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黃河科技學(xué)院畢業(yè)設(shè)計(jì)（文獻(xiàn)翻譯） 第 5 頁
液壓系統(tǒng)常見故障分析及處理
摘要：文章以液壓系統(tǒng)工作原理為基礎(chǔ)，研究了液壓系統(tǒng)故障的形式，詳述了解決此類故障的方法。
關(guān)鍵詞：液壓缸，控制閥，液壓泵
1.工作原理
液壓傳動是以液體為工作介質(zhì)，通過能量轉(zhuǎn)換來實(shí)行執(zhí)行機(jī)構(gòu)所需運(yùn)動的一種傳動方式。首先，液壓泵將電動機(jī)（或其它原動機(jī)）的機(jī)械能轉(zhuǎn)換為液體的壓力能，然后，通過液壓缸（或液壓馬達(dá)）將以液體的壓力能再轉(zhuǎn)化為機(jī)械能帶動負(fù)載運(yùn)動。
2.液壓系統(tǒng)的組成
液壓傳動系統(tǒng)通常由以下五部分組成。
（1）動力裝置部分。其作用是將電動機(jī)（或其它原動機(jī)）提供的機(jī)械能轉(zhuǎn)換為液體的壓力能。簡單地說，就是向系統(tǒng)提供壓力油的裝置。如各類液壓泵。
（2）控制調(diào)節(jié)裝置部分。包括壓力、流量、方向控制閥，是用以控制和調(diào)節(jié)液壓系統(tǒng)中液流的壓力、流量和流動方向，以滿足工作部件所需力（或力矩）、速度（或轉(zhuǎn)速）和運(yùn)動方向（或運(yùn)動循環(huán)）的要求。
（3）執(zhí)行機(jī)構(gòu)部分。其作用是將液體的壓力能轉(zhuǎn)化為機(jī)械能以帶動工作部件運(yùn)動。包括液壓缸和液壓馬達(dá)。
（4）自動控制部分。主要是指電氣控制裝置。
（5）輔助裝置部分。除上述四大部分以外的油箱、油管、集成塊、濾油器、蓄能器、壓力表、加熱器、冷卻器等等。它們對于保證液壓系統(tǒng)工作的可靠性和穩(wěn)定性是不可缺少的，具有重要的作用。
3.液壓缸
液壓缸是把液壓能轉(zhuǎn)換為機(jī)械能的執(zhí)行元件。液壓缸常見故障有：液壓缸爬行、液壓外泄漏、液壓缸機(jī)械別勁、液壓缸進(jìn)氣、液壓缸沖擊等。
3.1液壓缸爬行故障分析及處理
（1）缸或管道內(nèi)存有空氣，處理方法：設(shè)置排氣裝置；若無排氣裝置，可開動液壓系統(tǒng)以最大行程往復(fù)數(shù)次，強(qiáng)迫排除空氣；對系統(tǒng)及管道進(jìn)行密封。
（2）缸某處形成負(fù)壓，處理方法：找出液壓缸形成負(fù)壓處加以密封；并排氣。
（3）密封圈壓得太緊，處理方法：調(diào)整密封圈，使其不松不緊，保證活塞桿能來回用手拉動。
（4）活塞與活塞桿不同軸，處理方法：兩者裝在一起，放在V形塊上校正，使同度誤差在0.04mm以內(nèi)；換新活塞。
（5）活塞桿不直（有彎曲），處理方法：單個(gè)或連同活塞放在V形塊上，用壓力機(jī)控直和用千分表校正調(diào)直。
（6）導(dǎo)軌或滑塊夾得太緊或與液壓缸不平行，處理方法：調(diào)整導(dǎo)軌或滑塊的壓緊（條）的松緊度，既保證運(yùn)動部件的精度，又保證滑動阻力要小；若調(diào)整無效，應(yīng)檢查缸與導(dǎo)軌的平行度，并修刮接觸面加以校正。
（7）兩活塞桿兩端螺母扭得太緊，處理方法：調(diào)整松緊度，保持活塞桿處于自然狀態(tài)。
（8）缸內(nèi)壁或活塞表面拉傷，局部磨損嚴(yán)重或腐蝕等，處理方法：鏜缸內(nèi)孔，重配活塞。
3.2液壓缸的沖擊故障分析及處理
（1）未設(shè)緩沖裝置，處理方法：調(diào)整換向時(shí)間（>0.2秒），降低液壓缸動力速度；增設(shè)緩沖裝置。
（2）緩沖裝置中的柱塞和孔的間隙過大，處理方法：更換緩中柱塞或在孔中鑲套，便間隙達(dá)到規(guī)定要求；檢查節(jié)流閥。
（3）端頭緩沖的單向閥反向，處理方法：修理、研配單向閥與閥座或更換。
3.3液壓缸的外泄露故障分析及處理
（1）活塞桿表面損傷，處理方法：修復(fù)活塞桿損傷。
（2）密封圈邊緣傷或老化，處理方法：更換密封圈。
（3）管接頭密封不嚴(yán)，處理方法：檢查密封圈及接觸面有無傷痕，加以修復(fù)或更換。
（4）缸蓋處密封不嚴(yán)，處理方法：檢查接觸面加工精度及密封圈老化情況，及時(shí)更換或修復(fù)。
（5）由于排氣不良，使氣體絕熱壓縮造成局部高溫而損壞密封圈，處理方法：檢查排氣裝置，或增設(shè)排氣裝置；及時(shí)排氣。
（6）緩沖裝置處密封不嚴(yán)，處理方法：缸桿接觸面加工精度及密封圈老化情況，及時(shí)更換或修整。
3.4液壓缸的內(nèi)泄露故障分析及處理
（1）缸孔和活塞因磨損致使配合間隙增大超差，處理方法：活塞磨損嚴(yán)重時(shí)，應(yīng)鏜缸孔，將活塞車小，并車幾道糟裝上密封圈密封或新配活塞。
（2）活塞上的密封圈磨傷或老化，處理方法：密封圈磨傷或老化應(yīng)及時(shí)更換。
（3）活塞與缸筒安裝不同心或承受用偏心負(fù)荷，使活塞傾斜或偏磨，處理方法：檢查缸筒與活塞與缸蓋活塞桿孔的同心度，并修整對中。
（4）缸孔徑加工直線性差或局部磨損造成局部腰鼓形鏜缸孔，處理方法：重配活塞。
3.5聲響和噪聲
活塞下部空氣絕熱壓縮，處理方法：將活塞慢速運(yùn)動，往復(fù)數(shù)次，每次均走到頂端，以排除缸中氣體，即可消除此嚴(yán)重的噪聲，還可防止密封圈燒傷。
4.液壓控制閥
液壓控制閥是液壓傳動系統(tǒng)中的控制調(diào)節(jié)元件，它控制油液的流動的方向、壓力、流量以滿足執(zhí)行元件所需要的壓力、方向和速度的要求，從而使執(zhí)行機(jī)構(gòu)帶動負(fù)載實(shí)現(xiàn)預(yù)定的動作。
4.1液壓閥的性能要求
在液壓系統(tǒng)中，對液壓閥的性能要求，主要有以下幾點(diǎn)。
（1）動作靈敏、使用可靠，工作時(shí)沖擊和振動要小，使用壽命長。
（2）油液流過液壓時(shí)壓力損失要小，密封性能要好，內(nèi)泄漏要小，無外滲漏。
（3）結(jié)構(gòu)緊湊，安裝、維護(hù)、調(diào)整方便，通用性好。
4.2液壓閥分類
（1）壓力控制閥（簡稱壓力閥）。是用來控制液壓系統(tǒng)中的壓力以滿足執(zhí)行元件所需力(或力矩)的要求。包括溢流閥、減壓閥、順序閥、壓力繼電器等。
（2）方向控制閥（簡稱方向閥）。是用來控制液壓系統(tǒng)中油液的方向，以滿足執(zhí)行元件運(yùn)動方向的要求。包括單向閥、換向閥等。
（3）流量控制閥（簡稱流量閥）。是用來控制液壓系統(tǒng)中的流量，以滿足執(zhí)行元件運(yùn)動速度的要求。包括節(jié)流閥、調(diào)速閥等。
（4）復(fù)合閥（也稱多元閥）。是用來控制液壓系統(tǒng)中的方向、壓力、流量三個(gè)參數(shù)的兩個(gè)或全部。例如，單向減壓閥，既能控制油液的方向，同時(shí)還控制油液的壓力。
4.3溢流閥常見故障分析與處理
液壓閥以溢流閥為例，簡單介紹。
故障內(nèi)容
處理方法
溢流閥的調(diào)節(jié)裝置出現(xiàn)問題
拆開檢查，更換合適的調(diào)壓彈簧
電磁換向閥的閥芯卡住。通電后，電磁力不能使閥芯換向到位，使閥口有微小開度
拆開檢查，清洗，修磨電磁閥閥芯
溢流閥的先導(dǎo)閥的錐閥芯不良
(1)拆開檢查，修磨錐閥芯密封表面。損傷嚴(yán)重時(shí)，應(yīng)換用新的合格零件。(2)拆開清洗并檢查液壓油被污染程度，根據(jù)情況過濾油液或換油
溢流閥中的電磁換向閥的閥芯磨損嚴(yán)重，內(nèi)部泄漏加劇
拆開檢查，清洗液壓元件和系統(tǒng)，消除引起液壓元件不正常磨損的因素，再更換新的換向閥
溢流閥中的電磁換向閥的閥芯磨損嚴(yán)重，內(nèi)部泄漏加劇
拆開檢查，清洗液壓元件和系統(tǒng)，消除引起液壓元件不正常磨損的因素，再更換新的換向閥
主閥故障
拆開檢查，清洗、修整閥芯與閥孔。必要時(shí)檢查油液污染度，過濾或更換油液，裝配時(shí)注意保持閥芯與閥孔的同心度
5.液壓泵
液壓泵是液壓動力元件，它是將電動機(jī)（或其他原動機(jī)）輸入的機(jī)械能轉(zhuǎn)變成液壓能的能量轉(zhuǎn)換裝置。其作用是向液壓系統(tǒng)提供壓力油。
5.1液壓泵的分類：
（1）齒輪泵（外嚙合齒輪泵和內(nèi)嚙合齒輪泵）
（2）葉片泵（單作用葉片泵和雙作用葉片泵）
（3）柱塞泵（軸向柱塞泵和徑向柱塞泵）
5.2齒輪泵常見故障分析與處理
齒輪泵是常見于生產(chǎn)線的液壓泵。在此，僅就齒輪泵故障縫隙與處理方法介紹如下：
（1）油泵齒輪與泵殼的配合間隙超過規(guī)定極限，處理方法：更換泵殼或采用鑲套法修復(fù)，保證油泵齒輪齒頂與殼體配合間隙在規(guī)定范圍之內(nèi)。
（2）齒輪軸套與齒輪端面過度磨損，使卸壓密封圈預(yù)壓縮量不足而失去密封作用，導(dǎo)致油泵高壓油腔與低壓油腔串通，內(nèi)漏嚴(yán)重，處理方法：在后軸套下面加補(bǔ)償墊片（補(bǔ)償墊片厚度一般不宜超過2mm），保證密封圈安放的壓縮量。
（3）拆裝油泵時(shí)，在2個(gè)軸套（螺旋油溝的軸套）結(jié)合面處，將導(dǎo)向鋼絲裝錯(cuò)方向，處理方法：保證導(dǎo)向鋼絲能同時(shí)將2個(gè)軸套按被動齒輪旋轉(zhuǎn)方向偏轉(zhuǎn)一個(gè)角度，使2個(gè)軸套平面貼合緊密。
（4）在拆裝油泵時(shí)，隔壓密封圈老化損壞，卸壓片密封膠圈被裝錯(cuò)，處理方法：若隔壓密封圈老化，應(yīng)更換新件：卸壓片密封膠圈應(yīng)裝在吸油腔（口）一側(cè)（低壓腔），并保證有一定的預(yù)緊壓力。如裝在壓油腔一側(cè)，密封膠圈會很快損壞，造成高壓腔與低壓腔相通，使油泵喪失工作能力。
6.總結(jié)
關(guān)于液壓系統(tǒng)各部分組成的常見故障及處理方法的簡單介紹，是我們長期實(shí)踐證明的結(jié)果。它可以使我們少走彎路,能快速、準(zhǔn)確地查找出故障，并且在短時(shí)間內(nèi)將其解決。從而提高生產(chǎn)效率，降低生產(chǎn)成本；能創(chuàng)造良好的經(jīng)濟(jì)效益。
Hydraulic system and the typical fault mechanism analysis
Abstract: 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 cylinder
The 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 don't 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 valves
Hydraulic 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 can't 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 is enough and lose the sealing function, leading to high pressure oil chamber pump to low voltage oil chamber in collusion, inside the severe leakage, processing methods: under the collar and compensation gasket (compensation shim thickness should not be commonly more than 2 mm) and to ensure that the sealing ring of compression was laid.
(3) disassembling the oil pump, in 2 bushings (spiral oil groove sleeves) combined with surface place, will be loaded in the wrong direction oriented steel wire, processing methods: ensure oriented steel wire can at the same time will be two collar passive gear rotating direction according to deflect a Angle, make two collar plane joint closely.
(4) in the disassembly oil pump, the pressure seal aging damage, discharging pressure piece of gasket was wrong, processing methods: if the pressure seal aging, should replace new thing: discharging pressure piece of gasket must be packed in oil absorption cavity (mouth) side (low pressure chamber), and ensure that there is a certain pre-tightened stress. Such as into pressure oil chamber side, gasket will soon damage, cause high pressure chamber and low pressure chamber are interlinked, make the oil pump to lose working ability.
6.Summary
The hydraulic system on the parts of the common faults and processing method of simple introduction, is our long-term practice shows results. It may help us to avoid detours, fast and accurately find fault, and in a short time to solve it. So as to improve the production efficiency, reduce production cost; Can create good economic benefit.