The last time we looked at single rod cylinders, which are pointed with their stems extending towards the sky.

We found that the directional valve closed two ports of the cylinder is the only way to push the cylinder down to allow the loss of fluid outside of the bottle. We have found that can not fall down the rod and the piston, otherwise a solid cylinder of liquid no additional space for the volume of steel that has the trunk.

Lets end this week with a look at the bottles that are attached to the head. The stem of the cylinder extends downward.

Again, this is a fairly common misconception that a worn piston seal to move fluid to the piston rod side of the cylinder side, crawl so in line.

We will start with the directional control valve is closed (we ball valves at each cylinder port in the vicinity has just made clear) and the stem is fully retracted. Suppose that the cylinder is filled with hydraulic fluid.

If the piston seal is absent, and we have to crawl a load on the cylinder rod?

When the bottle full of steel (piston and rod was) and liquid () largely non-compressible fluid, what would happen if the parent does not give creep into the expansion?

If the rod goes well, the cylinder open and closed, the amount of volume occupancy lose accordingly. What fills the gap which is generated inside the cylinder?

A large force (heavy) pulling on the end of the stalk may cause some expansion, but the whole movement would be very low. Since the blank would be very long in a tiny fraction of an inch.

And a heavy burden lifted, the forces of labor, the cylinder down. But if ports are closed by valves, which blocked the flow path?

 It popular is that the piston seal is broken inside the cylinder and the movement of drift occurs because the fluid by gravity under pressure is forced by the piston. But is this possible?

Can a single rod cylinders really behave in this manner when the piston seal fails?

To answer these questions we need to consider some basic principles of volume.

Imagine a six-foot, 6 “diameter pipe closed at one end and sitting on a surface. Imagine that the hose is already filled with liquid. Then you come to drop with a length of 2 inch diameter rod in solid steel pipe open end at the top.
What happened? Liquid overflows and spills, because the pipe was already full. He was put in place over the line for the volume of steel in him and you because of the displaced liquid was left.
cylindermyth6

Now consider a vertical cylinder with the tip of the stem upward. Rod End gland and seal are in good shape.

Let’s start with the stem fully extended, and suppose that there is no air in the fluid under the piston. The cylinder is lifting a heavy load. Both the ground (barrel end) and above (rod end) will be closed ports ball valves.

If we now remove the piston seal, so there is a noticeable gap between the piston and cylinder wall, what will happen?
If the piston and rod assembly, or it will drift down in his seat?

Brittle Magnetic Leads
Problem statement :
    The continued use of the magnetic coil over a period of time is a fragile cable insulation. This creates the possibility of isolation and / or broken wire can cause a short circuit in the magnet coil
Cause of the error are:
                         1. The drivers are generated by the coil affects the heart. This situation is exacerbated by high ambient temperatures.
2. Hydraulic fluid type can be eaten or isolation.
3. Coolant can be used by the machine to destroy the insulation.

Magnets fireproof exposed to liquids:
Problem statement :
    The exposure of magnetic coils fire resistant fluids such as phosphate esters will lead shorts between windings of the coil. These liquids also dissolve the varnish on the coil and magnet-black color. The liquid on the insulation of the wires go, so it has become too vague and leave eventually. This condition can be avoided through the purchase of magnetic coils or rolls that are compatible with corrosive liquids.

Cause of failure:

1. Chemical reaction with the magnet.
Solenoid failure – burns continuous output current coil of nylon boot cast causes of failure:
1. Mechanical stop
2. Line voltage low
3. Overtemperature
4. Acceleration cycle.
5. Excessive or high-voltage line.

Solenoid failure – shorted:
Problem statement :
1. Refrigerants containing metal shavings
2. Voltage transients
3. Fire resistant fluids

Solenoid failure – Mechanical destruction
Problem statement :
1. Surge
2. Cycle on Rates
3. Zealous mechanic.

Solenoid shorted:
Problem statement :
A magnet for use in or near water coolant are saturated with fine particles of metal susceptible to short-circuit between coil cable links
Cause of the error are:
1. Soaking the cooling coil.

A large tables hose concrete bearing can be precisely controlled. They start a stop to all the wrong places, causing hours of additional staff to physically relocate 50 ‘x 35′ tables in place.

Solution: Engine PLC system asser some thought to the hydrostatic drive designed a Summer installed. Today, nip Way to see a clear move stops from 0.15 “to Desiree position.

Description of issue:Rapid speed of the shift valve trouble.
Causes: air in the system
Corrections DESIGN: Feather non-return valve is too weak to convert. Enter the dampers and springs in the ends of the valve. Floating coil horizontally.
Reviews for: Check for broken springs. Valve plunger depressed too far. Cams and / or worn rollers. The valve remains partially open.

Description of issue:Overheating oil (active normal operating temperature around 130 ° 140 ° ° C).
Causes: Too much oil is blowing through the safety valve. (The pump is too large for the system)
Corrections: Pump capacity must be at least 10 to 15% higher than the requirements.
Review of: controlling the pressure relief valve for pressure and leakage. Check the pressure of work on the pump. Add a heat exchanger.

Description of issue: slow-acting engine
Causes: The minimum oil temperature is too cold.
Corrections DESIGN: Enter the immersion heater.
Reviews on: Make it controls oil pressure relief valve Across blown until warm.

CAUSES
Excessive friction loses in the system. Oil speed limit

Corrections DESIGN
 Use as little pipe arches. Hold the ideal radius of the pipe and pipe bends. Port Areas, holes

Corrective measures
Hoses and pipes should comply with the oil rate of 15 frames per second at pressure lines. 10 fps for the return lines.

Symptoms
Frequent dropping courses

CAUSES
Vibration machines.

Corrections DESIGN
Design more brackets

Corrective measures
Oil executives firmly attached. More Support

Symptoms
Overheated oil (active normal operating temperature is about 130 ° 140 ° degrees F).
CAUSES
1.Too much oil to blow through the pressure relief valve. (Pump too large for the system)
2.Insufficient oil or oil is too low.
3.Highpressure help too long.
4.Oil too bright
5.Obstructions or decrease the flow
6.Oil in pipes

Corrections DESIGN
1.Pump capacity must be at least 10 to 15% higher than the requirements.
2.Increase capacity at least 34 times the oil tank pump.
3.Use small pump for high pressure
4.Specify right SSU oil.
5.Avoid sharp bends in the pipe, particularly in copper pipes.
6.Specify ideal bending radius.

Corrective measures
1.Check safety valve for pressure and leakage. Check the pressure at the pump to function. Add a heat exchanger.
2.Add oil
3.And high volume pumps for low pressure.
4.Use heavier oil.
5.Check position valves for neutral and congestion.
6.Pump components can be worn. Check back pressure valve for high pressure.

Many service company can start your preventative maintenance program, and more with an in-house staff Tribologist, your lubricant can quickly and correctly analyzed.

The 3, 6, 12, 18 and 24 months of preventive maintenance program is specifically designed for critical hydraulic systems, but the overall goal can be achieved with electric and pneumatic powered equipment also.

THREE (3) months INTERVAL

1. Fluid Sampling

    1.1. Install valve removal of fluid return line, upstream of the filter return line.

    1.2. Sampling of liquids: (link to oil-analysis) using an approach that analyzes trends (link here to page analysis of fluids)

        1.2.1. Take a sample of new, clean oil

        1.2.2. Use this report as your oil “basic”

            1.2.2.1. Select your “Go – No Go” levels:

                Silica
                Water
                T.A.N (acid)
                Additives
                Metals
                I.S.O. Cleanliness levels

    1.3. Verify the location of the filter and calibration. (link to the filter) filters must provide a minimum of 800 hours of operation under normal conditions. This is assuming that the system was flushed before commencement, Beta 3> 200 elements in-line filter used, and an effective Beta 1> 200 air breather is used. When the oil is clean, except for maintenance, the pollution levels to be coherent.

2. Clean equipment to full service and check for leaks.

    2.1. Look for things like broken plugs, loose connections, blocked oil passages in the engine and broken gauges. Repair if necessary.

    2.2. List the location of leaks, damaged or broken parts and state of general operation of the equipment.

    2.3. Check the status and parameters of pressure and temperature. This is important for troubleshooting, to ensure the hydraulic system is functioning properly.

    2.4. Check the fan assemblies for cooling the electric motor

    2.5. Check control valves for leaks at the seals, including the bases and tips of control, where the trees connect the valve body.

    2.6. Note anything unusual, listening to strange sounds and locate the source.

    2.7. In general, the devices, whether operating within its design.

3. Hose, Tubing and Fittings.

    3.1. Look for cracks or signs of aging such as brittleness. It is a sign that the tube has been in use for too long, or the area near the pipe is too hot. If the operating temperatures of equipment and environment is too high a class upgrade the pipes must be considered.

    3.2. Check hose connections for leaks and damage

    3.3. In case of a metal tube, look for crimping or other mechanical damage.

    3.4. Make sure the hose runs and follow the standard installation practices.

    3.5. Pipe to Pipe and Fittings, sure they have enough room to prevent wear and tear on other parts.

    3.6. For repair or replacement of damaged pipes and fittings, whether they can be protected by conversion or relocation of the trail.

        3.6.1. Many leaks occur because of clearance issues to enable them to strike or rub against anything.

Six (6) months (plus 3-month inspection interval above):

1. Motors, pumps, the state coupling and adaptation:

    1.1. Make adjustments and electrical controls. Observe mode coupling and alignment by measuring the manufacturer’s recommendations.

    1.2. Check mounting bolts and the engine feet to ensure they are in good condition and free from cracks.

        1.2.1. The bolts must be in place and tight.

Twelve (12) months (in addition to 3 and 6 months for inspection intervals above):

1. Tank Maintenance:

    1.1. Absolutely pure fluid, wipe with a lint-free cloth.

    1.2. Examine the internal baffle and repair, if needed.

    1.3. Inspect, clean and repair or replace everything inside the tank before you reinstall the tank lid.

    1.4. Clean the sealing surfaces and replace the seals or gaskets around the eyelids.

    1.5. Prevent new dirt back into the tank before closing up.

    1.6. Drain and clean the equipment, fittings, hoses, pipes and fittings.

    1.7. Perform a pressure and flow tests on water-cooled heat exchanger fouling to check the pipes.

        1.7.1. Send in for repair, if necessary

        1.7.2. Air / oil cooler? Back stroke all baffles, if necessary.

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Twenty-four (24) months (beyond the 3, 6 and 12 months inspection interval above):

1. Maintenance of main components:

    1.1. Maintenance of pumps

        – Check the pump (s) for leaks, broken and / or damaged accessories.
        – The pump rotating group can be rebuilt in place in May and seals can be replaced without removing the device from its support.
        – The recast of 24 months is best completed on a bench, complete with a new seal kit.

    1.2. Valve Maintenance

        – Dirty oil is the most common cause of valve insufficiency.
        – After removing the valve, clean and inspect.
        – Replacement of spare parts, including springs, seals and parts recommended by the manufacturer.

    1.3. Actuator maintenance

        – Check for leaks, broken or damaged fittings, damaged body parts, misalignment and wear.
        – Leaks usually occur at the shaft seals and sealing surfaces.
        – Seal leaks are caused by dry seals or joints damaged by a dirty work environment.

    1.4. Maintenance of electrical motors

        – Checks should include a visual inspection, vibration analysis, current measurement and temperature control on the frame and bearings.
        – As the majority of electrical failures are mechanical, it is important that access to journals and housing must be measured.
        – The frame and the tree must be free of cracks or areas weakened by corrosion.
        – The correctness of the shaft and rotor balance also affect performance.
        – Electrical tests must be performed by a commercial electrical service.
        – The tests should include the phasing out of control because the inspection, the condition of the winding coils, inspection and squirrel cage rotor.
        – The current in an AC motor increases with load, but diffuse load varies from 20 to 70% of full load current in various constructions, the slow and low HP motors have more power vacuum.
        – It is important to obtain values from the manufacturer before attempting measurements.

A paving stone manufacturer uses two large, complex, servo-controlled, German designed hydraulic presses. These machines continue to overheat and cause huge loss of pain production and downtime problems.

Solution:

Each print has been physically surveyed included hot air gun readings in the 15 hydraulic distributors were included digital photos, and copies of original patterns plumbers were reviewed. Two (2)-phase proposal was accepted, with the phase 1, the above survey and analysis. Phase 2 should include all necessary repairs and / or updates to eliminate the problems. On time and within budget.

Problem:

A major producer of brown paper uses a large German hydraulic pump in their processing department. This pump is no longer available from the manufacturer and only one (1) replacement was available. Upgrading to a new pump would lead to major structural changes in style and seedlings. Then the pump is dead.

Solution:

The old pump was removed immediately and replaced with the pump parts. The pump of the deaths, it was disassembled to determine the cause of failure (dirty / hot). New parts were installed reverse engineering, and tested. All proceeds as planned, with the client again with a reliable operation of the pump parts.

Problem:

Hydraulic Control System Panel

The major oil refinery, a massive hydraulic system for the control of six (6) slide controls important. This slider (12 large cylinders each) continue to fail, and thus has a life in danger because of the very dangerous situation for the people, very high heat, and leaking hydraulic fluid.

Solution:

To redesign was completed large-scale plant (3 + years later, when the project), each week a qualified electrician plumber would go around the existing hydraulic system to provide tips for repairing oil refinery. A normal working day would be the round off, the change of the cylinder loses 2-3, 1-2 leaking hydraulic hoses and fittings, needs cleaning. Reliability level soared. Loss of hydraulic systems has dropped dramatically, and there was no one more evil. This mission lasted 127 weeks, the plant could be built to be redesigned.

To destroy the problem:

A large food manufacturing remains the hydraulic motors. These engines are used in a process of agitation.

Solution:

new epoxied hydraulic motors were installed. The reliability of the system is extended from 5 weeks to 125 weeks.

Problem:

A stove was the loss of important key oven every few months. The consumption of stainless steel chains are replacing costly and time.

Solution:

A Lincoln was installed Automatic chain lubrication system, with very high temperatures, oils, food grade. Chain reliability of the level soared.
   
Problem:

A principal city recently launched a new school, all automatically. The school will) by automotive high-pressure air and water for several automatic functions (air tools, tire storage, utilization of the coolant, but nothing was planned, but the pipes in the head. Students are not entitled to air or the supply of tap water.

Solution:

Twenty-four (24) Lincoln Individual roles, is installed in the school, allowing access of students to take the necessary air and water. Air hoses were colored red. Water jets were colored blue.

Problem:

A large collection of hydraulic machine used to the speed of each conveyor control. The machine kept killing various conveyor components due to over-pressurization of the hydraulic system.

Solution:

A complex hydraulic relief distribution has been developed, manufactured and installed (2.0 “Hydraulic Hoses, 6000 psi), so that the main hydraulic motors, when more pressure on the hydraulic pressure on the engine deliver immediately, rather than pressure to spike and back rose to power.