壓機(jī)液壓系統(tǒng)課件

1、Table of contents 目錄1 Safety instructions 1-1 安全操作說(shuō)明1.1 General 1-1 概論1.2 Safety valves 1-1 安全閥1.3 Hose lines 1-1 軟管2 Safety precautions 2-1 安全預(yù)防2.1 General information 2-1 概論2.2 Depressurizing the pressure vessel 2-1 給壓力容器減壓2.2.1 Manual depressurization of plunger accumulator 2-2 活塞儲(chǔ)能器的手動(dòng)減壓2.3 Depr

2、essurizing pipelines 2-2 給管道減壓2.4 Measuring and venting hydraulic systems 2-3 測(cè)量和給液壓系統(tǒng)排氣2.4.1 General information 2-4 概論2.4.2 Preparing to vent the system 2-4 給系統(tǒng)排氣的準(zhǔn)備工作2.4.3 Venting process 2-4 排氣步驟3 Maintenance instructions 3-1 維護(hù)說(shuō)明3.1 General 3-1概論3.2 Cleaning the hydraulic system 3-1液壓系統(tǒng)的清潔3.3 F

3、lushing the hydraulic system 3-2 液壓系統(tǒng)的沖洗 3.3.1 Flushing time 3-2 沖洗時(shí)間3.3.2 Flushing procedure 3-2 沖洗步驟3.3.2.1 Switch on the cooling and filter pump 3-2 打開冷卻過(guò)濾泵3.3.2.2 Switch on the main drives 3-2 打開主驅(qū)動(dòng)設(shè)備3.3.2.3 Flush the ring line 3-2 沖洗油缸管道3.3.2.4 Flush the blocks 3-4 沖洗集成閥塊Flush the main cylinder

4、 blocks 3-4 沖洗主油缸塊3.3.3 Install control valves 3-5 控制閥安裝3.3.3.1 Storing control valves 3-5 控制閥的儲(chǔ)存3.4 Hydraulic oil 3-6 液壓油3.4.1 Hydraulic tank and filling 3-6 液壓油箱和液壓油的填充3.4.2 Oil change 3-6 液壓油的更換3.4.3 Notes on the miscibility of hydraulic oils 3-7 關(guān)于液壓油的黏度的說(shuō)明3.5 Recharging with nitrogen 3-7填充 氮?dú)?.

5、6 Taking back into operation 3-9 1 Safety instructions 安全說(shuō)明1.1 General 概論It is indispensible to have read and understood the “Safety” chapter.In addition, follow the safety instructions in the "Maintenance" chapterfor maintenance, servicing and repair work.In addition, follow the safety in

6、structions in the "Maintenance" chapterfor maintenance, servicing and repair work.It is essential to comply with all safety regulations!認(rèn)真閱讀和理解安全說(shuō)明在進(jìn)行維修和維護(hù)工作時(shí)嚴(yán)格遵守安全操作說(shuō)明1.2 Safety valves 安全閥Pressure limiting valves preventing excessive pressure buildup are installedon the oil sides. The pre

7、ssure setting is locked by a lead seal andmust never be modified.限制過(guò)多的壓力形成的壓力控制閥被安裝在閥體的油側(cè)。 壓力裝置被鉛密封鎖定，注意這個(gè)設(shè)定的壓力千萬(wàn)不能被改動(dòng) 。Never modify the safety valve settings ！千萬(wàn)不要更改安全閥裝置Safety block of nitrogen bottles ，oil sided 液壓油側(cè)的 氮?dú)馄康陌踩y塊 1 manual release 手動(dòng)減壓2 accumulator safety valves 儲(chǔ)能器的安全閥3 electrical r

8、elease 自動(dòng)減壓 Refer to the “Certificates” chapter for the official acceptance certificate.Pressure limiting valves are safety-related parts. Never repair replaced pressure limiting valves yourself. Pressure limitingvalves must not be repaired by anyone other than the equipmentmanufacturer. 千萬(wàn)不要更換壓力限制閥

9、。 除設(shè)備供應(yīng)商外任何人不能夠修理和更換此閥。1.3 Hose lines 軟油管The owner is responsible for ensuring that hose lines are replaced at suitableintervals, at least every 5 years, including the time of storage (max.2 years).Hose lines must be replaced even if there are no signs of defects whichcould affect their safety. 至少5年

10、對(duì)軟管更換一次（這個(gè)時(shí)間段包括最多的2年的儲(chǔ)存時(shí)間）即使軟油管沒有明顯的殘缺在5年內(nèi)必須更換一次。 2 Safety precautions 安全預(yù)防措施Depressurize the pipeline system and block the low-pressure tank beforecommencing maintenance or repair work on the hydraulic equipment.在給液壓設(shè)備開始進(jìn)行維護(hù)和修理工作前， 要給液壓系統(tǒng)減壓和堵塞低壓油箱。 In addition, it is a requirement that the press mu

11、st not be subject to anyweight loads and must be supported on mechanical stops.此外， 壓機(jī)不受任何的重量負(fù)荷在壓機(jī)停止時(shí)壓機(jī)必須被支撐起來(lái)。Furthermore, all pumps must be switched off and prevented from restarting(see "2 Switching off for mechanical and electrical work" in the“Maintenance electrical system” chapter).Th

12、ese precautions are also necessary when tightening pipelines in orderto seal leaks. 所有的油泵必須被關(guān)閉防止油泵重新啟動(dòng)。 在擰緊管道密封泄露時(shí)這些預(yù)防措施也是必要的。 2.2 Depressurizing the pressure vessel 給壓力容器減壓Switching off the electrical power supply causes the pressure relief valveson the pressure tank to be switched to the tank. Thi

13、s automaticallydepressurizes the pressure tank oil sided.Work must only be carried out on the device once the container has beendepressurised. Risk of explosion.在壓力容器上進(jìn)行工作前必須給壓力容器減壓否則有爆炸的危險(xiǎn)。 The sign shown also points out this urgently required work.下面這個(gè)標(biāo)志出示了這個(gè)緊急必須要做的工作（給壓力容器減壓） Measure the system b

14、efore continuing work to check it isdepressurized!在繼續(xù)進(jìn)行工作之前要測(cè)量系統(tǒng)是否被減壓，。2.2.1 Manual depressurization of plungeraccumulator 活塞儲(chǔ)能器的手動(dòng)減壓Safety block of nitrogen bottles ，oil sided 液壓油側(cè)的 氮?dú)馄康陌踩y塊 1 manual release 手動(dòng)減壓2 accumulator safety valves 儲(chǔ)能器的安全閥3 electrical release 自動(dòng)減壓Open the manual pressure re

15、lief valve slowly. 慢慢打開壓力安全閥pressure vessels ：壓力容器1 nitrogen bottles 氮?dú)馄? pressure gauge 壓力表3 charging and testing unit 充氣和檢測(cè)裝置Depressurize the system before continuing work if pressure is detected.The system can be depressurized as follows:在連續(xù)進(jìn)行工作前給系統(tǒng)減壓， 減壓的方法如下： Turn the master switch "off&qu

16、ot;. This automatically depressurises thepressure vessels關(guān)閉主開關(guān)， 此時(shí)自動(dòng)給壓力容器減壓 Operate the vent valve until the pressure is no longer present對(duì)排氣閥進(jìn)行操作直到壓力不存在 Open the manually operated shut-off valves to the tank打開通向油箱的手動(dòng)操作的關(guān)閉閥 Operate the valves to the tank using the emergency manual operatingsystem 用緊

17、急手動(dòng)操作系統(tǒng)操作通向油箱的閥門。 Also note that a static pressure (pressure column) may be present as theresults of containers being on a higher level. These pressures also haveto be relieved in order to prevent oil loss in the system.注意一個(gè)靜態(tài)壓力可能存在如果容器被放在一個(gè)很高的位置。 為防止系統(tǒng)的液壓油損失這些壓力也必須被排除。 Measure the system again befo

18、re starting repair work to make sure it isstill depressurized.在開始維護(hù)工作之前測(cè)量系統(tǒng)確保系統(tǒng)已經(jīng)被減壓。 2.4 Measuring and venting hydraulic systems 液壓系統(tǒng)的測(cè)量和排氣Measure the system before starting repairwork to check itis depressurized在開始維護(hù)工作之前測(cè)量系統(tǒng)確保系統(tǒng)已經(jīng)被減壓。Keep all parts of your body away from the venting openings.The g

19、as and fluid emerging from venting openingsis pressurized and may be hot. Danger of injuryand scalding.保持你的身體遠(yuǎn)離排氣孔。 從排氣孔流出的液體和氣體已經(jīng)被減壓但可能溫度很高，這些液體和氣體會(huì)對(duì)人體造成燒傷。Secure the press before venting the system. If fitted,engage the ram locking device or, at the very least,prevent access to the press space. 在給

20、系統(tǒng)排氣前確保壓機(jī)的安全 。 要啟動(dòng)壓機(jī)框架鎖定裝置。 至少要防止進(jìn)入壓機(jī)空間的途徑。 venting hydraulic systems 液壓系統(tǒng)的排氣1 cap 螺帽2 venting valve 排氣閥2.4.1 General information 概論Any air caught in the system must be vented in order to ensure that thehydraulic system functions correctly. Venting points have been installedin the system in order to

21、 do this. These venting points are marked on thehydraulic diagram.為確保液壓系統(tǒng)的正常工作，任何存在于液壓系統(tǒng)中的氣體必須被排除。 排氣孔已經(jīng)在液壓系統(tǒng)中被安裝。 這些排氣空在液壓圖表中已經(jīng)被表明。 2.4.2 Preparing to vent the system 給系統(tǒng)排氣的裝備工作The press must not be at maximum operating pressure when the completehydraulic system is vented. 在給液壓系統(tǒng)排氣時(shí)壓機(jī)不能處在最大的工作壓力狀態(tài)。

22、 A pressure of approximately 100 bar is quite adequate for venting thecomplete hydraulic system. 大約100 bar的壓力對(duì)于完成液壓系統(tǒng)排氣已經(jīng)足夠了。 Perform the venting process at all venting and measuring points, particularlyon the working and retract cylinders (highest point on the piping oron the system).在所有的排氣點(diǎn)和測(cè)量點(diǎn)進(jìn)行排

23、氣工作， 特別在回程油缸上（在系統(tǒng)或管道的最高點(diǎn)）上工作時(shí)。 If a venting hose is used for venting, secure the free end of the hose tostop it from whirling. 如果一個(gè)排氣軟管被用來(lái)排氣，保證排氣管的任意一端扭曲旋轉(zhuǎn)。 2.4.3 Venting process 給系統(tǒng)排氣In order to perform the venting process, unscrew the cap from the ventingpoint and attach the supplied vent actuator

24、 to that point (turn throughapprox. two rotations but do not tighten it down under any circumstances).從排氣點(diǎn)松開螺帽 。 把排氣裝置連接在排氣點(diǎn)上 vent actuator 排氣裝置1 pipe section with nut for diverting emerging fluid 排除從液壓系統(tǒng)流出的液體管道2 container 容器3 hydraulic line 液壓管4 connection for venting valve 螺帽5 venting valve 排氣閥6 v

25、ent actuator with knurled nut 帶螺母的排氣裝置venting 排氣1 venting valve 排氣閥2 cover cap 螺帽3 hydraulic line 液壓管Turn the pipe elbow and the venting hose so its opening is pointing awayfrom anyone or anything nearby. Attach a small container to the end ofthe vent actuator, but do not hold it there by hand.轉(zhuǎn)動(dòng)液壓管

26、肘和排氣管使得排氣孔遠(yuǎn)離任何人和附近的物體， 把一個(gè)小容器連接在排氣裝置的末端注意不要用手握著它。 venting valve 排氣閥1 hose for diverting emerging fluid 排除從液壓系統(tǒng)流出的液體軟管2 support venting hose 排氣軟管的支架3 container 容器4 hydraulic line 液壓管5 connection for venting valve 排氣閥的接頭6 cover cap 螺帽7 venting valve 排氣閥8 knurled nut of venting hose 帶螺母的排氣管If there is

27、very little space available, it is a good idea to use a ventinghose. Make sure the hose is not pointing towards people or objects in theimmediate vincinity.Never hold the end of the hose by hand. Always secure it well by mechanicalmeans.如果有很小的空間可利用， 可以使用一個(gè)排氣管。保證軟管不要朝著在它附近的任何人和物體。 千萬(wàn)不要用手握著排氣管的末端。 要使用

28、機(jī)械的方法來(lái)穩(wěn)固它。Lead the end of the venting hose into a collecting vessel.Slowly turn the knurled nut on the venting valve clockwise by hand inorder to screw it onto the venting point until you can hear air escaping.Start unscrewing the knurled nut anti-clockwise as soon as hydraulic fluidbegins to emerge

29、 from the vent opening. This concludes the venting processat this venting point.Screw the cap back onto the venting point after completing the ventingprocess. 把排氣管通到末端盛液體容器中。 用手慢慢的順時(shí)針轉(zhuǎn)動(dòng)排氣閥上的螺母（為了把它擰緊在排氣點(diǎn)上）直到你能夠聽到有空氣流通的聲音，一旦有液壓液體從排氣孔流出開始逆時(shí)針?biāo)蓜?dòng)螺母。此操作包括了在這個(gè)排氣點(diǎn)上的排氣過(guò)程。 Screw the cap back onto the venting

30、point after completing the ventingprocess.在排氣過(guò)程完成后， 把排氣點(diǎn)上的螺帽擰上。 3 Maintenance instructions 液壓系統(tǒng)的維護(hù)3.1 GeneralCheck the oil level in the tank, check the screw connections are tight andvent pipes at the highest point.檢查液壓油箱的油位。 檢查螺紋接頭是否上緊，排氣管是否在最高位置。 Depressurize the plant before tightening screw conn

31、ections.在上進(jìn)螺紋接頭前給系統(tǒng)減壓Flush through the system with the standard flushing volume whenevermore than 10% of the tank volume is topped up or each time the oil ischanged.每次當(dāng)加注的液壓油量達(dá)到油箱油量的10%時(shí)或在更換液壓油時(shí)要對(duì)系統(tǒng)進(jìn)行沖洗。 Observe instructions regarding miscibility遵守液壓油的黏度說(shuō)明。 Your oil supplier or filter supplier can p

32、erform a precise analysis on youroil samples.液壓油和過(guò)濾器的供應(yīng)商能夠?qū)σ簤河偷臉悠愤M(jìn)行準(zhǔn)確的分析。 Please observe our table of lubricants.遵守潤(rùn)滑的油量。 Replace hydraulic hose lines at the specified intervals or wheneverappropriate, even if there are no signs of damage which could impairsafety.在固定的時(shí)間更換液壓油管（即使沒有損壞的跡象）3.2 Cleaning

33、the hydraulic system 液壓系統(tǒng)的清洗The service life of components and reliability of the system depend to alarge extent on the purity of the hydraulic oil.系統(tǒng)部件的使用壽命和系統(tǒng)的穩(wěn)定性在很大程度上取決與液壓油的純度。 The ingress of dirt in the oil circuit can often not be completely avoidedeven by exercising great care when installing

34、 hydraulic components andhydraulic system lines.在安裝液壓部件和液壓系統(tǒng)管道時(shí)，細(xì)心的操作不能夠完全避免液壓油循環(huán)入口被污染和弄臟。 Consequently, flush the hydraulic system before taking it into operation.Any dirt in the tank can be removed via the cleaning openings. Ensureadequate ventilation when working in the oil tank.因此在進(jìn)行設(shè)備運(yùn)轉(zhuǎn)前要清洗液壓系統(tǒng)

35、。 在油箱中的任何臟物可通過(guò)清潔口取除。 在油箱上工作時(shí)注意充足的排氣。 The hydraulic system must always be cleaned before being filled withhydraulic oil.在安裝液壓油之前， 液壓系統(tǒng)必須保持清潔。Use special solvents or cleaning agents for the purpose of cleaning.用特殊的溶液或清洗劑來(lái)給液壓系統(tǒng)清洗。 Observe regulations concerning fire and potential health hazards. Always

36、clean thoroughly every time the hydraulic fluid is changed.遵守關(guān)于火災(zāi)和危險(xiǎn)區(qū)的說(shuō)明。 在每次更換液壓油時(shí)徹底的清洗系統(tǒng)。 3.3 Flushing the hydraulic system 液壓系統(tǒng)的沖洗 3.3.1 Flushing time 沖洗時(shí)間(All item numbers refer to the hydraulic diagram.)The flushing time should total approx. 48 hours.沖洗的時(shí)間總共應(yīng)該是48小時(shí)。 The flushing time is primari

37、ly determined by the purity of the hydraulicfluid.沖洗的時(shí)間原則上根據(jù)液壓油的純度而定。 Max. admissible degree of impurity in systems equipped with control valves.Oil purity class 15/11 (ISO 4406)系統(tǒng)中配備了檢測(cè)液壓油的純度的控制閥，液壓油的純度等級(jí)為15/11 (ISO 4406)Repeat flushing if the value fails to meet this requirement.如果數(shù)值不能夠滿足這個(gè)需求進(jìn)行重新清

38、洗。 3.3.3 Install control valves 控制閥的安裝Install the control valves with due regard to cleanliness on complection ofthe flushing procedure. 在完成液壓系統(tǒng)的沖洗后安裝控制閥1 install the valve here after the flushing procedure 在在完成液壓系統(tǒng)的沖洗后安裝控制閥All pressure limiting valves must be set to the values states in the hydraul

39、icdiagram.所有的壓力限制閥必須設(shè)置為液壓圖表中的規(guī)定的狀況。 3.3.3.1 Storing control valves 控制閥的儲(chǔ)存Store in a dry and dust-free room which is free from corrosive substancesand vapors. When storing control valves for more than three months, fillthe valve housing with preservative oil and seal it.把控制閥儲(chǔ)存在一個(gè)干燥無(wú)灰塵的房間，確保此房間無(wú)腐蝕物質(zhì)和氣

40、體。 在控制閥儲(chǔ)存3個(gè)多月后，給閥座加防腐油并密封。 Observe the manufacturers instructions!遵守生產(chǎn)商的說(shuō)明。 3.4 Hydraulic oil 液壓油 3.4.1 Hydraulic tank and filling 液壓油箱和液壓油的填充Fill the oil tank with oil up to the top inspection glass. 油箱的油位填加到油位檢測(cè)玻璃的頂部。 hydraulic tank 液壓油箱1 inspection glass 油位檢測(cè)玻璃The pump switches off if the oil lev

41、el falls below the minimum oil level.如果油位降到最底的油位值關(guān)閉油泵。 Oil is filled via the cooling and filtering pump. The filling fixture is identifiedby an information notice attached to it.液壓油通過(guò)冷卻過(guò)濾泵填加。填充的裝置被帖在油泵上的信息通知出示。 When filling new hydraulic oil or when performing a complete oil change,use a 5 m ultrafi

42、ne filter for filling. This is necessary to ensure faultlessfunction of the pump, the proportional hydraulics and the servohydraulics.為確保油泵、伺服液壓的正常工作當(dāng)加入新的液壓油或進(jìn)行油更換時(shí)用一個(gè)過(guò)濾芯非常細(xì)的過(guò)濾器。3.4.2 Oil change 液壓油的更換For further information about the oil change procedure see point "14 Oilchange" in the "Maintenance general" chapter.液壓油的更換步驟的詳細(xì)情況參見維護(hù)章節(jié)的14點(diǎn)液壓油的更換3.4.3 Notes on the miscibility of hydra