Rapid maintenance method for oil cylinder

Abstract

The invention discloses a rapid oil cylinder maintenance method, and particularly relates to the field of oil cylinder maintenance, which comprises the following steps: step S100, carrying out appearance inspection on the whole oil cylinder, checking whether obvious oil stain leakage and external part damage exist or not, emphatically marking the oil stain leakage part, and preliminarily judging the position of a fault point; and step S200, carrying out pressure maintaining tests of different pressure levels on the oil cylinder. Under the condition that an original non-standard sealing ring is difficult to obtain and high in cost, the sealing ring mounting groove is subjected to additional machining, then the standard sealing ring is mounted, non-standard parts are reasonably replaced by standard parts, the maintenance cost is effectively reduced, the maintenance waiting time is shortened, the scratches of the inner wall of the cylinder barrel are subjected to targeted maintenance according to mild, moderate and severe scratches, and the service life of the cylinder barrel is prolonged. And different methods such as honing, honing after cladding and metal repairing agent filling and repairing are selected according to the scratch degree, the situation of excessive maintenance or insufficient maintenance is avoided, and the maintenance effect and efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the field of oil cylinder maintenance, and more particularly to a method for quickly maintaining an oil cylinder. Background Art

[0002] The cylinder is a hydraulic actuator that plays a key role in converting hydraulic energy into mechanical energy in the hydraulic system. It is mainly used to achieve linear reciprocating motion or swinging motion. When the hydraulic oil enters a chamber in the cylinder barrel through the oil inlet of the cylinder, the pressure of the hydraulic oil acts on the piston (or plunger). According to Pascal's law, the liquid pressure is equal in all directions, so the piston (or plunger) will move under the push of the hydraulic oil. If it is a double-acting cylinder, when the hydraulic oil enters the chamber on the other side of the piston, the piston will move in the opposite direction, thereby achieving linear reciprocating motion. By controlling the flow and direction of the hydraulic oil, the movement speed and direction of the cylinder can be precisely controlled.

[0003] Oil cylinders are widely used in various mechanical equipment in industrial production, such as construction machinery, metallurgical equipment, mining machinery, etc. Since oil cylinders work under high load and complex working conditions for a long time, they are prone to failures such as seal wear, cylinder inner wall scratches, piston rod corrosion or bending. Traditional oil cylinder maintenance methods often have problems such as long maintenance time, complicated maintenance process, and difficult to guarantee performance after maintenance. For example, when dealing with the problem of cylinder inner wall scratches, it may be necessary to completely disassemble the oil cylinder and perform complex grinding, repair or even replace the cylinder, which not only consumes a lot of manpower and time, but also may cause the entire equipment to shut down for a long time, increasing production costs and the risk of production delays.

[0004] Based on the existing standard cylinders, after long-term use, the cost and difficulty of obtaining non-standard sealing ring replacements will increase. At this time, if you continue to look for and purchase original replacements, both the economic cost and time cost will be very high.

[0005] In order to solve the above problems, a technical solution is now provided. Summary of the invention

[0006] In order to overcome the above-mentioned defects of the prior art, an embodiment of the present invention provides a method for quickly repairing an oil cylinder to solve the problems raised in the above-mentioned background technology.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A method for quickly repairing an oil cylinder comprises the following steps:

[0009] Step S100, perform an appearance inspection on the entire oil cylinder to check whether there is obvious oil leakage or damage to external components, and mark the oil leakage site to preliminarily determine the location of the fault point;

[0010] Step S200, performing pressure holding tests at different pressure levels on the oil cylinder;

[0011] Step S300, using an endoscope or other equipment to inspect the inside of the oil cylinder to check the finish of the inner wall of the cylinder and the status of the seal;

[0012] Step S400, replacing the original non-standard sealing ring;

[0013] Step S500, repairing the inner wall of the cylinder.

[0014] In a preferred embodiment, step S200 specifically includes the following contents:

[0015] Connect the oil inlet and outlet of the oil cylinder to the hydraulic test equipment through high-pressure oil pipes. Before starting the test, it is necessary to remove the air in the oil cylinder and hydraulic system, turn on the oil pump of the hydraulic test equipment, and slowly fill the oil cylinder with hydraulic oil at a low flow rate. At the same time, open the exhaust valve of the oil cylinder to let the air out from the exhaust port. When you see that hydraulic oil is continuously flowing out of the exhaust port without bubbles, close the exhaust valve;

[0016] According to the rated working pressure of the oil cylinder, set the pressure regulating valve of the hydraulic test equipment to the pressure value of the low pressure stage, which is 30%-50% of the rated working pressure;

[0017] Start the oil pump of the hydraulic test equipment and slowly fill the hydraulic oil into the cylinder to gradually increase the pressure in the cylinder to the set low pressure value;

[0018] When the pressure reaches the set low pressure value, close the oil pump and the oil inlet valve to make the oil cylinder enter the low pressure holding state. The holding time is set to 10-30 minutes.

[0019] Reset the pressure regulating valve of the hydraulic test equipment to the pressure value of the high pressure stage, which is 80%-100% of the rated working pressure;

[0020] Restart the oil pump and slowly increase the pressure in the oil cylinder to the set high pressure value. When the high pressure value is reached, close the oil pump and the oil inlet valve to enter the high pressure holding state. The holding time is set to 10-30 minutes.

[0021] After completing the pressure holding test, first open the oil outlet valve of the hydraulic testing equipment, slowly release the pressure in the cylinder, and allow the hydraulic oil to flow back into the oil tank of the testing equipment.

[0022] In a preferred embodiment, under the low pressure holding state, closely observe the reading of the pressure gauge, if the pressure drops slowly, record the speed and amplitude of the pressure drop, and check whether there is a slight leakage in the oil cylinder;

[0023] Under the high-pressure maintaining state, carefully observe the stable state of the pressure gauge reading. If there is a sudden drop in pressure, violent fluctuations, or abnormal shaking or noise in the cylinder, stop the test immediately, inspect the cylinder, and check whether there is a large amount of oil leakage outside the cylinder.

[0024] In a preferred embodiment, step S300 specifically includes the following contents:

[0025] Slowly insert the probe of the endoscope into the inspection port of the oil cylinder, and adjust the direction of the probe of the endoscope according to the structure of the oil cylinder and the part to be inspected;

[0026] Turn on the light source and imaging system of the endoscope, observe the surface condition of the inner wall of the cylinder, adjust the focal length and imaging parameters of the endoscope, and obtain a clear image of the inner wall;

[0027] Find the location of the seal, observe the integrity of the seal, and check the contact areas between the seal and the inner wall of the cylinder and the piston.

[0028] In a preferred embodiment, step S400 specifically includes the following contents:

[0029] Disassemble the oil cylinder, take out the old non-standard seal ring and related parts, separate the parts with the seal ring installation groove, measure the outer diameter, inner diameter and thickness of the standard seal ring, measure the relevant dimensions of the seal ring installation groove, and calculate the allowance that needs to be processed;

[0030] According to the size and installation requirements of the standard seal ring, determine the location and approximate processing amount of material to be removed from the seal ring installation groove;

[0031] Fix the component with the sealing ring installation groove on the milling machine workbench, widen and deepen the sealing ring installation groove, and after the processing is completed, use sandpaper to grind and polish the surface of the processed sealing ring installation groove to remove the processing burrs and thoroughly clean the processed sealing ring installation groove;

[0032] Apply grease to the standard seal ring and install it into the seal ring installation groove after additional processing;

[0033] Reassemble the parts with the standard seals machined and installed.

[0034] In a preferred embodiment, the assembled oil cylinder is connected to the hydraulic system, and no-load debugging is first performed, and the hydraulic system is started, and the oil cylinder is made to reciprocate several times, and the movement of the oil cylinder and the condition of the standard sealing ring are observed;

[0035] After no-load debugging is normal, load debugging can be carried out. Gradually increase the load of the cylinder, and test step by step from low load to high load. Run for 10-30 minutes at each load level to check the movement of the cylinder under load and the condition of the standard sealing ring.

[0036] In a preferred embodiment, step S500 specifically includes the following contents:

[0037] The scratches on the inner wall of the cylinder are divided into light scratches, moderate scratches and heavy scratches;

[0038] For minor scratches, a honing machine is used. The honing head on the honing machine is inserted into the cylinder barrel to hone the scratched part to remove the scratches and restore the smoothness of the inner wall of the cylinder barrel. During the honing process, coolant is used to cool the cylinder barrel.

[0039] For moderate scratches, a layer of metal powder is melted on the scratched part, and then honing is performed until the required dimensional accuracy and surface finish are achieved;

[0040] For severe scratches, metal repair agent is used to fill and repair. The metal repair agent is applied to the scratched area, and after it solidifies, it is ground and polished to make it flush with the inner wall surface of the cylinder.

[0041] In a preferred embodiment, after the inner wall of the cylinder is repaired, the oil cylinder is assembled, and the assembled oil cylinder is connected to the hydraulic system, and no-load debugging is first performed, and the hydraulic system is started, and the oil cylinder is made to reciprocate multiple times to observe the movement of the oil cylinder;

[0042] After no-load debugging is normal, carry out load debugging, gradually increase the load to 50%, 70% and 90% of the rated load, run each load for 10-30 minutes, and check the performance of the cylinder under load.

[0043] The technical effects and advantages of the oil cylinder quick maintenance method of the present invention are as follows:

[0044] 1. When the original non-standard sealing ring is difficult to obtain and the cost is high, the sealing ring installation groove is processed and then the standard sealing ring is installed. The standard parts are reasonably used to replace the non-standard parts, which effectively reduces the maintenance cost and shortens the maintenance waiting time;

[0045] 2. The scratches on the inner wall of the cylinder are divided into mild, moderate and severe for targeted maintenance. Different methods such as honing, honing after cladding, and metal repair agent filling and repair are selected according to the degree of scratches. Excessive or insufficient maintenance is avoided, and the maintenance effect and efficiency are improved. Appropriate repair methods are used for scratches of different degrees, such as a relatively simple honing method for mild scratches and an economical filling and repair method for severe scratches. Under the premise of ensuring the quality of repair, maintenance resources are reasonably allocated to reduce maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 The present invention is a schematic flow chart of a method for rapid maintenance of an oil cylinder. DETAILED DESCRIPTION

[0047] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0048] Example 1

[0049] Figure 1 The present invention provides a method for quickly repairing an oil cylinder, which specifically comprises the following steps:

[0050] Step S100, perform an appearance inspection on the entire oil cylinder to check whether there is obvious oil leakage or damage to external components, and mark the oil leakage site to preliminarily determine the location of the fault point;

[0051] Step S200, performing pressure holding tests at different pressure levels on the oil cylinder;

[0052] Step S300, using an endoscope or other equipment to inspect the inside of the oil cylinder to check the finish of the inner wall of the cylinder and the status of the seal;

[0053] Step S400, replacing the original non-standard sealing ring;

[0054] Step S500, repairing the inner wall of the cylinder.

[0055] Step S200 specifically includes the following contents:

[0056] Connect the oil inlet and outlet of the oil cylinder to the hydraulic test equipment through high-pressure oil pipes. Before starting the test, it is necessary to remove the air in the oil cylinder and hydraulic system, turn on the oil pump of the hydraulic test equipment, and slowly fill the oil cylinder with hydraulic oil at a low flow rate. At the same time, open the exhaust valve of the oil cylinder to let the air out from the exhaust port. When you see that hydraulic oil is continuously flowing out of the exhaust port without bubbles, close the exhaust valve;

[0057] According to the rated working pressure of the oil cylinder, set the pressure regulating valve of the hydraulic test equipment to the pressure value of the low pressure stage, which is 30% of the rated working pressure;

[0058] Start the oil pump of the hydraulic test equipment and slowly fill the hydraulic oil into the cylinder to gradually increase the pressure in the cylinder to the set low pressure value;

[0059] When the pressure reaches the set low pressure value, close the oil pump and the oil inlet valve to make the oil cylinder enter the low pressure holding state, and the holding time is set to 10 minutes;

[0060] Reset the pressure regulating valve of the hydraulic test equipment to the pressure value of the high pressure stage, which is 80% of the rated working pressure;

[0061] Restart the oil pump and slowly increase the pressure in the oil cylinder to the set high pressure value. When the high pressure value is reached, close the oil pump and the oil inlet valve to enter the high pressure holding state. The pressure holding time is set to 10 minutes.

[0062] After completing the pressure holding test, first open the oil outlet valve of the hydraulic testing equipment, slowly release the pressure in the cylinder, and allow the hydraulic oil to flow back into the oil tank of the testing equipment.

[0063] It should be added that a low pressure test with the pressure regulating valve set to 30% of the rated working pressure can be used to initially detect whether there is a slight leak in the cylinder. At this lower pressure, some minor sealing problems or internal structural defects may cause the pressure to drop slowly. These potential problems can be discovered in time by observing the pressure gauge reading and checking whether there is oil seepage on the outside of the cylinder.

[0064] The sealing performance of the oil cylinder seal under lower pressure can be evaluated to a certain extent. This is because the sealing effect of the seal under different pressures may be different. The low-pressure test can be used as the basic state for evaluating the sealing performance and provide a comparative reference for subsequent high-pressure tests.

[0065] High-pressure holding test can detect the performance of the oil cylinder under close to the working limit pressure. Under such high-pressure environment, the seals, cylinder barrel and piston rod inside the oil cylinder are under greater pressure, which is more likely to expose potential serious leakage, component deformation or damage.

[0066] Many cylinders are often under high pressure in actual work. High-pressure pressure holding test can better simulate this actual working condition, so as to more accurately judge whether the cylinder can operate normally in actual work and ensure its reliability and safety under high pressure.

[0067] In the low pressure maintenance state, closely observe the pressure gauge reading. If the pressure drops slowly, record the speed and amplitude of the pressure drop. At the same time, check whether there is any slight leakage in the cylinder.

[0068] Under the high-pressure maintaining state, carefully observe the stable state of the pressure gauge reading. If there is a sudden drop in pressure, violent fluctuations, or abnormal shaking or noise in the cylinder, stop the test immediately, inspect the cylinder, and check whether there is a large amount of oil leakage outside the cylinder.

[0069] It should be added that by closely observing the pressure gauge readings and recording the speed and amplitude of the pressure drop, the sealing performance of the oil cylinder can be quantitatively evaluated. By analyzing the pressure drop data, the severity of the leak can be preliminarily determined, providing a basis for determining the scope and method of subsequent repairs. For example, if the pressure drops slowly and the amplitude is small, it may be that the seal is slightly worn; if the pressure drops quickly and the amplitude is large, there may be a seal rupture or other more serious leakage channels.

[0070] Carefully observe the stable state of the pressure gauge reading under high pressure maintenance to promptly detect abnormal conditions such as sudden pressure drops and violent fluctuations. Sudden changes in pressure may mean serious leakage, component rupture or other dangerous conditions inside the cylinder. Immediately stopping the test and checking can avoid further expansion of the fault and prevent possible serious safety accidents such as explosions and cylinder flying out.

[0071] Step S300 specifically includes the following contents:

[0072] Slowly insert the probe of the endoscope into the inspection port of the oil cylinder, and adjust the direction of the probe of the endoscope according to the structure of the oil cylinder and the part to be inspected;

[0073] Turn on the light source and imaging system of the endoscope, observe the surface condition of the inner wall of the cylinder, adjust the focal length and imaging parameters of the endoscope, and obtain a clear image of the inner wall;

[0074] Find the location of the seal, observe the integrity of the seal, and check the contact areas between the seal and the inner wall of the cylinder and the piston.

[0075] It should be added that adjusting the probe direction according to the structure of the cylinder and the part to be inspected can ensure a comprehensive and detailed inspection of the key areas of concern. For example, targeted observations can be made on specific locations on the inner wall of the cylinder (such as areas near seals, parts susceptible to wear, etc.), so as to more accurately discover potential fault hazards.

[0076] Finding the location of the seal and observing its integrity are key steps in judging the sealing performance of the cylinder. Damage to the seal is one of the common causes of cylinder leakage. By directly observing whether the seal is torn, aged, deformed or falling off through an endoscope, sealing problems can be discovered in advance to avoid hydraulic oil leakage and system failure caused by seal failure.

[0077] Step S400 specifically includes the following contents:

[0078] Disassemble the oil cylinder, take out the old non-standard seal ring and related parts, separate the parts with the seal ring installation groove, measure the outer diameter, inner diameter and thickness of the standard seal ring, measure the relevant dimensions of the seal ring installation groove, and calculate the allowance that needs to be processed;

[0079] According to the size and installation requirements of the standard seal ring, determine the location and approximate processing amount of material to be removed from the seal ring installation groove;

[0080] Fix the component with the sealing ring installation groove on the milling machine workbench, widen and deepen the sealing ring installation groove, and after the processing is completed, use sandpaper to grind and polish the surface of the processed sealing ring installation groove to remove the processing burrs and thoroughly clean the processed sealing ring installation groove;

[0081] Apply grease to the standard seal ring and install it into the seal ring installation groove after additional processing;

[0082] Reassemble the parts with the standard seals machined and installed.

[0083] Connect the assembled oil cylinder to the hydraulic system, conduct no-load debugging first, start the hydraulic system, make the oil cylinder perform reciprocating motions for several times, and observe the movement of the oil cylinder and the condition of the standard sealing ring;

[0084] After no-load debugging is normal, load debugging can be carried out. Gradually increase the load of the cylinder, and test step by step from low load to high load. Run for 10 minutes at each load level to check the movement of the cylinder under load and the condition of the standard sealing ring.

[0085] It should be added that when non-standard sealing rings are difficult to obtain and the cost is high, this method can reasonably use standard sealing rings for replacement, reducing maintenance costs and shortening maintenance waiting time.

[0086] The sealing ring installation groove can be widened and deepened to customize the installation groove according to the size requirements of the standard sealing ring. After processing, sandpaper grinding and polishing are used to remove burrs, which can make the surface of the installation groove smooth, provide a good foundation for the installation of the sealing ring, avoid damage to the sealing ring due to the rough surface of the installation groove, and ensure the sealing performance and service life of the sealing ring after installation.

[0087] Step S500 specifically includes the following contents:

[0088] The scratches on the inner wall of the cylinder are divided into light scratches, moderate scratches and heavy scratches;

[0089] For minor scratches, a honing machine is used. The honing head on the honing machine is inserted into the cylinder barrel to hone the scratched part to remove the scratches and restore the smoothness of the inner wall of the cylinder barrel. During the honing process, coolant is used to cool the cylinder barrel.

[0090] For moderate scratches, a layer of metal powder is melted on the scratched part, and then honing is performed until the required dimensional accuracy and surface finish are achieved;

[0091] For severe scratches, metal repair agent is used to fill and repair. The metal repair agent is applied to the scratched area, and after it solidifies, it is ground and polished to make it flush with the inner wall surface of the cylinder.

[0092] After the inner wall of the cylinder is repaired, assemble the cylinder and connect the assembled cylinder to the hydraulic system. First, perform no-load debugging, start the hydraulic system, make the cylinder perform multiple reciprocating movements, and observe the movement of the cylinder.

[0093] After no-load debugging is normal, carry out load debugging, gradually increase the load to 50%, 70% and 90% of the rated load, run each load for 10 minutes, and check the performance of the cylinder under load.

[0094] It should be added that by classifying the scratches on the inner wall of the cylinder into different degrees and treating them accordingly, an accurate repair plan can be formulated according to the actual situation of the scratches. Different degrees of scratches have different effects on the performance of the cylinder, and the required repair methods and processes are also different. This classification method helps to select the most suitable repair method in a targeted manner and improve the repair effect and efficiency.

[0095] Through classification, over-repair or under-repair can be avoided. For minor scratches, a relatively simple honing method is used, and for severe scratches, a filling repair method is used. Under the premise of ensuring the quality of repair, maintenance resources can be reasonably allocated and maintenance costs can be reduced. For example, for minor scratches, there is no need to use complex and costly cladding or repair agent repair methods.

[0096] Example 2

[0097] Figure 1 The present invention provides a method for quickly repairing an oil cylinder, which specifically comprises the following steps:

[0098] Step S100, perform an appearance inspection on the entire oil cylinder to check whether there is obvious oil leakage or damage to external components, and mark the oil leakage site to preliminarily determine the location of the fault point;

[0099] Step S200, performing pressure holding tests at different pressure levels on the oil cylinder;

[0100] Step S300, using an endoscope or other equipment to inspect the inside of the oil cylinder to check the finish of the inner wall of the cylinder and the status of the seal;

[0101] Step S400, replacing the original non-standard sealing ring;

[0102] Step S500, repairing the inner wall of the cylinder.

[0103] Step S200 specifically includes the following contents:

[0104] Connect the oil inlet and outlet of the oil cylinder to the hydraulic test equipment through high-pressure oil pipes. Before starting the test, it is necessary to remove the air in the oil cylinder and hydraulic system, turn on the oil pump of the hydraulic test equipment, and slowly fill the oil cylinder with hydraulic oil at a low flow rate. At the same time, open the exhaust valve of the oil cylinder to let the air out from the exhaust port. When you see that hydraulic oil is continuously flowing out of the exhaust port without bubbles, close the exhaust valve;

[0105] According to the rated working pressure of the oil cylinder, set the pressure regulating valve of the hydraulic test equipment to the pressure value of the low pressure stage, which is 40% of the rated working pressure;

[0106] Start the oil pump of the hydraulic test equipment and slowly fill the hydraulic oil into the cylinder to gradually increase the pressure in the cylinder to the set low pressure value;

[0107] When the pressure reaches the set low pressure value, close the oil pump and the oil inlet valve to make the oil cylinder enter the low pressure holding state, and the holding time is set to 20 minutes;

[0108] Reset the pressure regulating valve of the hydraulic test equipment to the pressure value of the high pressure stage, which is 90% of the rated working pressure;

[0109] Restart the oil pump and slowly increase the pressure in the oil cylinder to the set high pressure value. When the high pressure value is reached, close the oil pump and the oil inlet valve to enter the high pressure holding state. The pressure holding time is set to 20 minutes.

[0110] After completing the pressure holding test, first open the oil outlet valve of the hydraulic testing equipment, slowly release the pressure in the cylinder, and allow the hydraulic oil to flow back into the oil tank of the testing equipment.

[0111] In the low pressure maintenance state, closely observe the pressure gauge reading. If the pressure drops slowly, record the speed and amplitude of the pressure drop. At the same time, check whether there is any slight leakage in the cylinder.

[0112] Under the high-pressure maintaining state, carefully observe the stable state of the pressure gauge reading. If there is a sudden drop in pressure, violent fluctuations, or abnormal shaking or noise in the cylinder, stop the test immediately, inspect the cylinder, and check whether there is a large amount of oil leakage outside the cylinder.

[0113] Step S300 specifically includes the following contents:

[0114] Slowly insert the probe of the endoscope into the inspection port of the oil cylinder, and adjust the direction of the probe of the endoscope according to the structure of the oil cylinder and the part to be inspected;

[0115] Turn on the light source and imaging system of the endoscope, observe the surface condition of the inner wall of the cylinder, adjust the focal length and imaging parameters of the endoscope, and obtain a clear image of the inner wall;

[0116] Find the location of the seal, observe the integrity of the seal, and check the contact areas between the seal and the inner wall of the cylinder and the piston.

[0117] Step S400 specifically includes the following contents:

[0118] Disassemble the oil cylinder, take out the old non-standard seal ring and related parts, separate the parts with the seal ring installation groove, measure the outer diameter, inner diameter and thickness of the standard seal ring, measure the relevant dimensions of the seal ring installation groove, and calculate the allowance that needs to be processed;

[0119] According to the size and installation requirements of the standard seal ring, determine the location and approximate processing amount of material to be removed from the seal ring installation groove;

[0120] Fix the component with the sealing ring installation groove on the milling machine workbench, widen and deepen the sealing ring installation groove, and after the processing is completed, use sandpaper to grind and polish the surface of the processed sealing ring installation groove to remove the processing burrs and thoroughly clean the processed sealing ring installation groove;

[0121] Apply grease to the standard seal ring and install it into the seal ring installation groove after additional processing;

[0122] Reassemble the parts with the standard seals machined and installed.

[0123] Connect the assembled oil cylinder to the hydraulic system, conduct no-load debugging first, start the hydraulic system, make the oil cylinder perform reciprocating motions for several times, and observe the movement of the oil cylinder and the condition of the standard sealing ring;

[0124] After no-load debugging is normal, load debugging can be carried out. Gradually increase the load of the cylinder, and test step by step from low load to high load. Run for 20 minutes at each load level, and check the movement of the cylinder under load and the condition of the standard sealing ring.

[0125] Step S500 specifically includes the following contents:

[0126] The scratches on the inner wall of the cylinder are divided into light scratches, moderate scratches and heavy scratches;

[0127] For minor scratches, a honing machine is used. The honing head on the honing machine is inserted into the cylinder barrel to hone the scratched part to remove the scratches and restore the smoothness of the inner wall of the cylinder barrel. During the honing process, coolant is used to cool the cylinder barrel.

[0128] For moderate scratches, a layer of metal powder is melted on the scratched part, and then honing is performed until the required dimensional accuracy and surface finish are achieved;

[0129] For severe scratches, metal repair agent is used to fill and repair. The metal repair agent is applied to the scratched area, and after it solidifies, it is ground and polished to make it flush with the inner wall surface of the cylinder.

[0130] After the inner wall of the cylinder is repaired, assemble the cylinder and connect the assembled cylinder to the hydraulic system. First, perform no-load debugging, start the hydraulic system, make the cylinder perform multiple reciprocating movements, and observe the movement of the cylinder.

[0131] After no-load debugging is normal, carry out load debugging, gradually increase the load to 50%, 70% and 90% of the rated load, run each load for 20 minutes, and check the performance of the cylinder under load.

[0132] Example 3

[0133] Figure 1 The present invention provides a method for quickly repairing an oil cylinder, which specifically comprises the following steps:

[0134] Step S100, perform an appearance inspection on the entire oil cylinder to check whether there is obvious oil leakage or damage to external components, and mark the oil leakage site to preliminarily determine the location of the fault point;

[0135] Step S200, performing pressure holding tests at different pressure levels on the oil cylinder;

[0136] Step S300, using an endoscope or other equipment to inspect the inside of the oil cylinder to check the finish of the inner wall of the cylinder and the status of the seal;

[0137] Step S400, replacing the original non-standard sealing ring;

[0138] Step S500, repairing the inner wall of the cylinder.

[0139] Step S200 specifically includes the following contents:

[0140] Connect the oil inlet and outlet of the oil cylinder to the hydraulic test equipment through high-pressure oil pipes. Before starting the test, it is necessary to remove the air in the oil cylinder and hydraulic system, turn on the oil pump of the hydraulic test equipment, and slowly fill the oil cylinder with hydraulic oil at a low flow rate. At the same time, open the exhaust valve of the oil cylinder to let the air out from the exhaust port. When you see that hydraulic oil is continuously flowing out of the exhaust port without bubbles, close the exhaust valve;

[0141] According to the rated working pressure of the oil cylinder, set the pressure regulating valve of the hydraulic test equipment to the pressure value of the low pressure stage, which is 50% of the rated working pressure;

[0142] Start the oil pump of the hydraulic test equipment and slowly fill the hydraulic oil into the cylinder to gradually increase the pressure in the cylinder to the set low pressure value;

[0143] When the pressure reaches the set low pressure value, close the oil pump and the oil inlet valve to make the oil cylinder enter the low pressure holding state, and the holding time is set to 30 minutes;

[0144] Reset the pressure regulating valve of the hydraulic test equipment to the pressure value of the high pressure stage, which is 100% of the rated working pressure;

[0145] Restart the oil pump and slowly increase the pressure in the oil cylinder to the set high pressure value. When the high pressure value is reached, close the oil pump and the oil inlet valve to enter the high pressure holding state. The pressure holding time is set to 30 minutes.

[0146] After completing the pressure holding test, first open the oil outlet valve of the hydraulic testing equipment, slowly release the pressure in the cylinder, and allow the hydraulic oil to flow back into the oil tank of the testing equipment.

[0147] In the low pressure maintenance state, closely observe the pressure gauge reading. If the pressure drops slowly, record the speed and amplitude of the pressure drop. At the same time, check whether there is any slight leakage in the cylinder.

[0148] Under the high-pressure maintaining state, carefully observe the stable state of the pressure gauge reading. If there is a sudden drop in pressure, violent fluctuations, or abnormal shaking or noise in the cylinder, stop the test immediately, inspect the cylinder, and check whether there is a large amount of oil leakage outside the cylinder.

[0149] Step S300 specifically includes the following contents:

[0150] Slowly insert the probe of the endoscope into the inspection port of the oil cylinder, and adjust the direction of the probe of the endoscope according to the structure of the oil cylinder and the part to be inspected;

[0151] Turn on the light source and imaging system of the endoscope, observe the surface condition of the inner wall of the cylinder, adjust the focal length and imaging parameters of the endoscope, and obtain a clear image of the inner wall;

[0152] Find the location of the seal, observe the integrity of the seal, and check the contact areas between the seal and the inner wall of the cylinder and the piston.

[0153] Step S400 specifically includes the following contents:

[0154] Disassemble the oil cylinder, take out the old non-standard seal ring and related parts, separate the parts with the seal ring installation groove, measure the outer diameter, inner diameter and thickness of the standard seal ring, measure the relevant dimensions of the seal ring installation groove, and calculate the allowance that needs to be processed;

[0155] According to the size and installation requirements of the standard seal ring, determine the location and approximate processing amount of material to be removed from the seal ring installation groove;

[0156] Fix the component with the sealing ring installation groove on the milling machine workbench, widen and deepen the sealing ring installation groove, and after the processing is completed, use sandpaper to grind and polish the surface of the processed sealing ring installation groove to remove the processing burrs and thoroughly clean the processed sealing ring installation groove;

[0157] Apply grease to the standard seal ring and install it into the seal ring installation groove after additional processing;

[0158] Reassemble the parts with the standard seals machined and installed.

[0159] Connect the assembled oil cylinder to the hydraulic system, conduct no-load debugging first, start the hydraulic system, make the oil cylinder perform reciprocating motions for several times, and observe the movement of the oil cylinder and the condition of the standard sealing ring;

[0160] After no-load debugging is normal, load debugging can be carried out. Gradually increase the load of the cylinder, and test step by step from low load to high load. Run for 30 minutes at each load level to check the movement of the cylinder under load and the condition of the standard sealing ring.

[0161] Step S500 specifically includes the following contents:

[0162] The scratches on the inner wall of the cylinder are divided into light scratches, moderate scratches and heavy scratches;

[0163] For minor scratches, a honing machine is used. The honing head on the honing machine is inserted into the cylinder barrel to hone the scratched part to remove the scratches and restore the smoothness of the inner wall of the cylinder barrel. During the honing process, coolant is used to cool the cylinder barrel.

[0164] For moderate scratches, a layer of metal powder is melted on the scratched part, and then honing is performed until the required dimensional accuracy and surface finish are achieved;

[0165] For severe scratches, metal repair agent is used to fill and repair. The metal repair agent is applied to the scratched area, and after it solidifies, it is ground and polished to make it flush with the inner wall surface of the cylinder.

[0166] After the inner wall of the cylinder is repaired, assemble the cylinder and connect the assembled cylinder to the hydraulic system. First, perform no-load debugging, start the hydraulic system, make the cylinder perform multiple reciprocating movements, and observe the movement of the cylinder.

[0167] After no-load debugging is normal, carry out load debugging, gradually increase the load to 50%, 70% and 90% of the rated load, run each load for 30 minutes, and check the performance of the cylinder under load.

[0168] The oil cylinder was repaired using Examples 1-3, and the effects after the repair were compared. The results are shown in the following table:

[0169]

[0170] It can be seen from the above content that embodiments 1-3 can better repair the oil cylinder, and embodiment 2 is the best embodiment.

[0171] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

[0172] Finally: The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for rapid maintenance of an oil cylinder, characterized in that: The steps include: Step S100, perform an appearance inspection on the entire oil cylinder to check whether there is obvious oil leakage or damage to external components, and mark the oil leakage site to preliminarily determine the location of the fault point; Step S200, performing pressure holding tests at different pressure levels on the oil cylinder; Step S300, using an endoscope or other equipment to inspect the inside of the oil cylinder to check the finish of the inner wall of the cylinder and the status of the seal; Step S400, replacing the original non-standard sealing ring; Step S500, repairing the inner wall of the cylinder.

2. A method for rapid maintenance of an oil cylinder according to claim 1, characterized in that: Step S200 specifically includes the following contents: Connect the oil inlet and outlet of the oil cylinder to the hydraulic test equipment through high-pressure oil pipes. Before starting the test, it is necessary to remove the air in the oil cylinder and hydraulic system, turn on the oil pump of the hydraulic test equipment, and slowly fill the oil cylinder with hydraulic oil at a low flow rate. At the same time, open the exhaust valve of the oil cylinder to let the air out from the exhaust port. When you see that hydraulic oil is continuously flowing out of the exhaust port without bubbles, close the exhaust valve; According to the rated working pressure of the oil cylinder, set the pressure regulating valve of the hydraulic test equipment to the pressure value of the low pressure stage, which is 30%-50% of the rated working pressure; Start the oil pump of the hydraulic test equipment and slowly fill the hydraulic oil into the cylinder to gradually increase the pressure in the cylinder to the set low pressure value; When the pressure reaches the set low pressure value, close the oil pump and the oil inlet valve to make the oil cylinder enter the low pressure holding state. The holding time is set to 10-30 minutes. Reset the pressure regulating valve of the hydraulic test equipment to the pressure value of the high pressure stage, which is 80%-100% of the rated working pressure; Restart the oil pump and slowly increase the pressure in the oil cylinder to the set high pressure value. When the high pressure value is reached, close the oil pump and the oil inlet valve to enter the high pressure holding state. The holding time is set to 10-30 minutes. After completing the pressure holding test, first open the oil outlet valve of the hydraulic testing equipment, slowly release the pressure in the cylinder, and allow the hydraulic oil to flow back into the oil tank of the testing equipment.

3. A method for rapid maintenance of an oil cylinder according to claim 2, characterized in that: In the low pressure maintenance state, closely observe the pressure gauge reading. If the pressure drops slowly, record the speed and amplitude of the pressure drop. At the same time, check whether there is any slight leakage in the cylinder. Under the high-pressure maintaining state, carefully observe the stable state of the pressure gauge reading. If there is a sudden drop in pressure, violent fluctuations, or abnormal shaking or noise in the cylinder, stop the test immediately, inspect the cylinder, and check whether there is a large amount of oil leakage outside the cylinder.

4. The method for rapid maintenance of an oil cylinder according to claim 1, characterized in that: Step S300 specifically includes the following contents: Slowly insert the probe of the endoscope into the inspection port of the oil cylinder, and adjust the direction of the probe of the endoscope according to the structure of the oil cylinder and the part to be inspected; Turn on the light source and imaging system of the endoscope, observe the surface condition of the inner wall of the cylinder, adjust the focal length and imaging parameters of the endoscope, and obtain a clear image of the inner wall; Find the location of the seal, observe the integrity of the seal, and check the contact areas between the seal and the inner wall of the cylinder and the piston.

5. A method for rapid maintenance of an oil cylinder according to claim 4, characterized in that: Step S400 specifically includes the following contents: Disassemble the oil cylinder, take out the old non-standard seal ring and related parts, separate the parts with the seal ring installation groove, measure the outer diameter, inner diameter and thickness of the standard seal ring, measure the relevant dimensions of the seal ring installation groove, and calculate the allowance that needs to be processed; According to the size and installation requirements of the standard seal ring, determine the location and approximate processing amount of material to be removed from the seal ring installation groove; Fix the component with the sealing ring installation groove on the milling machine workbench, widen and deepen the sealing ring installation groove, and after the processing is completed, use sandpaper to grind and polish the surface of the processed sealing ring installation groove to remove the processing burrs and thoroughly clean the processed sealing ring installation groove; Apply grease to the standard seal ring and install it into the seal ring installation groove after additional processing; Reassemble the parts with the standard seals machined and installed.

6. A method for rapid maintenance of an oil cylinder according to claim 5, characterized in that: Connect the assembled oil cylinder to the hydraulic system, conduct no-load debugging first, start the hydraulic system, make the oil cylinder perform reciprocating motions for several times, and observe the movement of the oil cylinder and the condition of the standard sealing ring; After no-load debugging is normal, load debugging can be carried out. Gradually increase the load of the cylinder, and test step by step from low load to high load. Run for 10-30 minutes at each load level to check the movement of the cylinder under load and the condition of the standard sealing ring.

7. The method for rapid maintenance of an oil cylinder according to claim 1, characterized in that: Step S500 specifically includes the following contents: The scratches on the inner wall of the cylinder are divided into light scratches, moderate scratches and heavy scratches; For minor scratches, a honing machine is used. The honing head on the honing machine is inserted into the cylinder barrel to hone the scratched part to remove the scratches and restore the smoothness of the inner wall of the cylinder barrel. During the honing process, coolant is used to cool the cylinder barrel. For moderate scratches, a layer of metal powder is melted on the scratched part, and then honing is performed until the required dimensional accuracy and surface finish are achieved; For severe scratches, metal repair agent is used to fill and repair. The metal repair agent is applied to the scratched area, and after it solidifies, it is ground and polished to make it flush with the inner wall surface of the cylinder.

8. A method for rapid maintenance of an oil cylinder according to claim 7, characterized in that: After the inner wall of the cylinder is repaired, assemble the cylinder and connect the assembled cylinder to the hydraulic system. First, perform no-load debugging, start the hydraulic system, make the cylinder perform multiple reciprocating movements, and observe the movement of the cylinder. After no-load debugging is normal, carry out load debugging, gradually increase the load to 50%, 70% and 90% of the rated load, run each load for 10-30 minutes, and check the performance of the cylinder under load.

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