The function of the hydraulic system is to increase the force by changing pressure. A complete hydraulic system consists of five parts: power components, actuating components, control components, auxiliary components (accessories), and hydraulic oil. Hydraulic systems can be divided into two categories: hydraulic drive systems and hydraulic control systems. The hydraulic drive system primarily functions to transmit power and motion. The hydraulic control system aims to ensure that the output of the hydraulic system meets specific performance requirements (especially dynamic performance). The term "hydraulic system" commonly refers to the hydraulic drive system.
Maintenance:
The quality of a hydraulic system depends not only on the rationality of the system design and the performance of the system components, but also on the system's protection against and treatment of contamination. System contamination directly affects the reliability of the hydraulic system's operation and the lifespan of the components. Statistics show that about 70% of hydraulic system failures globally are caused by contamination.
Fault Diagnosis:
Hydraulic transmission systems are gaining more and more widespread application in various fields due to their unique advantages, such as broad process adaptability, excellent control performance, and low cost. However, due to the unstable quality of components and accessories, as well as improper use and maintenance, and the fact that all components and working fluids operate within a closed oil circuit, which is not as直观 as mechanical equipment or as easily measurable with various testing instruments as electrical equipment, hydraulic systems rely solely on a limited number of pressure gauges, flowmeters, etc. to indicate the working parameters of certain parts of the system. Other parameters are difficult to measure, and the root causes of general malfunctions can be of many kinds, making fault diagnosis for hydraulic systems quite challenging.
On the production site, due to constraints from production schedules and technical conditions, it is required that fault diagnosis personnel accurately and simply identify hydraulic equipment failures; maintenance staff should utilize existing information and on-site technical conditions to minimize disassembly work, save on maintenance time and costs, and use straightforward technical methods to accurately locate the fault and its cause within the shortest possible time. This should include repairing the issue to restore system operation and strive to prevent the recurrence of similar faults in the future.
System Maintenance:
A system typically undergoes flushing prior to its formal launch to remove pollutants, metal shavings, fiber compounds, iron cores, and other debris within the system. During the initial two-hour operation, even without causing complete system damage, it can trigger a series of malfunctions. Therefore, follow these steps to clean the system's oil circuit:
1) Clean the oil tank with a quick-drying solvent, then remove any residue with filtered air.
2) Clean all piping in the system, and in some cases, it is necessary to soak the piping and joints.
3) Install oil filters in the pipeline to protect the valve's supply pipeline and pressure pipeline.
4) Install a flushing plate on the manifold instead of a precision valve, such as an electro-hydraulic servo valve.
5) Verify all pipeline sizes are appropriate and connections are correct.
If the system utilizes electro-hydraulic servo valves, I might as well add a few more points. The flushing plate of the servo valve must allow oil to flow from the supply line to the collector and then directly back to the oil tank. This allows for the oil to circulate repeatedly, cleaning the system and letting the oil filter remove solid particles. During the flushing process, check the oil filter every 1 to 2 hours to prevent it from being clogged by contaminants. Do not open the bypass at this time. If you notice the oil filter beginning to clog, replace it immediately.
The flushing cycle is determined by the system's construction and the degree of system contamination. If the filter medium sample has little or no external contaminants, install a new oil filter, remove the flushing plate, and install the valve to operate!
Scheduled Maintenance: Establish a regular maintenance system for the hydraulic system
