Created on:2021-12-15 14:19

Commissioning of hydraulic equipment

Commissioning of hydraulic equipment

Before the products leave the factory, the manufacturer of hydraulic equipment, the user unit must debug the hydraulic equipment according to relevant standards after the installation of new equipment and the repair of equipment.

1. Make technical preparations and be familiar with the debugged equipment

First, carefully read the equipment operation manual to fully understand the purpose, technical performance, main structure, equipment accuracy standard, operation requirements, safety technical requirements, operation methods, commissioning precautions, etc. of the hydraulic equipment.

To digest the hydraulic system diagram and clarify the working principle and performance requirements of the hydraulic system, it is necessary to clarify the functions of hydraulic, mechanical and electrical and their relationship, action sequence and interlocking relationship, and be familiar with the actual position of various components in the hydraulic system on the equipment, their function, performance, structural principle and adjustment method. Also analyze the action cycle and movement sequence of each actuator of the hydraulic system and the corresponding oil circuit, pressure and flow. How to take effective prevention and reliable response measures for the parts where equipment safety accidents may occur.

Based on the above considerations, determine the commissioning contents, steps and methods.

2. Inspection before commissioning

(1) Before commissioning, the exposed hydraulic components and pipelines shall be scrubbed again. Sponge shall be used during scrubbing, and cotton yarn shall be prohibited.

(2) The guide rail, each oil filler and other sliding pairs shall be fully lubricated as required.

(3) Check whether the rotation direction of the oil pump and the inlet and outlet oil pipes of the oil cylinder, oil motor and oil pump are connected incorrectly.

(4) Check whether the connections of hydraulic components and pipelines are correct and reliable, and correct the wrong installation.

(5) Check the position of each handle, confirm the "stop", "reverse" and "unloading" positions, and fasten each travel stop at the appropriate position.

(6) Loosen the overflow valve handle and properly tighten the safety valve handle to adjust the overflow valve to the minimum working pressure. Adjust the flow valve to the minimum.

(7) Turn on the power.

3. Commissioning

(1) Jog: jog the pump first and observe whether the steering of the oil pump is correct. If the power supply is connected reversely, there will be no oil output, and sometimes accidents may occur. Therefore, remember that only "jog" can be performed at the beginning of operation. The continuous operation and no-load commissioning can be put into operation only when the sound of the pump is normal and the oil is continuously output and there are no other abnormal phenomena.

(2) System exhaust: after starting the hydraulic pump, adjust the system pressure to about 10MPa, respectively control the reversing of the solenoid valve to make the oil circulate to each branch, screw the exhaust valve set on the pipeline to discharge the gas in the pipeline; When the oil overflows continuously, close the exhaust valve. When the hydraulic cylinder exhausts, the piston rod of the hydraulic cylinder can be extended, the exhaust valve on the side is opened, the solenoid valve acts, the piston rod moves, extrudes the air, and closes the exhaust valve when it rises to the top dead center. Open the exhaust valve on the other side, make the hydraulic cylinder go down, discharge the air in the rodless chamber, and repeat the above exhaust method until the air in the hydraulic cylinder is completely discharged.

(3) System pressure test: mainly refers to the pressure test of field pipeline and hydraulic equipment, which shall be carried out in the manufacturer. For hydraulic pipeline, the pressure of pressure test shall be 1.5 times of the maximum working pressure. For high-pressure system with working pressure ≥ 21MPa, the pressure of pressure test shall be 1.25 times of the maximum working pressure. If the hydraulic pump of the system can reach the pressure resistance value, it is not necessary to use the electric pressure test pump. The pressure boosting process shall be carried out gradually in sections, and the peak value shall not be reached at one time. When each level is raised, it shall be maintained for several minutes, and observe whether the pipeline is normal. It is forbidden to operate the directional valve during the pressure test.

(4) No load commissioning: first run at low speed for 10-20min. Sometimes it is necessary to remove the connection between the oil cylinder or oil motor and the load. Especially in the cold season, this low-speed operation without load (warm-up operation) is particularly important. Some imported equipment often have strict requirements for this, and some are equipped with heaters to heat up the oil in the oil tank. Test run the actions that can operate at low speed and low pressure first.

(5) The specific operation method is to tighten repeatedly, immediately loosen the pressure or flow regulating handle of overflow valve and flow valve for several times, and use the pressure gauge to observe the rise and fall of pressure, the speed change of actuator, the heating, vibration and noise of oil pump. Problems found shall be analyzed and solved in time.

(6) According to the action cycle table, combined with electrical machinery, debug each single action first, and then turn to cycle action commissioning to check whether each action is coordinated. There will be some problems in the commissioning process, such as crawling, impact and non commutation. For complex domestic and imported equipment, if there are problems that are difficult to solve, we can consult together and turn to the manufacturer of hydraulic equipment if necessary.

(7) Finally, enter the full load commissioning, that is, carry out the maximum working pressure and maximum (small) working speed test according to the technical performance of hydraulic equipment, and check the power, heating, noise, vibration, high-speed impact, low-speed crawling, etc. Check the oil leakage of each part. Oil leakage often occurs when the pressure of the no-load part increases. Find problems, eliminate them in time, and make written records.

If everything is normal, the test piece can be processed. After commissioning and shutdown, the machine tool shall generally be restored, and detailed commissioning records shall be kept on file. Commissioning records of some imported equipment can be used as the basis for claims.

(8) Generally, do not move the handles of the hydraulic equipment debugged by the above methods. For the equipment to be packaged and delivered, all hand wheels shall be loosened. For equipment not used for a long time, the hand wheel of the pressure valve shall be loosened to prevent permanent deformation of the spring from affecting various faults and performance when the mechanical equipment is started.

(9) During the commissioning of the hydraulic system, all design values shall be inspected according to the design contents, and the operation status of the hydraulic system shall be determined according to the actual recorded results. The design, user, manufacturer and installation unit shall carry out handover acceptance and sign on relevant documents.

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