Contrôle de la qualité de la conception et de la fabrication des blocs de collecteurs hydrauliques

In order to improve the operational efficiency of equipment, achieve the standardisation and integration of hydraulic systems, save raw materials, reduce industrial costs, and improve precision and accuracy, the study of the rational design and manufacture of hydraulic manifold block has become a key concern in the current field.

This paper takes the quality standard of hydraulic manifold block as the premise and goal, reduces the difficulty of the actual and manufacturing process of hydraulic valve block as much as possible, saves the processing cost, and clarifies the reasonable control of the quality of hydraulic manifold block from the three stages of hydraulic valve block’s design, manufacturing and commissioning respectively, so as to guarantee the proper functioning of the hydraulic system.

The research in this paper has an important value in the relevant industrial field, can give the relevant industrial personnel to provide reliable and effective advice and suggestions.

First, the design of hydraulic manifold block

Hydraulic manifold block design often exists some unreasonable factors, which in turn affects the quality of the hydraulic manifold block, this paper first of all on the hydraulic valve block design unreasonable reasons for analysis, a comprehensive grasp of the design of the hydraulic valve block, the manufacturing process, so as to effectively control the overall reasonableness of the hydraulic manifold block.

Hydraulic manifold block design unreasonable reasons mainly include the following aspects:

(1) The arrangement of the orifice does not comply with the principle of fluid transmission.

(2) The design of too many oblique holes, resulting in processing difficulties.

(3) The hydraulic valve block involves too many integrations, resulting in machining difficulties.

(4) Simply consider the design of the hydraulic valve block, while ignoring the process requirements of the supporting original.

(5) Hydraulic valve block design is not conducive to maintenance, resulting in the total life of the product is affected.

(6) Manifold block space is not fully utilised, resulting in material waste.

In the design process of the hydraulic valve block, aim to minimize slant holes and deep holes. Pay careful attention to the direction and location of the inlet and outlet ports. Give thorough consideration to enhancing portability and improving practicality.

In the hydraulic manifold block design process to try to meet several requirements:

(1) Hydraulic valve block hole arrangement should be in line with the principle of fluid transmission, according to the actual situation, the reasonable development of the number of integrated valve parts;.

(2) Try to design fewer deep holes and slant holes in the manifold block, so that the oil circuit in the hydraulic valve block is simple and clear, and the reliability of the fluid rotation is higher.

(3) In accordance with the intended design requirements, pay attention to the direction of the inlet and outlet ports, as well as their location.

(4) When designing the hydraulic manifold block, consider the requirements for installing the components in the manifold block.

(5) Service the components in the manifold block from time to time, and the components should be set up in a location where they can be easily serviced.

(6) Try to ensure that the valve is compact but does not interfere.

To control the quality of the hydraulic valve block, specific control methods are necessary. Understanding the design process comprehensively helps identify irrational design factors. Effective quality control during preparation is crucial for subsequent tasks. In addition, for the larger weight of the valve block, to design lifting threaded holes, lifting and installation.

Second, the processing and manufacturing of hydraulic manifold block

After finalizing the overall design scheme, the hydraulic manifold block proceeds to processing and manufacturing. The manufacturing process comprises pretreatment, machining, deburring, cleaning, and assembly stages. During processing, milling and planing operations are crucial for smoothing surface burrs. This ensures the sealing surface roughness meets specified requirements. Thoroughly removing burrs at the runner intersections is critical during manifold block manufacturing. During component assembly, careful consideration of connectivity and portability is essential.

However, during the processing and manufacturing of hydraulic valve blocks, deformation can occur due to contact between the tool and the valve block. This contact can deform the material, often stemming from improper heat treatment practices. To ensure the quality of the machining and manufacturing process, it is essential to employ appropriate control means and methods. This includes accurately predicting the thermal processing requirements and ensuring adequate machining allowances are left. Additionally, selecting the appropriate tools helps prevent operational deformations caused by contact.

The manufacturing process of manifold blocks is susceptible to surface damage and other issues. Surface damage can impair the normal operation of the entire hydraulic system, leading to problems like oil leakage. Major causes of surface damage include debris and chips entering the hydraulic valve block during processing, improper selection of cutting tools causing dull blades and processing errors, and operational errors by staff. During packaging, assembly, and cleaning, collisions can occur, damaging the surface. Therefore, it’s essential to implement proper quality control methods. Timely replacement of worn-out tools and ensuring the rigidity and performance of processing materials are crucial. Rigorous technical training for operators helps minimize errors during work. During cleaning and assembly, precautions should be taken to prevent collisions and ensure the safety and stability of components.

Hydraulic valve block pore damage is also a major quality problem, should fully analyse the causes of this damage, choose a reasonable control method. In general, the pore damage will lead to the manifold block commutation performance decline, resulting in oil leakage phenomenon, affecting the normal operation of the hydraulic system. Poor cutting tool performance can cause orifice damage due to ineffective cutting effects. During thermal machining, material deformation is a factor in orifice damage. Irrational construction practices during installation, drilling, and pilot hole operations can also cause damage.Inadequate implementation of processing procedures further contributes to orifice damage. The main control method involves replacing the tool with a new one to ensure tool quality. Technical training of construction personnel is crucial for maintaining quality. Strict adherence to construction routes and processes further ensures the quality of the hydraulic manifold block.

Third, the debugging of the hydraulic manifold block

After constructing the hydraulic manifold block, the performance debugging process includes two main parts.Pressure testing is crucial, and Table 1 specifies pressure control settings.It emphasizes selecting a test pressure not exceeding 31.5 MPa to prevent component damage.

Table 1:Test Pressure Selection Comparison Table

Working pressure Ps/MPa≤16>16~25>26~31.5
Test pressure/MPa1.5Ps1.5Ps less than 24MPa according to 24MPa test 1.5Ps less than 24MPa according to 31.5MPa test

During the pressure resistance test, potential leakage may occur, requiring careful analysis of the causes and prompt solutions to ensure the rationality of the entire hydraulic manifold block component design.

During the functional test of each valve in the hydraulic manifold block, ensure proper operation of the relief valve, unloading valve, and other valves. Adjust valve speed ratios to meet actual operating conditions. If a failure occurs during commissioning, professionals analyze the operation principles to identify key failure factors promptly. They then proceed to resolve the issue in a timely manner.

This paper thoroughly analyzes the manufacturing process of hydraulic manifold blocks. These blocks have become vital components in various large-scale industrial equipment. Ensuring the quality of hydraulic manifold blocks is crucial for the reliable operation of hydraulic systems. The analysis begins with the design process, identifying potential design issues and proposing effective solutions. It then covers quality control during manufacturing and commissioning to address possible quality issues comprehensively.

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