延长液压油使用寿命分析.docx

THE 300 PROJECTAuthor:Mark G. KeenYes its an aggressive target ! But, achievable !是的,它是个富有挑战性的目标,但是我们达到了!Target 1: Increasing the useful “full performance life” of Hydraulic Oil in the system by 300%提高系统中的液压油有用的全性能寿命300%Target 2: Reducing total “Life Cycle Costs” & “Reducing the use of Oil generally for the environment”减少油的总生命周期成本,减少对环境的影响New technical advances in chemical formulation of oil and additives, combined with “best practice” in management of pollutants that destroy the oil over time and the introduction of “smart condition monitoring” a completely new concept in system management, all of these when combined mean that our goal of +300% oil life and at the same time “total life cost reduction” are achievable simultaneously!最新的系统管理概念通过新技术提高了油和添加剂的化学性能,再结合油的污染管理最佳策略,即消除累积性问题和引进智能状态监控系统,所有这些结合到一起的时候,我们油的寿命+300%的总目标和降低总生命周期成本可以同时达到.Hydac have the technology, the products and the “know how” to achieve this for you!贺德克有这些技术、产品和专有技术可以帮你达到这些目标!What are the “important concepts”?重要观点有哪些?1. Why does oil break down and need replacing?为什么油会劣化,需要更换?a) Time- working oil gets old ! Yes, but just ask the ladies and they will tell you that “antiaging formulas” are nothing new. For oil, this means additives! Now we all know that Hydraulic and Lubrication oils contain additives and have done so for many years (antifoaming, anti-rust, anti-wear, stabilising & anti-oxidising etc.).在用油会老化!是的,如果你去问女士们,她们会告诉你抗衰老的配方,这没什么新鲜的。对于油而言,这个配方就是添加剂.现在我们都知道,液压油和润滑油含有很多添加剂成分并且这样采用了很多年(抗泡,抗锈蚀,抗磨.稳定剂和抗氧化剂等)What you may not know however is that there are new oils being released with new formulas and additives that have advanced “anti-aging characteristics”, they have different “Base Oil” with lower Sulphides (Group 2 and Group 3 base-stocks), they have the latest formulations of Esters, with Phenols & Amines typically used as antioxidants and with polyol esters blended into PAOs to facilitate additive stability. The result is that with proper conditioning & maintenance they have the potential to last longer than ever before.你可能还不知道的是许多新油加入了新的配方和高级抗老化特性的添加剂,他们使用含有低硫化物的特殊基础油(第二代和第三代基础油),他们使用最新配方的酯类物质,有代表性的就是酚和胺常常被当做抗氧化剂和多元醇酯被加入到合成油当中,起到稳定剂的作用。结果就是他们需要适当的状态维护才能长期发挥作用。b) Contamination! All types of contaminants accelerate the aging and break down of the oil. This is a well researched and proven fact, all forms of contamination accelerate the aging, some contaminants however are seldom recognised for what they are.污染物,所有类型的污染物都能加快油的老化和劣化,大量的研究证明,所有的污染物都会促进油的老化,而一些污染物却很少被人们发现认识.(i) These include “Heat”, the Arrhenius equation (as officially defined by IUPAC) is well known and well proven, it states that for every 10 C. increase in oil temperature we the life of the oil based on acceleration of the oxidisation process and thus the depletion / degradation of the additives, (for an oil working at 60 Deg. C that means a projected life of compared to an oil working at 40 Deg. C). You can see from this that “Heat Pollution” is a major and very significant pollutant contributing to shorter oil lifetime, the good news is we can manage heat build up in systems quite easily and therefore optimize the lifetime.首要的污染物是”热”,众所周知的阿伦纽斯等式(IUPAC官方定义的)证明,油温每增加10度,基于氧化反应过程,油的寿命会减少1/2,因而会消耗或分解添加剂,(预计运行油的寿命在温度60度是40度时的1/4),你可以看到热污染是很重要的,并且在降低油的寿命中发挥主要作用.有个好消息是我们能够在系统中很容易的管控热量并延长油的寿命.(ii) Secondly yet also very importantly is the “Dissolved Moisture” as a pollutant,其次,也很重要的是溶解水污染(as opposed to free water). Water contamination starts at a molecular level, we should always remember that oil is hygroscopic in nature and even though it does not mix well with water certainly it attracts water and absorbs it from the humidity in the atmosphere during normal operation. It is also very important to note that the damage from water takes place long before you have “free water” evident in the system. By the time you have free water you have already exceeded 100% saturation and normal methods of looking for water contamination (cloudiness or milkiness) are useless as they only are evident at above saturation points. The “invisible absorbed moisture” at below saturation point is already damaging your oil, accelerating the oxidisation and costing you money.(相对于自由水)水污染最初是分子级别,我们一定记得油具有吸水性,在正常运行时,即使油和水不能很好的结合但是油仍然会从潮湿的大气中吸收水分。在系统中发现有明显的自由水以前,你要注意水产生的危害 ,这时你看见自由水,说明你的系统里水分含量已经超过100%。一般情况下,在饱和点以上,你寻找对付水污染(浑浊或乳化)的方法是没有用的,这种在水饱和点下的看不见的吸收水已经损害了你的系统,加速了氧化过程并增加了你的费用.(iii) Particulate the dust, dirt and wearing down of components that are breathed into the system, added to it by mechanical wear and chemical reaction/breakdown through oxidisation or chain shear etc . These contaminants we rely on filtration to control and to remove. What is clear from many tests and long experience is that most of the dangerous particles that damage our system and components are microscopic in size (that is below the visual spectrum), therefore we need sensors that can see them and quantify the level and the changes in level (these are typically laser and LED particle counters). The particulate contamination at levels below normal filtration (ie. 1020um) can contribute significantly to the aging of the oil and spiralling damage contamination levels.3)颗粒物-粉尘、泥土和悄悄进入系统的零件磨屑,这些物质通过机械磨损和化学反应/氧化分解或剪切链等不断增加,这些物质需要通过过滤来控制和脱除。长期的实验和经验表明,多数对我们的系统和部件有危害的是细小颗粒物(低于可见光谱),因而我们需要能发现它们的传感器,并量度指标和参数变化(典型的是激光和LED计数器),这些颗粒污染物在通常的过滤等级(1020um)以下,能够明显增加油的老化和急剧加速污染的损害程度。Conclusion结论Yes its an aggressive target! But, achievable!By starting clean, maintaining clean & reacting quickly to changes we can easily reach the targets, the good news is the solutions are very affordable and cost effective. They not only pay for themselves, they even save operators money in the medium/long term.从现在开始清洁,维护清洁和快速行动来实现容易达成的目标,好消息是解决方案非常实惠和有成本效益的,它们不仅价格低,也能在中/长期节省运行成本.Hydac have the sensors, t