延長液壓柱(zhu)塞泵使用壽命的(de)有效方法
系統的效率主要取決于液壓泵的容積效率,當容積效率下降到72%時,就需(xu)要進行(xing)常規維修,更換(huan)軸承和老化的(de),要更換或修復超出配合間隙的磨擦副,使其性能得到恢復。
1、液(ye)壓(ya)(ya)(ya)(ya)(ya)泵(beng)(beng)(beng):直軸斜(xie)盤式柱塞(sai)泵(beng)(beng)(beng)分為壓(ya)(ya)(ya)(ya)(ya)力(li)供(gong)(gong)油(you)(you)(you)(you)(you)型的(de)(de)自(zi)吸(xi)油(you)(you)(you)(you)(you)型兩種。壓(ya)(ya)(ya)(ya)(ya)力(li)供(gong)(gong)油(you)(you)(you)(you)(you)型液(ye)壓(ya)(ya)(ya)(ya)(ya)泵(beng)(beng)(beng)大都采(cai)用(yong)有氣壓(ya)(ya)(ya)(ya)(ya)的(de)(de)油(you)(you)(you)(you)(you)箱(xiang),也有液(ye)壓(ya)(ya)(ya)(ya)(ya)泵(beng)(beng)(beng)本身帶有補(bu)油(you)(you)(you)(you)(you)分泵(beng)(beng)(beng)向(xiang)液(ye)壓(ya)(ya)(ya)(ya)(ya)泵(beng)(beng)(beng)進油(you)(you)(you)(you)(you)口提供(gong)(gong)壓(ya)(ya)(ya)(ya)(ya)力(li)油(you)(you)(you)(you)(you)的(de)(de)。自(zi)吸(xi)油(you)(you)(you)(you)(you)型液(ye)壓(ya)(ya)(ya)(ya)(ya)泵(beng)(beng)(beng)的(de)(de)自(zi)吸(xi)油(you)(you)(you)(you)(you)能力(li)很強,無需外(wai)力(li)供(gong)(gong)油(you)(you)(you)(you)(you)。氣壓(ya)(ya)(ya)(ya)(ya)供(gong)(gong)油(you)(you)(you)(you)(you)的(de)(de)液(ye)壓(ya)(ya)(ya)(ya)(ya)油(you)(you)(you)(you)(you)箱(xiang),在每次(ci)啟(qi)動(dong)機器后,必須等液(ye)壓(ya)(ya)(ya)(ya)(ya)漬箱(xiang)達到使用(yong)氣壓(ya)(ya)(ya)(ya)(ya)后,才能操作機械(xie)。如液(ye)壓(ya)(ya)(ya)(ya)(ya)油(you)(you)(you)(you)(you)箱(xiang)的(de)(de)氣壓(ya)(ya)(ya)(ya)(ya)不足(zu)時就擔(dan)任(ren)機器,會(hui)對液(ye)壓(ya)(ya)(ya)(ya)(ya)泵(beng)(beng)(beng)內(nei)的(de)(de)與滑鞭造(zao)成(cheng)(cheng)拉脫現象,出會(hui)造(zao)成(cheng)(cheng)泵(beng)(beng)(beng)體內(nei)回程板與壓(ya)(ya)(ya)(ya)(ya)板的(de)(de)非正(zheng)常磨損。采(cai)用(yong)補(bu)油(you)(you)(you)(you)(you)泵(beng)(beng)(beng)供(gong)(gong)油(you)(you)(you)(you)(you)的(de)(de)柱塞(sai)泵(beng)(beng)(beng),使用(yong)3000h后,操作(zuo)人(ren)員(yuan)每(mei)日需對柱塞泵檢查(cha)1-2次(ci),檢查液壓泵運轉聲響是否正(zheng)常。如發現速(su)度下降(jiang)或悶車時,就應(ying)該對(dui)補油泵解體(ti)檢(jian)查,檢(jian)查葉輪邊沿是否(fou)有刮(gua)傷現象,內泵間隙是否(fou)過大(da)。
2、對于自(zi)吸油型(xing)柱塞泵(beng),液(ye)壓(ya)(ya)油箱內(nei)的油液(ye)不(bu)得低(di)于油標下限,要保持(chi)足(zu)夠(gou)數量的液(ye)壓(ya)(ya)油。液(ye)壓(ya)(ya)油的清潔度越(yue)高,液(ye)壓(ya)(ya)泵(beng)的使用壽命越(yue)長。
3、液(ye)壓泵用(yong)軸(zhou)(zhou)承(cheng)(cheng)柱塞(sai)泵最(zui)重(zhong)要的(de)部件是軸(zhou)(zhou)承(cheng)(cheng),如(ru)果軸(zhou)(zhou)承(cheng)(cheng)出現游隙,則不能(neng)保證(zheng)液(ye)壓泵內部三對磨(mo)擦副的(de)正常間隙,同時也會(hui)破壞各磨(mo)擦副的(de)靜液(ye)壓支承(cheng)(cheng)油膜(mo)厚度(du),降(jiang)低柱塞(sai)泵軸(zhou)(zhou)承(cheng)(cheng)的(de)使用(yong)壽命。據液(ye)壓泵制造(zao)廠提供(gong)的(de)資(zi)料,軸(zhou)(zhou)承(cheng)(cheng)的(de)平均使用(yong)壽命為10000h,超過此值就需要更換新口。拆卸(xie)下來的(de)(de)軸(zhou)承,沒有專業(ye)檢(jian)測(ce)儀器是(shi)無(wu)法檢(jian)測(ce)出軸(zhou)承的(de)(de)游隙的(de)(de),只(zhi)能采用目(mu)測(ce),如(ru)(ru)發現滾柱表面(mian)有劃痕(hen)或變色,就必(bi)須更換。在(zai)更換軸(zhou)承時,應注意原軸(zhou)承的(de)(de)英文(wen)字母和(he)型號,柱塞泵(beng)軸(zhou)承大都(dou)采用大載荷容量軸(zhou)承,最好購(gou)買原廠家,原規(gui)格(ge)的(de)(de)產品,如(ru)(ru)果更換另(ling)一種(zhong)品牌,應請教對軸(zhou)承有經驗的(de)(de)人(ren)員查表對換,目(mu)的(de)(de)是(shi)保持(chi)軸(zhou)承的(de)(de)精度等(deng)級和(he)載荷容量。
4、三對磨擦副檢查與修復(fu):柱塞桿與缸體(ti)孔(kong)根據(ju)柱塞泵(beng)零(ling)件(jian)(jian)的更換(huan)標準,當零(ling)件(jian)(jian)的各種(zhong)間隙超差時(shi),可按下(xia)述方法修復(fu):
(1)缸體鑲裝銅套的,可以采(cai)用(yong)更換銅套的方法修復。首先(xian)把一組(zu)柱(zhu)塞桿(gan)處徑修整到(dao)統一尺(chi)寸,再(zai)用(yong)1000#以(yi)上的砂紙拋光外徑(jing)。缸體安裝銅套的三種方法(fa):(a)缸(gang)體加溫(wen)熱(re)裝或銅套低溫(wen)冷凍擠壓(ya),過(guo)盈裝配(pei);(b)采有樂泰膠(jiao)粘著裝配,這咱方(fang)法要求銅外套(tao)外徑表面有溝槽;(c)缸孔攻(gong)絲,銅套(tao)外徑加(jia)工(gong)螺紋,涂樂泰膠后,旋入裝配。
(2)熔燒結合(he)方式(shi)的缸體與銅(tong)套,修復方法如(ru)下:(a)采(cai)用(yong)研磨棒(bang),手(shou)工或機械方法(fa)研磨修(xiu)復缸孔;(b)采用座標鏜床(chuang),重新鏜缸(gang)體孔(kong);(c)采用鉸刀(dao)修(xiu)復缸體(ti)孔。
(3)采用“表面工程技術(shu)”,方法如下:(a)電鍍(du)技術(shu):在柱塞表面鍍(du)一(yi)層(ceng)硬鉻(ge);(b)電(dian)刷鍍技術:在柱塞表面刷鍍耐(nai)磨材(cai)料;(c)熱(re)噴涂或電(dian)弧噴涂或電(dian)噴涂:噴涂高(gao)碳馬氏體(ti)耐磨材(cai)料(liao);(d)激(ji)光熔(rong)敷:在柱(zhu)塞表面熔(rong)敷高硬度耐磨合金粉末。
(4)缸(gang)體孔(kong)無銅套的缸(gang)體材料大都(dou)是球墨鑄鐵的,在缸(gang)體內壁(bi)上制(zhi)備非晶態薄膜或(huo)涂層。因為(wei)缸(gang)體孔(kong)內壁(bi)有(you)了這種(zhong)特殊(shu)物(wu)質,所以才能組成硬—硬配對的磨(mo)擦副。如果(guo)盲目(mu)地研(yan)磨(mo)缸(gang)體(ti)孔(kong),把缸(gang)體(ti)孔(kong)內壁這層表(biao)面(mian)材料研(yan)掉(diao),磨(mo)擦更加的結構性能(neng)也就(jiu)改變了。被去掉(diao)涂層的磨(mo)擦副,如果(guo)強行使用(yong),就(jiu)會磨(mo)擦面(mian)溫(wen)度急劇升高,柱(zhu)塞桿(gan)與缸(gang)孔(kong)發生膠(jiao)合
5、另外在柱塞桿(gan)表(biao)面制備一種獨(du)特的薄膜(mo)涂(tu)層(ceng),涂(tu)層(ceng)含有減磨(mo)+耐(nai)磨+潤滑功能,這組磨擦副實際還(huan)是(shi)硬-軟配對(dui),一旦人地改變涂(tu)層(ceng),也就(jiu)破壞了(le)最(zui)佳配對(dui)材料的磨(mo)擦(ca)副,修理這些特殊(shu)的柱塞泵,就(jiu)要(yao)送到專業修理廠。