闭式液压系统介绍及使用）
Zhang Xin（张新）
DCCN-SVH/Pk
Dec.13th.2010
闭式液压系统构成
A4VG180EP泵介绍
A6VM160EP马达介绍
管路安装
系统清洁度保证
A4VG180EP泵常见故障的诊断及排除
A6VM160EP马达常见故障的诊断及排除
问题讨论
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DCCN/SVH-001-PR-F15
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DCCN/SVH-001-PR-F15
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闭式液压系统介绍 DCCN/SVH-001-PR-F15
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DCCN/SVH-001-PR-F15
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增
加
冲
洗
阀
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闭式液压系统介绍 DCCN/SVH-001-PR-F15
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方向控制阀：规格小 => 仅进行先导控制；（开式系统中的规格大）
过滤器和散热器：规格小=> 只需与补油泵的流量匹配；
液压油箱：小尺寸=> 只需与补油泵流量匹配；
运转速度：补油泵限制=> 补油泵的结构及连轴套上的平键
安装位置：任意位置
驱动：可逆的=> 泵马达工况可逆，可实现静压制动
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DCCN/SVH-001-PR-F15
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容积泵一种
密封容腔
容腔体积可变
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12
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DCCN/SVH-001-PR-F15
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1
泵 2 EP控制 3 压力切断
阀
过滤
器带
冷启
动阀
及指
示器
4 变量活 塞
5 高压溢流
阀（带补油
阀）
6 低压溢
流阀/补
油阀
2
3
4
Ps
6
X1，X2
MA，MB
R
T
G
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DCCN/SVH-001-PR-F15
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轴端无应力安装 => 安装时不可以敲击 轴端，放置时不可以轴端着地；
检查泵的旋向：与电机（发动机）一致
保证油液清洁度
清洁度等级：至少ISO4406
20/18/15
油液温度较高时（90度~115度）：
至少ISO4406 19/17/14 保证同轴度 => 联轴器安装时，要根据 生产厂家的要求保证同轴度；
吸油压力：不能低于0.8bar（绝对压 力），表测压力不低于-0.2bar；
壳体压力：不能高于3bar（绝对压 力），表测压力不高于2bar
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DCCN/SVH-001-PR-F15
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壳体加油，排气：向壳体内加满干净的
液压油，从高处的油口排气（第一次试车、
长时间不用或更换油管后，启机前）
泄油管连接：
接在泵壳体上方的T口，直接回油箱；
接头要符合欧洲标准的超轻型系列
油管选用单层钢丝的低压油管
吸油过滤：尽可能不要采用吸油过滤；
如果要用吸油过滤，过滤器精度要大于
100U，通流量大于补油泵流量的2.5倍；
有关清洁度的保证措施，后面专门论述
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DCCN/SVH-001-PR-F15
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A6VM160EP马达使用要求
轴端无应力安装 => 安装时不可以敲击 轴端，放置时不可以轴端着地；防止顶轴 保证油液清洁度
清洁度等级：至少ISO4406 20/18/15
油液温度较高时（90度~115度）：
至少ISO4406 19/17/14 保证同轴度 => 联轴器安装时，要根据 生产厂家的要求保证同轴度； 壳体压力：不能高于3bar（绝对压 力），表测压力不高于2bar
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DCCN/SVH-001-PR-F15
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壳体加油：试车时壳体内要加满干净的
液压油，将马达壳体内气排净
泄油管：要求同前面泵的要求
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DCCN/SVH-001-PR-F15
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旁通阀
2bar
R壳体压力测量口
G补油压力测量口
B侧高压测量
泵上各油口尺寸
X1X2 变量活塞控
制油测量口
B测高压溢流阀
机械零位调整杆
低压溢流阀
A测高压溢流阀
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各测量口用压力表量程
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DCCN/SVH-001-PR-F15
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在储存、运输的过程中，油管开口要用干净的塑料堵等密封保护；
最好使用没有经过涂敷的无氧化皮的；
锯完后，应仔细去除毛刺；
冷态折弯
尽可能避免焊接接头。若无法避免，在焊接时要考虑焊杂的易处理；
不要使用棉纱和废布清理管路，最好使用稠缎；
对于液压油箱，一定要认真处理掉焊渣，并用面沾干净油箱的内部
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任何时候，吸油和泄油管都要在液面
下至少2.5倍的管子直径；但不能小于
100mm；（防止起泡）
泄油管（或回油管）要高于吸油管，
并注意：回油不可以直接被吸走
吸油管，回油管和泄油管的油口间的
距离要大于200mm；
Emin ≥ 2.5倍管径（100mm）
Amin ≥ 200mm
Bmin ≥ 200mm
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DCCN/SVH-001-PR-F15
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吸油区的油液不可 紊流区 以急速流动
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DCCN/SVH-001-PR-F15
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吸油區內油液不可急
速流動
calm oil in suction
chamber
Allg. 090.10 VST1/VST6 09.AA
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P suction
最少有2.5倍油管直徑
的距離
at least 2.5 pipe i.d.
minimal distance
紊流區
turbulent zone
必須安裝隔板
baffle absolutely
necessary
DCCN/SVH-001-PR-F15
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液位
oil level
液位變化 swinging level
注意！
回油管必須經常低於最底
液位
ATTENTION!
Return line must always
end under the minimum
oil level
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Allg. 090.6 VST1/VST6 06.AA
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使用兩個喉碼時必須 分開安裝
When using two hose clamps, mounting needs to be offset
氣谷
longitudinal airgap
安裝一對喉碼須以
90°分隔開
Hose clamps have
to be assembled
with a set of 90°
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无应力安装
折弯半
径3倍
于管径
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元件损坏
系统性能下降/
动作失灵
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DCCN/SVH-001-PR-F15
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液压系统污染的来源
外部污染
装配时造成污染
启动系统时造成的污染
内部污染
磨损
新的油液
维修造成的污染
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不同清洁度液压油比较
油桶里新的液压油
ISO4406 22/20/18 级
（NAS12级）
新安装系统内的污染
ISO4406 23/22/20
（大于NAS12级）
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DCCN/SVH-001-PR-F15
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经常规过滤器过滤的液压油
ISO4406 20/18/16
（NAS 9级）
柱塞泵和
马达的最
低要求
经过3〉200的精过滤器
过滤的油液
ISO4406 14/13/11
（NAS4级）
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过滤精度
压差特性
纳污能力
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反应的是过滤器对不同直径颗粒的过滤能力
为检验其性能，人为规定的指标；是在特定的条件下通过试验 测得的；
这一指标越高，其过滤能力越强；但它无法表征出过滤器在系 统中的真实净化能力（受多种因素影响）
国际通用的过滤精度表示方法
x = 75 的X值
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| 平均过滤比 | 2 | 10 | 75 | 100 | 200 | 1000 |
| 颗粒尺寸 | – | 7.80 | 13.7 | 14.6 | 15.9 | 18.7 |
油液的清洁度 ≠诉 过滤器精度
两者没有一一对应的关系
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进出口的压力差，是油液黏度、流量、 孔径、孔形状、过滤面积的函数
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过滤器的滤芯不可以清洗，只
能更换
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安装前所有管路进行清洗；
油箱内一般不要涂油漆，安装前仔细去除焊渣，用面沾，最好采用不锈钢油箱；
换油时要彻底清洗油箱和管路，加油时采用过滤精度10um的滤油机加注；
吸油管、泄油管、回油管要正确安装（方法参考前面）；必要时可在系统的高处 设置放气阀；
保证油箱温升不超过液压油规定，一般不得超过70度（超过80度后，每增加10 度，元件损坏的速度呈指数级增加）；
及时更换不良密封（防止系统进气），及时更换水冷却器等（防止系统进水）；
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a〉
b〉
c〉
d〉
油液不足；吸油不畅
磨损严重，内泄过大；
系统排气不彻底；
连轴器安装不合适；
泵工作无压力或流量异常
a〉电气故障（电磁阀未能送上电） b〉补油压力异常（补油溢流阀卡滞，补油泵磨损） c〉磨损，内泄过大； d〉切断压力设定不合适（或切断阀芯被异物卡住） e〉马达工作异常造成（马达磨损，冲洗阀异常）
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a〉
b〉
c〉
内泄，泄油管堵塞；
磨损；
溢流阀故障；
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a〉油液不足；
b〉磨损严重，内泄过大； c〉超速；
d〉过载，溢流阀溢流； e〉制动响声；
a〉磨损内泄过大； b〉溢流压力设定不合适（或阀芯被异物卡住） c〉泵工作异常造成；
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a〉EP阀电器故障；
b〉控制油路堵塞；
c〉变量机构卡滞；
d〉变量活塞密封磨损；
a〉内泄，泄油管堵塞；
b〉磨损；
c〉排量选择不合适，过小；
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