黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 1 附 錄 附錄 A Understanding of concrete pump hydraulic system Pumping Hydraulic system Boom hydraulic system Outrigger hydraulic system Hydraulic system diagram Daily check and maintenance of the hydraulic system The functions of the truck mounted concrete pump, hydraulic system can be divided into pumping hydraulic system, boom hydraulic system, outrigger hydraulic system. Pumping Hydraulic system Is divided into three parts: main pumping system, distribution and lubricating system, mixing and cooling and cleaning system. Main pumping system There are two hydraulic loops: open and close loop. The Open loop: uses an A11VLO190 variable displacement of axial piston pump. It is fitted with a constant power control device, pressure cut-off valve and electrical stroke limiter with proportional solenoid. The constant power control device has been set in the factory. The displacement can be adjusted from 0 to Maximum by turning the oil pump displacement potentiometer on the control panel from low to high. Fig. 1 A11VLO 190 A， B Service port (without charging pump) 420 bar 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 2 S Suction port (with charging pump) 35 bar T1, T2 Air bleed, tank R Air bleed, oil drain M1 Measuring point, regulating chamber M Measuring point, service port G Port for positioning pressure (controller) for version with stroke limiter (H., U2), HD and EP with screwed fitting GE10 PLM (otherwise port G closed) The other is the control line, which can change the flow direction and the displacement of main pump through constant power valve, proportional solenoid pressure reducing valve, directional control valve and servo valve of main pump. The Closed loop: There is an auxiliary pump with relief valve that the setting pressure is 3.5Mpa in A4VG180. The auxiliary pump has two output ways. One is the charge oil line, which connects with suction line of main pump through the check valve in two pressure relief valves and add oil to main pump. At the same time excessive hydraulic oil return to oil tank through flushing valve and cooler to realize heat exchange for closed loop. 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 3 A, B Service line ports SAE 1 1/4, high pressure series 420 bar T1 Case drain or filling port T2 Case drain M332； 18 deep MA, MB Pressure gauge - operating pressure A, B R Air bleed S Boost suction port X1, X2 Control pressure ports (before the orifice) G Pressure port for auxiliary circuit PS Control pressure supply Fa Filter outlet Fa1 Filter outlet (filter assembly) Fe Filter inlet M332； 18 deep FS Port from filter to suction line (cold start) MH Port for balanced high pressure Y1, Y2 Remote control ports (only for HD control) Flushing valve Used for closed loop to prevent excessive heat build-up in closed circuit operation. The setting pressure of flushing valve is 3.0MPa Pressure reducing valve with proportional solenoid Used for closed loop. The Output pressure is connected with the remote control port of main pump to control the displacement and is controlled by a proportional current signal and constant power valve. The displacement can be adjusted from 0 to Maximum by turning the displacement adjusting potentiometer. Constant power valve Used for closed loop. When the hydraulic system pressure is over the setting pressure, the valve works to reduce the output pressure of the pressure reducing valve and maintain the constant power. Power setting 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 4 Fig.3 Constant power valve Main pump suction filter Open loop: filtration fineness 100u. Close loop: filtration fineness 20u. When the indicator in the vacuum gauge exceeds the safe area or the electric signal instrument gives a warning, the cartridge may be blocked. It should be clean or replace filter cartridge promptly. Filter filtration fineness is 20u in open loop. When the reading pressure of the vacuum gauge exceeds 0.35Mpa, the cartridge may be blocked. It should be clean or Return filter replace filter cartridge promptly. Filter filtration fineness is 10u in closed loop. When the electricity deliver reports to the police, the cartridge may be blocked, it should be clean or replace filter cartridge promptly. Distribution and lubricating system Constant pressure pump Fig.4 Constant pressure pump An A10VO28 constant pump is used for the distribution system of supply oil. The setting of the pressure control valve of the pump is 16Mpa. Once the system Pilot pressure s tting Setting screw for pressure control zero /Stroke pressure 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 5 pressure is reached, the bump will keep this pressure then decrease the displacement. There is a pressure relief valve in the distribution circuit to act as a safety valve, which is set to 18Mpa. Plate ball valve (shut-off valve) Used to discharge the accumulator. It must be rotated the lever of shut-off valve anti-clockwise when the pumping finishes or stopped for maintenance, in order to discharge the pressure of theaccumulator. (Pressure gauge of distribution system is zero) Accumulator Inflation pressure is 8-9Mpa. Use Only Nitrogen to fill the accumulator. Charging pressure should not exceed these figures. Lubricating system There are two types. One is reciprocating centralized lubrication that is driven by oil from the swing cylinders of distribution system includes lubricating single pump (or double pump), distributor, damper and filter. The other is automatic centralized lubrication that is driven by a D.C motor with an independent grease tank and independent from the hydraulic system. The interval time of lubrication is carried out in the factory. The lubrication system works automatically when pumping. Mixing, cooling, cleaning system Only the Mixing, cooling, cleaning system are driven by motor in open loop. Gear pump Gear pump supplies oil to the mixing, cooling, cleaning system. Sandwich type relief valve The pressure is set to 14Mpa. Ressure relay If the mixing blade is stuck, the system pressure will raise. When the pressure exceeds the setting value (usually 10Mpa), the pressure relay will give a warning. The Solenoid directional control valve changes direction to let the mixing motor to rotate anti-clockwise. After 6 second the solenoid valve will reset, and the mixing motor will rotate clockwise again. Return filter The filtration fineness is 10u in closed loop. The cartridge may be blocked when the electric alarm sounds. It should be replace promptly. 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 6 Boom hydraulic system Boom pump Boom and outrigger use the same pump. 37m and 40m truck mounted concrete pumps: A2FO23 fixed displacement pump 44m and 47m truck mounted concrete pumps: A7VO55LRDS variable displacement pump, or A7VO55DRS variable displacement pump 46m and 49m truck mounted concrete pumps: A7VO55LRDS variable displacement pump Fig.5 A7VO55DRS Fig.6 A7VO55LRDS Fig.7 A2FO23 Boom proportional directional spool valve The proportional directional spool valve with electro-hydraulic consists of pressure relief valve, pressure reducing valve, and flow control valve, and can be controlled manual or by remote control. 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 7 Fig.8 Boom proportional directional spool valve Load-holding valve Load-holding valve has three functions. (1) It acts as a lock when the cylinder isnt moving. (2) Load-holding valve has twice relief function to protect boom against vibrating. It will be adjusted in the factory. (3) When the boom moves downward as Slewing load-holding valve gravity load, it can limit speed to prevent the boom falling too quickly and shaking. There are three main functions. Lock, overload protection and speed limiting. Outrigger hydraulic system Outrigger hydraulic system and boom hydraulic system are used the same pump to supply oil. Outriggers should be set up before the boom is operated by the control levers or electric control button on both sides of the truck mounted concrete pump. Outrigger proportional directional spool valve It is an integrated unit with a relief valve inside to control maximum pressure of the outrigger hydraulic system. Fig .9 Outrigger proportional directional spool valve Outrigger hydraulic lock It is used to lock the outrigger cylinders and pay attention to the vertical moving of the outrigger cylinder when working . Pressure relief valve 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 8 附錄 B 混凝土泵車(chē)液壓系統(tǒng)的認(rèn)識(shí) 泵送單元液壓系統(tǒng) 臂架液壓系統(tǒng) 支腿液壓系統(tǒng) 液壓原理圖 液壓系統(tǒng)的日常保養(yǎng)及維護(hù) 泵車(chē)液壓系統(tǒng)按泵車(chē)功能可劃分為泵送單元液壓系統(tǒng)、臂架液壓系統(tǒng)、支腿液壓系統(tǒng)。 泵送單元液壓系統(tǒng)：泵送單元液壓系統(tǒng)按功能可分為三大部分：主泵送油路系統(tǒng)；分配及潤(rùn)滑 油泵驅(qū)動(dòng)系統(tǒng)；攪拌、冷卻、清洗油路系統(tǒng)。 主泵送油路系統(tǒng) ：主泵送系統(tǒng)按油液循環(huán)方式分為開(kāi)式液壓回路和閉式液壓回路兩種。 開(kāi)式液壓回路：采用一個(gè)軸向變量柱塞泵，該泵帶有恒功率控制裝置、壓力截流閥和電控變量控制閥，恒功率控制裝置出廠時(shí)已設(shè)定好。電控面板上油泵排量按鈕由小變大范圍內(nèi)調(diào)節(jié)時(shí)，主油泵排量在 0最大范圍內(nèi)變化。 A， B 工 作 油 口 （ 不 帶 升 壓 泵 ） 420bar S吸油 口 （ 帶 升 壓 泵 ） 35bar T1, T2 放氣 口 ， 油 箱 圖 1 泵 A11VLO190 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 9 R放氣 口 ， 放 油 M1變 量 缸 測(cè) 壓 口 M工 作 油 口 測(cè) 壓 口 G控 制 壓 力 油 口 對(duì)于 排 量可限制型（ HU 2 ） 和 HD、 EP 帶 緊固 螺栓 GE10-PLM（其他情況下油口 G堵?。?閉式液壓回路： 采用 A4VG180 雙向周向變量柱塞泵 ， 該泵帶內(nèi)置補(bǔ)油泵， 補(bǔ)油溢流閥調(diào)定壓力 3.5 MPa，其出口油路可分為兩路：第一路為補(bǔ)油油路，通過(guò)兩高壓溢流閥內(nèi)的單向閥，始終與主泵吸油油路相通，對(duì)主泵送油路進(jìn)行補(bǔ)油，同時(shí)多余的油液經(jīng)沖洗閥、冷卻器流回油箱，實(shí)現(xiàn)對(duì)閉式油路系統(tǒng)的熱交換。 第二路為控制油路，經(jīng)恒功率閥、電磁比例減壓閥、 換向閥及泵內(nèi)伺服缸伺服閥，實(shí)現(xiàn)主泵的變量及液流流動(dòng)方向的改變。 圖 2 油泵 A4VG180 A, B 工作油口 SAE 11/4 高壓系列 420bar T1 殼體泄油或注油口 T2 殼體泄油口 M33 2，深 18 MA, MB 壓力表、工作壓力 A， B R 放氣口 S 吸油口 X1, X2 控制壓力口（在節(jié)流孔前） G 輔助回路壓力口 PS 控制壓力供油口 Fa 過(guò)濾器出口 Fa1 過(guò)濾器出口（裝配過(guò)濾器） Fe 過(guò)濾器進(jìn)口 M332， 深 18 FS 從過(guò)濾器到吸油管的接口（冷啟動(dòng)） MH 平衡高壓油口 Y1, Y2 遙控 口（僅對(duì)于 HD控制）沖洗閥 僅用于閉式液壓回路，用于實(shí)現(xiàn)閉式回路油液的交換。沖洗閥的設(shè)定壓力為 3.0 MPa 電磁比例減壓閥 僅用于閉式液壓回路，其出口壓力接主油泵遠(yuǎn)程控制口，控制油泵排量。出口壓黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 10 力受比例電流及恒功率閥的控制。遙控器或電控柜面板上油泵排量旋鈕由小變大范圍內(nèi)調(diào)節(jié)時(shí)，主油泵排量在 0 最大范圍內(nèi)變化。 恒功率閥僅用于閉式回路，當(dāng)回路工作壓力超過(guò)設(shè)定壓力時(shí)，恒功率閥起作用 。 圖 3 恒功率閥 主泵吸油濾油器 開(kāi)式回路：過(guò)濾精度為 100 閉式回路：過(guò)濾精度為 20 當(dāng)真空表指示超出安全區(qū)或電發(fā)訊器報(bào)警時(shí)，濾芯可能堵塞，應(yīng)及時(shí)清洗或更換。 回油濾油器 開(kāi)式回路：過(guò)濾精度為 20。當(dāng)真空壓力表超過(guò) 0.35MPa 時(shí)，濾芯可能堵塞，應(yīng)及時(shí)清洗或更換。 閉式回路：回油過(guò)濾精度為 10。電發(fā)訊器報(bào)警時(shí)，濾芯可能堵塞，應(yīng)及時(shí)清洗或更換。 分配及潤(rùn)滑油泵驅(qū)動(dòng)系統(tǒng) 恒壓泵 分配系統(tǒng)采用 A10VO28 恒壓泵供油 ， 其自帶的壓力控制閥設(shè)定壓力為 16Mpa。 圖 4 恒壓泵 用于零點(diǎn)壓力設(shè)定的控制螺桿 報(bào)警壓力 黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) 11 當(dāng)系統(tǒng)壓力達(dá)到設(shè)定壓力時(shí) ， 泵保持設(shè)定壓力不變，但油泵排量減小，僅供圖 4給執(zhí)行元件所需流量。分配油路中另有溢流閥起安全閥作用，設(shè)定壓力為 18Mpa. 板式球閥： 板式球閥用于蓄能器卸荷，當(dāng)泵送完畢和停機(jī)維修時(shí)