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Decisive solution for plunger pump repair

2018-05-14View Original

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A plunger pump is an important component in hydraulic systems. It relies on the reciprocating movement of the plunger within the cylinder body to change the volume of the sealed working chamber, thereby achieving oil suction and oil compression. Plunger pumps feature high rated pressure, compact structure, high efficiency, and easy flow regulation, and are widely used in applications that require high pressure, large flow rates, or flow regulation, such as hydraulic presses, construction machinery, and ships. The working principle: A plunger pump is a type of reciprocating pump and belongs to the category of positive displacement pumps. Its plunger is driven to move back and forth by the eccentric rotation of the pump shaft, and both its suction and discharge valves are check valves. When the plunger is pulled outward, the pressure in the working chamber decreases, causing the outlet valve to close. When the pressure drops below the inlet pressure, the inlet valve opens and liquid flows in. When the plunger is pushed inward, the pressure in the working chamber increases, causing the inlet valve to close. When the pressure rises above the outlet pressure, the outlet valve opens and liquid is discharged. When the drive shaft rotates the cylinder block, the swash plate pulls the plunger out of or pushes it back into the cylinder block, thereby completing the process of oil suction and discharge. The oil in the working chamber formed by the plunger and the cylinder bore is connected to the suction and discharge chambers of the pump through the oil distribution plate. The variable mechanism is used to change the inclination angle of the swash plate; by adjusting this angle, the displacement of the pump can be altered. In terms of structural design, piston pumps are divided into two main types: axial piston pumps and radial piston pumps. As radial piston pumps represent a new type of high-efficiency pump with a high level of technical complexity, and given the accelerating development in this field, they will inevitably become an important part of the piston pump industry. Wear-resistant repair materials used: NPT wear-resistant repair materials (room temperature) series (first generation): NPT-1-C30, NPT-1-C16, NPT-1-C6-8, NPT-1-C3-5; NPT wear-resistant repair materials (heated) series (first generation): NPT-1-J30, NPT-1-J16, NPT-1-J12, NPT-1-J6-8, NPT-1-J3-5 ; NPT wear-resistant repair materials (high temperature) series (first generation): NPT-1-G30, NPT-1-G16, NPT-1-G12, NPT-1-G6-8, NPT-1-G3-5 ; NPT wear-resistant repair materials (room temperature) series (second generation): NPT-2-C30, NPT-2-C16, NPT-2-C6-8, NPT-2-C3-5 ; NPT wear-resistant repair materials (heated) series (second generation): NPT-2-J30, NPT-2-J16, NPT-2-J12, NPT-2-J6-8, NPT-2-J3-5 ; NPT wear-resistant repair materials (high temperature) series (second generation): NPT-2-G30, NPT-2-G16, NPT-2-G12, NPT-2-G6-8, NPT-2-G3-5 ; NPT special wear-resistant repair material series: NPT-YHG (2.0-2.5), NPT-Z80 (3.0-3.5), NPT-TSG (1.0-1.4), NPT-TSG (3.0-3.5), NPT-YHL (1.0-1.4). Repair methods: 1. Surface treatment: Perform patch welding, degreasing, and sandblasting to remove rust on the workpiece to be repaired. ①Repair welding: Repair welding is required for areas that have suffered excessive erosion and are not strong enough to support the adhesive. ②Degreasing and dehumidification: Remove the grease from the surface of the workpiece; wipe the surface with cotton yarn that is free of oil or moisture. Use oxygen and acetylene to adjust the flame to a length of 10 cm, and move it back and forth over the surface of the workpiece at a speed of 5 cm/min, in order to evenly heat that surface and remove any grease or moisture present there. ③Sandblasting for rust removal: Removes the oxide layer from the surface of the workpiece; upon visual inspection, a uniform natural metal color is visible on the sandblasted surface. Workpieces that have been sandblasted must not be touched directly on the sandblasted surface with gloves coated in grease; after sandblasting, these workpieces need to be protected from moisture. 2. Preparation: Prepare the molds and tools, preheat the workpiece as well as the adhesive. Mix the components strictly according to the specified adhesive ratio. After mixing, place the adhesive in a tray and apply it to the preheated workpiece. The mixed adhesive should not remain in the tray for more than 3 minutes, in order to ensure proper bonding of the adhesive to the workpiece. After the construction is completed, any defects identified are repaired promptly. 3. Heating and curing: The workpiece after completion of construction is left for 30 minutes to undergo heating and curing. 4. Grinding: The workpiece that has been cured by heating is subjected to grinding in strict accordance with its dimensions, and the sealed mating surfaces must be properly fitted together. 5. Painting: After passing the inspection, the workpiece is painted, with the requirement that the paint coating be even and without any sagging.

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