毕业论文外文译文组合机床动力滑台液压系统常见故障的分析与排除.doc

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1、 毕业论文（设计）外文译文题 目 组合机床动力滑台液压系统常见故障的分析与排除学 院 机械工程学院 专 业 机械设计制造及其自动化 年级 2012级 组合机床动力滑台液压系统常见故障的分析与排除摘要：动力滑台是组合机床液压装置的一部分。然而，组合机床动力滑台运行很长一段时间后，经常会遇到“没有工作进给”的故障。在维护实践经验的基础上，本文提出的方法来排除故障。关键词：组合机床 液压系统 故障分析 故障排除组合机床是由通用部件和部分专用部件组成的高效、专用、自动化程度高的机床，可以完成钻、扩、铰、镗、铣和攻丝等加工以及完成各种复杂进给工作循环。根据加工工艺要求，可在滑台台面上装置动力箱、多轴箱及

2、各种专用切削头等动力部件。液压动力滑台用液压缸驱动，在运行很长一段时间后经常遇到“没有进入测试”的现象。根据维修经验做法，笔者在本文结束提出排除故障的方法。1 YT4543动力滑台液压系统原理分析在机床的维护中，有必要首先分析工具机的液压系统的原则YT4543在机床动力滑台液压系统的的液压系统发生故障时的原则，示于图1。图1：YT4543动力滑台液压系统1.1快进按下启动按钮，让电磁铁1YA收取电费和左框架阀电磁换向阀5到系统的访问，控制油机液压换向阀阀芯使阀门离开进入系统工作。可以被指定为以下的控制油路。进油路：单向变量泵2电磁换向阀5的左框架单向阀6换向阀4左腔;出口油路：左腔的液压换向阀

3、4节流阀9电磁换向阀5的左框架石油盒;主油路如下：进油路：单向变量泵2单向阀3液压方向控制阀4的左侧的右侧的动作阀11液压缸10的左腔室;清仓油路：液压缸右腔10左侧的液压方向控制阀4单向阀17右侧的动作阀11液压缸10的左腔室。1.2 进给当滑动台达到所需的位置，快进，旅行铁块压行程阀11，使左框架对系统的访问，快进油路切断，但油只能进入左腔通过速度控制阀16和两位置两通电磁阀，因为油通过液压缸的后速度控制阀，可以使系统压力高的液压顺序控制阀18打开，然后右腔室中的油在液压缸的流量后，通过背压阀19的回油。然后，可以实现滑动台的第一工作进给，其运动速度控制的速度控制阀16。由于在系统中的压力

4、上升的limitedpressure可变叶片泵2的流速是自动降低，以免符合要求的工作进给。油路可以具体描述如下：进油路：变量泵2单向阀3换向阀4的左框架速度控制阀16电磁阀14液压缸左腔10出口油路：液压缸10的右腔换向阀4顺序阀背压阀1819油盒的左框架。1.3进给“我的工作进给之后”结束，旅行熨斗停止按压电动行驶开关和发送的信号，使电磁阀14的电磁铁3YA带电，然后在左框架的阀访问的断油线的系统和CUTA的，但油只能通过速度控制阀15后，流入液压缸10的左腔室。现在，滑台转换成“第二频道”，它的运动速度是由速度控制阀15的，但只能比“我的工作进给”的小范围内调节，但其他部分的入口油路，以及

5、出口油路是相同的“我的工作进给”。1.4留死挡铁“第二频道”的速度移动到目的地时，滑台会遇到死铁停止和停止移动。然而，现在，液压泵2的压力油继续流入液压泵2 ，使油在系统中的压力进一步增加，当油的压力是相等的压力继电器13的稳定的压力，压力继电器动作的发送信号的时间继电器;下一运动前的停留时间是由控制时间继电器，处理部件的端面，在目前情况下，油的泵的输送量是非常小的，这是唯一用于弥补泄漏，在系统运行时的压力维持状态。1.5快速反转在滑动台停留在上死铁停止了一段时间后，时间继电器发出一个信号，让电磁铁1YA断电，但2YA电源，然后两个方向控制阀5和4接入到系统中的正确的帧的实现的反相。油进入液压

6、缸10的右腔，使滑动台倒置迅速。因为它是一个空载时，滑动台是反相时，油系统中的压力较低，和限压型单向变量泵2的流量被自动放大到最大，有效面积之间的比例为2:1的液压缸无杆腔和无杆腔，所以滑台以相同的速度迅速反转快进。当滑动台迅速反转快进终止，在行走阀11被松开，而回油是平滑的。控制油路可以描述如下：进油路：变量泵22单向阀7换向阀右方向阀室2的右侧框架中;出口油路：的左腔方向阀48节流阀换向阀右腔5油盒主油路中，如下所示：进油路：变量泵2单向阀3换向阀4右室右腔的液压缸10出口油路：液压缸10单向阀换向阀12右室右框架4油盒1.6快退原位停止当滑动表中迅速反转到原位，铁停止按压终止行程开关和发

7、送一个信号，使电磁铁1YA，2YA和3YA断电的，然后电磁换向阀5和液压方向控制阀4的中央框架，和液压缸的左，右腔室的油线被切断，然后液压缸在夹紧状态下，滑动台停止工作。到现在为止，油流入到回油框中，然后由可变泵2的流量不一定要通过单向泵3和4，然后在系统处于卸荷状态。2分析“没有工作饲料”Faultof动力滑台和拆卸步骤2.1故障原因分析组合机床动力滑台在保持以正常速度在快速进给，并来停止在初加工。基于各种液压元件的原则，对所学的知识和维护工作经验，并通过一个详尽的分析，导致“没有工作饲料”故障的主要原因可能是强大的切割，系统压力不足，漏电无油供给液压泵输油量不足，耐磨损的液压阀的内部组件，

8、虚线或锁定，或磨损，导致内漏的液压缸的内部元件或密封元件圆筒壁内的挤压，以唤起越来越大的阻力，执行元件等。2.2故障排除步骤由于液压系统的气密性，是液压故障不直观的机械故障，故障测量电动问题不是很方便，是真的不安直接判断的。这是非常难以修复如检查是液压站开始，没有理由不仅会被发现，但也某些组件将盲目拆卸，因此，新的故障将导致搜索的原因。为了液压故障具有效率高，是建立一个合理的故障检测序列每个故障原因的可能性，液压元件或部件的拆卸和安装容易。也就是说，序列是“按照先在压力表的故障检查的大方向，然后拆解石油管检查故障（egthe内部泄漏液压泵和液压缸，或爬行的滑动，表），然后恒等式的真正的液压阀故

9、障。首先，工作进给的切断力进行检测：通过检查的液压系统中的压力的米数，可以确认的工作进给的切断力是否超过正常压力的泵或不和产生的噪声从切削有无异常或不处理。表示切削力过大，如果出现异常。由于限压变量叶片泵的使用，如图2中所示的在多数组合机床，“大的发货量和低压力的快进，发货量小，高压力的工作进给”的需要，可满足自然，和液压系统的工作进给切削力的增加，随着压力升高。反馈液压油的作用下，柱塞5驱动定子3的向左移动，直到定子提供什么，是与该转子同心，从而不存在压力油的进油口线的滑动表停止工作。这种类型的问题的原因主要包括切削工具的磨损，清晰度不足，不一致的组件材料，现有的硬点，尤其是多发性混合硬点的

10、毛坯。故障排除方法，包括“检查和更换高品质的切削刀具，检验毛坯的硬度，提高毛坯的质量”。图2：限压变量叶片泵的原理第二，可变叶片泵的供油是否正常与否进行检测。 （1）故障分析：组合机床滑台的电源时，保持正常的速度在快速进给，故障等原因，作为反向安装的液压泵的进油口和出口，所述液压泵的反相，相对的偏心方向的定子，叶片夹紧在凹槽中的叶片，过油的粘度高，导致柔性叶片运动，可以完全除去。但是，转换成的工作馈送模型，系统的外部负载的增加以及滑动台时，停止移动，并因此导致泵的出口压力越来越高，和所述液压泵遇到巨大的泄漏，由于内部耐磨损的液压泵，再不能出口的压力油，因此，有没有工作的饲料。 （2）故障的去除

11、方法：在液压泵可以更换第一，然后为了下次方便，可以进行维护。如果所有这些任务都试图和内部泄漏仍然过大，这是必要的，使用具有高粘度的液压油，尤其是在夏天。第三，油盒被检查，以查看它是否是上述的最低油位置，过滤器的油面以上时，油返回管高于油位，油过滤器阻塞的杂质和污物，或不等。四，系统管，耦合和组件进行检查，看他们是否泄漏与否。第五，在液压缸进行检查，以查看是否有一个内部泄漏或过大的内阻。 （1）故障分析：如果有一个在液压缸内壁上的局部加热现象，它表示密封环老化或液压缸的内孔的磨损，导致液压缸内部泄漏和系统压力无法建立，因此，工作进给是无法实施的。如果高温油，使活塞或活塞杆上的油封被密封在液压缸岁

12、结束，变形，软化，或壁球活塞和汽缸壁之间的密封环，活塞杆和端盖产生孔，随后巨大的摩擦力以抵消某些液压压力，因此不能应对的工作进给切削力，并且有没有工作在滑动工作台的进给。 （2）故障排除方法：先在最后的位置让滑台停留，然后打开回油管，以检查是否有油流（如果是这样，有一个内部的液压缸泄漏）。接下来，观察压力计在快进中的号码，它表示在汽缸内的电阻是非常大的，如果快进的压力高得多，也可以卸载，石油管的滑动表压力板可以松开，可解除滑动台（如果可以感觉到高的重量，可以证明在气缸的内部电阻会很大）。可以肯定的确认，如果这种情况下，有必要改变液压缸的第一，然后展开液压缸，检查，修理或更换密封环和液压缸机构，

13、为了下次方便。六，液压阀检查。 （1）故障分析：由于液压阀不能正常工作，由于阀芯夹紧的油污染，压力油直接流入回油返回框，还有的是没有压力油在液压缸的油入口，或反压过高，由于回油不畅，从而将被强制为无法移动的液压缸。 （2）的故障的去除方法可以被划分成3步骤：第1步：检查电动液压方向阀：如果在主阀4和伺服阀5的操作手册电动液压方向阀的阀芯可以不被推向，它指示被夹紧线轴，它是必要的展开它们，然后使用重新组装，可以替换旧的或新的阀门的阀体和阀芯必须清洗。如果方向控制阀可以改变和的滑动工作台移动，它表明的电磁方向控制阀5的电力线遇到故障，因此，有必要首先检查是否电源是或，在电磁线圈被打破由火灾或不是。

14、现在，认真听取噪声的电磁线圈操作可以继续进行，发现存在的问题，并且，如果有一个问题，有必要改变在电磁线圈。否则，步骤2继续进行正常工作，如果电动液压方向控制阀4和5。步骤2：检查速度控制阀：手动速度控制阀15和16放大openmouths，如果在液压缸的动作，它表明，在速度控制阀16和15被阻止，并且需要卸载它是清洗。否则，在速度控制阀16和15可以旋转，直到松开。然后，步骤3中，可以进行。第3步：请查看的顺序阀和背压阀：如果的手动顺序阀18和的回压阀19的阀芯有没有任何动作，它表示，线轴被钳位在关闭位置，所以油可以不通过和油线遇到相当高的反压，造成液压缸造成无法动弹。这种情况下的主要的原因，

15、可能是太脏度的油，油过滤或更换。3结论在分析和切除故障的液压系统的工作原理、结构和功能的液压元件和系统首先必须已知。在故障搜索，它是必要逐一检查，直到发现的根本原因。此外，还有两个方面的建议，强调在每一个可能的原因：（1）检查是否遇到相关的电气元件故障或不实施清除;（2）它是必要的，以确定是否有相关的外围条件之前分析的关键部件正常与否。第一液压泵和液压缸的故障分析和删除，然后分析的液压阀的故障是必要的，因为液压泵和液压缸的故障进行分析更容易，但需要很长一段时间以进行修理。因此，为了减少维护时间，液压泵和液压缸的故障检查，除去上面的第一，如果存在问题的，应首先执行它们的替代，然后它们的维护应准备

16、下一次。这种方法特别适用于生产线，因为有许多同类型的模块化机床在生产线上用多个预留的液压元件，快速的生产时间和机器停机时间短。因此，这种方法的应用，不仅可以减少停机时间，提高工作效率和正确性，也可以缓解矛盾“大部分时间没事做，但一个非常短的时间内很忙”机械师最企业。参考文献1刘彦君。液压系统的使用和维护。北京：化学工业出版社，2006。2黄志坚，：吴百海。液压设备故障诊断与维修案例精选。北京：化学工业出版社，2009。3张勤，徐钢涛。液压与气压传动技术。北京：高等教育出版社，2009。Analysis and Removal of Common Faults of the Hydraulic

17、System of Power Sliding Table in Modular Machine ToolZhongqin SUNZaozhuang Vocational College, Zaozhuang, China, 277800Abstract: The power sliding table is a general part of modular machine tool, and is driven by hydraulic device. However, the power sliding table frequently encounters the no working

18、 feedfault after the modular machine tool is running for a long time. Based on the maintenance experience from practices, a method to remove the fault is proposed in this paper.Keywords: Modular Machine Tool, Hydraulic System, Fault Analysis, Fault RemovalThe modular machine tool features with high

19、efficiency,exclusive use and high automation, and is composed of general parts and some special parts, and also can fulfill the drilling, expanding, cutting off, boring, milling, tapping and other processing. Also, the power sliding table is a general part of the modular machine tool, and is equippe

20、d with multiple rotating tools, and also is driven by the hydraulic device to complete the feed movement.However, the power sliding table frequently encounters he no entering task phenomenon after the modular machine tool is in the running for a long time. Based on the maintenance experience from pr

21、actices, a method to remove the fault is proposed is concluded by the author in this paper.1 Analysis on the Principle of the Hydraulic System of YT4543 Power Sliding TableIn the maintenance of machine tool, it is necessary to firstly analyze the principle of the hydraulic system of the machine tool

22、 when the faults of hydraulic system happen.The principle of hydraulic system of the YT4543 power sliding table in the machine tool is shown in figure 1.Figure 1: Hydraulic System of the YT4543 Power Sliding Table1.1 Fast-ForwardPress the start button to let the electromagnet 1YA of the solenoid dir

23、ectional valve 5 charged with electricity and the valve left frame accesses to the system; the control oil drives the spool of hydraulic directional valve 4 to let the valve left to access to the system to work. The control oil line can be specified as the following.Inlet oil line: one-way variable

24、pump 2 the left frame of solenoid directional valve 5 one-way valve 6 the left chamber of hydraulic directional valve 4;Outlet oil line: the left chamber of hydraulic directional valve 4throttling valve 9the left frame of solenoid directional valve 5 oil box;The main oil line is below:Inlet oil line

25、: one-way variable pump 2one-way valve 3the left of hydraulic directional valve 4the right of motion valve 11the left chamber of hydraulic cylinder 10;Outlet oil line: the right chamber of hydraulic cylinder 10the left of hydraulic directional valve 4one-way valve 17the right of motion valve 11the l

26、eft chamber of hydraulic cylinder 10;1.2 Working FeedWhen the sliding table reaches the desired location with fast-forward, the travel iron block presses the travel valve 11 to makes its left frame access to the system and cut off the fast-forward oil line, but the oil can only enter the left chambe

27、r of the hydraulic cylinder after passing through the speed control valve 16 and the two-position two-way solenoid valve, because the oil passing throughthe speed control valve can make the system pressure higher and the hydraulic sequence control valve 18 opened, and then the oil in the right chamb

28、er of the hydraulic cylinder flows back to the oil after passing through the back pressure valve 19. Then, the sliding table can implement the first working feed, and its motion speed is controlled by the speed control valve 16. As the pressure in the system rises, the flow rate of the limitedpressu

29、re variable vane pump 2 is automatically lower soas to meet the requirements of the working feed. The oil line can be specifically described below:Inlet oil line: variable pump 2one-way valve 3the left frame of hydraulic directional valve 4speed control valve 16solenoid valve 14the left chamber of h

30、ydraulic cylinder 10Outlet oil line: the right chamber of hydraulic cylinder 10 the left frame of reversal valve 4sequence valve 18back pressure valve 19oil box1.3 Working FeedAfter the I working feed comes to an end, the travel iron stop presses the electric travel switch and sends a signal to make

31、 the electromagnet 3YA of the solenoid valve 14 charged with electricity, and then the left frame of the valve accesses to the system and cuta off the oil line, but the oil can only flow into the left chamber of hydraulic cylinder 10 after passing through the speed control valve 15. Now, the sliding

32、 table is converted into the “II Working Feed, and its motion speed is controlled by the speed control valve 15, but can only be adjusted within the smaller scope than the I working feed. However, the other parts of the inlet oil line as well as the outlet oil line are identical to the I working fee

33、d.1.4 Stay of the Dead Iron BlockWhen moving to the travel destination at the speed of the “II Working Feed, the sliding table will come across the dead iron stop and stop moving. However, by now, the hydraulic pump 2 continues to flow the pressure oil to hydraulic pump 2, and makes the oil pressure

34、 in the system increased further. When the oil pressure is equal to the settling pressure of the pressure relay 13, the pressure relay motion sends a signal to the time relay; the stay time before next motion is controlled by the time relay, to process the end face of the parts. Under the present ci

35、rcumstances, the oil delivering amount of the pump is highly small, which is only used to make up the leakages,while the system is in the pressure-keeping state.1.5 Fast ReverseAfter the sliding table stays at the dead iron stop for a while, the time relay sends a signal to let the electromagnet 1YA

36、 power off but the 2YA power on, and then the right frames of both the directional valves 5 and 4 access to the system to realize the inverting. The oil enters the right chamber of the hydraulic cylinder 10 and makes the sliding table invert speedily. As it is an idle load when the sliding table is

37、inverting, the oil pressure in the system is low, and the flow amount of the limited pressure type one-way variable pump 2 is automatically enlarged to the maximum, and the effective areas ratio between the rodless chamber and rod chamber of the hydraulic cylinder is 2:1, so the sliding table rapidl

38、y invert at the same speed to the fast forward. When the sliding table rapidly inverts to the termination of the fast forward, the travel valve 11 is loosened, and the oil return is smoother. The control oil line can be described below:Inlet oil line: variable pump 2right frame of directional valve

39、2one-way valve 7right chamber of directional valve 2;Outlet oil line: left chamber of directional valve 4throttling valve 8right chamber of directional valve 5oil boxThe details of the main oil line are as shown below:Inlet oil line: Variable pump 2one-way valve 3right chamber of directional valve 4

40、right chamber of hydraulic cylinder 10Outlet oil line: right frame of hydraulic cylinder 10one-way valve 12right chamber of directional valve 4oil box1.6 Fast Retreat In-Situ to StopWhen the sliding table rapidly inverts to the in-situ, the iron stop presses the termination travel switch and sends a

41、 signal to make the electromagnets 1YA, 2YA and 3YA power off, and then the solenoid directional valve 5 and hydraulic directional valve 4 are in the central frame, and the oil lines of both the left and right chambers of hydraulic cylinder are cut off and then the hydraulic cylinder is in a clamp s

42、tate, and the sliding table stops working. By now, the oil flowed by the variable pump 2 flows into the oil return box necessarily after passing through the one-way pumps 3 and 4, and then the system is in an unloading state.2 Analysis on the No Working Feed Faultof the Power Sliding Table and the R

43、emoval Steps2.1 Analysis on the Reasons for the FaultThe power sliding table in modular machine tool keeps a normal speed in the fast feeding, and comes to a halt at the beginning of processing. Based on the learnt knowledge of the principles of all kinds of hydraulic components and the maintenance

44、experiences from work, and through a detailed analysis, the main reasons for causing the no working feed fault may be the powerful cutting, insufficient system pressure, leakage, no oil supply by hydraulic pump or insufficient oil delivery amount, abrasion of hydraulic valve internal components, bro

45、ken line or locking, or the abrasion of hydraulic cylinder internal components resulting in the inner leakage or the sealing components squashing in the cylinder wall to arouse the increasing resistance of the executive components, etc.2.2 Fault Removal StepsDue to the leak tightness of the hydrauli

46、c system, the hydraulic fault is not as intuitional as the mechanical failures; the fault measurement is not as convenient as that of electric problems and is really uneasy to judge directly. It is highly difficulty to repair if the examination is started from the hydraulic station; not only will no

47、 reasons be found, but also some components will be disassembled blindly, and hence new faults will be resulted in. In order to search the reasons for the hydraulic faults with high efficiency, a reasonable fault detection sequence is built per the possibilities of the fault reasons and disassemblin

48、g and installing easiness of the hydraulic components or parts. Namely, the sequence is check the general orientation of the fault per the number in the pressure meter first, and then disassemble the oil tube to check the faults (e.g.the internal leakages of the hydraulic pump and cylinder, or the crawling of the sliding table), and then indentify the real fault of the hydraulic valve.First, the cutting force of the working feed is examined: the cutting force of the working feed can be confirmed by examining t