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I. Structure and Principle
1. Oil Pressure System
The motor (Y112M-4) drives the gear pump (YBC-314) as power. The pump inlet is equipped with an oil filter (XV-100×100). Through the overflow valve, the pump pressure is adjusted, and the direction of the cylinder piston is controlled by the directional valve.
2. Hydraulic System
The motor (Y100L-4) drives the plunger pump for liquid injection. The pump suction port is equipped with a filter (XV-100×100), and the discharge port is equipped with a low-pressure overflow valve to adjust the liquid pump pressure and for liquid return. The booster cylinder adopts double-acting double-action, with both ends being high-pressure emulsion cylinders. The emulsion is injected through one-way valves by the liquid pump, and after pressurization, both ends discharge high-pressure emulsion, enabling performance testing of hydraulic components and ultra-high-pressure performance tests.
3. Low-Pressure Gauge Protection System
This machine is equipped with a low-pressure gauge protection system at the emulsion low-pressure gauge port. When the pressure exceeds 2MPa, the high pressure can automatically close and seal the valve stem in the protection valve, thereby protecting the low-pressure gauge.
II. Product Overview
The ultra-high-pressure valve column testing machine is a product designed and manufactured by our factory, widely used in coal mines, machinery, chemical industry, metallurgy, scientific experiments, etc.
Main Technical Features
Working Pressure: 80MPa
Rated Working Pressure: 60MPa
High-Pressure Discharge Capacity: 1.2 liters/time
Oil Pressure Working Fluid: 30# Machine Oil
Valve Testing and Liquid Injection: 2～5% Emulsion
Motor: 4KW/3KW
This testing bench has a simple structure, is easy to operate, and is safe and reliable. The system consists of two parts: an oil pressure system and an emulsion system, with an overall split-box structure. The main features of this product: it can quickly and at medium speed discharge 1.2 liters per time under high pressure, with a working pressure of 80MPa, meeting the performance testing needs of various hydraulic components, and can also be used with other auxiliary equipment for characteristic tests. The high-pressure shut-off part adopts a soft sealing device, which can maintain pressure for a long time without leakage under high pressure. The low-pressure part is equipped with a low-pressure gauge protection valve, which adopts a self-locking and self-sealing structure. Even if the low-pressure gauge is not closed, the working pressure of 80-100MPa will not damage the low-pressure gauge.
This machine incorporates the experience of various existing testing benches in China, with good performance and complete functions, meeting the performance testing requirements of various hydraulic components at low, high, and ultra-high pressures.
III. Usage and Maintenance
1. Transportation and Installation of the Testing Machine
When transporting the testing machine, the packaging box must not be tilted or inverted. After unpacking, prepare for transportation. When lifting, pad with soft materials to avoid scratching the machine. During installation, first check whether all parts are loose or damaged.
2. Pre-Test Preparations
First, add liquid (oil) to the liquid tank and oil tank. After normal, connect the power supply, and the button indicator light should be on. (The motor rotation direction should be clockwise.) Start the liquid pump motor and close the shut-off valve. At this time, the low-pressure gauge should read 2. If not, adjust the low-pressure overflow valve to reach the specified pressure. Then start the oil pump. At this time, the oil pressure gauge should read 7MPa. If not, adjust the oil pressure overflow valve (YF-B10) (usually adjusted at the factory). Only after everything is normal can testing proceed.
3. Operating Procedure of the Testing Bench
After installing the valve on the valve seat, close the shut-off switch, start the liquid pump motor to inject liquid and use the unloading wrench to exhaust air. After the air is exhausted and the low pressure has a reading, low-pressure testing can be conducted. The emulsion pump can be stopped. After the low-pressure holding test passes, start both the oil pump and emulsion pump simultaneously, switch the booster switch to the suction position for boosting. At this time, the high-pressure gauge pressure rises. The safety valve of the three-way valve may start to unload at a certain pressure. At this time, use the pressure-adjusting wrench to adjust the safety valve to unload at the specified pressure. The overflow rate can be adjusted by the flow control valve (clockwise increases flow, counterclockwise decreases flow, generally adjusted to 20-30ml/min). Then close the liquid pump and oil pump. The safety valve of the three-way valve closes at the closing pressure. At this time, the high-pressure gauge maintains a certain pressure unchanged, and the pressure-holding test passes. After the test, open the unloading switch to release the pressure completely before removing the tested valve.
In addition, this machine is equipped with an accumulator to stabilize pressure and reduce pressure pulses. The end face of the testing bench is equipped with an external interface, which can input the pressure source to other auxiliary equipment for special product testing. (For single prop testing, see below.)
IV. Detailed Maintenance Techniques
1. Maintenance of the Hydraulic System
a. If the emulsion pressure cannot be stabilized, there may be dirt on the one-way valve, which should be carefully cleaned.
b. If the emulsion high-pressure gauge cannot be stabilized, first check whether there is obvious leakage at the pipeline return liquid joint. If not, first check the unloading shut-off valve, and see whether the safety valve pad on the upper end of the shut-off valve stem has dirt or damage. If not, it indicates leakage in the one-way valve at the outlet of the booster cylinder, which should be disassembled for cleaning or the seals replaced.
Note: The above information and technical parameters are compiled and released by Yangzhou Darui Electric Co., Ltd.
