液压油的清洁度,加强日常检查和维护。 经改进液压系统设计,齿轮泵工作更加平稳,不再出现过载情况。同时油路设计合理,提高系统效率,而且充分发挥整机使用性能,提高了工作效率。转向动作平滑可靠,避免了高速时转向“飘”的现象。

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原文:
A fault occurrence and cause analysis I plant ZL04 Wheel Loader, often appear when the boom load large throttle slowly lifting, overload fault phenomena without action. Aircraft hydraulic system for the single pump series circuit. We repair the following three reasons to find fault, and the system has been improved, are presented below. (1) Check the inner boom cylinder leak. The easiest way is to boom raised, to see whether they have the freedom to decline significantly. Obviously would be demolished if the whereabouts of the fuel tank inspections, seals should be replaced if worn. (2) Check the control valve. First clean the safety valve, check valve is worn, such as wear and tear should be replaced. Safety valve installed, if still no change, and then check the control valve spool wear, generally limits the use of its space 0.06mm, severe wear and tear should be replaced. (3) measuring the pressure of hydraulic pump. If the pressure is low, then adjust the pressure increase was still not get stressed, it indicates severe pump wear. The inspection is only measurement of the pressure pump 5-7MPa, significantly lower than the rated pressure of hydraulic system. Demolition hydraulic pump has been found that sleeve worn area of low pressure gear pump casing wall has been seriously "sweep mode," and has some wear wall. Thus, resulting in boom with set can not be the main reason for the upgrade: a. pump serious wear. Running at low speed pump leak serious; high-speed operation, the pump pressure increased slightly, but the wear and internal pump leakage, volumetric efficiency decreased significantly, it is difficult to achieve the rated pressure. Hydraulic pump wear and tear aggravated by long working hours, oil temperature increased, the resulting wear of hydraulic components and seals of aging, damage, loss of ability of the seal, hydraulic oil deterioration, leading to failure occurs. b. Selection of hydraulic components unreasonable. Boom cylinder non-standard specifications for the 70/40 series, is also non-standard seals parts, manufacturing costs are high and the seals replaced inconvenience. Boom cylinder bore small, is bound to make the system having a set pressure is high. c. Hydraulic system design unreasonable. , Control valves and hydraulic steering gear with a single pump in series, the safety valve set pressure adjustment sub-16MPa, while the rated working pressure hydraulic pump for 16MPa. Pump full load or a long time often overload (high pressure) conditions of work, and system hydraulic impact, long-term non-oil changes, hydraulic oil pollution, increased pump wear, so pump pump shell burst (after he was found such failure). Improvement and effect 2 (L) improving the hydraulic system. After much argument, the last priority in the use of advanced valve and load sensing hydraulic steering gear form, shown in Figure 2. The new system will shift in accordance with the requirements of priority to their distribution traffic, regardless of load size, high and low speed the steering wheel guarantee a sufficient oil supply, the rest can all work equipment supply circuit, thereby eliminating excess oil as a result of turning the power circuit losses, improve system efficiency and reduce the work pressure of hydraulic pump. (2) optimizing the design of the boom cylinder and hydraulic modeling, reducing system operating pressure. Calculated by optimizing the boom cylinder with standard system Out of 80 / 4. By the hydraulic pump displacement 10ml / r increased to 14ml / r, the system having a set pressure of 14MPa, to meet the boom lift cylinder force and speed requirements. (3) in the course of the loader should also pay attention to proper use and maintenance, periodically add or replace the hydraulic oil, hydraulic oil cleanliness to maintain, strengthen routine inspection and maintenance. The improved hydraulic system, gear pump work more smoothly, no overload condition occurs. Meanwhile oil circuit designed to improve system efficiency, and give full play to machine performance, improve work efficiency. Turning movements smooth and reliable, avoiding the high speed to "drift" phenomenon.


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