The hydraulic transmission system includes five parts: oil pump, oil cylinder, various valves, and working medium.
The hydraulic system converts the mechanical energy of the prime mover into hydraulic pressure energy based on the hydraulic pump, and transmits energy by combining the change in hydraulic pressure energy. Through the transmission of diversified valves and pipelines, the hydraulic cylinder converts the hydraulic pressure energy into mechanical energy, thereby guiding the working mechanism to achieve linear reciprocating motion and rotary motion.
The characteristics of hydraulic transmission systems are mainly divided into the following points:
Firstly, it has a very small volume and light weight, with a weight of only 10% to 20% of that of a power hydraulic motor. Due to the low inertia force, there will be no significant impact in the event of overload or stoppage of operation;
Secondly, it can smoothly adjust the traction speed within the specified range and achieve the goal of infinite speed regulation;
Thirdly, it is easy to reverse direction, which can better transform the rotation and linear reciprocating motion of the working mechanism without changing the rotational force of the motor;
Fourthly, the hydraulic pump and hydraulic motor are connected through oil pipes and are not constrained by each other in terms of spatial design;
Fifthly, because oil is used as the working medium, lubricants will be generated during the relative motion of the parts, resulting in low wear and a very long application time;
Sixth, the operation is very simple and the degree of automation is very high;
Seventh, it can provide overload protection;
Eighth, ensuring the standardization and standardization of hydraulic components helps to better design and apply them.
Common faults and troubleshooting solutions in hydraulic transmission systems
Classification of hydraulic transmission system problems
In general, problems can be classified into three categories based on the hydraulic systems and hydraulic component applications of various types of hydraulic facilities: first, common problems, which are hydraulic problems that often occur in the hydraulic systems and hydraulic components of various types of hydraulic facilities. Secondly, personality issues refer to the special problems that arise from the unique hydraulic functions of hydraulic systems and components in hydraulic facilities. Thirdly, there is the issue of rationality, which refers to the problems caused by the unscientific or incomplete design of hydraulic systems, as well as the unscientific design or selection of hydraulic components.
Judgment of hydraulic transmission system problems
It is mainly divided into the following points: firstly, hope. That is to observe whether there are problems with the pressure, speed, oil, leakage, and vibration of the hydraulic system. Secondly, smell. That is to say, listen to the sound of the hydraulic system, such as impact sound, pump sound, abnormal noise, etc., to clarify whether the hydraulic system is working safely and normally. Thirdly, ask. That is to say, communicate with the facility operator to clarify the working conditions of the facility, including whether the hydraulic system is working properly and whether there are any abnormal working conditions of the hydraulic pump. In actual work, it is necessary to conduct a comprehensive analysis of the above content in order to make a reasonable judgment on the problem. Fourth, cut. That is to say, it indicates the temperature, vibration, and degree of tightness at the connection, and clarifies the effectiveness and safety of the moving parts.
Common problems and solutions in hydraulic transmission systems
Firstly, the system either lacks pressure or has insufficient pressure. The influencing factors for this problem include the following: firstly, when the overflow valve is opened, the valve core is obstructed, making it difficult to close, resulting in blockage of the damping air, poor cooperation between the valve core and seat, or loss of function of the spring; Secondly, other control valve cores are obstructed, resulting in unloading; Thirdly, hydraulic components are severely worn or seals are affected, leading to internal and external leakage problems; Fourthly, the liquid level is low, the oil suction is blocked, or the oil temperature is too high; Fifthly, there is a problem with the pump steering, such as low speed or insufficient power. When this problem arises, the following solution can be applied, which is the elimination method. The actual job responsibilities mainly include the following: firstly, repairing and researching valve cores and shells, cleaning damping holes, and replacing springs; Secondly, identify the location of the problem, conduct cleaning or maintenance research, and promote the flexible application of the valve core in the valve body; Thirdly, check the sealing of pumps, valves, and pipeline connections, repair or replace parts and seals; Fourthly, refueling, cleaning the oil suction pipe or cooling system; Fifth, check the power source.
Secondly, there is insufficient traffic. The reasons for this problem are as follows: firstly, the oil level in the tank is too low, the viscosity of the oil is too high, and the filter is clogged, resulting in very high suction resistance; Secondly, there are problems with the steering of the hydraulic pump, such as low speed or significant wear caused by idling, resulting in a gradual decrease in performance. When this problem occurs, the elimination method can be used to solve it. The actual work mainly includes the following points: firstly, detecting the liquid level, replenishing the oil, changing the hydraulic oil with appropriate viscosity, and ensuring the diameter of the suction pipe; Secondly, check the prime mover, hydraulic pump, and hydraulic pump variable mechanism, and replace the pump in severe cases.
Thirdly, leakage. The main reasons for this problem are as follows: firstly, loose joints with low sealing performance; Secondly, during the process of plate or flange connections, the pre tightening force of screws is poor or the sealing performance is not strong; Thirdly, the system pressure is higher than the rated working pressure of hydraulic components or accessories for a long time; Fourthly, a water-cooled cooler is installed inside the fuel tank. For example, if the oil level increases, but water leaks into the oil, and if the oil level decreases, the oil will leak into the water. When this problem occurs, it can be solved according to the elimination method, which mainly includes the following points: firstly, tighten the joint and replace the seal; Secondly, the pre tightening force should be greater than the hydraulic pressure to change the sealing performance; Thirdly, the pressure inside the component housing should not exceed the pressure present in the oil seal, and the seal should be replaced; Fourthly, dismantle and repair.
Fourthly, overheating. There are several reasons for this problem: firstly, the liquid level is too low or the viscosity is not suitable; Secondly, incorrect pressure regulation and prolonged work under high pressure. During the process of encountering the above problems, troubleshooting can be used to solve them, which mainly includes the following points: firstly, troubleshooting or replacing the cooler; Secondly, refuel or replace the oil with a suitable viscosity; Adjust the pressure of the overflow valve to the standard value, and make important changes to the circuit at critical moments.
Fifth, vibration. There are many reasons for this problem, such as low hydraulic oil level, insufficient insertion of oil into the suction pipe, high oil viscosity, clogged filtration, and low agility of other valve cores. When the above problems occur, it is necessary to solve them according to the elimination method. On the one hand, the sealing inlet can be changed, and on the other hand, the equipment can be clearly specified. Of course, it is also possible to re weld, replace the spring parts, clean and study the configuration of the valve core and valve body.
Sixth, impact. The main reasons for this problem are as follows: firstly, the insufficient inflation pressure of the accumulator; Secondly, the work pressure is relatively high; Thirdly, the pilot valve and directional valve brake are not sensitive, and the throttling buffer is too slow; Fourthly, there is no buffering equipment designed at the end of the hydraulic cylinder; Fifthly, the overflow valve problem leads to a continuous increase in pressure; Sixth, there is a large amount of air in the system. When the above situation occurs, the problem can be solved according to the elimination method. The actual work content can be divided into the following points: firstly, inflating the accumulator; Secondly, adjust the pressure to the required value; Thirdly, reduce the inclination angle of the brake cone or increase the length of the brake cone, and repair the throttling buffer equipment; Fourthly, enhance buffering equipment or back pressure valves; Fifth, repair and modification; Sixth, clear the air.
In summary, due to the characteristics and practical working principles of hydraulic transmission systems, various problems are bound to arise during their operation, ultimately affecting the normal functioning of the system and posing significant safety concerns. Therefore, in practical work, it is necessary to control the hydraulic transmission system according to the operating standards, clarify several common problems in development, comprehensively analyze the problems, design high-quality solutions, implement relevant maintenance work, regularly implement protection and testing work, so as to ensure the stability and effectiveness of the hydraulic transmission system.
2026 April 2nd Week VAFEM Product Recommendation
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