波音机械标准施工tubeppt课件.ppt

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1、管路的制作及安装,管路注意事项,Installation Repair Hydraulic TubeCAUTION: YOU MUST BE CAREFUL WITH THE TUBES TO PREVENT IMPACTS, DISTORTIONS AND SCRATCHES. 小心别碰伤、弯曲和刮伤管子CAUTION: WHEN DUST CAPS ARE USED FOR THE PROTECTION OF OPEN LINES AGAINST CONTAMINATION, ALWAYS BE SURE TO INSTALL THE CAPS AROUND THE TUBE ENDS A

2、ND NOT IN THE TUBE ENDS. THERE CAN BE BLOCKAGE OF THE FLOW THROUGH THE TUBES IF THESE TUBES ARE INSTALLED ACCIDENTALLY WITH DUST CAPS IN THE TUBE ENDS当给脱开的管子安上防尘盖时，请确认安装在管子端头的周围而不在管子端头内。否则可能会忘记取下防尘盖从而导致管路堵塞。,管路注意事项,CAUTION: USE A SECOND WRENCH TO APPLY COUNTERTORQUE TO THE UNION WHEN YOU DISCONNECT/

3、CONNECT HYDRAULIC LINES ON UNIONS. IF YOU USE THE SECOND WRENCH, YOU WILL NOT LOOSEN OR TIGHTEN THE UNION TOO MUCH,管路注意事项,CAUTION: YOU MUST ALWAYS PUT CAPS ON DISCONNECTED HOSES AND FITTINGS. IF YOU DO NOT DO THIS, YOU MAY CAUSE:- CONTAMINATION OF THE HOSES, - DAMAGE TO THE SYSTEM COMPONENTS, - HYDR

4、AULIC FLUID LEAKS. IF HYDRAULIC FLUID LEAKS OCCUR OR IF YOU LET HYDRAULIC FLUID FALL, YOU MUST CLEAN IT UP IMMEDIATELY. HYDRAULIC FLUID CAN CAUSE DAMAGE.CAUTION: PUT DRY, CLEAN, METAL OR PLASTIC PLUGS ON ALL PIPES OR UNITS REMOVED TEMPORARILY. PUT EACH PIPE OR UNIT IN A SEALED VINYL BAG.,管路注意事项,CAUT

5、ION: MAKE SURE THAT THE NEW RING FOR THE FLARED TUBE IS CORRECTLY INSTALLED. THIS WILL PREVENT OXYGEN LEAKS.CAUTION: MAKE SURE THAT THE FLEXIBLE HOSES ARE NOT TWISTED OR PULLED TIGHT. IF THE HOSES ARE TWISTED OR PULLED TIGHT, THE CONNECTIONS WILL BREAK AND CAUSE A LEAK.,管路注意事项,CAUTION: APPLY ONLY A

6、THIN LAYER OF (CP5063) SILICON LUBRICANT TO THE THREADS OF THE HOSE TUBE ASSEMBLY COUPLING NUTS AND FITTING ON THE VALVES, AND REMOVE UNWANTED LUBRICANT. KEEP LUBRICANT FROM GOING INTO THE HOSE TUBE ASSEMBLY AND VALVES. IF TOO MUCH LUBRICANT IS USED, THEN LUBRICANT MAY CLOG THE HOSE TUBE ASSEMBLY AN

7、D ENTER THE VALVES AND DAMAGE THOSE COMPONENTS.,Tube fault 60-80% is leak Technique innovention flare-flarelessStandard practice procedure /seal/lubricant,HYDRAULIC FLUID SAFETY PRECAUTIONS,Do not mix hydraulic fluid of the phosphate ester type with hydraulic fluid of the mineral-base type.This mixt

8、ure causes a jelly in the hydraulic systems which can damage the system.This could cause a reduction in aircraft safety.These types of fluid are used in the hydraulic systems and landing gear respectively.Thus there must be precautions to prevent any mixture of the fluids.Know where your eye wash fa

9、cilities are.Make sure that the hydraulic fluid does not touch these aircraft materials :- rubber- copper- titanium- plastics- paints.,Make sure that the hydraulic fluid does not touch the aircraft other than components in the hydraulic system.Clean up such hydraulic fluid so that it can not go into

10、 adjacent areas.This is also to prevent future incorrect reports of hydraulic fluid leaks.When you clean up hydraulic fluid, use dry cloth and clean the area with the correct solvent.For more information, refer to AMM chapters 12-12-29 , 12-13-29 and 12-32-29.,内 容,管路知识介绍管路接头介绍管路的制作与测试管路的拆卸管路的安装管路间距与

11、管卡的安装,管路知识介绍,管路系统的组成: 飞机管路系统由导管、接头、管螺帽、套筒、封严、管卡等组成一个封闭的通道,以保证液体或气体在通道中流动和传递能量。,管路知识介绍,管螺帽,喇叭口接头,管卡,圆锥形衬套,锥形座接头,管路知识介绍,金属密封垫,带凸缘法兰固定座,固定法兰盘,密封圈,型锻接头,管路知识介绍,飞机管路系统应用21 空调系统（引气、加温、空调和冷气）28 燃油系统 29 液压系统35 氧气系统38 污水/水79 滑油系统Contact Boeing before performing any oxygen system tubing repairs.,pressure defin

12、itions,Hydraulic system are below.(1) Maximum working pressure: (a) Anytime repairs to the tubes are made on the airplane, or when any hydraulic component is to be checked.(2) Proof Pressure: (a) If the tubes are repaired and to be tested in the shop.(3) Burst Pressure: (a) This is for design refere

13、nce only.,管路知识介绍,The tubing assembly configuration and the tubing material must be identified before removal.,管路知识介绍,管路知识介绍,航空软管按材料分：纯橡胶系列软管棉线加强橡胶系列软管钢丝、棉线加强橡胶系列软管特氟隆塑料系列软管钢丝加强特氟隆塑料系列软管,管路知识介绍,软管的优点：富有挠性、走向方便, 对弯曲无严格的要求，能吸收液压冲 击及隔离机械振动的作用。软管的缺点：流阻损失大,航空软管常用于强烈振动或挠度大的地方。连接 运动部件和静止部件，也用于金属管道与软管之 间的连接（

14、Temporary repair）。,管路知识介绍,橡胶软管,四层缠绕钢丝加固,加固层,保护蒙皮,内管,管路知识介绍,橡胶软管,两层棉编织带,双金属丝编织带,合成内管道,合成内管道,单金属丝编织带,防火、抗滑油软管,飞机管路的识别,飞机管路系统的标志识别分为两种第一种英文标记的识别,TOXIC (有毒),PHPAN (危险),FLAM (易燃),PRESSURE (压力),RETURN (回油),DRAIN (排泄),红色,易燃管路 FLAM,燃油FUEL,飞机管路的识别,第二种彩带或印花,燃 油,滑 油,液压油,氧 气,水 管,压缩气体,供水管,排污管,防 火,气源管,空 调,除 冰,管路接

15、头介绍,按接头分类：(refer manual)喇叭口接头（AN、AC）非喇叭口接头（MS） BACS13BX Flareless Sleeves BACS13AP Flareless Sleeves CRYOLIVE Flareless Sleeve BACC42W H-Coupling 3P02111 or 3PHS111 Cryofit Coupling Permaswage Fittings Rynglok Union,接头的类型,There are two types of connections :- permanent connections (permaswage).- rem

16、ovable connections (standard straight or special fittings).,Lubrication the threads,Apply the thread compound that is applicable to the system. Fully apply the thread compound to the external threads, shoulder, and conical seal surface of the flareless sleeve immediately before installationNOTE: Do

17、not get thread compound in the internal part of the tube or in the bore of the fitting. Do not apply thread compound when you assemble the dri-lubed B-nuts.,管路接头介绍,管路接头介绍,无喇叭口管接头封严（MS）装有锥形衬套的管子插入端接头组件中，管子前端面与管接头内沟槽接合，实现第一次封严。锥形衬套与接头组件内表面紧密贴合。实现第二次封严。锥形衬套上的凸台与接头端面紧密贴合，实现第三次封严。,管路接头介绍,AC(Air Corp Stan

18、dard)和AN(Air Force - Navy Aeronautical Standard)喇叭口接头的差别,37度,退刀槽,35度,管路接头介绍,AN(空海军标准接头)喇叭口接头,管子,平管嘴,外套螺母,管路接头介绍,喇叭口管接头封严 插入式端接头：有一锥面与喇叭口内表面紧密贴合。衬套筒：在喇叭口外 面，支撑管子，防止 喇叭口边缘的振动。螺帽：套在套筒外， 上紧时带动喇叭口和 套筒，使喇叭口紧贴 在接头上，实现封严。,管路接头介绍,1.弯管接头 2.锁紧螺帽 3.封圈保持环 4.预成形封圈,喇叭口与非喇叭口弯接头,管路知识介绍小结,飞机有那些系统管路？管路接头有那些种类？你能区分AN、A

19、C、MS接头吗？ 你能通过彩带标识识别系统吗？管路按材料分类，硬管有那些？,管路接头的制作与测试,管道的预加工 金属管路的弯曲管路端头加工渗漏校验,管路接头的制作与测试,管道的预加工包括除油、下料和去毛刺。 除油：就是除去管材内、外表面的油封油和油脂。下料：根据需要从一根长管取下适当的 长度。下料可单根、多根或批量。常用下料的方法有切管器、手据、车床、铣床等。,管路接头的制作与测试,切管器的正确使用,管子的切断,管路接头的制作与测试,去毛刺：手工、机械方法。如：锉刀、 刮刀等工具。注意：无论用哪种方法去毛刺，都应保证 管端内外辟有圆滑过度，以防止在 加工时管端出现裂纹。,管路的制作加工,管路接

20、头的制作与测试,内旋转式铰刀去毛刺,管路的制作加工,管路接头的制作与测试,指示标记,卡子,半径块,滑杆,弯管的步骤,1、向上提起滑杆。,2、放置管子。,3、准备放卡子于管子上。,金属导管的弯曲,管路接头的制作与测试,注意0位标记与杆上标记应对齐,4、把卡子放于管子上,弯管的步骤,金属导管的弯曲,管路接头的制作与测试,弯管的步骤,弯管到希望的角度,6、提起滑杆手柄，取出弯好的管子,90度标记,5、弯管到希望的角度。,金属导管的弯曲,管路接头的制作与测试,导管弯曲过程,管路接头的制作与测试,金属导管弯曲的要求： 弯曲加工质量的高低，对导管的工作影响很 大，所以金属管子在弯曲时，常出现以下现 象须注

21、意。管子弯曲部分横截面积变成椭圆甚至压瘪。管子的外壁会变薄，甚至破裂。管子的内壁会变厚，甚至起皱。当施加力的弯管松开后，管子会产生弹性回跳。,管路接头的制作与测试,弯折的弯曲,起皱的弯曲,压扁弯曲,好的弯曲小于原外经的75%,正确的和不正确的管子弯曲,管路接头的制作与测试,金属导管弯曲方法有专用的弯管器。用金属混合物或者干砂填料弯曲。使用一种易熔合金代替砂，把管子 放在热水中，71C（160F）熔化的 易熔合金灌满。,管路接头的制作与测试,导管的端头加工导管弯曲成型后，需要进入端头加工，就是把导管端头加工成需要的连接头。如：扩口连接、无扩口连接等。,管路接头的制作与测试,注意：制作的喇叭口和管

22、子必须没有裂缝、压痕、刻痕、擦伤或者任何别的缺陷。手工扩口工具由扩口模块或夹模（阳模、阴模）、轭架和扩口销组成。,管路接头的制作与测试,手工扩口工具,管子,夹在虎钳上的夹模,管子,轭架,夹模,扩口工具阳模,扩口夹具,俯视图,侧视图,阴模,喇叭口的制作,管路接头的制作与测试,导管的端头扩口方法：导管弯曲成型后清除所有毛刺，将接头配件螺帽和套筒套在管子上并将管子放入扩口工具（阴模）中合适尺寸的孔内。将夹模放入轭架内，对准夹模中的管子中心。旋转拧紧固定夹模以防滑动。,管路接头的制作与测试,导管的端头扩口方法：进行扩口时，用一轻锤或者槌轻敲阳模几次，每敲一次，将阳模转动半圈，确定已合适地就位，再将管子

23、从扩口工具上取下，将套筒滑到喇叭口上，以检查喇叭口的外径应当延伸到套筒端面之外1/16英寸，但不能大于套筒较大的外径。,管路接头的制作与测试,非喇叭口接头的制作(lubrication),管路接头的制作与测试,非喇叭口接头的制作,管路接头的制作与测试,无喇叭口管组件的特点 无喇叭口与喇叭口导管相比较具有强 度高、密封性好、重量轻、自锁抗震 性好等特点，适用于高压系统。MS接头无喇叭口制作方法（预装操纵）按需要正确切管，将管子的两端 面挫平，清除管内外的毛剌，装 上衬套、螺帽。,管路接头的制作与测试,MS接头无喇叭口制作方法（预装操纵）用滑油润滑接头和螺帽的螺纹部分， 将接头放在虎钳上并夹紧，并

24、将管子 牢固且垂直地保持在接头的管座中底部。拧紧螺帽（同时用手来回在转动管子） 直到套筒的切割边夹紧管子为止。,管路接头的制作与测试,MS接头无喇叭口制作方法（预装操纵）最后的拧紧取决于管子的材料。外径小 于或等于1/2英寸的铝合金管，拧紧螺 帽转动1-1+1/6圈，对钢管外径超过1/2 英寸铝合金管，拧紧为1+1/6圈。 从接头拆下管子进行检查。(refer manual),管路接头的制作与测试,松开螺帽，检查如下（refer manual）MS接头制作完毕后，管子应伸出套筒的尺寸,挤压后管壁的变形量衬套可以转动，但不可上下移动。,管路接头的制作与测试,管路接头的制作与测试,将液力管路连接到

25、液力实验台系统中将制作好的液力管路连接到液力实验台，在连接时要以适当的力矩拧紧螺帽。 注意：安装时应用手将螺纹带到底部，使 用扳手拧紧螺帽的1/6圈即可。切勿直接 用扳手硬拧，容易损坏接头。,管路接头的制作与测试,进行液压压力试验 检查液力管路全部连接完好 接通电源。 打开截止阀。 提供压力测试液力管路。如果液力 管路出现漏油现象应停止供压，检查 漏油原因并排除。,管路的拆卸及安装,液压系统安全防护措施,当对液压系统进行维护时，应采取哪些安全防护措施 对液压系统失效做出警示，对驾驶舱相应电门及的操纵手柄挂牌对液压系统充分释压断开管路, 要使用必要的防护措施防止液体的泄露，如封堵工具、接油盘准备

26、到位用正确方法清除溅落在人体和飞机上的油液地面和工作梯油污清理干净。保持环境整洁，防止人员滑倒不要改变管路的弯曲度，会导致错装、导致额外的内压，引起管路裂纹,CAUTION: KEEP THE HYDRAULIC LINES AND FITTINGS SEALED WITH CAPS. DIRT OR UNWANTED MATERIALS CAN CAUSE CONTAMINATION OF HYDRAULIC LINES,DAMAGE TO SYSTEM COMPONENTS, AND LEAKAGE OF HYDRAULIC FLUID CAN OCCUR.,WARNING:DO NOT

27、USE THIS PROCEDURE ON OXYGEN TUBING. GREASE, DIRT, OR OTHER FLAMMABLE MATERIALS IN THE OXYGEN TUBING WHEN EXPOSED TO PRESSURIZED OXYGEN CAN IGNITE AND CAUSE AN EXPLOSION.,WARNING: DO NOT USE TITANIUM FITTINGS IN THE OXYGEN SYSTEM TUBING. TITANIUM FITTINGS CAN CAUSE A FIRE OR INJURY TO PERSONS.,WARNI

28、NG: MAKE SURE EACH TUBE AND THE PORT FITTINGS HAVE TAGS TO IDENTIFY THE CORRECT INSTALLATION LOCATION. IF YOU DO NOT PUT TAGS ON THE TUBES AND PORT FITTINGS, CROSS-CONNECTION OF THE TUBES CAN OCCUR DURING INSTALLATION. IF THE TUBES ARE CROSS-CONNECTED, UNINTENDED OPERATION OR MALFUCTION OF AIRPLANE

29、SYSTEMS CAN RESULT AND CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.,液压系统安全防护措施,1、对管路系统释压,并对管路接头做标识,准备好接油盘,5、对管路接头进行必要封堵,3、用两把扳手拧松管螺帽,2、拆下管路夹子或支撑架,4、再用手拧下螺帽,6、对管路挂上适当标签,并放在规定的地方,拆卸飞机管路的注意事项有哪些,管路的拆卸,管路的安装,管路安装前的检查 检查管路及接头组件密封是否完好。仔细检查管路是否有压坑和擦伤。管路无变形或裂纹管螺帽、衬套和管接头无裂纹管螺帽和管接头的螺纹无损伤,管路的安装,1、去掉管座及相配的管

30、接头上的保护盖,检查管路外表及接头组件,2、对管螺帽上的螺纹及管接头等三处进行必要的润滑,3、将管子安装在相配的管接头上，并用手带紧,5、确保所安装的夹子及螺栓没有对管子造成应力或载荷,4、磅紧螺帽并打保险,安装飞机液压管路的一般工作程序,Put the tubing assembly in its position and let the tube clamps stay loose to permit you to align the tube in the fitting.,Look at the tags to make sure the tubes are aligned with

31、the correct port fittings.,Align the tube and fitting by hand and put the tube end at the bottom of the fitting.,Use your hand to tighten nuts you cannot get access to with a wrench. Tighten until the torque increases. Then tighten the nut 1/6 to 1/3 (one or two hex flats) turns more.(use flare nut

32、wrench),管路安装,管路安装注意事项不同系统的管路接头螺纹所使用的润 滑剂不同。螺纹润滑剂不得进入管道内腔。管卡的规格和安装位置不得随意更改， 若需更换或加装须按维护手册的要求 施工。,CAUTION: THE CLAMPS MUST ALWAYS BE TIGHT. THIS HELPS KEEP UNWANTED MATERIALS AND CONTAMINATION OFF OF THE TUBE AND THE CLAMP SURFACES. IT IS VERY IMPORTANT THAT THESE SURFACES BE KEPT AS CLEAN AS POSSIBLE

33、 TO PREVENT ABRASION.,If you disconnected more than one hydraulic tube and you think there is a possibility you connected the tubes incorrectly or cross-connected the tubes, do an operational check: NOTE: Use your own judgement to determine if a check is necessary.Do a leak test: Pressurize the syst

34、em for a minimum of 15 minutes.With the system pressurized, rub the tube and fittings with a clean white cloth to find leakage.,管路安装,管路安装间隙,管路间隙机械系统的最小间隙。(除液压系统) （a）有支承的位置应为0.10英寸。 （b）没有支承的位置应为0.20英寸。 （C）易燃气体：如燃油、氧气系统，和电气 线路、钢索之间无论有无支承架，间隙 均为2英寸。,管路安装间隙,管路间隙液压系统的最小管路间隙。 A 有支承架，间隙应为0.06英寸。 B 没有支承架，间隙

35、应为0.25英寸。 C 电气线路的间隙，应为0.05英寸。 D 盘状的管路，每一圈之间的间隙 应为0.06英寸。,管卡安装间隙,管路间隙安装液压管路时，应使管卡与管子的应力最小。确认管卡的位置，管子与邻近结构应保持至少 0.10英寸。对于直接固定到结构上的管路，其 间隙应大于管卡的厚度。确认在没有管卡的部位，所有管路与相邻的结 构或设备，应保持最小0.25英寸的间隙。,管卡安装间隙,管路间隙确认组件的位置与管路之间的间隙不少于0.36 英寸，在所有管卡与管路不发生摩擦或接触的 地方，可以为0.25英寸。 当管路与另一根管路发生交叉或平行于另一 管 路时，应有充足的管卡，以保持它们之间的间 隙不

36、少于0.25英寸。,管卡安装间隙,管路间隙不能在同一处同时使用六个以上的垫块。 如果超过四块垫块，你就应检查你的管 路是否安装正确。确认管路与操纵钢索的断点或导索板，以 及操纵连杆之间的间隙不少于0.625英寸。 确认排卡中的管路每根之间的间隙不少于 0.06英寸。,管卡安装间距,管卡安装,Tighten all clamp bolts and nuts to recommended standard torque values without distorting the clamp cushion material.,管卡安装,管卡安装,CLAMPSHELL CLAMPS,CLAMPSHE

37、LL CLAMPS,The clampshell clamp assemblies have 3 parts: 2 of the same type clampshells and one of two types of clamps (cushioned or uncushioned).There are two types of clampshell clamps.(1) Unplated shells - used in high vibration and high temperature (up to 800F) areas.(2) Cadmium plated shells - u

38、sed with aluminum tubing only and limited to temperature of 400F.,CLAMPSHELL CLAMPS,If there is a worn area in only one component part, replace all of the clamp assembly.CAUTION: DO NOT PUT THE CLAMPSHELLS ON A TUBING BEND. CLAMPSHELLS CAN CAUSE DAMAGE TO THE TUBE.Attach the clampshell clamp assembl

39、y with a number 10 fastener,Protective Lacing,软管安装,软管安装,软管安装,软管安装,Make sure the new flexible hose has sufficient slack, flex, twisting, bending, clearance, and support specifications as shown below 20-10-51/828,O-RINGS REMOVAL/INSTALLATION,O-rings,CAUTION: DO NOT MAKE THE LASTOMERIC O-RING INNER DIA

40、METERS LARGER BY MORE THAN 50 PERCENT DURING INSTALLATION. DO NOT MAKE THE TEFLON AND PLASTIC O-RING INNER DIAMETERS LARGER BY MORE THAN 5 PERCENT DURING INSTALLATION. FAILURE COULD OCCUR.,O-rings,管壁厚度,管路修理方法,You can repair tubes if you obey the permitted repair limits. When it is possible do the fo

41、llowing:replace the damaged tubereplace the damaged part with a tube splicerepair the damaged tube with a fitting (if the damaged are is sufficiently small).completely remove all corrosion and treat affected surface area as described in the corrosion prevention manual.,管路修理限制,管路修理方案,A repair of a tu

42、be section can be in one of three groups. The groups have a relation to the location of the tube damage and the quantity of damage. The three groups are as follows:(a) Replace a tube end section that has a flareless end fitting you can move apart, with an assembled tube and fitting assembly (Figure

43、806).(b) Replace a tube center section that has a short damaged segment with a single union (Figure 805).(c) Replace a tube center section that has very much damage with an assembled tube and fitting assembly (Figure 809).,修理管路程序（Make a splice）,修理管路程序（Make a splice）,(e) Measure all of the tube assem

44、bly length (L1) (see Fig. 806 and 809).(f) To find the necessary cutout length (L2) as shown on Figure 806 and 809, use the procedure given in Figure 810.(g) Remove the pressure from the systems where you will do the repairs.(h) Cut out the damaged tube (L2). Trim the tube ends as shown in Figure 80

45、4.,手工制作BACS12AP接头,To preset the sleeve by hand do the following:(a) Use the correct mandrel for the tube sleeve set fitting kit, SPL-1589 or the (Figure 819).(b) Lubricate the threads, sleeve shoulder, and conical seal area of the fitting with anti-scoring lubricant, D50174. Do not lubricate the tub

46、e.(c) Assemble the sleeve on the tube. Insert the tube into the tube sleeve set fitting kit, SPL-1589 union. Tighten the nut as shown in Figure 821.(d) If the ST879A preset tool is not available, you can preset the sleeves with a carbon steel union and nut as shown in procedure A or B of Figure 821.,手工制作BACS12AP接头,案例,2007年11月18日，B2388执行CA934/北京至浦东航班，在下降过程中，ECAM上出现绿系统低压警告信息，放下起落架后舱门收不上。机组按操纵程序复飞，重新放下起落架，舱门仍收不上。着陆在滑行时，发现飞机不能转弯。,案例,1立刻下发了对所有A340机队的普查工作单，马上针对此下锁作动筒液压供压管和回油管外表和安装情况进行检查。2航线部、大修部提出管路检查的培训要求，加强对员工的技能培训。同时针对软管检查的不同情况，结合标准施工，要求一旦发现此类软管有断丝、鼓包、磨损的情况，立即更换。,