轮边制动液压系统使用说明书
- 格式:doc
- 大小:2.73 MB
- 文档页数:12
轮边式全封闭湿式多盘制动器设计书汽车制动器是汽车上用以使外界(主要是路面)在汽车某些部分(主要是车轮)施加一定的力,从而对其进行一定程度的强制制动的一系列专门装置。
1.1 汽车制动器的作用制动器作用是:使行驶中的汽车按驾驶员的要求进行强制减速甚至使其停车;使已停驶的汽车在各种道路下(包括坡道)稳定驻车;使正下坡行驶的汽车的速度保持稳定。
而对汽车起制动作用的只能是作用在汽车上并且方向与汽车行驶方向相反的外力,而这些外力的大小都是随意的、不可以控制的,因此汽车上就必须安装一系列专门装置用来实现上述功能。
汽车制动器是指为了在技术上保证汽车的安全行驶,提高汽车的平均速度等,而在汽车上安装专门制动装置的制动机构。
1.2 汽车制动器的分类汽车制动器一般包括行车制动装置和停车制动装置两种独立的装置。
其中行车制动装置是由驾驶员用脚来操纵的,所以又称脚制动装置。
停车制动装置是由驾驶员用手操纵的,所以又称手制动装置。
行车制动装置的功能是使正在行驶的汽车减速或在最短的距离内停车。
而停车制动装置的功能是使已经停在各种路面上(包括坡道)的汽车保持静止不动。
但是,有时在紧急情况下,两种制动装置可以同时使用使其增加汽车制动效果。
但是有些特殊用途的汽车和经常在山区行驶的汽车,由于长期而又频繁地制动将会导致行车制动装置过热,所以在这些汽车上往往会增加各种不同型式的辅助制动装置,使其在运行时稳定车速。
制动器还可以分为摩擦式和非摩擦式两大类。
摩擦式制动器是靠制动件与运动件之间的摩擦力制动;而非摩擦式制动器通过其结构形式可分为磁粉制动器(利用磁粉磁化所产生的剪力来制动)、磁涡流制动器(利用调节励磁电流来调节制动力矩的大小而是汽车制动)和水涡流制动器等。
按照制动件所处工作状态还可以分为常闭式制动器(常处于紧闸状态,需施加外力才可以解除制动)和常开式制动器(常处于松闸状态,需施加外力才可以进行制动)。
按照操纵方式可分为人力、液压、气压和电磁力操纵的制动器。
SpecificationsTechnical Information*1 : RS, L S *2:GS-R *3:RS*4:LS,GS-Rpage 198page199Anti-lock Brake SystemThe Anti-lock Brake System (ABS)is standard equipment on the LS and GS-R models. It is not available on the RS model.The ABS works by measuring how fast the wheels are turning during braking and comparing their speed.If any wheel is rotating much slower than the others (on the verge of locking up and skidding),the system reduces hydraulic pressure to that wheel's brake caliper. When that wheel's speed matches the other wheels, the system applies normal hydraulic pressure. This can take place several times per second at each wheel. You feel the ABS working as rapid pulsations in the brake pedal.Each wheel has a wheel speed sensor assembly. As the wheel rotates, the sensor sends electrical pulses to the ABS control unit. The pulse frequency varies with the wheel speed.The electrical output of the ABS control unit is connected to the modulator/solenoid unit. During braking, the ABS control unit monitors the pulse frequencies from the four wheels. When the control unit detects a wheel locking up, it energizes the appropriate solenoid in the modulator/solenoid unit. There are three solenoids: one for each front wheel, and one for the rear wheels. The energized solenoid reduces hydraulic pres-sure to one side of a modulatorvalve. This, in turn, reduces hydrau-lic pressure in the brake line going to the affected wheel. When that wheel speeds up because of the re-duced braking effort, the controlunit de-energizes the solenoid. This builds hydraulic pressure on the modulator valve. The pressure in-creases in the hydraulic line to the wheel.For the system to react quickly, the modulator/solenoid unit must have brake fluid under high pressure.This is supplied by an accumulator that is pressurized by an electric pump. A pressure-sensing switch on the accumulator controls this pump.The control unit also contains error detection circuitry. It monitors the operation of the wheel sensors,solenoids, pump, and electronics. If the control unit detects any faults,it shuts off power to the pump motor and solenoids. The light on the instrument panel comes on.The brakes then work like aconventional system without anti-lock capabilities.Technical InformationSupplemental Restraint SystemThe SRS includes the steering wheel airbag assembly, sensors in the dashboard, and a control unit with sensors behind the center console.(All models except the Canadian RS model)The system also has a dashboard-mounted airbag assembly for the passenger.The sensors are decelerometers,set to trigger in a severe frontal impact that generates more force than a 25 mile per hour crash into a parked vehicle of similar size. For the SRS to activate, at least two sensors must trigger. This duplica-tion is to prevent accidental activa-tion.When the control unit receives trigger signals from at least two sensors, it sends voltage to the airbag. The control unit stores this charge in capacitors to insure reliability even if a severe impact damages the car's battery or electrical connections.The electrical charge sent to the airbag assembly ignites its propel-lant, which burns instantaneously.The gas produced by the burning propellant inflates the airbag instantly.The airbag is vented so it stays inflated for only an instant and does not block the driver's vision.Smoke from the burned propellant comes out of the airbag and into the car's interior. This is normal and does not mean there is a fire.The airbag collapses onto the driver's lap.The airbag must be replaced after it is activated. After use, your Acura dealer must check the complete Supplemental Restraint System and replace the airbag assembly.To ensure long-term reliability, the SRS uses gold-plated electrical connections throughout. Exposed components are sealed with epoxy.The control unit monitors the SRS circuitry whenever the ignition is ON (II). If the control unit senses any faults, it turns on the SRS indicator light on the instrument panel. Take the car to your Acura dealer to diagnose and repair the system as soon as possible.The SRS needs no regular mainte-nance other than an inspection by your Acura dealer ten years after manufacture.Technical InformationEmission ControlsThe burning of gasoline in your car's engine produces several by-products. Some of these are carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC).Gasoline evaporating from the tank also produces hydrocarbons. Con-trolling the production of NOx, CO,and HC is important to the environ-ment. Under certain conditions of sunlight and climate, NOx and HC react to form photochemical "smog."Carbon monoxide does not contri-bute to smog creation, but it is a poisonous gas.The Clean Air ActThe United States Clean Air Act*sets standards for automobile emissions. It also requires that automobile manufacturers explain to owners how their emission controls work and what to do to maintain them. This sectionsummarizes how the emission con-trols work. Scheduled maintenance is on page 125.* In Canada, Acura vehicles comply with the Canadian Motor Vehicle Safety Standards (CMVSS) for Emissions valid at the time they are manufactured.Crankcase Emission Control SystemYour car has a Positive Crankcase Ventilation System. This keeps gasses that build up in the engine's crankcase from going into the atmosphere. The Positive Crank-case Ventilation valve routes them from the crankcase back to the intake manifold. They are then drawn into the engine and burned.Evaporative Emission Control SystemAs gasoline evaporates in the fuel tank, an evaporative emissioncontrol canister filled with charcoal adsorbs the vapor. It is stored in this canister while the engine is off.After the engine is started andwarmed up, the vapor is drawn into the engine and burned during driving.Technical InformationEmission ControlsExhaust Emission Controls The exhaust emission controls include three systems: PGM-FI,Ignition Timing Control and Three Way Catalytic Converter. These three systems work together to control the engine's combustion and minimize the amount of HC,CO, and NOx that comes out the tailpipe. The exhaust emission control systems are separate from the crankcase and evaporative emission control systems.PGM-FI SystemThe PGM-FI System uses sequen-tial multiport fuel injection.It has three subsystems: Air Intake,Engine Control, and Fuel Control.The Engine Control Module (ECM)uses various sensors to determine how much air is going into the engine. It then controls how much fuel to inject under all operating conditions.Ignition Timing Control System This system constantly adjusts the ignition timing, reducing the amount of HC, CO and NOx produced.Three Way Catalytic Converter The three way catalytic converter is in the exhaust system. Through chemical reactions, it converts HC,CO, and NOx in the engine's exhaust to carbon dioxide (CO 2),dinitrogen (N 2), and water vapor.Replacement PartsThe emission control systems are designed and certified to work to-gether in reducing emissions to levels that comply with the Clean Air Act. To make sure the emis-sions remain low, you should use only new genuine Acura replace-ment parts or their equivalent for repairs. Using lower quality parts may increase the emissions from your car.The emissions control systems are covered by warranties separate from the rest of your car. Read your warranty manual for more information.Technical InformationThree Way Catalytic ConverterThe three way catalytic converter contains platinum, palladium and rhodium. These metals serve as catalysts, promoting chemical reactions to convert the exhaust gasses without affecting the metals.The catalytic converter is referred to as a three-way catalyst, since it acts on HC, CO, and NOx. A re-placement unit must be an original Acura part or its equivalent.The three way catalytic converter must operate at a high temperature for the chemical reactions to take place. It can set on fire any com-bustible materials that come near it.Park your car away from high grass, dry leaves, or other flamma-bles.A defective three way catalytic converter contributes to air pollution, and can impair yourengine's performance. Follow these guidelines to protect your car'sthree way catalytic converter.Always use unleaded gasoline.Even a small amount of leaded gasoline can contaminate the catalyst metals, making the three way catalytic converter inef-fective.Keep the engine tuned-up.Have your car diagnosed and repaired if it is misfiring, back-firing, stalling, or otherwise not running properly.Technical InformationTHREE WAY CATALYTIC CONVERTER。
丰田皇冠制动系统使用手册串联总泵制动系统是一种具有二个独立的辅助制动系统的液压系统。
如果其中的一个辅助制动系统失效,则另一个仍然能起制动作用。
不过踩制动踏板将比平时费力,而且停车距离也将增加。
同时,制动系统警告灯将点亮。
不要在只有一个制动系统工作的情况下驾驶车辆。
须立刻将失效的制动系统修复。
制动助力器制动助力器是利用发动机的真空动力来加强制动的效果。
如果在行驶过程中发动机停止了,可用正常的制动踏板压力使车辆停止。
后备真空压力足够停一次或两次车——但不能超过两次!1 如果发动机熄火,不要泵制动踏板。
因为,每踩一次踏板就会消耗一部分真空压力。
2 即使完全丧失真空动力,制动器仍然有效。
但踩制动踏板要更用力,较正常情况要用力得多。
制动停车距离也将增加。
防抱死制动系统防抱死制动系统是用于在紧急制动或在打滑的路面上制动时防止车轮的锁定。
这有助于在上述情况下提供稳定的方向和车辆的转向性能。
踩ABS制动踏板的有效方法:当防抱死制动系统在发挥作用时,将会感到制动踏板的脉动并能听到噪音。
在这种情况下,只要更用力地踩住制动踏板就可以使防抱死制动系统工作。
在紧急制动时不要反复踩制动器。
这将造成停车距离增加。
车辆加速至10km/h(公里/小时)以上时,防抱死制动系统进入工作状态。
车辆减速至5km/h(公里/小时)以下时,防抱死制动系统停止工作。
下雨天在窨井盖、现场的钢板、桥的连接处等光滑的路面上踩制动踏板将激活防抱死制动系统工作。
当发动机起动时或车辆刚起动后,可能会听到发动机至中有咔嗒声或马达的声音持续数秒钟,这表示防抱死制动系统在自行校验,不表示存在故障。
当防抱死制动系统在工作时,可能发生下列情况。
这并不表示系统有故障:1 会听到防抱死制动系统的操作并感到制动踏板的脉动和车身以及方向盘的振动。
即使将车辆停止以后仍会听到发动机室内部的马达声。
2 在防抱死制动系统工作的最后,制动踏板可能会向前移动一点。
不要过高估计防抱死制动系统:虽然防抱死制动系统有助于保持车辆的控制,但是遵守所有应注意的事项以及保持适当的车速和前车之间的安全距离进行驾驶仍然是非常重要的,因为即使防抱死制动系统起作用,对于车辆的稳定和方向盘的操作也是有限的。
明阳风电1.5MW风电液压系统使用说明书版本号:A编制:孟令旗校对:杨勇审核:赵宏日期:2008.12伊顿流体动力(上海)有限公司目录1 范围 (1)2液压系统总成 (1)2.1液压系统组成 (1)2.2 液压泵站主要工作参数 (1)2.2.1 油泵电机组 (1)2.2.2 油箱 (1)2.2.3 供电要求 (1)2.2.4 液压工作介质 (1)2.3外形及安装说明 (2)2.3.1 液压站总成外形尺寸 (2)2.3.2 外形安装尺寸 (2)2.4 泵站运输储存 (2)2.5泵站油液油温 (2)3液压系统功能说明 (2)3.1 总则 (2)3.2 功能原理 (2)3.2.1 泵组 (2)3.2.2 主轴刹车 (2)3.2.3 主轴刹车监控 (3)3.2.4 偏航刹车 (3)3.2.5 手动泵 (3)3.3 液压原理图 (4)3.4 油箱及附件功能说明 (5)3.4.1 液位控制 (5)3.4.2 温度控制 (5)3.4.3 污染控制 (5)4 运行维护 (5)4.1检测 (5)4.2 维护保养 (5)4.3记录 (6)5 故障排除 (6)5.1电机无法启动 (6)5.2 泵站压力不足,刹车不能正常工作 (6)5.3刹车不能正常卸压 (6)5.4刹车钳速度太慢 (6)5.5刹车钳速度太快 (6)5.6电气元件无信号 (7)附件1 泵站外形图 (8)附件2 电气原理图-1 (9)附件3 电气原理图-2 (10)附件4 电气接线盒 (11)附件5 压力设定 (12)附件 6 元件清单 (13)附录资料附录 (14)技术文件明阳风电1.5MW风力发电液压系统液压系统使用说明书Engineering Document DOC.No.: 228P0100YSM/081. 范围本使用说明书适用于228P0100DWG/08液压系统(以下简称液压系统)。
本使用说明书规定了液压系统的使用方法,常规保养和常见故障的处理方法。
Eaton®June, 1995 Heavy Duty HydrostaticsInstallation &Operating InstructionsConstant Speed Control2Operating Instructions for Constant Speed Control(The valve package, speed sensor and electronic control box are installed by following the instructions and diagrams ona 12 VDC system.)1.The motor will remained stopped if: A) The manual control valve is in the center position; B) The switch on the elec-tronic controller is in the “OFF” position.2.The direction of the motor rotation is controlled by the manual control handle. The electronic controller does not affect the direction of motor rotation.3.The speed of the motor is determined by the position ofmanual control handle when the electronic controller is in the “NORMAL” position. With the switch in the "normal" position,the manual control handle has the same (normal) effect on motor rotation as it does when there is no electronic controller on the pump.4.With engine at minimum rpm and the manual control handle displaced from center enough to cause the drum to rotate at least two revolutions per minute (rpm), placing the controller switch in the “AUTOMATIC” position will cause the drumspeed to be controlled automatically. (The manual control handle may be placed all the way forward or reverse without affecting the speed at which the motor is automaticallycontrolled). Drum speed will be limited to approximately one and 11/2 rpm.5. Drum rotation can be stopped or started with an electrical switch wired across the "remote" terminals (in place of the electrical jumper strap which may have been across the terminals when the controller was received). The switch can act as a remote switch by attaching it to an electrical cable extending from the controller to the back of the truck or other location within 100 feet of the controller.Note:The controller switch must be in the “NORMAL” positionto enable the remote switch to control the motor. Also note that the remote switch must be in the “ON” position to empower motor rotation.The electronic transit mixer control requires the use of an Eaton motor with the digital speed sensor option to monitor the speed of the hydraulic motor. The digital speed sensor (PN 106768)has a three pin connector that mates with the wiring harness connector shown on page 5.Screw the digital speed sensor into the motors’s end cover until it touches the shaft. Unscrew the sensor until the flats are parallel with the motor shaft (see figure 3).To provide running clearance between the motor shaft and speed sensor, unscrew the speed sensor an additional 1/2 turn.The total amount the speed sensor is unscrewed must not exceed 270˚.Tighten the sealing hex nut against the end cover and torque it to 14Nm [10 lb-ft ]*. Make sure that the sensor flats are still parallel with the motor shaft.*Caution: More torque than the specified amount may permanently damage the sensor.Installing the Digital Speed Sensor5˚3Electrical CableUse an oil resistant, weather resistant cable such as industrial type SJOW, 2 wire, AWG size 18 or heavier.A molded assembly with the connector molded on the cable will have superior resistance to weather and washing. Route the wires in a protected area and secure them frequently to prevent snagging.ConnectorsThe pump connectors must meet DIN 43650 specification such as Hirschmann GDM 209, IMEX # MPM-182-09-N or equivalent. The cable to connector joint must be weather tight. The connector lug cavity should be filled with an electrical corrosion resistant grease. NOCO Company,NCP–2 battery corrosion preventative works well. The speed pick-up has a weather pack connector, #12015793.ConnectionsThe polarity of the solenoid and speed sensor wiring is interchangeable on the pump and motor connections.Constant Speed Control Installation RequirementsThe solenoid with the external tube fitting must have one wire going to the control box lower terminal strip marked “solenoid” (see wiring diagram).MountingReplace the S1 orifice under the controller following the instructions below. The solenoid valves must be oriented on the pump as shown. Failure to do so will result in bending the tube assembly unnecessarily, causing erratic operation of the control. Remove the two plugs on the manual control and mount the valve package with the fittings provided. The plug on the pump housing isreplaced with the fitting provided and the tube is connected to it. Tighten all fittings to 22 Nm[16 lb-ft].FailuresSee attached troubleshooting. In the event of an electrical or solenoid failure, the particular solenoid can be overrid-den by turning the screw on the end in about 11/2 turns.Note: The orifice size is stamped on the orifice in thousandths of an inch, example: 21 = .021 in.Orifice Removal and Installation1. Place the .021 inch orifice in the ‘S1’ Orifice pocket so the size is visible.2 Stake the orifice in three places with a center punch.3 Insure that the orifice is properly seated after staking.4 Reinstall the manual control valve with a new gasket and thecontrol line attached. Torque the controller mounting bolts to 122 Nm[16 lb-ft].Orifice Pockets S2S1PGasket Surface of Control ValveTrouble Shooting GuideProblem Cause Corrective Action Motor will not run with the Control lever centered.Move manual control lever one-inchswitch in NORMAL or(or more) from the center position.AUTOMATIC position.Loose or corroded wire Tighten and/or clean theattached to POWER (+12)connection and secure the wire.or GROUND (-12)terminal on the controller.Modulating valve Remove valve and clean outstuck open.debris or replace valve.Solenoid bad.Replace solenoid valve.Control and/or secondary Remove and clean holes in orifices.orifice plugged.Fuse blown in controller.Remove and replace fuse. Check wiring forshort from solenoid to ground. Exchangecontroller with known good unit. Checksolenoid coils on valves for shorts.NOTE: To override control system and restoremotor rotation, turn the screw in until thevalve is seated.Incorrect wiring.Insure the jumper or remote switch is attachedto the correct terminals.Incorrect wiring.Insure the 2 solenoid connections arenot reversed.Motor will not rotate when No electrical power to the Change position of remote switch to ON.the controller switch is in modulation / controlthe NORMAL position.solenoid because theremote switch is OFF.4Trouble Shooting GuideProblem Cause Corrective ActionMotor speed changes very Bypass Solenoid Valve Remove and clean Solenoid Valve spool.slowly (that is, speed stuck shut or orifice(s)Re-assemble valve and test for spool movement changes from highest to a clogged.when 12 volts are applied to the two solenoidstop takes more than three terminals. If spool does not respond, install a seconds with warm oil) when new solenoid valve. If system continues tothe controller switch is in respond slowly, orifice(s) may be partiallythe NORMAL position.clogged. Inspect orifices in the manualcontrol valve and clean holes if necessary.Incorrect plumbing.External tube should connect the solenoid tothe S1 port and not to the charge pressureport on the side of the pumpMotor speed higher than the Defective sensor Replace sensor.speed the controller is set on the motor.for (when the controllerswitch is in the Loose connection or Tighten screws / nuts and/or replaceAUTOMATIC position).broken wire in sensor cable.sensor cable.Sensor located too far Check clearance between the tip of thefrom spline of shaft inside sensor and the surface of the spline. Providethe motor.proper clearance (.003 to .005) by carefullythreading sensor in until the tip touches thehighest point on the spline on the shaft andthen rotate the sensor 20˚counter-clockwise.Torque the jam nut to 19 N·m [14 ± 1 lb ft].CAUTION: More torque than the specified amountmay permanently damage the sensor!Motor speed uneven in Bypass solenoid not Check wiring to BYPASS SOLENOIDAUTOMATIC mode of closing in AUTOMATIC the solenoid should have electricaloperation and motor speed mode.power (12 VDC) when the controllerchanges as quickly in switch is in the AUTOMATIC position.AUTOMATIC as inNORMAL mode.Secondary orifice missing.Remove manual control valve and install orifice. Automatic speed control is not Either the 021 orifice Inspect orifices in the manual control and clean working. Drum runs at what-manual control is plugged or holes if necessary. Remove and clean solenoidever speed the manual control the solenoid is stuck.valve spool. Re-assemble valve and test for spoolis set at.movement when 12 volts are applied to the twosolenoid terminals. If spool does not respond, install anew solenoid valve.5© 2008 Eaton Corporation All Rights Reserved Printed in USADocument No. E-PUPI-TI010-E Supersedes 04-513January 2009EatonFluid Power GroupHydraulics Business USA 14615 Lone Oak Road Eden Prairie, MN 55344USATel: 952-937-9800Fax: 952-294-7722/hydraulicsEatonFluid Power GroupHydraulics Business Europe Route de la Longeraie 71110 Morges SwitzerlandTel: +41 (0) 21 811 4600Fax: +41 (0) 21 811 4601EatonFluid Power GroupHydraulics Business Asia Pacific11th Floor Hong Kong New World Tower 300 Huaihai Zhong Road Shanghai 200021 ChinaTel: 86-21-6387-9988 Fax: 86-21-6335-3912。
工作原理该系列液压推杆制动器由制动架和相匹配的yt1型电力液压推动器两大部分组成。
当通电时,电力液压推动器动作,其推杆迅速升起,并通过杠杆作用把制动瓦打开(松闸);当断电时,电力液压推动器的推杆在弹簧力的作用下,迅速下降,并通过杠杆作用把制动瓦合拢(抱闸)。
□制动器的安装及调整●制动器安装方式:○纵装:松开螺母4、5使主弹簧处于自由状态,松开6、8螺母,转动螺杆7撑开制动臂,再将制动器套装在制动轮节器9—弹簧座spring base 上。
10—弹簧架刻度机 spring notches ○横装:当制动轮已装在电机与其它机件之间时,松开螺母4、5、6、7、8,转动螺杆取下螺杆3和7,将制动臂放倒。
从侧南装到制动轮上。
●制动器的调整○推动器工作行程的调整在保证闸瓦最小退距的情况下,推动器的工作行程愈小愈理想,因此需要调节其安装高度h1,其调整方法:松开螺母6和8(见图),转动螺杆7,使h1安装尺寸符合表1的要求。
调好后拧紧螺母6、8。
○制动力矩的调整松开螺母4,夹住螺杆的尾部方头,转动螺母5,使方形弹簧座位于弹簧架刻线以内,调整发后将螺母4和5拧紧退即可。
○制动瓦的退距调整当制动瓦打开时,调整螺栓1,使两边退距基本保持一致。
○固定制动瓦的螺母(见图),应松紧适当,使制动瓦与制动轮可以随位。
□使用和维修要定期检查制动器的工作状况。
检查时应着重以下各项:○制动器的构件无能运动是否正常,调整螺母是否紧固。
○推动器的构件是否正常,液压油是否足量。
有无漏油和渗油现象。
引入电线的绝缘是否良好。
○尺寸h1不得小于表1所列之最小尺寸,如超出要求须立即调整,否则失去制动作用。
○制动瓦是否正常的靠在制动轮上,磨擦表面的状态是否完好,有无油腻脏物。
当制动衬垫的厚度达到表2中的数值时,则应更换制动衬垫。
○制动轮的温度不应超过200℃。
○杠杆和弹簧发现裂纹应更换。
篇二:制动器说明书(参考) 1 绪论1.1 课题背景及目的汽车的普及伴随着能源消耗的增多,而如今的生活,汽车已经是人们日常生活离不开的必要工具。
文件号:ZC/JS006-85日期:2010年6月版本号:Ⅰ修订日期:BPC旁路液压控制系统说明书编制:校对:批准:德国莱纳克测量控制技术有限公司中国北京目录1、情况简述2、液压站部分2.1 液压站的防护2.2 液压站工作原理及主要部件2.2.1 液压站的工作原理2.2.2 液压站的主要部件2.2.3 液压站的特点2.2.4 液压站的对外接口2.2.5 液压站的电源要求2.3 液压站现场安装与调试2.3.1 液压站的安装2.3.2 液压站压力的整定方法及整定值2.3.3 压力开关、压差开关、压力变送器和液位开关动作的整定值2.3.4 蓄能器充气与充气压力2.3.5 泵联锁试验2.3.6 系统耐压试验2.4 启动液压站前必须做的工作3、油管路系统及执行机构部分3.1 油管路系统3.2 执行机构3.2.1 HBP、HBPE、LBP和LBPE阀的执行机构3.2.2 HBD和LBD阀的执行机构1、情况简述BPC旁路液压控制系统由液压站(含再生装置)、高旁减温减压阀执行机构、高旁喷水调节阀执行机构、高旁喷水隔离阀执行机构、低旁减温减压阀执行机构、低旁喷水调节阀执行机构、低旁喷水隔离阀执行机构和高压蓄能器组件,以及将上述部套连接在一起的油管路系统组成。
2、液压站部分2.1液压站的防护液压站是旁路液压系统的重要组成部分之一。
液压站在运行过程中需要维护、检修。
如何及时、正确地维护、检修对液压站的安全、可靠运行是非常重要的。
在旁路液压站投入运行之前,请阅读本手册。
说明:液压站在投入使用后必须每天检查设备上的防护及油漆是否遭到环境的破坏,如发现必须在第一时间进行修复。
2.2 液压站工作原理及主要部件2.2.1液压站的工作原理2.2.1.1主油泵回路的工作原理(见附图旁路液压站原理图)由交流马达通过联轴器驱动恒压变量泵,泵的入口油通过油箱、泵入口截止阀、吸油滤器、恒压变量泵将抗燃液压油吸入,高压油经泵出口滤芯、单向阀、泵出口截止阀进入高压油母管,蓄能器与高压油母管并联。
液压轮边制动系统 使用说明书
湘潭市恒欣实业有限公司 2
目 录 一、 轮边制动系统结构特征和工作原理 二、 轮边制动系统液压站明细表和主要技术参数表 三、 轮边制动系统调试方法 四、 轮边制动器的安装 五、 注意事项 六、 维护保养 七、 常见故障分析与排除 附1:压力变送器使用说明书 附2:液压钳盘式制动器使用说明书 3
一、轮边制动系统结构特征和工作原理 1.结构特征 主要由液压钳盘制动器、液压站、液压胶管等组成
2 、工作原理:开启电机,带动油泵输出压力油,当控制制动器的换向阀电磁铁得电时,液压站向制动器油缸供给压力油,制动器开启。当制动压力达到设定压力值时,压力变送器检测信号提供给电控系统控制电机停止工作,此时由单向阀保压,并由蓄能器补压;当制动压力低于设定值时,压力变送器检测信号并控制电机开启,向制动器补给压力油。 本液压站具有紧急制动功能:当电磁换向阀阀芯被卡,导致制动器不能制动时,或可打开手动球阀进行紧急制动。 4
二、轮边制动系统液压站明细表和主要技术参数表 1轮边制动系统液压站明细表
序号 名 称 规 格 型 号 序号 名 称 规 格 型 号
1 泵出油管 13I-380A3 M22*1.5 V0 2 油泵 2.5MCY14-1B
3 泵泄油管 13I-480 A3 V0°M22*1.5 4 二位四通换向阀2(备用) GDFW-02-2B2-D24-50
5 电机 YB2-90L-4 1.5KW 6 二位四通换向阀1(制动) GDFW-02-2B2-D24-50 7 压力控制器 GPD60K(0-25MPa) 8 加油过滤器 QUQ2-20×1.0 9 蓄能器 NXQ-4/20-L-A 10 安全警告牌 11 液压站铭牌 12 单向阀 CRG-03-05-10 13 板式球阀 KHP-06 14 泵压力溢流阀 MCR-07
15 耐压压力表 DT-63-350K-B1-T-02 (共2个) 16 管道过滤器 ZU-H63×10B (滤芯HX-63×10)
17 表线 2-700 A/Q MG1 配14铰接头 (共2根) 18 泵吸油管 13I-260 A M22*1.5 备注:油箱内含吸油过滤器,型号为WU-100*80
1 2 3 5 4 6 7 10 12 13 14 15 9 11 8 17 18 16 5
2液压轮边制动系统液压站及制动器主要技术参数表 型号 YZL-12 额定输出流量 3.5L/min 额定输出压力 8MPa 最大输出压力 12MPa 油泵公称排量 2.5ml/r 油箱储油量 160L-180L 制动油缸有效活塞面积 YQP50系列 YQP100系列 YQP120系列 6890mm2 13940 mm2 18850 mm2 液压站外形尺寸 1110mm×660mm×890mm 备注:轮边制动器详细参数详见液压钳盘制动器使用说明书 三、轮边制动系统调试方法 1调试前准备 1.1检查液压站的电机、压力控制器以及其他部件型号是否与供货清单要求一致。 电气接线:根据图纸把电气操作台、PLC箱与液压站之间的相关连线连接好;将磁力启动器和小液压站上的电机线连接好,磁力启动器选择远控档位。 1.2 确认所有连接管道安装正确无误,管接头内已配密封圈,管接头螺母已拧紧;各液压阀安装正确无误;油泵内已注满液压油。 确认按要求加注了合格的液压油(昆仑牌L-HM68抗磨液压油)。为确保油质,选用塑料小桶装的,初次注油量约为160~180升,油箱中油位应在油标中位刻度以上。 确认接线正确无误。 调试前应将板式球阀关闭(手柄水平放置) 2 液压系统调试 2.1 首先按下电气操作台上的“开车预警”按钮,查看液压站上的电机启动后;按下“停止”按钮,面对电机风扇观察电机转向,应为顺时针方向旋转(如果逆时针方向旋转,则电机动力线接反。解决方法:将电机线其中两相互换或者通过拨动磁力启动器上的正、反开关来调 6
节。) 2.2电机运行正常,然后查看油泵能否正常运行,油泵压力油表指针应上升至12Mpa左右,检查油泵和油管各接头处是否有漏油现象。 2.3设备正常运行,将制动压力调到8~9Mpa(溢流阀内六角螺杆顺时针方向旋为上调压力,一般我公司出厂时已经调好,现场请勿操作)。 2.4 将二位四通换向阀2通电,制动压力应为零,手动打开球阀,制动压力应为零 四、轮边制动器的安装 1将轮边制动器用安装螺栓挂在安装横梁上,或安装支座上并靠近安装位置; 2 连接制动器与液压站之间的高压胶管,连接胶管时应注意密封圈良好无损坏; 3 启动液压站,将制动器打开; 4 将轮边制动器按设计安装位置固定在横梁上或安装支座上; 5按照轮边制动器使用说明书中的要求,核实弹簧长度,若弹簧长度不符合轮边制动器使用说明书中的长度,则需调整使其符合要求。(详见附2液压钳盘式制动器使用说明书) 五、注意事项: 1安装调试前检查磁力启动器的型号、规格、参数和功能是否与设计图相符合。 2熟悉电气安装图、接线图及电气设备与液压站之间的相关接线图及原理图。 3 检查自备清单及发货清单核实电气、液压站配件是否齐全。 4 电机电压应与电源电压相符 5 所有电气设备的接地点都必须与接地极相连,严禁带电操作。 六、维护与保养 每次开机前应进行如下检查: 1 有无泄露油点 2 液压油油位应在油标中位刻度以上 7
3 可调元件(液压阀等)是否被人调动过 4 液压油和过滤器是否需要更换 首次更换吸油过滤器和精过滤器的时间为运行200小时,以后每运行500小时必须进行更换。首次更换液压油的时间为运行200小时后更换,以后每1000小时左右更换,液压油为昆仑牌L-HM68抗磨液压油,严寒地区地面使用时应使用L-HV46低温抗磨液压油(倾点为-36℃),严禁使用任何牌号再生油,且两种牌号的液压油不得混用。 特别提醒:每次更换滤芯和更换液压油时不能有任何异物进入到油箱或管路中,加新油时必须通过过滤器注入油箱。换油时,应将油泵、油缸及油管中的残存油液置换干净。 5 液压钳盘式制动器的安装、维护和保养详见其使用说明书(附2)
警 告 液压钳盘式制动器在使用一段时间后,制动片会磨损,弹簧长度会变长,导致制动力减小,因此必须经常检查制动片的磨损情况和及时调整弹簧长度,以保证制动力的可靠性。
七、常见故障分析与排除 故障现象 原因分析 排除方法 备注 开机后电机 不工作
1.电机没得电 2.磁力启动器未选择远控档位 1.给电机上电
2.在磁力启动器内部选择远控档位
设备运行调节溢流阀压力上不来
1.油泵不工作,油路中没油 2.张紧电磁阀接线错或电磁阀坏掉 3.溢流阀坏 4.油路中有杂质,油路块堵塞 1.换油泵 2.重新按图纸接线或换电磁阀 3.换溢流阀 4.清除杂质,清除油路块中堵塞物或换油路块 5.换显示仪表 8
5.显示仪表坏 系统保压效果 不好
1. 油路密封性不好,有漏油现象 2. 溢流阀调节不到位 3. 蓄能器压力不符 4. 单向阀卡滞 1.重新拧紧油管确保不漏油 2.把溢流阀调节到位 3、调整氮气压力 4、清洗、更换阀组
设备运行制动器打不开 1.制动油压太低 2.制动电磁阀连线错或电磁阀坏 3. 制动器与液压站之间的油管未接 4. 制动器坏 1.把制动油压调高 2.重新按图纸接线或换电磁阀 3.连接好制动器与液压站之间的油管 4.换制动器
油泵漏油 1.油封损坏 2.油泵磨损严重 1.更换油封 2. 更换油泵
附件1:压力变送器使用说明书 1. 面板示意图
下限开关动作时,下限指示灯亮 上限开关动作时,上限指示灯亮 2、操作说明 出厂时已按用户要求设定好的仪表安装接线 完成后可直接使用。若需调整,可参照以下步骤调整(A、B键见面板示意图): 2.1 开机后仪表自检完成后进入表头显示界面。 2.2 设置零点,按 “A+B”键,显示零点设置菜单“SET2” 。 按 “A+B”键进入零点设置界面,显示当前设置的零点数值(出厂默认值为量程下限值)。零点可设置为4mA,百分比,或其他物理量。 按“A”键移动光标,“B”键改变光标所在位数值。 设好数值后,按 “A+B”键确认并返回菜单。 2.3 满量程设置 9
继续按 “A”键显示满量程设置菜单“SET5”。 同时按 “A+B”键进入满量程设置,界面显示当前设置的满量程数值 (出厂默认值为量程上限值) ,满量程可设置为20mA,百分比,或其他物理量。 按“A”键移动光标,“B”键改变光标所在位数值。 设好数值后,按 “A+B”键确认并返回菜单。 2.4 小数点位置设置 继续按“A”键显示小数点设置菜单“dot”。 同时按“A+B”键进入小数点设,界面显示当前小数点位置“--.--”。“A”键左移小数点 ,“B”键右移小数点。设定完毕,按“A+B”键确认并返回菜单。 2.5 阻尼时间设置 继续按“A”键显示阻尼时间设置菜单“dAP”。设置方法同 2,阻尼时间设定范围为0~20s,设置时数值按 0.5倍数改变。设定完毕,按“A+B”键确认并返回菜单。 2.6 报警开关设置 继续按“A”键显示报警开关设置菜单“HILo”。 按“A+B”键进入报警开关设置,显示当前设置值“oFF”,表示以下报警参数不生效。按“A”或“B”可切换为“on” ,表示以下的设置报警参数生效。 设定完毕,按“A+B”键确认并返回菜单。 2.7 第一报警点设置 继续按“A”键显示第一报警点设置菜单“StPL”, 设置方法同 2,报警点的设定数值按满量程的百分比计算。 设定完毕,按“A+B”键确认并返回菜单。 2.8第二报警点设置 继续按“A”键, 显示第二报警点设置菜单“StPH”, 其余同 7。设定完毕,按“A+B”键确认并返回菜单。 2.9 第一报警点报警方向设置 继续按“A”键显示第一报警点报警方向设置菜单LdIr 。 按“A+B”键显示当前设置值“uP”,表示数值由低向高变化报警。