Exploring the causes and countermeasures of hydraulic system leakage
Exploring the Causes and Countermeasures of Hydraulic System Leakage
Leakage in hydraulic systems is a common problem that affects machinery performance, especially in dock equipment where oil leakage is frequently encountered. The main reason for this issue is the pressure difference between the flowing oil inside the components and pipelines, combined with small gaps between parts, which leads to oil escaping. Severe leakage can result in system pressure failure, compromising equipment safety, causing unsightly appearances, polluting the environment, increasing production costs, and reducing efficiency. Therefore, it's essential to control and manage hydraulic system leakage effectively.
There are two primary types of leakage: fixed seal leakage and moving seal leakage. Fixed seal leakage typically occurs at cylinder bases and joint connections, while moving seal leakage is found around piston rods and multi-way valve stems. Additionally, leakage can be categorized as external or internal. External leakage happens when oil escapes from the system into the surroundings, whereas internal leakage refers to oil moving from high-pressure to low-pressure areas within the system due to pressure differences and faulty seals.
The causes of leakage are multifaceted. First, design factors play a significant role. Poor selection of seals, lack of consideration for compatibility between hydraulic oil and materials, and improper design of sealing structures can lead to leaks. Dust and contaminants in the environment also increase the risk, so dust-proof seals should be used to prevent foreign particles from entering the system and damaging seals or contaminating the oil.
Second, manufacturing and assembly errors contribute to leakage. If components are not manufactured to precise tolerances or if there are surface imperfections such as burrs, pits, or chrome peeling, the seals may fail. During assembly, excessive force can damage sensitive parts like copper rods, and improper cleaning using gasoline instead of diesel can cause rubber seals to age prematurely, losing their elasticity and sealing ability.
Wear and damage to dynamic seals also lead to leakage. Over time, oil-resistant rubber seals can degrade, crack, or become damaged due to abrasive particles in the oil or mechanical impact. This wear increases the likelihood of internal leakage.
Environmental conditions further exacerbate the issue. Exposure of piston rods to dust and moisture can introduce contaminants into the system, accelerating seal and component wear. Humid environments may allow water to mix with hydraulic oil, forming acids and sludge that reduce lubrication and damage valves. High temperatures also shorten seal life, with every 10°C rise potentially halving the lifespan of a seal. Air dissolved in the oil can form bubbles, which, under pressure changes, may burst and cause damage to component surfaces, leading to further leakage.
To prevent and control leakage, it's crucial to ensure geometric accuracy in design and manufacturing, choose appropriate seals, minimize shock and vibration by using accumulators and pressure control valves, and install proper pipe joints. Regular maintenance, timely replacement of damaged components, and correct assembly techniques are also essential. In addition, controlling the working environment by testing oil quality, cleaning filters, and preventing contamination from external sources like dust and water is vital. Implementing cooling systems can help maintain optimal oil temperature below 65°C. In summary, addressing hydraulic system leakage requires a comprehensive approach, considering all contributing factors and implementing effective, long-term solutions.
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