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双头组合车床的液压系统设计
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黄河科技学院毕业设计（文献翻译） 第 5 页液压系统常见故障分析及处理摘要：文章以液压系统工作原理为基础，研究了液压系统故障的形式，详述了解决此类故障的方法。关键词：液压缸，控制阀，液压泵1.工作原理液压传动是以液体为工作介质，通过能量转换来实行执行机构所需运动的一种传动方式。首先，液压泵将电动机（或其它原动机）的机械能转换为液体的压力能，然后，通过液压缸（或液压马达）将以液体的压力能再转化为机械能带动负载运动。2.液压系统的组成液压传动系统通常由以下五部分组成。（1）动力装置部分。其作用是将电动机（或其它原动机）提供的机械能转换为液体的压力能。简单地说，就是向系统提供压力油的装置。如各类液压泵。（2）控制调节装置部分。包括压力、流量、方向控制阀，是用以控制和调节液压系统中液流的压力、流量和流动方向，以满足工作部件所需力（或力矩）、速度（或转速）和运动方向（或运动循环）的要求。（3）执行机构部分。其作用是将液体的压力能转化为机械能以带动工作部件运动。包括液压缸和液压马达。（4）自动控制部分。主要是指电气控制装置。（5）辅助装置部分。除上述四大部分以外的油箱、油管、集成块、滤油器、蓄能器、压力表、加热器、冷却器等等。它们对于保证液压系统工作的可靠性和稳定性是不可缺少的，具有重要的作用。3.液压缸液压缸是把液压能转换为机械能的执行元件。液压缸常见故障有：液压缸爬行、液压外泄漏、液压缸机械别劲、液压缸进气、液压缸冲击等。3.1液压缸爬行故障分析及处理（1）缸或管道内存有空气，处理方法：设置排气装置；若无排气装置，可开动液压系统以最大行程往复数次，强迫排除空气；对系统及管道进行密封。（2）缸某处形成负压，处理方法：找出液压缸形成负压处加以密封；并排气。（3）密封圈压得太紧，处理方法：调整密封圈，使其不松不紧，保证活塞杆能来回用手拉动。（4）活塞与活塞杆不同轴，处理方法：两者装在一起，放在V形块上校正，使同度误差在0.04mm以内；换新活塞。（5）活塞杆不直（有弯曲），处理方法：单个或连同活塞放在V形块上，用压力机控直和用千分表校正调直。（6）导轨或滑块夹得太紧或与液压缸不平行，处理方法：调整导轨或滑块的压紧（条）的松紧度，既保证运动部件的精度，又保证滑动阻力要小；若调整无效，应检查缸与导轨的平行度，并修刮接触面加以校正。（7）两活塞杆两端螺母扭得太紧，处理方法：调整松紧度，保持活塞杆处于自然状态。（8）缸内壁或活塞表面拉伤，局部磨损严重或腐蚀等，处理方法：镗缸内孔，重配活塞。3.2液压缸的冲击故障分析及处理（1）未设缓冲装置，处理方法：调整换向时间（0.2秒），降低液压缸动力速度；增设缓冲装置。（2）缓冲装置中的柱塞和孔的间隙过大，处理方法：更换缓中柱塞或在孔中镶套，便间隙达到规定要求；检查节流阀。（3）端头缓冲的单向阀反向，处理方法：修理、研配单向阀与阀座或更换。3.3液压缸的外泄露故障分析及处理（1）活塞杆表面损伤，处理方法：修复活塞杆损伤。（2）密封圈边缘伤或老化，处理方法：更换密封圈。（3）管接头密封不严，处理方法：检查密封圈及接触面有无伤痕，加以修复或更换。（4）缸盖处密封不严，处理方法：检查接触面加工精度及密封圈老化情况，及时更换或修复。（5）由于排气不良，使气体绝热压缩造成局部高温而损坏密封圈，处理方法：检查排气装置，或增设排气装置；及时排气。（6）缓冲装置处密封不严，处理方法：缸杆接触面加工精度及密封圈老化情况，及时更换或修整。3.4液压缸的内泄露故障分析及处理（1）缸孔和活塞因磨损致使配合间隙增大超差，处理方法：活塞磨损严重时，应镗缸孔，将活塞车小，并车几道糟装上密封圈密封或新配活塞。（2）活塞上的密封圈磨伤或老化，处理方法：密封圈磨伤或老化应及时更换。（3）活塞与缸筒安装不同心或承受用偏心负荷，使活塞倾斜或偏磨，处理方法：检查缸筒与活塞与缸盖活塞杆孔的同心度，并修整对中。（4）缸孔径加工直线性差或局部磨损造成局部腰鼓形镗缸孔，处理方法：重配活塞。3.5声响和噪声活塞下部空气绝热压缩，处理方法：将活塞慢速运动，往复数次，每次均走到顶端，以排除缸中气体，即可消除此严重的噪声，还可防止密封圈烧伤。4.液压控制阀液压控制阀是液压传动系统中的控制调节元件，它控制油液的流动的方向、压力、流量以满足执行元件所需要的压力、方向和速度的要求，从而使执行机构带动负载实现预定的动作。4.1液压阀的性能要求在液压系统中，对液压阀的性能要求，主要有以下几点。（1）动作灵敏、使用可靠，工作时冲击和振动要小，使用寿命长。（2）油液流过液压时压力损失要小，密封性能要好，内泄漏要小，无外渗漏。（3）结构紧凑，安装、维护、调整方便，通用性好。4.2液压阀分类（1）压力控制阀（简称压力阀）。是用来控制液压系统中的压力以满足执行元件所需力(或力矩)的要求。包括溢流阀、减压阀、顺序阀、压力继电器等。（2）方向控制阀（简称方向阀）。是用来控制液压系统中油液的方向，以满足执行元件运动方向的要求。包括单向阀、换向阀等。（3）流量控制阀（简称流量阀）。是用来控制液压系统中的流量，以满足执行元件运动速度的要求。包括节流阀、调速阀等。（4）复合阀（也称多元阀）。是用来控制液压系统中的方向、压力、流量三个参数的两个或全部。例如，单向减压阀，既能控制油液的方向，同时还控制油液的压力。4.3溢流阀常见故障分析与处理液压阀以溢流阀为例，简单介绍。故障内容处理方法溢流阀的调节装置出现问题拆开检查，更换合适的调压弹簧电磁换向阀的阀芯卡住。通电后，电磁力不能使阀芯换向到位，使阀口有微小开度拆开检查，清洗，修磨电磁阀阀芯溢流阀的先导阀的锥阀芯不良(1)拆开检查，修磨锥阀芯密封表面。损伤严重时，应换用新的合格零件。(2)拆开清洗并检查液压油被污染程度，根据情况过滤油液或换油溢流阀中的电磁换向阀的阀芯磨损严重，内部泄漏加剧拆开检查，清洗液压元件和系统，消除引起液压元件不正常磨损的因素，再更换新的换向阀溢流阀中的电磁换向阀的阀芯磨损严重，内部泄漏加剧拆开检查，清洗液压元件和系统，消除引起液压元件不正常磨损的因素，再更换新的换向阀主阀故障拆开检查，清洗、修整阀芯与阀孔。必要时检查油液污染度，过滤或更换油液，装配时注意保持阀芯与阀孔的同心度5.液压泵液压泵是液压动力元件，它是将电动机（或其他原动机）输入的机械能转变成液压能的能量转换装置。其作用是向液压系统提供压力油。5.1液压泵的分类： （1）齿轮泵（外啮合齿轮泵和内啮合齿轮泵） （2）叶片泵（单作用叶片泵和双作用叶片泵） （3）柱塞泵（轴向柱塞泵和径向柱塞泵）5.2齿轮泵常见故障分析与处理齿轮泵是常见于生产线的液压泵。在此，仅就齿轮泵故障缝隙与处理方法介绍如下：（1）油泵齿轮与泵壳的配合间隙超过规定极限，处理方法：更换泵壳或采用镶套法修复，保证油泵齿轮齿顶与壳体配合间隙在规定范围之内。（2）齿轮轴套与齿轮端面过度磨损，使卸压密封圈预压缩量不足而失去密封作用，导致油泵高压油腔与低压油腔串通，内漏严重，处理方法：在后轴套下面加补偿垫片（补偿垫片厚度一般不宜超过2mm），保证密封圈安放的压缩量。（3）拆装油泵时，在2个轴套（螺旋油沟的轴套）结合面处，将导向钢丝装错方向，处理方法：保证导向钢丝能同时将2个轴套按被动齿轮旋转方向偏转一个角度，使2个轴套平面贴合紧密。（4）在拆装油泵时，隔压密封圈老化损坏，卸压片密封胶圈被装错，处理方法：若隔压密封圈老化，应更换新件：卸压片密封胶圈应装在吸油腔（口）一侧（低压腔），并保证有一定的预紧压力。如装在压油腔一侧，密封胶圈会很快损坏，造成高压腔与低压腔相通，使油泵丧失工作能力。6.总结关于液压系统各部分组成的常见故障及处理方法的简单介绍，是我们长期实践证明的结果。它可以使我们少走弯路,能快速、准确地查找出故障，并且在短时间内将其解决。从而提高生产效率，降低生产成本；能创造良好的经济效益。Hydraulic system and the typical fault mechanism analysisAbstract: the article to hydraulic system working principle as the foundation, study the hydraulic system failure form, described the methods for solving this kind fault. Keywords: hydraulic cylinder Control valvesHydraulic pump 1.Working principle Hydraulic transmission is based on liquid medium for work, through the energy conversion to implement executive agency needs a kind of movement transmission mode. First of all, hydraulic pump will motor (or other prime mover) mechanical energy into liquid pressure can, and then, through the hydraulic cylinder (or hydraulic motor) will with liquid pressure can be transformed into mechanical energy to drive the load movement. 2.Hydraulic system composition Hydraulic transmission system is usually the following five parts. （1）The power plant parts. Its role is to motor (or other prime mover) provide mechanical energy into liquid pressure. Say simply, it is to the system to provide the pressure oil device. Such as all kinds of hydraulic pump. （2）Control adjusting device parts. Including pressure, flow rate, direction control valves, is to control and adjustment of the hydraulic system the fluid flow pressure, flow and flow direction, in order to meet the required force working parts (or torque), speed (or speed) and the movement direction (or movement cycle) requirements. （3）Actuators parts. Its role is to pressure liquid into mechanical energy to drive the working parts of sports. Including hydraulic cylinder and hydraulic pressure motor. （4）Automatic control parts. Is mainly refers to the electrical control device. （5）Auxiliary devices parts. In addition to the four other than most of the oil tank, oil tube, integrated blocks, oil filters, accumulator, pressure gauge, heater, cooler, and so on. They work to ensure the reliability of hydraulic system and stability is indispensable, has the vital role. 3.Hydraulic cylinderThe hydraulic cylinder is put into mechanical energy of hydraulic actuators. The hydraulic cylinder common faults are: hydraulic cylinder, hydraulic external leakage, crawling hydraulic cylinder mechanical strength, hydraulic cylinder dont air intake, hydraulic cylinder impact, etc. 3.1The hydraulic cylinder crawling failure analysis and processing (1) cylinder or conduit memory with air, processing methods: set exhaust device; If not exhaust device can start the hydraulic system to the largest travel reciprocating several times, eliminate air force; On the system and line seal. (2) cylinder somewhere form negative pressure, and processing methods: to find the hydraulic cylinder formation in negative pressure to seal; And exhaust. (3) pressure sealing ring too tight and processing methods: adjust the sealing ring, make its not loose not tight, ensure the piston rod can by hand pull back and forth. (4) the piston and axial piston rod, processing methods: both pack together, in V piece of correction, make with degrees in error within 0.04 mm; Change new piston. (5) the piston rod is not straight (have curve), processing methods: a single or together with the pistons on V block, with pressure straight and equipped with dial indicators correction to the upright. (6) guide or the slider clip too tight or is not parallel with hydraulic cylinder, processing methods: adjust guide or slide block pressure (a) the tightness of rewinding, not only ensure the precision of moving parts, and ensure the sliding resistance to small; If the adjustment is invalid, should check cylinder and guide rail parallel degree, and blow the interface to correction. (7) two piston rod ends and nuts too tight and processing methods: adjust tightness of rewinding, keep the piston rod in a natural state. (8) cylinder wall or the piston surface is pulled, the local badly worn or corrosion, processing methods: boring hole in cylinder, heavy with the pistons. 3.2The impact of the hydraulic cylinder fault analysis and processing (1) does not have a buffer device, processing methods: adjusting the commutation time ( 0.2 seconds), reduce speed hydraulic cylinder power; Add buffer device. (2) buffer installations in the piston and the hole large clearance, processing methods: to replace delay of piston or in holes set in the set, and clearance to regulations; Check the throttle valve. (3) end of the buffer fitting reverse, processing methods: repair, grind with one-way valve seat or replace with. 3.3Hydraulic cylinder of the leak fault analysis and treatment (1) the piston rod surface damage, processing methods: repair the piston rod damage. (2) sealing ring edge injuries or aging, processing methods: replace the sealing ring. (3) pipe joint seal lax, processing methods: check the sealing ring and contact surfaces have scars, try to repair or replacement. (4) in the cylinder head seal lax, processing methods: check the surface machining accuracy and sealing ring aging, to replace or repair. (5) with exhaust bad, make the gas adiabatic compression leading local high temperature and damage the sealing ring, processing methods: check the exhaust device, or add exhaust device; Timely exhaust. (6) buffer device sealing in lax, processing methods: cylinder rod surface machining accuracy and sealing ring aging, change in time or trim. 3.4Hydraulic cylinder of fault analysis and treatment in the leak (1) cylinder piston wear for the hole and with increasing gap of tolerance, processing methods: the piston wear serious when, should be boring cylinder hole, the piston car is small, and the car a few way worse loaded on sealing ring seal or new match the piston. (2) on the piston seal ring abrasion or aging, processing methods: sealing ring abrasion or aging should change in time. (3) the piston and cylinder install different heart or bear with eccentric load, make the piston tilt or partial grinding, processing methods: check the cylinder piston and cylinder, piston rod with holes of concentricity, and trimmed to. (4) cylinder aperture processing straight sex differences or local wear leading local YaoGu form boring cylinder hole, processing methods: heavy with the pistons. 3.5Sound and noise The adiabatic compressed air piston, processing methods: will the piston slow motion, reciprocating several times, each time all walk to the top, to rule out of gas cylinder, can eliminate the serious noise, still can prevent 4.Hydraulic control valvesHydraulic control valves is hydraulic transmission system of control regulation components, it control the oil flow direction, pressure, and flow rate in order to meet the need of the actuator pressure, direction and speed requirements, and drives the execution for achieving the load of the action. 4.1The performance requirements of hydraulic valves In the hydraulic system, the performance requirements of hydraulic valve, basically have the following points. (1) action quick, reliable operation, the work of the impact and vibration to small and long service life. (2) the oil flow through hydraulic pressure loss to small, sealed performance is better, internal leakage to small, no outside leakage. (3) compact structure, installation, maintenance, easy to adjust, excellent versatility. 4.2 Hydraulic classification (1) pressure control valves (hereinafter referred to as pressure valve). Is used to control the pressure in the hydraulic system to meet the execution element required force (or torque) requirements. Including the relief valve, pressure reducing valve, order valve, pressure relay, etc. (2) the direction control valves (hereinafter referred to as the direction valve). Is used to control the hydraulic system in the direction of oil, in order to meet the requirements of the actuator movement direction. Including the check valve, reversing valves, etc. (3) flow control valves (hereinafter referred to as flow valve). Is used to control the hydraulic system of flow, to meet the requirements of the speed of executive element movement. Including the throttle valve, speed control valves, etc. (4) composite valve (also called multiple valve). Is used to control the hydraulic system of direction, pressure, and flow rate three parameters of two or all. For example, one-way pressure reducing valve, can not only control the oil direction, and also control the oil pressure. 4.3The relief valve common fault analysis and processing Hydraulic valve to overflow valve as an example, introduces simply. Fault content processing method The relief valve adjusting device problems disassemble, replace the appropriate pressure regulating spring Electromagnetic valve core of the directional control valve stuck. After electrify, electromagnetic force cant make directional control valve core are in place so that the tiny opening mouth have disassemble, cleaning, the grinding electromagnetic valve core The relief valve pilot valve cone valve core bad (1) disassemble, the grinding conical valve core seal surface. Serious damage, should be replaced with a new qualified parts. (2) apart and check the hydraulic oil is washing pollution levels, according to the circumstances of oil or oil filter Relief valve of the directional control valve of the electromagnetic valve core badly worn, internal leakage aggravate disassemble, cleaning hydraulic components and systems, eliminate the cause hydraulic components not normal wearing of factors, and then replace new directional control valves Relief valve of the directional control valve of the electromagnetic valve core badly worn, internal leakage aggravate disassemble, cleaning hydraulic components and systems, eliminate the cause hydraulic components not normal wearing of factors, and then replace new directional control valves The main valve failure disassemble, cleaning, trim valves and valve core hole. When necessary check the oil pollution, filter or replace the oil, assembling keep valve core and valve of concentricity hole 5.Hydraulic pump Hydraulic pump is hydraulic components, it is will motor (or other prime mover) input mechanical energy into a hydraulic energy conversion devices. Its function is to provide the hydraulic system pressure oil. 5.1Hydraulic pump classification: (1) the gear pump (the meshing gear pump and internal meshing gear pump) (2) vane pump (single function and dual action vane pump vane pump) (3) piston pump (axial piston pump and radial piston pump) 5.2The gear pump common fault analysis and processing The gear pump is common in the production line of the hydraulic pump. In this, the only fault aperture and treatment gear pump is introduced as follows: (1) the oil pump gear and pump shell with clearance of more than the specified limit, processing methods: replacement pump shell or use set set repair method, ensure top gear pump and shell with clearance in a set area. (2) gear collar and gear end excessive wear, make discharging pressure sealing ring the compression i
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