Power Cube Complete machine fabrication: Difference between revisions

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==Assembly==
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===General===
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<ref>[http://hydraulics.eaton.com/products/pdfs/694.pdf Hydraulic Hints and Troubleshooting Guide, Eaton]</ref>
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* Keep the area and parts clean.
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* All openings should be sealed after cleaning.
* No grinding or welding operations should be done in the area where hydraulic components are being installed.
* All open connections should be sealed and/or capped until just prior to use.
* All pipe and tubing ends should be reamed.
* When installing pumps or motors, always align coupling halves as closely as possible, within 0.007 inch.
* When using flexible couplings, follow the manufacturer’s recommendations or allow 1/32 to 1/16 inch clearance between the coupling halves.
* Do not drive couplings on pump or motor shafts. They should be a slip fit, or shrunk on using hot oil.
* Always use a dry spray-on lubricant on splines when installing.
 
Pipes
* pipes have numbers from 10 through 160. The larger the number, the heavier the wall thickness. The outer pipe diameter stays the same for a given pipe size, while the inside opening becomes smaller as schedule number increases.
* In many cases, flanges are welded to the pipe ends and gaskets or “O” rings are used to seal the connections.
* Pipe fittings can be threaded or welded in place for routing. Threaded connections are used in low pressure applications and welded connections are used if high pressure, high temperature, or a severe mechanical load exists.
* All piping should be secured with clamps to prevent vibration and excessive stress due to the weight of the fluid. Do not weld the clamps to the pipe as it may weaken the pipe and cause a stress crack.
 
Tubing
* Don’t take heavy cuts on thin wall tubing with a tubing cutter. Use light cuts to prevent deformation of the tube end.
* Ream tubing only for removal of burrs.
* DO NOT over ream tubing as it can weaken the connection.
* Do not allow chips to accumulate in the tubing. They can be difficult to remove after bending.
* Don’t overtighten the feed screw handle on a compression type flaring tool.
* Bend tubing instead of cutting and using a fitting. The minimum radius of a tubing bend should be at least three times the inside diameter of the tube. Larger bends are preferred.
* Sketch the optimum tubing route before beginning the bending process. Be sure to use tubing with the proper temper to prevent wrinkles and flattened bends.
* The standard flare angle is 37 degrees from the centerline.
* For best results, heavy wall tubing should be cut, deburred, and flared and bent using power equipment.
 
===System Design===
* One inadequately sized/spec'ed component can cause problems that cascade through the whole system.
* Lines must be big enough and have gentle enough bends.
* Some parts have to maintain a certain orientation either with other parts or with gravity.
* Consider integrating adequate test points into the system from the beginning
* Don't load things beyond their operating pressures. If unknown, then use the lowest pressure that allows adequate system performance and is below maximum ratings.
* When system is functioning properly, make a note of important measurements like pressure and electrical power levels.
* If sound is a problem, the pump should operate at or below 1200 RPM.
* Noise can be reduced by mounting the pump/motor with rubber isolation mounts and connecting with rubber hoses. However, long lengths of hoses generate sound, instead use short lengths of hoses to join long lengths of tube/pipe.
* Mechanical isolation is more effective than acoustic isolation.
* Acoustically isolate a pump by enclosing it completely in a non-porous shell >=10kg/sqmeter without any openings.
* You don't want bubbles. Suppress their formation by keeping inlet lines short and/or large, keeping the reservoir at or above the pump, and use inlet filters that signal a low pressure drop.
* Oil leaving the reservoir should be 120 to 150*F.
* Water-based fluids should be 100 to 120*F.
* A reservoir should have baffles that force the liquid to take a twisted path and be large enough to hold 2 to 3 minutes of maximum pump flow, with room to spare.
* Fluid contamination is marked by oxidation, gummy deposits, sludge, bubbles and noise. Not to mention premature wear and/or failure.
 
 
 
 
 
 
==References==
<references />

Latest revision as of 12:22, 25 December 2011

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