Power Cube Complete machine fabrication: Difference between revisions

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===General===
===General===
<ref>[http://hydraulics.eaton.com/products/pdfs/694.pdf Hydraulic Hints and Troubleshooting Guide, Eaton]</ref>
<ref>[http://hydraulics.eaton.com/products/pdfs/694.pdf Hydraulic Hints and Troubleshooting Guide, Eaton]</ref>
* Most important – cleanliness.
* Keep the area and parts clean.
* All openings in the reservoir should be sealed after cleaning.
* All openings should be sealed after cleaning.
* No grinding or welding operations should be done in the area where hydraulic components are being installed.
* No grinding or welding operations should be done in the area where hydraulic components are being installed.
* All cylinder, valve, pump and hose connections should be sealed and/or capped until just prior to use.
* All open connections should be sealed and/or capped until just prior to use.
* Mineral spirits should be kept in safety containers.
* All pipe and tubing ends should be reamed.
* Air hoses can be used to clean fittings and other system components. However, the air supply must be filtered and dry to prevent contamination of the parts.
* Examine pipe fittings and hose assemblies prior to use to be certain that burrs, dirt and/or scale are not present.
* All pipe and tubing ends should be reamed to prevent restriction and turbulent flow.
* Do not use Teflon tape on straight thread connections.
* When installing pumps or motors, always align coupling halves as closely as possible, within 0.007 inch.
* 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.
* 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.
* 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. This prevents wear and adds to the life of the splines.
* Always use a dry spray-on lubricant on splines when installing.
* When using double universal joint couplings, the shafts must be parallel and the yokes must be in line.
* When installing V-belt pulleys on pumps or motors, line up both pulleys as closely as possible. Always install the pulleys with a minimum amount of overhang as close to the pump or motor face as possible. This increases bearing service life.


Pipes
Pipes
* pipes are classified by schedule number as specified by the American National Standards Institute (ANSI). The schedule numbers vary 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.
* 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.
* In many cases, flanges are welded to the pipe ends and gaskets or “O” rings are used to seal the connections.
* Various pipe fittings are used to route the piping to and from each system component. These fittings can be threaded or welded in place as the need arises. Threaded connections are used in low pressure applications and welded connections are used if high pressure, high temperature, or a severe mechanical load exists.
* 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.
* 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
Tubing
* Don’t take heavy cuts on thin wall tubing with a tubing cutter. Use light cuts to prevent deformation of the tube end. If the tube end is out or round, a greater possibility of a poor connection exists.
* 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.
* Ream tubing only for removal of burrs.
* DO NOT over ream tubing as it can weaken the connection.
* 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.
* Do not allow chips to accumulate in the tubing. They can be difficult to remove after bending.
* Follow the manufacturers recommendations on the use of flaring tools. Don’t overtighten the feed screw handle on a compression type flaring tool.
* Don’t overtighten the feed screw handle on a compression type flaring tool.
* Improper use of a tool can cause washout and/or splitting of the flare connection.
* 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.
* Bend tubing instead of cutting and using a fitting. This reduces pressure drop and minimizes system losses. 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.
* 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.
* Most flares are made by hand or power tools that swage the tube end over a split die. 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.
* 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.
 
 
 


==References==
==References==
<references />
<references />

Revision as of 05:38, 20 December 2011

Assembly

General

[1]

  • Keep the area and parts clean.
  • 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.



References

  1. ↑ Hydraulic Hints and Troubleshooting Guide, Eaton
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