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壓路機液壓振動系統(tǒng)典型故障診斷及維修

2015-5-24 9:04:17

Typical fault diagnosis and maintenance of hydraulic vibration system of roller

1. 典型故障及原因分析

1 typical failures and reasons analysis

故障1：發(fā)動機工作正常，開啟振動開關后，振動系統(tǒng)不工作。

1: the engine works properly, after the vibration switch, the vibration system does not work.

根據(jù)工作原理分析，主要原因有：

According to the principle of work, the main reasons are:

(1) 發(fā)動機飛輪與振動泵輸入軸之間的彈性傳動盤脫落或損壞，造成振動液壓泵沒有動力輸入，不能實現(xiàn)能量轉(zhuǎn)換。

(1) the elastic transmission disc between the engine flywheel and the input shaft of the vibration pump can fall off or damage, resulting in the vibration hydraulic pump without power input, and the energy conversion can not be realized.

(2) 振動液壓馬達與振動軸之間的聯(lián)軸節(jié)損壞，造成振動液壓馬達動力不能輸出。

(2) the coupling vibration between the hydraulic motor and the vibration shaft damage caused by vibration, hydraulic motor power cannot output.

(3) 液壓油箱缺油或吸油濾清器嚴重堵塞，系統(tǒng)主回路內(nèi)不能及時補油，造成吸空，無法傳遞動力。

(3) the hydraulic oil tank is lack of oil or oil absorption filter, the main circuit can not fill up the oil in time, resulting in suction, can not pass power.

(4) 電磁換向閥沒有或有很小的電流通過，使電磁閥內(nèi)的先導閥芯不能推動排量控制閥芯動作，從而液壓泵的排量控制液壓缸不能供油，造成液壓泵的斜盤不能傾斜，排量為零。

(4) solenoid valve with no or very small current through, the electromagnetic valve of the pilot valve can not promote displacement control valve action, so as to control the displacement of the hydraulic pump hydraulic cylinder can not supply oil, resulting in hydraulic pump of swash plate can not tilt, the displacement is zero.

(5) 系統(tǒng)補油壓力太低或沒有，使振動液壓泵排量控制液壓缸不能正常工作。

(5) the oil pressure of the system is too low or there is no, so that the hydraulic pump can not control the hydraulic cylinder can not work properly.

(6) 振動液壓泵或振動液壓馬達磨損，內(nèi)泄嚴重，建立不起系統(tǒng)壓力。

(6) the vibration hydraulic pump or vibration hydraulic motor wear and tear, within the serious, can not establish the system pressure.

故障2：振動液壓馬達轉(zhuǎn)速太低，達不到設計要求。

Fault 2: vibration hydraulic motor speed is too low, can not reach the design requirements.

根據(jù)工作原理分析，主要原因有：

According to the principle of work, the main reasons are:

(1) 發(fā)動機轉(zhuǎn)速沒有達到額定值。

(1) the engine speed is not up to the rated value.

(2) 系統(tǒng)補油壓力沒有達到額定值，不能推動振動液壓泵斜盤處于最大排量位置。

(2) the oil pressure without the system is not up to the rated value and can not drive the inclined plate of the vibration hydraulic pump in the maximum displacement position.

(3) 振動軸運動阻力太大，運轉(zhuǎn)不靈活。

(3) the movement of the vibrating shaft is too high and the movement is not flexible.

(4) 振動液壓泵或振動液壓馬達內(nèi)泄漏，使系統(tǒng)效率降低。

(4) vibration hydraulic pump or hydraulic Madane leakage, so that the system efficiency is reduced.

故障3：系統(tǒng)只能在單一振幅狀態(tài)下正常工作（即只能在大振幅狀態(tài)下正常工作，而在小振幅狀態(tài)不能工作；或者只能在小振幅狀態(tài)下正常工作，而在大振幅狀態(tài)下不能工作）。

Fault 3: system can work normally under the single amplitude state (that is, only in the large amplitude under the condition of normal work, and in the small amplitude state cannot work; or only in small amplitude under the condition of normal work, and in large amplitude under the condition of not working).

根據(jù)工作原理分析，主要原因有：

According to the principle of work, the main reasons are:

(1) 電磁閥沒有或只有很小的電流通過，對應先導閥芯不能正常工作。

(1) the solenoid valve is not or only a small current passed, the corresponding pilot valve can not work.

(2) 振動液壓泵內(nèi)對應某一方向多功能閥損壞，建立不起高壓。

(2) the vibration hydraulic pump corresponding to a certain direction of the multi-function valve damage, can not afford to build.

(3) 振動液壓泵的排量控制閥內(nèi)故障使排量控制液壓缸只能向一個方向運動。

(3) the displacement control valve of the vibration hydraulic pump can cause the displacement control hydraulic cylinder to move only in one direction..

(4) 振動液壓馬達內(nèi)對應某一方向沖洗梭閥閥芯卡死，建立不起高壓。

(4) the vibration hydraulic Madane corresponding to a direction flushing shuttle valve spool card, can not afford to build.

2. 診斷及維修

2 diagnosis and maintenance

2.1. 診斷的原則及維修注意事項

The principle of 2.1. diagnosis and maintenance of attention

診斷的一般原則：根據(jù)液壓系統(tǒng)的工作原理，如下圖，由表及里，先機械電器，后液壓自身。

The general principles of diagnosis: according to the working principle of the hydraulic system, as shown in the following picture, from the outside to the inside, to mechanical and electrical, hydraulic itself.

維修的一般注意事項：保持液壓系統(tǒng)的清潔，防止污物和其它有污染的物質(zhì)進入系統(tǒng)；只能根據(jù)使用的保養(yǎng)說明書使用液壓油，禁止不同牌號液壓油混加；當更換液壓泵或馬達后，重新啟動液壓系統(tǒng)時，首先給液壓泵和馬達加滿液壓油，而后把振動液壓馬達與振動軸脫開，盡可能慢地運轉(zhuǎn)發(fā)動機，在不帶載荷情況下啟動液壓系統(tǒng)。當振動液壓泵2的Mc測壓口處補油壓力達到額定值2.4MPa時，再使發(fā)動機以額定轉(zhuǎn)速運轉(zhuǎn)，而后分別開啟大小振幅振動開關，使振動液壓馬達無負荷空轉(zhuǎn)。每個振動狀態(tài)下至少運轉(zhuǎn)5min，以便使液壓系統(tǒng)內(nèi)空氣排出。同

General considerations of maintenance: to maintain the cleanliness of the hydraulic system, to prevent dirt and other polluting substances into the system; only according to the use of the use and maintenance manual, hydraulic oil, prohibit different grades of hydraulic oil mixed with; when replacing the hydraulic pump or motor, restart the hydraulic system, first of all to the hydraulic pump and motor is filled with hydraulic oil. Then it vibration hydraulic motor and shaft vibration disengaged, slow running engine as much as possible, in without load under the condition of hydraulic system is started. When the hydraulic vibration pump 2 MC pressure at the mouth of the fill oil pressure reaches the rated value 2.4Mpa, then the engine running at rated speed, and then open a small amplitude vibration switch, the vibration of hydraulic motor no-load idling. At least 5min of each vibration state, so that the air discharge within the hydraulic system. The same

時觀察液壓油箱油面，待無汽泡冒出時，把振動馬達重新裝好，必要時添加液壓油，而后蓋好油箱蓋。液壓系統(tǒng)工作正常后，應檢查螺紋接頭和法蘭的密封性，必要時緊固。

Observation of hydraulic oil tank surface, to be no bubble burst out, the vibration motor re installed. If necessary, add the hydraulic oil, and cover the fuel tank cap. After the hydraulic system works, check the sealing of the threaded joints and flanges, and fastening when necessary.

2.2. 典型故障的診斷與排除

Diagnosis and removal of 2.2. typical fault

針對故障1“發(fā)動機工作正常，開啟振動開關后，振動系統(tǒng)不工作”的情況，首先應檢查液壓油箱油位，吸油濾清器真空表（在連續(xù)狀態(tài)下，當真空表讀數(shù)0.03MPa時，表示濾芯堵塞，應更換濾芯），排除原因（3）引起的故障。然后，在電磁閥a和b的線圈與電源線插頭之間串聯(lián)一塊電流表，開啟相應的起振開關，如果電流達到額定值2.5A，則表示電源的電磁閥線圈工作正常，否則，可判斷為由原因（4）引起的故障。排除故障（3）、（4）后，如果振動輪不振動，則在補油壓力測壓口Mc處接4MPa壓力表一塊。在發(fā)動機怠速運轉(zhuǎn)狀態(tài)下觀察壓力表讀數(shù)，當補油壓力大于或等于2.4MPa時，則表示正常；當補油壓力大于零域或小于2.4MPa時，則表示振動液壓泵上的補油壓力溢流閥有問題，應檢查排除；當補油壓力為零時，應先檢查傳力盤，排除故障原因（1）引起的故障。而后檢查振動泵內(nèi)的補油泵。當補油壓力在發(fā)動機怠速運轉(zhuǎn)狀態(tài)下正常時，使發(fā)動機在額定轉(zhuǎn)速下運轉(zhuǎn)，分別開啟大小振幅狀態(tài)的振動，再次觀察補油壓力。正常值為2.2MPa左右；如果補油壓力遠遠低于此值，則把4MPa壓力表接在振動液壓馬達3測壓口Ms處并觀察其讀數(shù)，如果Ms處壓力亦為2.2MPa左右則表示正常；否則當壓力讀數(shù)特別異常（遠遠偏低或偏高）時，應先檢查振動馬達上的沖洗梭閥及低壓溢流閥。經(jīng)查如果二者均正常，則應拆下振動泵上的排量控制閥，觀察其是否出現(xiàn)嚴重泄漏現(xiàn)象。通過以上檢查可排除補油壓力不正常即原因（5）引起的故障。當發(fā)動機怠速運轉(zhuǎn)和在額定轉(zhuǎn)速下運轉(zhuǎn)補油壓力均正常時，則在振動泵2的高壓測壓口MA、MB處接60MPa壓力表各一塊，分別開啟大小振動開關，并觀察壓力讀數(shù)。正常情況下：小振幅時MA為高壓，初始壓力為42MPa~45MPa，連續(xù)工作壓力14MPa左右；大振幅時MB為高壓，初始壓力為42MPa~45MPa，連續(xù)工作壓力22MPa左右。如果振動液壓泵2的MA或MB處高壓壓力很低，則首先應拆下裝振動馬達的法蘭檢查聯(lián)軸節(jié)是否損壞，排除由原因（2）引起的故障，而后恢復原狀。以上原因排除后，應先檢查振動泵2多功能閥上的BYPASS拖閥，再檢查多功能閥，觀察閥座與閥體是否劃傷，必要時更換或修復。排除多功能閥的原因后，應檢查泵的排量控制閥，把4MPa壓力表接在振動泵排量控制閥壓力測壓口S1處，并使柴油機在額定轉(zhuǎn)速下運轉(zhuǎn)，正常情況為：開啟小振幅開關，S1處壓力應近似等于補油壓力；關掉振動開關，S1處壓力應為零（相對于泵的殼體壓力）；同樣，開啟大振幅開關，檢查S2處壓力，它也相當于補油壓力；關掉開關，S2處壓力亦為零。如有異常，則清理閥內(nèi)的節(jié)流口或更換控制閥，而后，如還不能修復，則應拆下聯(lián)接振動液壓泵和液壓馬達的兩個高壓軟管，用干凈的螺塞封住振動液壓泵2的A口和B口，拉住柴油機熄火門，短時間啟動柴油機，然后，依次開啟大小振動，觀察振動液壓泵測定MA、MB處壓力表的讀數(shù)，如果二者壓力均能超過42MPa（不同時），則可判斷為振動液壓馬達損壞，反之，則可判斷為振動液壓泵損壞，從而排除原因（6）引起的故障。

Aiming at fault "engine working normally, open the vibration switch, vibration system does not work", first of all, we should check the hydraulic oil level in oil tank, oil filter vacuum table (in the continuous state, when the vacuum gauge readings 0.03mpa, said filter plugging, should replace the filter), excluding (3) causes of failure. Then, the electromagnetic valve A and B of the coils and a power supply line between the plug series a current meter and the corresponding vibration switch is opened, if the current reaches the rated value 2.5A, said power supply of the electromagnetic valve coil is normal, otherwise, judgment on the grounds of reason (4) is caused by the fault. After troubleshooting (3) and (4), if the vibration wheel is not vibration, then a 4MPa pressure gauge is received at the oil fill pressure Mc.. Under engine idling to observe the pressure gauge readings, when the fill oil pressure is greater than or equal to 2.4Mpa, said normal; when the oil pressure is greater than zero field or less than 2.4Mpa, hydraulic vibration pump fill oil pressure relief valve has a problem, should check out; when the oil pressure is zero should be, first check the transmission force pan, exclude fault reason (1) caused by the fault. And then check the pump in vibration pump. When the oil pressure in the engine idle operation state, the engine running at the rated speed, respectively, the vibration of the amplitude of the amplitude of the state, and then observe the oil pressure. Normal value is about 2.2 MPa; if the complement of the oil pressure is far below this value, the 4MPa pressure meter is connected in the hydraulic vibration motor 3 pressure export MS office and observe the reading, if MS pressure also is about 2.2 MPa said normal; otherwise when the pressure readings in particular abnormality (far lower or higher) should be first check vibration motor flush shuttle valve and pressure relief valve. If the two are normal, you should remove the vibration on the pump displacement control valve, to observe whether the serious leakage phenomenon. Through the above examination can rule out the oil pressure is not normal that the cause (5) of the failure. When the engine idling and under the rated speed operation fill oil pressure were normal, in vibration pump 2 high pressure manometry Ma and MB at connected 60MPa pressure table, a piece of, respectively, on the size of the vibration switch, and observe the pressure readings. Under normal circumstances: small amplitude Ma is a high voltage, initial pressure 42MPa~45MPa, continuous working pressure is 14MPa around; the large amplitude MB for high pressure, initial pressure 42MPa~45MPa, continuous working pressure 22Mpa around. If the hydraulic vibration pump 2 mA or MB at high pressure is very low, it should first split whether the damage to the bottoms of the vibration motor check the flange coupling, excluding by (2) causes of the fault, and then restore the status quo ante. After the above reasons are excluded, should first check the vibration pump 2 multi-function valve on the BYPASS drag valve, then check the multi-function valve, observe the valve seat and valve body is scratched, if necessary, replace or repair. After exclusion of the multifunctional valve, should check the pump displacement control valve to 4MPa pressure meter is connected in the vibration pump displacement control valve pressure testing port S1, and the engine at rated speed operation, normal: the small amplitude switch, S1 pressure should be approximately equal to fill the hydraulic force; vibration switch is switched off, the S1 pressure should be zero (relative to the pump casing pressure); similarly, open the large amplitude switch, check the S2 pressure. It also equivalent to fill oil pressure; turn off the switch, S2 pressure is also zero. 2 and if abnormal, clean the valve orifice or replace the control valve, such as can not repair, should remove the coupling vibration of hydraulic pump and hydraulic motor of the two high-pressure hose, clean plug to seal the hydraulic vibration pump port a and B, pull diesel engine flameout door, short time between the start of diesel engine, and then, followed by the opening size of the vibration, the observation of vibration hydraulic pump for Ma, MB pressure gauge readings, if the two pressure than 42MPa (not simultaneously), can be judged for the vibration of hydraulic motor damage. On the other hand, can be judged for the vibration of hydraulic pump damage, so as to eliminate the cause (6) caused by the fault.

針對故障2“振動液壓馬達轉(zhuǎn)速太低，達不到設計要求”的情況，首先應檢查液壓油箱油位、吸油濾真空表，其次，用轉(zhuǎn)速表或頻率儀檢查發(fā)動機轉(zhuǎn)速，標定額定轉(zhuǎn)速為2300r/min。如果該轉(zhuǎn)速正常，則可排除故障原因（1）。而后測量振動頻率。大振幅時，振動頻率為28Hz（1680r/min）；小振幅時，振動頻率為25Hz（2100r/min）。當頻率下降小于10%時，調(diào)整振動泵2上的雙向手動排量調(diào)節(jié)裝置，分別依照高低振動頻率調(diào)整轉(zhuǎn)速。

For fault 2 "vibration of hydraulic motor speed is too low, amounting to less than the design requirements", first of all, we should check the hydraulic oil level in oil tank, oil filter vacuum gauge. Secondly, tachometer or frequency of the instrument to check the engine speed, calibration rated speed 2300r/min. If the speed is normal, the cause of failure (1) can be excluded.. And then measure the vibration frequency. The vibration frequency of the large amplitude is 28Hz (1680r/min); the vibration frequency is 25Hz (2100r/min) when the small amplitude is. When the frequency drops is less than 10%, the bidirectional manual displacement adjustment device of the vibration pump 2 is adjusted according to the vibration frequency of the vibration frequency.

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