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密煉液(ye)(ye)壓(ya)(ya)(ya)系(xi)(xi)統安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)技術要點(dian)(精(jing)簡版)一、安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)前準備1.核對裝(zhuang)(zhuang)(zhuang)箱(xiang)清(qing)單,檢(jian)查液(ye)(ye)壓(ya)(ya)(ya)泵、閥(fa)組、油(you)(you)(you)缸等部(bu)件(jian)完整性(xing)2.準備安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)基(ji)礎(chu),確(que)保承(cheng)載面水平(ping)度(du)≤0.2mm/m,預留檢(jian)修通道3.清(qing)潔管路(lu)接頭,擠絲(si)機(ji)液(ye)(ye)壓(ya)(ya)(ya),使用(yong)清(qing)洗劑處理油(you)(you)(you)管內壁二(er)、主(zhu)體安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)流程(cheng)1.液(ye)(ye)壓(ya)(ya)(ya)站安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)?采用(yong)減震墊固定(ding)油(you)(you)(you)泵電(dian)機(ji)組,擠絲(si)機(ji)液(ye)(ye)壓(ya)(ya)(ya)系(xi)(xi)統,同軸度(du)誤差≤0.1mm?油(you)(you)(you)箱(xiang)注(zhu)油(you)(you)(you)前完成酸洗鈍化處理,清(qing)潔度(du)達NAS7級2.執(zhi)行(xing)機(ji)構安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)?主(zhu)油(you)(you)(you)缸安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)垂直度(du)偏差≤0.15mm/m?采用(yong)激光校(xiao)準密煉室與壓(ya)(ya)(ya)砣配合間隙3.管路(lu)施工(gong)?硬管采用(yong)法蘭連接,軟(ruan)管預留20%彎曲余(yu)量?按GB/T3766標準進(jin)行(xing)壓(ya)(ya)(ya)力試驗(1.5倍(bei)工(gong)作壓(ya)(ya)(ya)力)三、調(diao)試注(zhu)意(yi)事項1.啟動(dong)(dong)前點(dian)動(dong)(dong)電(dian)機(ji)確(que)認轉向2.分(fen)(fen)階(jie)段升壓(ya)(ya)(ya)調(diao)試:-低壓(ya)(ya)(ya)循環(3-5MPa)排氣30分(fen)(fen)鐘-中(zhong)壓(ya)(ya)(ya)測試(50%額定(ding)壓(ya)(ya)(ya)力)檢(jian)查泄漏-滿負荷試機(ji)時(shi)間≥2小(xiao)時(shi)3.系(xi)(xi)統油(you)(you)(you)溫控制55±5℃,異常溫升需排查四(si)、驗收標準1.保壓(ya)(ya)(ya)10分(fen)(fen)鐘壓(ya)(ya)(ya)降≤0.5MPa2.動(dong)(dong)作循環重復精(jing)度(du)±0.3mm3.噪(zao)聲等級≤75dB(A)(注(zhu):實(shi)際安(an)(an)(an)(an)裝(zhuang)(zhuang)(zhuang)應參(can)照設(she)備技術手冊,持(chi)證人員操(cao)作)
上(shang)頂(ding)栓(shuan)(shuan)液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)系(xi)統(tong)是密(mi)煉(lian)(lian)機(ji)等設(she)(she)備中用(yong)于(yu)控(kong)(kong)(kong)制(zhi)(zhi)上(shang)頂(ding)栓(shuan)(shuan)升(sheng)(sheng)(sheng)降(jiang)(jiang)與(yu)加(jia)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)的(de)裝(zhuang)置(zhi)(zhi),其組(zu)成主要包括以(yi)下部分:1.**動(dong)力(li)(li)單元**液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)泵(通(tong)(tong)(tong)常采用(yong)柱塞(sai)泵或(huo)變量泵)作(zuo)(zuo)為(wei)(wei)系(xi)統(tong)動(dong)力(li)(li)源(yuan),擠絲機(ji)液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya),將機(ji)械能轉化為(wei)(wei)液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)能,提供穩定(ding)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)油(you)流(liu)。系(xi)統(tong)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)由溢流(liu)閥(fa)(fa)(fa)設(she)(she)定(ding),確(que)保(bao)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)上(shang)限(xian)安(an)全(quan)。2.**執(zhi)行機(ji)構**雙(shuang)作(zuo)(zuo)用(yong)液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)缸(gang)(gang)是執(zhi)行元件(jian),通(tong)(tong)(tong)過活塞(sai)桿直接驅(qu)動(dong)上(shang)頂(ding)栓(shuan)(shuan)完(wan)成升(sheng)(sheng)(sheng)降(jiang)(jiang)動(dong)作(zuo)(zuo)。缸(gang)(gang)體需(xu)(xu)(xu)具(ju)備高(gao)剛性(xing),以(yi)承受(shou)混煉(lian)(lian)過程中的(de)高(gao)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(通(tong)(tong)(tong)常10-25MPa)及沖擊(ji)載(zai)荷。3.**控(kong)(kong)(kong)制(zhi)(zhi)模塊**-**方向(xiang)控(kong)(kong)(kong)制(zhi)(zhi)閥(fa)(fa)(fa)**:電磁換(huan)向(xiang)閥(fa)(fa)(fa)控(kong)(kong)(kong)制(zhi)(zhi)油(you)液(ye)(ye)(ye)流(liu)向(xiang),實現(xian)(xian)液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)缸(gang)(gang)升(sheng)(sheng)(sheng)降(jiang)(jiang)切換(huan)。-**壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)調節(jie)(jie)閥(fa)(fa)(fa)**:比例(li)溢流(liu)閥(fa)(fa)(fa)實時調節(jie)(jie)系(xi)統(tong)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li),泉州擠絲機(ji),適應不同工(gong)藝階段的(de)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)需(xu)(xu)(xu)求。-**流(liu)量控(kong)(kong)(kong)制(zhi)(zhi)閥(fa)(fa)(fa)**:節(jie)(jie)流(liu)閥(fa)(fa)(fa)或(huo)比例(li)流(liu)量閥(fa)(fa)(fa)調節(jie)(jie)液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)缸(gang)(gang)運動(dong)速(su)(su)度(du),確(que)保(bao)平穩啟停(ting)。-**液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)鎖**:液(ye)(ye)(ye)控(kong)(kong)(kong)單向(xiang)閥(fa)(fa)(fa)防(fang)(fang)止停(ting)機(ji)時上(shang)頂(ding)栓(shuan)(shuan)因自(zi)重下滑,確(que)保(bao)安(an)全(quan)鎖定(ding)。4.**輔助(zhu)系(xi)統(tong)**-**蓄能器**:吸(xi)(xi)收壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)脈(mo)動(dong),在(zai)快速(su)(su)動(dong)作(zuo)(zuo)時補充(chong)油(you)量,提升(sheng)(sheng)(sheng)響應速(su)(su)度(du)。-**過濾(lv)裝(zhuang)置(zhi)(zhi)**:多級(ji)過濾(lv)器(吸(xi)(xi)油(you)濾(lv)芯(xin)、高(gao)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)管路濾(lv)芯(xin))保(bao)障油(you)液(ye)(ye)(ye)清潔度(du)(NAS7-9級(ji))。-**溫(wen)控(kong)(kong)(kong)組(zu)件(jian)**:油(you)冷機(ji)或(huo)加(jia)熱(re)器維持油(you)溫(wen)在(zai)40-60℃佳工(gong)作(zuo)(zuo)區間。-**油(you)箱組(zu)件(jian)**:帶(dai)隔板的(de)分區油(you)箱,容量通(tong)(tong)(tong)常為(wei)(wei)泵流(liu)量的(de)3-5倍,配(pei)(pei)備液(ye)(ye)(ye)位(wei)、溫(wen)度(du)傳(chuan)感(gan)器。5.**安(an)全(quan)保(bao)護**壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)繼(ji)電器實時監(jian)測系(xi)統(tong)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li),超壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)時觸發停(ting)機(ji);機(ji)械安(an)全(quan)閥(fa)(fa)(fa)作(zuo)(zuo)為(wei)(wei)防(fang)(fang)線。液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)缸(gang)(gang)內(nei)置(zhi)(zhi)位(wei)移傳(chuan)感(gan)器,與(yu)PLC聯(lian)動(dong)實現(xian)(xian)位(wei)置(zhi)(zhi)閉環控(kong)(kong)(kong)制(zhi)(zhi),精度(du)可(ke)達±1mm。6.**電控(kong)(kong)(kong)集成**PLC通(tong)(tong)(tong)過比例(li)閥(fa)(fa)(fa)、伺服閥(fa)(fa)(fa)實現(xian)(xian)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)/速(su)(su)度(du)的(de)編(bian)程控(kong)(kong)(kong)制(zhi)(zhi),配(pei)(pei)合HMI界面(mian)設(she)(she)定(ding)工(gong)藝參(can)數,并具(ju)備故障自(zi)診斷功能。該系(xi)統(tong)通(tong)(tong)(tong)過電液(ye)(ye)(ye)協同控(kong)(kong)(kong)制(zhi)(zhi),實現(xian)(xian)上(shang)頂(ding)栓(shuan)(shuan)的(de)快速(su)(su)升(sheng)(sheng)(sheng)降(jiang)(jiang)(速(su)(su)度(du)可(ke)達0.2-0.5m/s)、定(ding)位(wei)及恒壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)保(bao)持,滿足密(mi)煉(lian)(lian)工(gong)藝對加(jia)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)密(mi)封與(yu)生(sheng)產(chan)的(de)雙(shuang)重需(xu)(xu)(xu)求。各(ge)組(zu)件(jian)通(tong)(tong)(tong)過高(gao)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)管路(額定(ding)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)力(li)(li)≥31.5MPa)連接,整體設(she)(she)計需(xu)(xu)(xu)符(fu)合ISO4413液(ye)(ye)(ye)壓(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)(ya)系(xi)統(tong)安(an)全(quan)標準(zhun)。
伺服(fu)液(ye)壓(ya)(ya)(ya)系(xi)統排除故障(zhang)的(de)方法主(zhu)要包括以(yi)(yi)下幾(ji)個方面:1.檢(jian)(jian)查壓(ya)(ya)(ya)力(li)與流(liu)量。首先要確(que)認系(xi)統壓(ya)(ya)(ya)力(li)和(he)流(liu)量的(de)穩定性(xing),如(ru)有問題則可(ke)能(neng)是(shi)泵或閥(fa)的(de)損(sun)壞導(dao)致(zhi);更換相應的(de)部件(jian)即可(ke)解決(jue)此類問題導(dao)致(zhi)的(de)系(xi)統故障(zhang)現(xian)(xian)(xian)象和(he)異響噪音等異常(chang)表現(xian)(xian)(xian)癥狀(zhuang)。如(ru)果液(ye)壓(ya)(ya)(ya)泵出現(xian)(xian)(xian)故障(zhang),可(ke)以(yi)(yi)清(qing)洗或更換液(ye)壓(ya)(ya)(ya)油(you)濾清(qing)器、濾網等設備以(yi)(yi)改善(shan)系(xi)統的(de)性(xing)能(neng)和(he)使用壽命以(yi)(yi)及保(bao)障(zhang)正常(chang)工作需求(qiu)。。另外還要注意油(you)箱液(ye)位的(de)高低對系(xi)統和(he)負載(zai)的(de)影(ying)響進行故障(zhang)排除處理(li)并(bing)檢(jian)(jian)查液(ye)壓(ya)(ya)(ya)油(you)的(de)清(qing)潔(jie)度是(shi)否達標(biao)以(yi)(yi)防止發生堵塞等問題造成損(sun)失(shi)及安(an)全問題產生影(ying)響!還需要定期檢(jian)(jian)查和(he)調整相關元件(jian)的(de)參數以(yi)(yi)確(que)保(bao)其正常(chang)運(yun)行狀(zhuang)態滿足使用要求(qiu)并(bing)解決(jue)可(ke)能(neng)出現(xian)(xian)(xian)的(de)異常(chang)情況(kuang)哦!。總之在排查過程中要綜(zong)合考慮各種因素(su)逐一(yi)分(fen)析解決(jue)問題確(que)保(bao)整個系(xi)統運(yun)行安(an)全地(di)完成各項任(ren)務目標(biao)實現(xian)(xian)(xian)預期的(de)經(jing)濟效益(yi)和(he)社(she)會效益(yi)雙贏的(de)局面出現(xian)(xian)(xian)喲!!
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