Partial User Manual for the Hydraulic System of the 6-meter Coke Oven Coal Loading Vehicle

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User Manual for the Hydraulic System of the 6-Meter Coke Oven Coal Loading Vehicle – Hydraulic System Section:
I. Main Technical Parameters:
1. Oil tank capacity: 1.5 M3
2. Working medium: Water–ethylene glycol
3. Operating pressures: P1 = 9 Mpa, P2 = 7.5 Mpa
4. Total motor power: 30 Kw + 2.2 Kw + 0.75 Kw (+30 Kw as backup)
5. Cooling method: Air-cooled cooler
6. Technical parameters of cylinders in various devices:
(1) Lid-lifting cylinders ×4: Φ80×Φ56-1200; Stroke S = 1100 mm; Speed V = 122 mm/s
(2) Lid-raising cylinders ×4: Φ80×Φ56-250; Stroke S = 220 mm; Speed V = 50 mm/s
(3) Kneading cylinders ×4: Φ80×Φ56-80; Stroke S = 80 mm; Speed V = 50 mm/s
(4) Guide sleeve lifting cylinders ×4: Φ80×Φ56-680; Stroke S = 650 mm; Speed V = 108 mm/s
(5) Gate opening/closing cylinders ×4: Φ80×Φ56-580; Stroke S = 550 mm; Speed V = 130 mm/s
(6) Smoke guide cart pushing cylinder: Φ80×Φ56-1300; Stroke S = 1250 mm; Speed V = 140 mm/s
(7) Electromagnet lifting cylinders ×2: Φ80×Φ45-680; Stroke S = 650 mm; Speed V = 65 mm/s
II. Hydraulic Station:
1. This system consists of two A7V117DR1RF00 type axial piston variable pumps and Y200L-4-B3 motors (one in use and one as backup), which supply the working medium to drive the cylinders in various devices. 2. A filtering and cooling circulation system, which consists of a circulation pump set made up of a PV2R3-94-L-R-A-A-40 type vane pump and a motor Y112M-4-B3, along with an AOA-360A air-cooled cooler and filters. 3. Fuel tank: 1.5M3. Inside the fuel tank: (1) YKJD24·BH-1200-1000 type level controller. When the float descends to the a2 set position, a signal is sent indicating that the liquid level has dropped to a level where refilling is necessary. The gas station can continue to operate. When the float descends to the set position a1 (slightly above the pump’s oil suction port), a signal is sent, the red light turns on, and an alarm is triggered. To prevent the oil pump from burning out due to vacuum suction, the fuel station automatically shuts down. (2). Electric contact thermometer: Model WSSX-411, T=0–100°C, L=300mm (a). The pump set cannot start when the working medium temperature is below 10°C. The electrical contact thermometer sends a signal, automatically turns on the electric heater, and the light comes on. When the working medium is heated to 25°C, the electric heater automatically stops heating. (b). During operation, when the temperature of the working medium rises to 50°C, the air-cooled cooler is activated automatically to cool the oil temperature. When the temperature drops to 40°C, the air-cooled cooler shuts down. (c). When the temperature of the working medium fails to cool down and continues to rise to 60°C, the red light turns on; when the temperature rises further to 65°C, an alarm is triggered. (3). Electric heater: SRY1-220/Z type, 2Kw, for heating the working medium. (4). Air filter: Type EF4-50. III. Hydraulic system (see the hydraulic schematic diagram of the 6-meter coke oven coal loading vehicle) 1. This system utilizes five sets of stacked valve assemblies to carry out the various operations related to the coal loading vehicle. 2. Coal loading equipment system (four sets identical to each other): composed of five groups of valve assemblies combined into one set, it can enable the movement of the cover-lifting device, the lifting and lowering of this device, the rubbing action, the lifting and lowering of the guide sleeve device, as well as the opening and closing of the gate plate. 3. The smoke guiding trolley device consists of four sets of valve assemblies combined into one set (with one set as a spare), and it can be used to push the smoke guiding trolley as well as to raise and lower the electromagnet device. 4. The hydraulic system has a manual/automatic switch. Each cylinder has a manual operation button; that is, the action is initiated by pressing the A or B electromagnet, and the action stops when the button is released. The on/off status of the electromagnet during the operation is shown in the electromagnet operation table. The sequence of operations is specified in the coal loading vehicle operation timing table. 5. The pressure relay (26.1) has a pressure setting of 5 MPa; when the system pressure drops to 5 MPa, the pressure relay sends a signal indicating that the system’s operating pressure is too low. In this case, the operator manually starts the backup pump and shuts down the original pump set. 6. The pump in the main pump unit of this system is an A7V117 variable displacement piston pump, with a pressure set at 9 MPa at the time of manufacture. 7. The pressure regulating device of the main pump unit, the A-BSG-06-2B2B type electromagnetic relief valve, is of the normally closed type. The pressure is set at 10 Mpa, which is the safe pressure level. The pump set has an automatic startup procedure; translation is only used for debugging and pre-startup inspections. IV. Installation 1. Familiarize yourself with the relevant installation diagrams and the locations of each cylinder. 2. The working medium of this hydraulic system is water-ethylene glycol. When on-site piping installation is required, the seals and piping treatments used must be compatible with water-ethylene glycol. 3. The installation of pipeline components, pipeline processing, welding, and the pickling of pipelines shall comply with the standards specified in the General Technical Requirements for Heavy Machinery JB/T5000.11-98. 4. The bending, cutting, and laying of each pipeline are all carried out on-site. The minimum bending radius of the pipe must be 3–5 times its outer diameter. 5. Connections such as pipes and fittings shall be welded using TIG welding, with the weld height equal to the wall thickness of the pipe being welded. 6. All pipelines are installed a second time. During the first installation, all pipes and pipe fittings are connected using spot welding; once one pipeline is completed, the welding is removed. After the first installation, all pipes are pickled (excluding hoses): first they are pickled in hydrochloric acid, then neutralized and rinsed with water, followed by passivation in phosphoric acid, and finally dried with compressed air. 7. During the second installation of the pipes, make sure they are clean and free from any impurities or foreign objects. Make sure to install sealing rings or combination washers at all pipe joints and tighten them. 8. Cylinder installation: Pay attention to the direction of the oil ports, and the outer surface of the cylinder piston rod must be free from defects such as dents or scratches. 9. Installation of the pump and motor: Ensure that the rotation direction of the pump is consistent with that of the motor, and check the accuracy of the coaxiality and alignment angle between the motor, coupling, and pump. 10. For valve components, ensure that the date of manufacture matches the model and the drawings. If the date of manufacture is too old, each valve should be disassembled and cleaned, and the quality of the seals should be checked for use during assembly. 11. The fuel tank must be cleaned thoroughly; there should be no rust or dirt on its inner surface. It is strictly prohibited to use cotton wads or similar materials to scrub the inner surface of the fuel tank. Clean the inner surface and apply rust preventive oil. 12. All pressure gauges and pressure relays have been inspected. V. Cyclic flushing 1. It is preferable to use a separate flushing device, avoiding the use of on-site devices. 2. If this system device is used for flushing (it is best to avoid flushing the valve assembly). (1). The fuel tank is filled with a filtered working medium, with a filtration precision of 10μ. (2). All pressure regulating valves, throttle valves, and pressure reducing valves should be set to their maximum open position. (3) The pipelines at both ends of the cylinder are short-circuited using pipe fittings (J615B-900-4). (4) Each pipeline should be flushed for over 24 hours, with the flushing direction changed from time to time, and the pipelines should be tapped with a wooden stick. (5). All pipelines have been flushed, and all connections have been made. (6). Remove the original working medium, clean the oil tank, and replace the filter element. Inject the filtered working medium again. 3. Rinsing test: The particle counting method is used for testing, with the sample liquid being taken after the final section of the pipeline has been rinsed. The contamination level of the hydraulic fluid meets China’s standards, with ISO 4406 standards applied equivalently; the grade codes are 19/16. VI. Pressure and sealing tests of the system Before conducting the pressure and sealing tests on the system, it is necessary to ensure that the circulating cooling pump set is operating properly (see the section on the commissioning of the circulating cooling pump set for details). (Pump set operation process ； Start the circulating cooling pump; after a delay, the solenoid of the pressure control valve assembly and the solenoid valve of the main pump set are energized. After another delay, the main pump set starts up, operating under low pressure at this point. After a delay, the electromagnet of the electromagnetic relief valve is activated, and the pump operates at its rated working pressure. (Automatic startup process). 1. Run the pump set at a constant speed for 20-30 minutes. 2. Note that the main pump in this system is an A7V117 variable displacement pump, whose pressure is set at 9 MPa at the time of manufacture. When the system is running idly, the corresponding electromagnetic relief valve should be powered. At this time, the pump set is operating under low-pressure unloading. The electromagnetic relief valve A-BSG-06-2B2B is of the normally closed type. When the electromagnetic relief valve is off, the pump outlet pressure is the pump’s set pressure. 3. Increase the pressure to the rated operating pressure in two stages, holding each pressure level for 10 minutes. Check the pipelines and all connections to ensure there are no leaks. 4. If a pressure test at 1.5 times the operating pressure is required, the pressure control lever of the A7V117 pump must be adjusted carefully to raise the pressure to 1.5 times the rated operating pressure. After the pressure testing is complete, make sure to adjust the pressure of the A7V117 pump back to the operating pressure of 9 MPa. 5. During the voltage withstand test, when the main pump starts operating, the circulating cooling system should be activated first. VII. Commissioning of the hydraulic system 1. System commissioning starts at the pump station, including pressure and flow, that is, the speed commissioning of the actuator. First, the individual cylinders move, followed by area interconnection, and then unit interconnection. 2. Pump station commissioning (1). First, commission the circulating cooling pump set. Open the relief valve and let the pump set operate under low-pressure unloading for 20 minutes. Check that the pump set is running smoothly and that the housing is heating up within normal limits. Then adjust the pressure to 0.8 MPa, and the pump operates normally. Then check the air-cooled cooler. The starter motor is running normally. The filter is working properly. (2). Debug the main pump unit by energizing the solenoid of the pilot relief valve, allowing the pump unit to operate under low-pressure unloading for 20 minutes. Check that the pump set is running smoothly and that the housing is heating up within normal limits. Adjust the pressure control lever of the A7V117 variable piston pump to reduce the pressure to zero. Then the electromagnetic relief valve loses power, allowing the pump pressure to be increased gradually in two stages to the operating pressure. 20 minutes each time, and finally increase the pump pressure further to 10 MPa, so that the pressure regulation of the electromagnetic relief valve matches the pump pressure. Fix the adjustment part of the electromagnetic relief valve; this is the set safety pressure of the electromagnetic relief valve. Make sure to adjust the pump pressure back to 9 MPa, which is the operating pressure for the system. The two pump sets are the same. (3). The accumulator is filled with nitrogen before being filled with oil. (4) The liquid level switch of the fuel tank is set to the designed height. When the liquid level changes to the desired position, a corresponding signal should be generated. (5). Electric contact thermometer, to adjust each temperature value to the required range per the design specifications. (6). Pump station pressure relay (26.1): a signal is sent out when the pressure drops to 5 MPa. 3. After the main pressure valve of the system is set, adjust the pressure valves of each branch one by one, ensuring smooth operation of each device. Careful attention must be paid to pressure regulation of the guide sleeve lifting device to prevent damage to the furnace mouth. First, adjust the pressure reducing valve to 5 MPa, and then adjust the throttle valve in the descending chamber so that the cylinder can adjust its descending speed under the weight of the guide sleeve assembly and a pressure of 4 MPa. Keep adjusting the pressure reducing valve and the throttle valve until the descent of the guide sleeve assembly is smooth. At this point, adjust the pressure relay so that the pressure is slightly higher than that of the pressure reducing valve; this will send a signal to turn off the electromagnetic directional control valve, with the main goal being to prevent damage to the furnace outlet. 4. Adjust the speed of each cylinder by tuning the throttle valve to ensure a steady and appropriate movement speed. 5. All limit switches operate correctly. 6. After individual cylinders have been adjusted, carry out regional coordination in accordance with the sequence requirements; finally, enable overall coordination of the entire machine by activating the limit switches. 7. After the overall machine operation has been adjusted, drain the working medium from the tank, clean the tank, and then refill it with the working fluid that has been filtered through a 10μ filter. VII. Painting of hydraulic system pipelines: The surfaces of the pipelines and accessories in the hydraulic station are painted with oil-resistant paint; the pressure oil pipelines are painted deep yellow, while the other pipelines are painted lemon yellow. The surfaces of the oil station and its accessories are painted apple green, or painted in accordance with the overall technical requirements. VIII. Maintenance of the hydraulic system: There should be standardized operating procedures, and operations and inspections must be carried out in strict accordance with these procedures. Operators and workers should be familiar with hydraulic principles and systems in order to use them properly, as well as carry out routine and periodic inspections. 1. Pre-start check: The working medium in the tank should be at the normal level. All indicator lights should display properly, and the electrical displays should function normally. The position of the automatic/manual switch is normal. Before starting operation, the pump set should be run idle for more than 10 minutes to ensure that its performance and the temperature of its casing are normal. 2. Monitor the operating conditions while the equipment is in use to ensure that all pressure gauges show stable readings within the specified range. Are there any abnormalities in noise and vibration? The oil temperature should be within the required range. Check the system for any oil leaks. 3. Since the working medium of this system is water-ethylene glycol. At high temperatures, water evaporates easily, which alters the properties of the working medium; therefore, regular inspections should be carried out after each change of the working medium. Ensure that the properties of the working medium remain within normal operating conditions. 4. When checking the working medium, replace the filtered working medium every six months. 5. Keep some seals on hand for regular replacement. 6. Pressure gauges, pressure relays, and thermometers should be checked regularly. 7. Conduct regular online inspections of components such as pumps, motors, valves, and cylinders.