Liang Dongliang Zhengwen Meng Lingbin Overview The production system of Henan Xinlianxin Fertilizer Co., Ltd. is equipped with 3 3135 air compressors produced by Nanjing Compressor Factory, mainly used for fine desulfurization system and urea system. Since the machine was put into operation in August 2006, it has gradually exposed the frequent maintenance of the door due to the small cooling ratio of the single-stage compression ratio and high cooling system, which has caused many disadvantages to the production process.

The air compressor is a single-acting two-stage compression structure. The stepped piston can compress the atmosphere to a maximum exhaust pressure of 3.0 cubits. 3. The working principle is that the air filtered by the wet muffler filter is sucked through the 1-stage combination valve. Class 1 cylinders are compressed into the buffer volume on the fixed crankcase. Then, it is compressed to the exhaust pressure through the air passage port through the stage cylinder, and is discharged by the stage combination valve, and is cooled by the air passage in the cylinder into the suspended stage cooler. Finally, the gas separation is carried out by the separation of the stages, and the purified compressed air is sent to the intake bottle.

The basic working parameters of the air compressor

There is a question and analysis that the air compressor is a vertical single-row single-cylinder differential water-cooled compressor, and the cooling water is secondary water. Because the inlet and outlet of the original cooling waterway design of the machine are in series, the cooling water circuit is in series. The cooling water must pass through the stage cooler and absorb the heat of the compressed air before reaching the stage cooler, thus causing poor cooling of the stage. The compressed air temperature cannot be cooled very well. On the other hand, the outlet pressure of the air compressor reaches 0.6 MPa, and the compression ratio is 6. The higher compression ratio causes the exhaust temperature of the section to be too high, and the heat exchange area of ​​the section water cooling is about 2, which causes the segment to enter. The gas temperature is as high as 100 feet in summer, which inevitably causes the exhaust temperature to reach 160 psi.

Due to the influence of the above series of high temperature, the overall temperature of the air compressor cylinder is too high, and the temperature of the lubricating oil also reaches about 80. Under the influence of the working medium air, the oxygen in the air promotes the oxidative decomposition of the lubricating oil at high temperature, resulting in The whole system has a lot of carbon deposits, especially the deposits on the shutters and heat sinks, which have a great impact on the normal operation of the air compressor. The carbon deposit on the heat sink will improve the cooling effect, while the carbon deposit on the valve will be It will cause damage to the valve spring, which will affect the intake and exhaust function of the valve. In severe cases, it will damage the piston or even the cylinder. Before the equipment was rebuilt, the plating of the cylinder was repaired several times. In the summer, the air compressor maintenance frequency is like a weekly, the annual maintenance cost is as high as 30,000 yuan.

Step by step, improve the cooling waterway. The stage cooling water is routed from the original design series to the parallel form. Install the inlet and outlet drain pipes for the grade cooling water passages to ensure that the stage cooling effect can be controlled from the source. The first step before and after the improvement, by adding the external cooler, change the gas cold cooling water outlet level cooling cooling water inlet cylinder in the original design of the equipment. Cover cylinder cooling water outlet; cooling water outlet 2 = cooling water inlet level cooling cylinder head cylinder cooling water inlet 4 improved before improved filling capacity rated exhaust pressure MPa level suction exhaust gas after cooling into gas cylinder equipment management And maintenance 2010, 4 full hydraulic forging manipulator tongs rotating hydraulic motor brake circuit to improve the hydraulic control principle of Deng Hong circuit and pilot sequence valve hydraulic brake circuit in the hydraulic motor hydraulic brake circuit application failure, the results The overflow bridge hydraulic brake circuit is superior to the pilot sequence valve hydraulic brake circuit.

1001; 250 full hydraulic rail forging manipulator is the supporting equipment purchased for 31.5MN forging hydraulic press in 2008. The equipment is designed and manufactured by Shandong Qingdao Huadong Construction Machinery Co., Ltd. After the production, the hydraulic cracking of the hydraulic motor cylinder of the tongs has appeared many times. Seriously affect the smooth progress of production. The cause of the fault is that the hydraulic brake circuit composed of the pilot sequence valve used in the hydraulic motor has design defects. For this reason, the hydraulic brake circuit is changed to the overflow bridge hydraulic brake circuit, which completely solves the problem. Improve the reliability of equipment operation Basic requirements of hydraulic motor brake circuit Here, the hydraulic motor is used for bidirectional rotation. When the electromagnet on the left side of the position change valve is energized, the pressure oil is passed to the port through the account, and the port is 5 ports. 7 ports return oil, which drives the hydraulic motor to rotate in the forward direction; conversely, when the electromagnet on the right side of the position change valve is energized, the corpse 3 simultaneously drives the hydraulic motor to rotate in the opposite direction.

In view of the performance requirements of the hydraulic motor, the working pressure of the hydraulic oil driving the hydraulic motor must be limited to the rated pressure range of the hydraulic motor used, and at the same time, due to the requirement for smooth running of the hydraulic motor, A pressure limiting valve or constant pressure valve must be provided.

The process of cooling from the rotating state to the stopped state can only be achieved in the cooling circuit of the compressor body, and the cooling effect is improved. The specific measures are as follows: a seamless carbon steel pipe of 253.5, 1 is used to make a serpentine tube heat exchanger, the heat exchange area is 512, the original section cooling process is changed, and the cooling process is divided into two ways, and the original cooling process is taken from the road. The gas is taken out from the oil section for secondary cooling, and the other road is taken out from the temperature measurement point of the cylinder for cooling. After the two gases are cooled, they are merged at the newly added filter, and after precision filtration, they enter the section cylinder for section compression.

Through the improvement of the first step, the cooling effect is improved, and the exhaust temperature of the stage is reduced to 60弋 and 80 by 100, 捅60 ft before the improvement, and the positional reversing valve is from the power state. When the power is turned to the power failure state, the hydraulic motor will not stop immediately, and the rotation will continue due to the inertia. During this process, the hydraulic motor is converted into the oil pump to discharge the oil on the driving side to the oil return side. The core has quickly returned to the middle position, so that the 43 households 71 ​​oil passages are not connected to each other, causing the driving side pressure to rapidly change to a negative pressure. If the oil is not immediately replenished, the hydraulic motor may be damaged and the pressure on the oil return side is rapidly increased to generate a hydraulic shock. The hydraulic shock will damage the hydraulic motor without slowing down the limit. Therefore, the pressure limiting valve and the charge valve must be installed in both of the 45 oil passages.

The basic needs of the hydraulic brake circuit of the hydraulic motor Through the above analysis, the basic composition of the hydraulic brake circuit of the two-way hydraulic motor must include the pressure limiting oil supply component. The pressure limiting oil replenishing component can be realized in various ways. The pressure limiting oil replenishing component involved herein is composed of a pilot caliper rotating structure principle with a one-way valve and existing design defects. 1. Pilot-operated sequential valve structure and work Principle Pilot-type sequence valve structure principle 2. Pilot-type sequence valve main valve and pilot valve are slide valve type structure, pressure oil enters the pilot-type sequence valve acting on the lower end of the main spool, while the pressure oil passage enters the left end of the pilot valve through the pipeline , acting on the left end surface of the spool valve, passing through the orifice to the upper end of the main spool, and entering the middle annular portion of the pilot valve. When the pressure outside the inlet port is lower than the adjustment pressure of the pilot valve, the main spool is closed, and the pilot-type sequence valve outlet has no oil to flow out. When the inlet pressure exceeds the adjustment pressure of the pilot valve, the pressure entering the left end of the pilot valve overcomes the adjustment spring pressure and pushes the spool to the right. At this time, the middle annular portion of the pilot valve communicates with the pilot sequence valve outlet. The main valve maintenance cycle of the oil through the orifice is extended from the original weekly maintenance to more than 20 days.

Through the improvement of the first step, the exhaust temperature of the section is reduced to about 50 feet, and the operating period of the air compressor reaches more than 45 days, which greatly reduces the failure time, reduces the labor intensity of the workers, and reduces the annual maintenance cost to 10,000 yuan. the following.

Editor Wang Qi Equipment Management and Maintenance 2010, 4

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