After the hydraulic equipment installation and circulation flushing are qualified, it is necessary to adjust the hydraulic system for test run, so that it can make necessary adjustments according to the actual production process requirements under the premise of meeting the technical parameters, so as to achieve normal operation under heavy load.
1.1 Preparation before commissioning of hydraulic system
① The hydraulic system to be debugged must be qualified in circulation flushing before it can enter the debugging state.
② The hydraulic drive of the host equipment is all installed, the moving parts are in good condition and qualified after inspection, enter the debugging state.
③ All electrical equipment and lines of the control hydraulic system have been installed and checked.
④ Familiar with the technical documents required for debugging, such as hydraulic schematic diagram, pipeline installation diagram, system operating instructions, system debugging instructions, etc. According to the above technical documents, check whether the pipeline connection is correct and reliable, whether the selected oil meets the requirements of the technical documents, whether the oil level in the tank reaches the specified height, and determine the position of each hydraulic component according to the schematic diagram and assembly drawing.
⑤ Remove the debris around the main engine and hydraulic equipment, and the commissioning site should have the necessary obvious safety facilities and signs, and be managed by a special person.
⑥ The debugging personnel should have a clear division of labor, unified command, necessary training for the operator, and be equipped with walkie-talkies if necessary to facilitate contact.
1.2 Hydraulic system commissioning procedure
1.2.1 Check before commissioning
① Check whether the connection is correct according to the system schematic, assembly drawing and piping drawing, and confirm that each hydraulic cylinder is operated by the electromagnetic directional valve of which branch.
(2) The electromagnetic directional valve is carried out no-load commutation respectively to confirm whether the electrical action is correct, flexible, and meets the requirements of the action sequence.
③ Open the stop valve on the pump suction pipe and return pipe, and loosen the pressure regulating handwheel of the relief valve at the pump outlet and the safety valve in the system; Set the reducing valve in the lowest pressure position.
④ The flow control valve is placed in a small opening position.
⑤ Fill the accumulator with nitrogen according to the instructions.
1.2.2 Start the hydraulic pump
1 Hand drive the coupling between the motor and the hydraulic pump to confirm that there is no interference and the rotation is flexible.
② Point the motor, determine whether the motor steering is consistent with the steering sign of the hydraulic pump, after confirming the continuous point several times, press the motor start button after no abnormal situation, and the hydraulic pump starts to work.
1.2.3 System Exhaust Gas
After starting the hydraulic pump, adjust the system pressure to about 1.0MPa, control the reversing of the solenoid valve respectively, so that the oil is circulated to each branch, and twist the exhaust valve set on the pipeline to discharge the gas in the pipeline; When the oil continues to overflow, close the exhaust valve. When the hydraulic cylinder is venting, the exhaust valve of the piston rod extending out of the hydraulic cylinder can be opened, the solenoid valve acts, the piston rod moves, the air is squeezed out, and the exhaust valve is closed when it rises to the top dead center. Open the exhaust valve on the other side, let the hydraulic cylinder down, discharge the air in the rodless chamber, repeat the above exhaust method until the air in the hydraulic cylinder is drained.
1.2.4 System withstand voltage test
The pressure test of the system mainly refers to the pressure test of the field pipeline, and the pressure test of the hydraulic equipment should be carried out in the manufacturer. For hydraulic pipelines, the pressure of the pressure test should be 1.5 times the maximum working pressure. For high pressure systems with working pressure ≥21MPa, the pressure of the pressure test should be 1.25 times the maximum working pressure. If the system's own hydraulic pump can reach the pressure value, it is not necessary to use an electric pressure test pump. During the pressure increase process, it should be gradually segmented, and it cannot reach the peak value at one time. When each level is increased, it should be kept for a few minutes, and observe whether the pipeline is normal. Do not operate the reversing valve during the pressure test.
1.2.5 No-load commissioning
After the pressure test, the system pressure is restored to the ready debugging state, and then the system pressure, flow, speed and stroke are adjusted and set according to the content specified in the debugging instructions, which can be carried out one by one in the order of manual and electric first, including the setting of pressure relay and stroke switch. After the manual adjustment is completed, the no-load linkage test should be started after the equipment, electricity and liquid are tested separately without load.
1.2.6 Load test
After the equipment starts to run, the load should be gradually increased, if the situation is normal, the maximum load test can be carried out. After the maximum load test is successful, the system should be checked in time to check whether the working condition is normal, and the pressure, noise, vibration, speed, temperature rise, liquid level, etc. should be comprehensively checked, and records should be made according to the test requirements.
1.3 Acceptance of hydraulic system
During the test of the hydraulic system, all the design values should be tested according to the design content, and the operating status of the hydraulic system should be determined according to the actual recorded results. The design, user, manufacturer and installation unit should hand in the acceptance and sign the relevant documents.
