液压系统安装调试及保养b.pptx

液压系统安装、调试及保养液压系统安装、调试及保养 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.2液压缸的安装、调试与维护保养液压泵和液压马达的安装、调试与维护保养管路的安装与维护保养液压油的选择、使用与污染度控制油箱与过滤器的使用与维护保养蓄能器的安装与充放气液压系统的调试与日常维护 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.3液压缸对所用油液要求液压缸对所用油液要求对矿物油基的液压油 温度：推荐用于长期运行+25.+55 C 最低/最高的允许值 0.+80 C 粘度 推荐用于长期运行 20.100 mm2/s 最高的允许值 12.500 mm2/s在所有工作中都要保持高度的洁净性，因为污染会导致故障和影响元件的安全功能。在松开管接头和元件之前，要对其外部周围进行清洁。所有的开口都必须用保护盖封闭，以使污染物不能侵入系统。在安装前要保持管道和所有连接面的清洁，无污物，轧屑，切屑等。特别是焊接管道的内部必须是光裸面和冲洗干净。不许使用清洁棉纱头进行清洁。在动力站冲洗时，不许将液压缸接在液压动力站上。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.4液压缸的存储液压缸的存储 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.5液压缸的存储液压缸的存储在长期库存之后，必须将液压缸拆开，并且用合适的清洗液清除残留的保护剂。因为不能肯定密封没有变形，所以在需要时，更换密封件。必须每年对液压缸进行一次彻底的检查。检查中必须注意下列事项：防腐保护；检查是否有损坏和是否有锈蚀生成 液压液体；检查是否氧化或酸化 对非免保养的铰接轴承进行检查和润滑 对配合面或机械连接点进行检查和加保护剂必须每年一次使液压缸驶入或驶出若干厘米，以避免密封粘住。为了避免密封的损坏，我们建议每六周将液压缸转动 90。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.6液压缸的泄漏1。内泄漏影响技术性能、出力不足、速度减慢、工作不平稳2。外泄漏污染环境，能源浪费液压缸的泄漏故障液压缸的泄漏故障 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.7液压缸的泄漏故障液压缸的泄漏故障泄漏的原因1。密封件的结构形式与材质 如材质太软，则易挤入间隙而损伤2。密封槽与密封接触表面的质量 密封槽的尺寸精度较低，表面粗糙度及形位公差较低将导致密封件的损伤产生泄漏3。密封件磨损与安装 密封件要求具有较高的尺寸精度与形状位置精度，密封件的磨损和在密封件装配过程中造成的损伤是液压缸泄漏的主要原因4。密封件的工作环境 在高温、粉尘及高水份的环境下将加速密封件老化，失效从而导致泄漏5。液压系统的污染 如果液压系统受到污染，含有颗粒物的液压油作用在密封件的表面产生研磨作用，从而导致密封失效而泄漏 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.8液压缸的泄漏故障液压缸的泄漏故障一般诊断方法 “问”向操作人员询问故障机械的基本情况，故障是突发的，还是渐发的，突发的故障大多是因液压系统受到污染或意外载荷造成阀或密封件失效引起的，渐发性故障，多数是因密封件磨损严重而出现的。“检”主要是维修人员亲自检查系统的工作情况，使液压缸运动到极限位置，观测液压系统的工作压力，一旦工作压力达不到规定值，而通过调节安全阀，压力仍不发生变化时，则可能因液压缸内泄造成。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.9拆检与维修拆检与维修一旦液压缸出现泄漏，就必须拆检，针对故障产生的原因，采取相应的维修方法。1。密封件的检查与维修 活塞密封是防止内泄的主要元件，对于唇形密封件应重点检查唇边有无伤痕和磨损情况，对于组合密封应重点检查密封面的磨损量及是否有伤痕，判定密封件是否可用。另外还需检查活塞与活塞杆之间的静密封有无挤伤情况。活塞杆密封应重点检查密封件和支承环的磨损情况。一旦发现密封件和导向支承环存在缺陷，应根据被修液压缸的密封形式，选用相同结构和适宜材质的密封件进行更换。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.10拆检与维修拆检与维修2。缸筒的检查与维修 液压缸缸筒内表面与活塞密封是引起液压缸内泄的主要因素，如果缸筒内产生纵向拉痕，即使更换新的活塞密封，也不能有效地排除故障，缸筒内表面主要检查尺寸公差和形位公差是否满足技术要求，有无纵向拉痕，并测量纵向拉痕地深度，以便采取相应的解决方法。（1）缸筒存在微量变形和浅状拉痕时 采用强力珩磨修复缸筒，但缸筒的尺寸公差、形位公差和粗糙度必须符合所选密封件的要求。（2）缸筒内表面磨损严重、存在较深纵向拉痕 2。1 按照实物重新制造 2。2 如能修补则 修补后珩磨，使缸筒的尺寸公差、形位公差和粗糙度达到符合所选密封件的要求。2。3 对一些特殊的，特大的非标缸在用户的同意下也可把内表面的缺陷珩磨掉后配活塞和密封件 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.11拆检与维修拆检与维修 3。活塞杆、导向套的检查与维修 活塞杆与导向套间的相对运动是引起外泄的主要原因。1：如果活塞杆表面镀层因磨损而剥落或产生纵向拉痕，将直接导致密封件的失效。因此，应重点检查活塞杆表面粗糙度和形位公差是否满足技术要求，如果活塞杆弯曲应校直达到要求或按实物重新制造。如果活塞杆表面镀层磨损、滑伤、局部剥落不是很严重，则把镀层去掉后，磨光再镀，后再磨光达到要求。如果局部很严重但能修补则修补后达到要求。不能修复则重新制造。2：检查导向套是否磨损，如果导向套磨损将引起活塞杆密封件的损伤或活塞杆表面拉伤，从而引起液压缸泄漏。因此如果导向套损伤则需要更换导向套。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.12拆检与维修拆检与维修4。其他 如缸头与缸筒，缸底与缸筒等地方的静密封也要检查是否损伤。活塞与活塞杆是否有松动。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.13Contents液压缸的安装、调试与维护保养液压泵和液压马达的安装、调试与维护保养管路的安装与维护保养液压油的选择、使用与污染度控制油箱与过滤器的使用与维护保养蓄能器的安装与充放气液压系统的调试与日常维护 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.14調調試的注意事項試的注意事項Important commissioning instructions All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.15APU液压泵的安装液压泵的安装液压泵的安装位置可以有多种选择。但前提条件是保证泵的壳体内充满液压油。长期停用后不得无润滑运转。如果液压泵安装在油箱内，为保证吸油效果，吸油口S要安装一吸油管。液压泵在油箱内不能保证自动充油，打开泄油口R，而U口用一根油管引出油箱，试运转时可以通过U口排气。正常工作时U口需封死。为防止壳体泄漏油直接被吸入吸油口，在T或L口需接另一根管子，把吸油口与泄油口分隔开。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.16Fill the pump with oil before starting APU泵在第一次启动前，或在更换备件时，要向泵的壳体中灌滿干净的液压油。这样在泵启动时很快在各有相互运动配合面上形成支撑油膜，不会产生磨损。同时，泵体轴承可以得到有效润滑，延长泵的使用寿命。特例：A8泵的吸油口与泄油口在设计上相通，不用在壳体中加油，但在打开吸油阀后要从泄油口放气。Oilplugged All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.17泵的不同安装位置泵的不同安装位置a:安装在油箱液面之上b:安装位置在油箱最低液面之下，位置可能在油箱内或油箱外。c:安装在油箱内最低液面之下 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.18泵的不同安装方向泵的不同安装方向1)泵轴水平安装2)泵轴垂直向上安装3)泵轴垂直向下安装4)泵轴水平侧向安装 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.19泄油管上安装止回阀泄油管上安装止回阀弯轴泵水平安装在油箱外部液压之上时，为保证壳体油液漏空，必要时加一单向阀。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.20泄油管向上弯曲一定长度泄油管向上弯曲一定长度泵安装在油箱外，位置有可能高于最低液面时，可以把泄油管向上弯曲一段，再接回油箱。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.21保证油箱的最低液位保证油箱的最低液位泵安装在油箱内时，注意最低液位不能低于最高的泄油口。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.22检查泵的旋向检查泵的旋向首次启动液压泵时，从电机后风扇位置正对泵轴，检查泵的旋向是否正确。如不正确可以对掉动力线的两个接线头。泵长时间反转会导致损坏。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.23泵轴的轴向力限制泵轴的轴向力限制在泵的安装过程中不可使用蛮力（用锤砸）。也不可产生顶轴现象，否则会破坏泵内各部件的预紧力，加大磨损或影响轴承寿命。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.24用万向轴驱动液压泵用万向轴驱动液压泵安装时万向轴的两端必须保持等角度。轴两端连接处应对称，转动接头应在同一平面内，无明显安装偏差。连接不对称 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.25泵的安装是否符合要求泵的安装是否符合要求:（以（以A10VSOA10VSO为例）为例）垂直安装，油箱之内。L1口需要一根油管，防止泄漏油直接被吸入S口。两管间距最小200mm.垂直安装，油箱之外。为使轴承得到有效冲洗，L1管需要向上折弯，高出轴端面。吸油管在液面之上距离最高hmax=800mm.浸入液面最小长度hmin=200mm.保证最小吸油压力0.8 bar.All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.26泵的安装是否符合要求泵的安装是否符合要求:（以（以A10VSOA10VSO为例）为例）水平安装，油箱之内。L1口需要一根油管，防止泄漏油直接被吸入S口。两管间距最小200mm.吸油口最小液面深度hmin=200 mm.水平安装，油箱之上。泄漏油口接上面的L口。吸油管在液面之上距离最高hmax=800mm.浸入液面最小长度hmin=200mm.保证最小吸油压力0.8 bar.隔板 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.27泵的安装是否符合要求泵的安装是否符合要求:（以（以A10VSOA10VSO为例）为例）水平安装，油箱之下。接上面的L1口。L口堵住。吸油管浸入液面最小长度hmin=200mm.保证最小吸油压力0.8 bar.All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.28泵的安装是否符合要求泵的安装是否符合要求:（以（以A10VSOA10VSO为例）为例）吸油压力：最小绝对压力0.8bar.泄油压力：不能高于吸油压力0.5 bar，最高不能超过2 bar(绝对压力)All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.29油油泵浸在油液中泵浸在油液中Oil immersed必必須使用吸油及回油管須使用吸油及回油管 隔隔板板baffle儘儘可能將距離增加可能將距離增加keep distance as wide as possibleeven under oil level always use suction-and return line 建建議裝置議裝置 recommendation All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.30穩穩固的底架固的底架Stiff frame for power units使使用用L或或U型鋼材以增加穩固性型鋼材以增加穩固性L-or U-beams for frame stiffness動動力單元的最佳設計：適用於小型動力單元力單元的最佳設計：適用於小型動力單元optimal design for small power units possible安安裝底架裝底架mounting base Alle Rechte bei Bosch Rexroth AG,auch fr den Fall von Schutzrechtsanmeldungen.Jede Verfgungsbefugnis,wie Kopier-und Weitergaberecht,bei uns.31“Slightly out of balance”重心失衡重心失衡Pulling forceforce of pressureGMGP1GP2base frame All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.32穩固的底架承托穩固的底架承托Strength frame for power unitsS使使用足夠重量的墊軌用足夠重量的墊軌Use heavy base rail(5dB(A)less把負載平均分佈在避震腳上把負載平均分佈在避震腳上Damping elements are optimally arranged with even load distribution All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.33Contents液压缸的安装、调试与维护保养液压泵和液压马达的安装、调试与维护保养管路的安装与维护保养液压油的选择、使用与污染度控制油箱与过滤器的使用与维护保养蓄能器的安装与充放气液压系统的调试与日常维护 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.34管子的选用准则管子的选用准则管子的选择先要根据对流速匹配来选择，一般原则是：油液在管子中流动时，管子内径能够容纳液压站的最大供油量时的稳定流动。不能出现空腔和紊流，也不能有太大的压力损失。对吸油管：0.50.8 m/s，以吸油压力不低于绝对值0.8bar为准则；对回油管：24 m/s对压力油管：100 bar以下24 m/s，315 bar 等级312 m/s安全起见，压力管路所能承受系统压力的1.5-2倍。管子内壁一定要光滑，减小油液流动时的阻力。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.35管路安装过程的实施管路安装过程的实施 管道的敷设排列和走向应整齐一致,层次分明,尽量采用水平或垂直布管，水平管道的不平行度应2/1000，垂直管道的不垂直度应2/400，用水平仪检测。一列平行布置的管道，各管道之间的平行度允差为2/1000。平行或交叉的管道之间应有10mm以上的空隙。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.36管路安装过程的实施管路安装过程的实施液压系统管子应用弯管机进行冷弯，较大直径的管子采用弯头配焊。严禁采用火焰热弯，或其他强行拼接方式。所有弯管其弯曲曲率半径3倍管径。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.37管路安装过程的实施管路安装过程的实施与管接头或法兰连接的管子必须是一段直管，此段直管的轴心线与管接头或法兰的轴心线应重合，且长度要大于或等于2倍管径。检查不到的弯管处可将其分做两部分，方便在管路堵塞时检查和排故。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.38管路安装过程的实施管路安装过程的实施管子安装间断期间，各管口应严格密封。管路系统安装时，不得有沙子、氧化铁皮、铁屑等污物进入管道。安装前不得预先把所有的管路保护清除，否则会污染管路。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.39管接头的使用管接头的使用在液压系统中常用的几种管接头：Walform.用于中高压系统，采用24度锥密封。适用于5-32的管径。碳钢与不锈钢均适用。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.40管接头的使用管接头的使用在液压系统中常用的几种管接头：SAE法兰。适用于35-125管径的密封，通过四个紧固螺栓和O圈形成可靠的密封。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.41管接头的使用管接头的使用在液压系统中常用的几种管接头：方形或圆形法兰。适用于50管径的密封，通过四个紧固螺栓和O圈形成可靠的密封。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.42管夹的使用管夹的使用我们利用管夹来固定液压管路，使用液压系统工作更稳定。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.43管夹的使用管夹的使用关于管夹在安装时的间隔，一般来讲，从遵从如下的基本准则：8D20L1000 mm20 D 48,3L1500 mmD48,3L2000 mm All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.44管路的焊接管路的焊接管子的焊接最好采用氩弧焊，氩气是惰气中较多的，相比成本低一点，焊接时熔化的焊剂与母材熔合时，为防止超高温状态下熔剂被氧化，采用惰气（氩气）进行隔离空气，保护焊点,保持化学成分，从而保护其机械性能。这样可以最大限度的减小焊渣的产生。1-钨极；2-导电嘴；3-绝缘套；4-喷嘴；5-氩气流；6-焊丝；7-焊缝；8-工件；9-进气管 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.45正确布置软管正确布置软管软件的布置的原则之一是平滑弯曲，不允许出现更弯和弯曲半径过小的情况。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.46正确布置软管正确布置软管保证最小的弯曲半径，必要时使用90度弯曲管接头。软管连接时，软管长度要保证大于连接距离，注意软管主要是用来连接有相对运动的部件的，要留有足够的变形空间。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.47正确布置软管正确布置软管软管连接不能扭劲，这样工作一段时间后容易漏油。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.48正确布置软管正确布置软管任何连接形式均要考虑最小的弯曲半径，防止软管在工作过程中由于疲劳效应发生断裂。All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.49最少有最少有1.5倍油管直徑的距離倍油管直徑的距離at least 1.5 pipe i.d.minimal distance隔板必須安裝隔板必須安裝baffle absolutelynecessary吸油區內油液不可急速流動吸油區內油液不可急速流動calm oil in suction chamber紊流區紊流區turbulent zone長而平放的吸長而平放的吸油管油管long horizontal suction line平切口的油管平切口的油管straight cut of pipe產生氣泡產生氣泡creationof air pocketAllg.090.9 VST1/VST6 06.AAP suctionBad suction line in tank All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.50Bad suction line in tankP suction吸油區內油液不可吸油區內油液不可急速流動急速流動 calm oil in suction chamber紊流區紊流區turbulent zone必須安裝隔板必須安裝隔板baffle absolutelynecessary最少有最少有1.5倍油管直徑倍油管直徑的距離的距離at least 1.5 pipe i.d.minimal distance All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.51Contents液压缸的安装、调试与维护保养液压泵和液压马达的安装、调试与维护保养管路的安装与维护保养液压油的选择、使用与污染度控制油箱与过滤器的使用与维护保养蓄能器的安装与充放气液压系统的调试与日常维护 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.52Temperature range at pump inlet for VG46 Oil71 41 All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.53 液压油的清洁液压油的清洁注意油液的污染度及湿度,避免任何污物进入油箱!加油时必须经过过滤器,最好是经过液压系统自身的过滤器进行加油,或利用移动式,带有精密过滤器的滤油小车.油箱内部如果涂有涂层的话,必须与所使用的油液相容!严防假油!All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.54新新 液液 壓壓 油油 2 33,121 5 7,820ISO 4406-22/20/18 10 5,010 (NAS 12)15 2,440新新 液液 壓壓 系系 本本 身身 的的 污污 染染 物物 2 79,854 5 21,070 ISO 4406-23/22/20 10 12,320 (NAS 12)15 8,228Contamination level comparison All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.55按按 裝裝 有有 基基 本本 液液 壓壓 過過 濾濾 的的 系系 统统 2 9,870 5 2.400ISO 4406-20/18/16 10 1,800 (NAS 9)15 540按按 裝裝 有有 過過 濾濾 x 200 的的 液液 壓壓 系系 统统 2 80 5 41ISO 4406-14/13/11 10 20 (NAS 4)15 12只只 有有 使使 用用 高高 過過 濾濾 比比 值值 的的 濾濾 芯芯 才才 能能 有有 效效 控控 制制 有有 害害 的的 间间 隙隙 體體 積積 粒粒 子子Contamination level comparison All rights reserved by Bosch Rexroth AG,as well in cases of trade mark rights applications.All rights of disposal as copy of passing by us.56人頭人頭 髮髮 粗粗 75um,10um 微微 粒粒 放放 大大 100 倍倍The Micrometer um All rights reserved by Bosch Rexroth AG,as well in cases of trade mark r