1、產(chǎn)品培訓(xùn),1. 油液中污染物的形成 2 NAS以及ISO標(biāo)準(zhǔn)所代表的含義 3 清潔度的直觀照片 4 不同的濾芯過濾精度所能達(dá)到的油液清潔度等級 5 污染物的滲透過程 6 軸承座磨損的直觀照片 7 固體顆粒物的種類，以及對工作元件的影響程度 8 依據(jù)顆粒物的種類不同的處理方法 9 過濾器的作用，好處 10 濾芯的過濾方式（表面和深層） 11 表面過濾以及深層過濾的特點 12 濾芯的參數(shù)以及值的介紹 13 濾芯的結(jié)構(gòu) 14 根據(jù)不同的安裝位置選擇不同的過濾器型式 15 壓力發(fā)訊器以及壓差發(fā)訊器的原理 16 常用的發(fā)訊器報警值 17 根據(jù)實際例子選型,Plant 3,Plant 4,Gegrndet

2、/Founded: September 1996 -1996.9 Hauptsitz/Head Office: Shanghai-上海 Niederlassungen/Branch offices: Beijing,Anshan,Wuhan,Guangzhou- 北京，鞍山，武漢，長沙，廣州，成都，重慶，沈陽。 Anzahl Hndler, Vertriebs-bzw. Service-partner/ Number of Distributors or Service Partners: 26 Anzahl Mitarbeiter / No. of employees: 350 Produk

3、tion, Montage/ production, assembly: ja / yes Service: ja /yes Lager/ stock: ja / yes,Hydraulic Power Station 電廠,Hydraulic Control Stand,System for Steel Plant In 2013 鋼廠系統(tǒng) 63.38 Million RMB,Pu Yang 3.5m Rolling Mill AGC Control System,MOOG three-stage servo valves Qn =800 l/min P=420 bar,Pu Yang 3.

4、5m Rolling Mill Balancing System,Piston Accumulator : 100 L x 2 Nitrogen Bottles: 100L x 20 Bladder Accumulator : 50 L x 12,Effects(影響結(jié)果）,70-80% of all failures of hydraulic systems and up to 90% of all bearing failures are caused by contamination of the hydraulic fluid or lubricant 70%-80%的液壓系統(tǒng)問題和超

5、過90%的軸承問題是液壓介質(zhì)污染引起的,Solid 固態(tài)物,Liquid液態(tài)物,Gaseous氣體,Types of Contamination,Core sand型砂 Weld splatter焊渣 Fibers纖維 Scale剝落 Rust銹蝕物 Packaging residue包裝材料 Paint油漆,Types of Solid Contamination（固態(tài)污染物類型）,Types of Liquid Contamination（液態(tài)污染物類型）,Water水 Adding incompatable new oil增加新油,Air空氣,Types of Gaseous Conta

6、mination,Origins of Contamination,External contamination外部 Internal contamination內(nèi)部 Assembly裝配 Initial contamination初始 Abrasion磨損 New oil新油 Repairs維修,Bearinglubrication film,Fine/coarseparticle,1,5,15,75,Diameter in m,Human hair,30,Particle Proportions（肉眼能看到的顆粒物直徑）,Contamination Class NAS 7 or ISO 1

7、7/14,dynamic,static,Errors of Measurement Ways of taking a Sample（取樣方法）,Errors of Measurement Place of the Micro Hose,Particle CounterCalibration,Particle CounterPrinciple,Measuring with Fluid Control Unit (FCU),Electronic Particle CounterPrinciple,NAS-Code,Number of particles / 100ml,(to NAS 1638),

8、2 - 5 m,5 - 15 m,15 - 25 m,25 - 50 m,50 - 100 m,100 m,00,625,125,22,4,1,0,0,1250,250,44,8,2,0,1,2500,500,88,16,4,1,2,5000,1000,176,32,8,1,3,10000,2000,352,64,16,2,4,20000,4000,704,128,32,4,5,40000,8000,1408,256,64,8,6,80000,16000,2816,512,128,16,7,160000,32000,5632,1024,256,32,8,320000,64000,11264,2

9、048,512,64,9,640000,128000,22528,4096,1024,128,10,1280000,256000,45056,8192,2048,256,11,2560000,512000,90112,16384,4096,512,12,5120000,1024000,180224,32768,8192,1024,13,-,2048000,360448,65536,16384,2048,14,-,4096000,720896,131072,32768,4096,Contamination Classes to NAS 1638,ISO-Code,Number of partic

10、les / 100ml,(to ISO 4406),from,up to,0,0,5,1,1,1,2,2,2,4,3,4,8,4,8,16,5,16,32,6,32,64,7,64,130,8,130,250,9,250,500,10,500,1000,11,1000,2000,12,2000,4000,13,4000,8000,14,8000,16000,15,16000,32000,16,32000,64000,17,64000,130000,18,130000,260000,19,260000,500000,20,500000,1000000,21,1000000,2000000,22,

11、2000000,4000000,23,4000000,8000000,24,8000000,16000000,25,16000000,32000000,26,32000000,64000000,27,64000000,130000000,28,130000000,250000000,Contamination Classes to ISO 4406,Contamination Classes to ISO 4406,Maximal number of particles in 1ml fluid,Contamination Classes to ISO 4406,Contamination C

12、lasses,NAS 5ISO 14/11 Required for modern hydraulic systems,Contamination Classes,NAS 7ISO 15/13 Fresh oil, delivery in mini containers,Contamination Classes,NAS 9ISO 18/15 Fresh oil, delivery in tank trucks,Contamination Classes,NAS 12ISO 21/18 Fresh oil, delivery in barrels,Dirt Penetratione.g. Cy

13、linder,Dirt Penetratione.g. Cylinder,Dirt Penetratione.g. Cylinder,Principle Dirt Penetration Test Bench,Dust channel,Particle counter,Driving unit,Gradually increase of the particle number 不斷增加的顆粒物,Dirt Penetratione.g. Cylinder,Clearance of a new sealing : 0,1 - 0,25 m Clearance after 500.000 cycle

14、s : 0,3 m,Dirt Penetratione.g. Cylinder,System pressure,P = 0 bar,v=26,4 cm/s,Effects of Solid Contamination,Increasedleakage增加泄露 Jamming of pistons and spools擾動 Componentfailure失效 Changes in controlcharacteristics改變特性,Initial Damage on Bearings,Wear on Plain Bearings,Contamination as consequential

15、damage,Wear on Plain Bearings,Impurities embed in parting planes,Wear on Plain Bearings,Embed chip 碎片嵌入,Wear on Roller Bearings,Impurities in a deep groove ball bearing,Effects of Solid Contaminatione.g. Gear Pump,Effects of Solid Contaminatione.g. Gear Pump,Added contamination: 2 mg/l ACFTD,Pulses/

16、100 ml,Q in the system in % of initial Q,time,Effects of Solid Contaminatione.g. Gear Pump,Effects of Solid Contaminatione.g. Gear Pump,Added contamination: 1 mg/l SiKa,Pulses/100 ml,Q in the system in % of initial Q,time,Parameters that determine the Amount of Wear caused by Solid Particles,Materia

17、l of the solid particles材料 Size and shape of the solid particles形狀尺寸 Ratio of particle size顆粒尺寸比率 / Working clearance Working pressure工作壓力 Flow rate工作流量 Fluid viscosity介質(zhì)黏度 Velocity of the gearchange,respectively shaft speed 元件動作速度,Effects of Liquid Contamination,Corrosion腐蝕 Decrease of the dynamic

18、viscosity 降低運動黏度 Lubrication film is diminished 降低潤滑膜 Touching surfaces 增加接觸面 Reduced oil life time 降低油的壽命 Change of the oil constitution 改變油的性狀 Creation of oil aging products 生成老化物 Creation of silt 淤積 此外水分可以使?jié)櫥腿榛?，使添加劑分解，促進油品氧化，增強低分子有機酸，從而對機械腐蝕，影響油品低溫流動性。,Effects of Gaseous Contamination,Cavitation

19、 氣穴現(xiàn)象 Local overheating of the oil 油的局部過熱 Oil aging 油的老化 Leads to unstable control reactions 爬行 Reduces the dynamic lubrication film 降低潤滑膜,Kinds of contamination,Gaseous,Liquid,Solid,Effects,Water,Air,Corundum 磨料,Forge 鑄屑,Rust 銹,Iron 鐵,Steel 鋼,Brass 銅,Bronze 青銅,Aluminium 鋁,Hard wovens,Fibres,Wear at

20、 sealings,Particles of rubber,Particles of lacquer,Oxidation products,from hoses,of the hydraulic fluid,Veryharmful,Harmful,Slightly harmful,Kinds and Effects - Summary,Effect,Origins污染源 Measures 解決辦法 Assembly, repairs（裝配維修）System flushing Breathing of cont. airAir breather filter Damaged seals onCo

21、ntrol of the seals pistons and piston rodsand evtl. Replacement Particle ingressionProtection of theduring cylinder stroke complete piston rod Badly sealed tankControl of the sealsandpipe connections,Measures - External Contamination,Origins Measures Initial contamination System filling withof the n

22、ew oil filtration Initial contamination System flushing with of the systemoil service units Abrasion Wear at control lands,cylinders and pistons Particles of rubber from hoses and seals Particles of paint andFiltration with internaloxidation products system filters,Measures - Internal Contamination,

23、Zahnrad-pumpe,Flgelzellen-pumpe,Servoventil,Kolben-pumpe,Ventil,0,5 bis 10m,0,5 bis 5m (J1),0,5 bis 1m (J2),5 bis 25m (J1),5 bis 8m (J1),Sensitive spots at hydraulic components,RecommendedCleanlinessClasses,Recommended Cleanliness Classesfor Various Hydraulic Components,Cleanliness class,Cleanliness

24、 class,recommended,recommended,Hydraulic-,Hydraulic-,components,components,to,to,absolute,absolute,NAS,NAS,1638,1638,ISO DIS,ISO DIS,4406,4406,filtration,filtration,rating,rating,m,m,Gear pumps,Gear pumps齒輪泵,9,9,10,10,Cylinders 油缸,Cylinders,9,9,10,10,Directional valves,Directional valves,9,9,10,10,R

25、elief valves,Relief valves 溢流閥,9,9,10,10,Throttle valves,Throttle valves 節(jié)流閥,9,9,10,10,Piston pumps,Piston pumps 柱塞泵,9,9,10,10,Vane pumps,Vane pumps 葉片泵,9,9,10,10,Pressure valves 施壓閥,Pressure valves,6-8,6-8,5,5,Proportional valves,Proportional valves,6-8,6-8,5,5,Servo valves,Servo valves 伺服閥,4,4,3,3

26、,Servo cylinders,Servo cylinders 伺服油缸,4,4,3,3,21/18/15,21/18/15,21/18/15,21/18/15,21/18/15,21/18/15,21/18/15,19/16/13,19/16/13,16/13/10,16/13/10,Recommended Cleanliness Classes,Typical, specificated contaminationclasses for hydraulic components: Rexroth piston pump: ISO 18 / 15 MOOG servo valve: ISO

27、 16 / 13,Tasks of an Hydraulic Filter,Prevent functional disturbances預(yù)防功能失效 Prevent variations in switching times預(yù)防動作節(jié)奏改變 Reduce downtime between maintenanceshutdowns降低維護費用 Maintain reliability between maintenanceshutdowns 提高維護可靠性 Increase component life延長元件壽命 Maintain the lubricity of the fluid提高介質(zhì)

28、性能 Extend the life of the fluid延長介質(zhì)壽命,Tasks of an Hydraulic Filter,Surface filter 表面過濾,Depth filter 深層過濾,Filter Element Material,Filter Element Material 濾芯材質(zhì)Features of Surface Filters 表面過濾特點,Filtration rating is defined by the mesh size 過濾精度由濾網(wǎng)大小決定 Small free filter area (30-40% of the total filter

29、 mat area) 小且自由的過濾區(qū)域 （ 總過濾材質(zhì)區(qū)域的30-40%） High differential pressure stability(especially with braided mesh) 壓差穩(wěn)定性高（特別是編織網(wǎng)） Simple cleaning 便于清洗 Low initial pressure drop 初始壓降低 Typical application: as protective filters 典型應(yīng)用：保護過濾器,Filter Element Material 濾芯材質(zhì)Features of Depth Filters 深層過濾特點,Filtration

30、rating must be defined by testing 過濾精度必須由測試來決定 Labyrinth effect 影響不確定 Not cleanable, disposable(exception: metal fibre) 不可洗，一次性（例外：金屬纖維） Excellent filtration performance 出色的過濾表現(xiàn) High dirt holding capacity 納污容量高 Typical application: sensitive components 典型應(yīng)用：敏感性元件,Surface filters 表面過濾,Wire mesh, 700

31、m 絲網(wǎng),Wire mesh, 100 m 絲網(wǎng),Braided mesh, 50 m 編織網(wǎng),Depth filters 深層過濾,Glas fibre, 20 m 玻璃纖維,Paper fibre 紙質(zhì)纖維,Metal fibre 金屬纖維,Filter Element Material 濾芯材質(zhì)blown up 15 times,Features of a High-Quality Element高質(zhì)量濾芯的特點,High x-values x 值高 High x-value stability x 值穩(wěn)定性高 High dirt holding capacity 納污容量高 Low l

32、ong term pressure drop 長期壓降低 High collapse stability 壓潰穩(wěn)定性好 High flow fatigue stability 油流疲勞穩(wěn)定性好 Wide fluid compatibility 介質(zhì)兼容性好,ISO 4572,ISO 4572,ISO 4572,ISO 2941,ISO 3724,ISO 2943,Multi Pass Test多通道試驗Determination of the x-Value 確定x 值,Nupstream上游,Ndownstream 下游,Test filter Element 測試濾芯,ISO 4572,B

33、N4HC BH4HC,Betafit,BN/AM,AM,Suction,Product Range Filter Elements 產(chǎn)品系列,Glas fiber elements forfinest filtration ofhydraulic fluids Dpmax= 25 bar (BN4HC)Dpmax= 210 bar (BH4HC) Filtration ratings:3, 5, 10, 20 m High dirt retentioncapacity High x-values across awide range ofdifferential pressure Multi-

34、Protection-CoverTechnique Good compatibility withmost hydraulic fluids,Betamicron (BN4HC/BH4HC),Betamicron - Benefits,Additional outer wrap 額外外包層 Efficient mesh pack design 高效的網(wǎng)包設(shè)計 Favourable longitudinal seam design 有效的縱向焊縫設(shè)計 Wide fluid compatibility介質(zhì)兼容性好,Betamicron - BenefitsAdditional Outer Wrap

35、 額外外包層,Carries the trade mark 可帶商標(biāo) Protects the mesh pack 保護網(wǎng)包免受回流侵害 against damage due to back flow against flow impact 免受油流沖擊 against damage due to mechanical effects 免受由于機械影響導(dǎo)致的損壞 Works as a flow diffuser 有分散油流的作用 Creates uniform flow on the mesh-pack surface 在網(wǎng)包表面產(chǎn)生均衡的油流 Prevents micro turbulenc

36、es between the pleats 以防褶皺間微小的紊流 Increases the flow fatigue resistance bycompressing the mesh-pack 通過壓縮網(wǎng)包來增加油流的抗疲勞能力,Betamicron - BenefitsEfficient Mesh Pack Design 有效的網(wǎng)包設(shè)計,Contaminated oil 臟油,Clean oil 清油,Betamicron - Benefits Efficient Mesh Pack Design,支撐管Support tube,支撐網(wǎng)Support mesh,初始層Preliminar

37、y layer,第一層玻璃纖維 First glass fibre layer,玻璃纖維層Glas fibre layer,初始層Preliminary layer,支撐層Support layer,外部包網(wǎng)External wrap around,端蓋End cap,端蓋End cap,Filter mat(mesh pack) 網(wǎng)包,Nr.DescriptionTask End cap 端蓋- High corrosion protection - For all hydraulic media 2External - Protection of the filter mat agains

38、t wrap around mechanical damage,- Works like a diffuser, avoids direct flow against the filter mat- Protection of the filter mat in case of short term back flow or back pressure3Support mesh- Drainage of the star pleated filter mat- Fluid flow is led to the pleat ground- Optimum dirt holding is guar

39、anteed,Betamicron - Benefits Efficient Mesh Pack Design,1,2,3,Nr.DescriptionTask 4Preliminary layer- Protection of main layer during manufacturing of filter mat- Wet strength stability5First glass - Separation of coarse particles; fibre layer mainly determines the retention capacity6Second glass - S

40、eparation of fine particles; mainly fibre layer determines the filtration degree (x),4,6,5,Betamicron - Benefits Efficient Mesh Pack Design,Nr.DescriptionTask 7Preliminary layer- Protects the preliminary and main filter layer during manufacturing of the filter mat- Ensures high x-value stability ove

41、r a wide range of differential pressure8Support mesh- Guarantees high collapse pressure stability9Support tube- Ensures high collapse pressure stability,9,7,8,Betamicron - Benefits Efficient Mesh Pack Design,Nr.DescriptionTask 10Longitudinal seam- Patented sealing of the open ends of the seam avoids

42、 fibre migration 11Glue to fit element - Suitable for all hydraulic fluidsparts together- Permanent elastic connection between end caps, support tube and filter mat- Suitable for temperatures from -40C up to +100C,10,11,Betamicron - Benefits Efficient Mesh Pack Design,Betamicron - Benefits Favourabl

43、e Longitudinal Seam Design有利的縱向焊縫設(shè)計,Betamicron - Benefits Favourable Longitudinal Seam Design,The additional wrap is firmly secured 額外外包安全穩(wěn)固 The open ends of the filter media are sealed 濾材開口端密封 No fiber migration 纖維不會移動 US Patent No. 5622624美國專利號： 5622624 Europe Patent No. 94908354.7 歐洲專利號：94908354.

44、7,Betamicron - Benefits Wide Fluid Compatibility,Zinc free elements (tin coating) 無鋅濾芯（錫涂層） Best corrosion protection 最好的防腐蝕保護 No electrochemical corrosion 無電化腐蝕 Best compatibility with high water based fluids 和高水基介質(zhì)的高度兼容性 Best compatibility with biodegradable fluids 和生化分解油的高度兼容性 No metallic soaps a

45、nd no clogging of thefilter pleats 無金屬皂，無濾芯褶皺堵塞,Elements to befitted into the suction line 濾芯安在吸油管路里 Filtration ratings:過濾精度 75, 125 m Optional withbypass valve (0,2 bar) 旁通閥可選（0，2bar) Fitting into the tank topfilter housing possible(SF, SFM, withoutillustration) 也可油箱頂部過濾器的殼體中（SF，SFM，無圖片）,Suction Fi

46、lter Elements 吸油過濾器濾芯,BETAFITHYDAC Performance at Market PricesHYDAC 濾芯表現(xiàn)對市場價格,High dirt retentioncapacity 高納污容量 High x - values and x - value stability x 值高且穩(wěn)定 Low initial pressure drop 初始壓降低 Improved flow fatigue stability 優(yōu)化的油流疲勞穩(wěn)定性 Wide compatibility with modern hydraulic fluids 現(xiàn)代液壓介質(zhì)的兼容性好,Elem

47、ents to separatewater from thehydraulic fluid 濾芯可分離水和液壓介質(zhì) Filtration ratings:過濾精度40 m absolute 絕對過濾 High flow rates(up to 870 l/min) 大流量（可達(dá)870 l/min) Water retentioncapacity up to 2,2 liters 含水量可達(dá)2,2升 Element sizes 330 to 2600濾芯大?。?30 到2600,AQUAMICRON (AM),Elements to separatewater from thehydraulic

48、 fluid andto filter the oil fromfinest particles 濾芯可分離水和液壓介質(zhì)，且過濾油液中的細(xì)微顆粒。 Filtration ratings:過濾精度3, 10 m High flow rates(up to 110 l/min) 大流量（可達(dá)110 l/min) Water retentioncapacity up to 1,6 liters 含水量可達(dá)1，6升 Element sizes 330 to 2600 濾芯大小：330 到2600,BETA-/AQUAMICRON (BN/AM),M,CONTROL,Suction Filters,El

49、ements to befitted into the suction line Filtration ratings:75, 125 m Optional withbypass valve (0,2 bar) Fitting into the tank topfilter housing possible(SF, SFM, withoutillustration),Suction Filter Elements,Suction FiltersAdvantages,保護泵,Suction FiltersDisadvantages,Fine filtration can not be achie

50、ved Pump must be protected against cavitation(vacuum switch) For wear protection, mounting of additionalfilters is necessary Danger of cavitation especially when coldstarting Filter is hardly accessible,M,Pressure Filters,CONTROL,Pressure FiltersInline Filter DF,High pressure filter for inline mount

51、ing pmax = 420 bar Sizes30, 60, 110, 140, 160,240, 280, 330, 500, 660,990, 1320 Sizes 660 to 1320 withtwo-piece filter bowl(size 660 optional) MaterialsHead: GGGBowl: cold impact formed steel Types of connectionThread: all sizesFlange: 330 and above,Pressure FiltersAdvantages,Filtration is made dire

52、ctly in front of thecomponents to be protected全過程保護 The desired cleanliness class is ensured能夠達(dá)到理想的清潔度,Pressure FiltersDisadvantages,Filter housing and filter element areexpensive價格貴 Complicated element design by reason ofthe necessary differential pressure stability 濾芯設(shè)計復(fù)雜 Pump is not protected對泵沒有

53、保護 For element change the system must beturned off更換濾芯必須停機,Parts: 1Filter head 2Filter bowl 3Filter element 4Cloggingindicator,Pressure FiltersPrinciple Inline Filters,M,Return Line Filters,CONTROL,Use in the backflow pmax = 10 bar (size 30, 2500)pmax = 25 bar (sizes 60-1300) Sizes30, 60, 110, 160,

54、240, 330, 660, 950,1300,25005200, 6500, 7800, 15000 MaterialsPlastic: size 30Alum.: sizes 60-330GGG: sizes 660-1300Welded steel: 2500 Types of connectionThread: Sizes 30-330Flange: 330 and above,Return Line Filters Tank Top Mounting Filter RF,Return Line FiltersAdvantages,Filtration of the whole bac

55、k stream fluid全回流過濾 No contamination from the systemwill enter the tank系統(tǒng)污染物不進油箱 Low-priced filter housing and filterelement價格較低,Return Line FiltersDisadvantages,At high quality components it is necessaryto install a pressure filter in addition對高精度元件而言還需加裝壓力過濾器 In most cases a bypass valve is requir

56、ed大部分情況下是需要旁通閥的 Elements with low differential pressurestability could be demolished by masspulsation濾芯對脈動壓力的耐受力低 For element change the system must beturned off更換濾芯需系統(tǒng)停止工作 Large filters are necessary at high volumeflows經(jīng)常在大流量狀態(tài)下工作,Parts: 1Connection flange 2Housing 3Cover 4Dirt holding retainer 5Fi

57、lter element 6Clogging indicator,Return Line Filters Principle Tank Top Mounting Filters,M,Bypass Filters,CONTROL,Either as inline filter ortank top mounting filter pmax = 25 bar Sizes1310, 2610, 5210, 7810,10410 MaterialsAluminium/founded Types of connectionFlange: all sizes,Bypass FiltersLow Pressure Filter NF,Bypass FiltersAdvantages,Filtration independent of the operatingprocess 工作不受主回路影響 High dirt holding capacity due to constantflow納污容