Control plan for controlling hydraulic system leakage

Option 1: Solution to design and manufacturing defects:
l. The selection of external matching of hydraulic components often plays a decisive role in the leakage of hydraulic systems. This determines that our technical personnel should carefully and systematically choose cylinders, pumps, valves, seals, hydraulic accessories, etc. in the design of new products and the improvement of old products, based on the principle of selecting the best from the best and selecting the cheapest from the best.
2. Reasonable design of installation and sealing surfaces: When the valve group or pipeline is fixed on the installation surface, in order to obtain satisfactory initial sealing and prevent the sealing element from being squeezed out of the groove and being worn, the installation surface should be straight, the sealing surface should be precision machined, and the surface roughness should reach 0.8 μ m. The flatness should reach 0.01/100mm. There should be no radial scratches on the surface, and the pre tightening force of the connecting screws should be sufficient to prevent surface separation.
3. During manufacturing and transportation, it is necessary to prevent critical surfaces from colliding and scratching. At the same time, the assembly and debugging process should be strictly monitored to ensure assembly quality.
4. The potential leakage hazards of some hydraulic systems should not be overlooked and must be eliminated.

Option 2: Reduce impact and vibration: In order to reduce the leakage of the hydraulic system caused by loose pipe joints that bear impact and vibration, the following measures can be taken:
1. Fix all pipes with shock absorbers to absorb shock and vibration;
2. Use low impact valves or accumulators to reduce impact;
3. Properly arrange pressure control valves to protect all components of the system;
4. Try to reduce the number of pipe joints and use welding connections as much as possible;
5. Use straight threaded joints, tee joints, and elbows instead of tapered pipe threaded joints;
6. Try to replace each piping with a return oil block;
7. According to the maximum pressure used, the torque of bolts and plug torque shall be specified during installation to prevent the joint surface and sealing components from being eroded;
8. Install the pipe joint correctly.

Option 3: Reduce the wear of dynamic seals: Most dynamic seals are precisely designed. If the dynamic seals are processed, installed correctly, and used reasonably, they can ensure long-term relatively leak free operation. From a design perspective, designers can take the following measures to extend the service life of dynamic seals:
1. Eliminate side loads on piston rods and drive shaft seals;
2. Protect the piston rod with dust rings, protective covers, and rubber sleeves to prevent impurities such as abrasives and dust from entering;
3. Design and select appropriate filtration devices and easy to clean oil tanks to prevent dust accumulation in the oil;
4. Keep the speed of the piston rod and shaft as low as possible.

Option 4: Requirements for static seals:

Static seals prevent oil leakage between rigid fixed surfaces. Reasonably design the size and tolerance of the sealing groove to deform the installed sealing element to a certain extent, in order to fill the micro depressions on the mating surface, and increase the internal stress of the sealing element to higher than the pressure being sealed. When the stiffness of the part or the pre tightening force of the bolt is not large enough, the mating surface will separate under the action of oil pressure, causing gaps or increasing the gaps that may exist from the beginning due to the insufficient flatness of the sealing surface. As the mating surface moves, the static seal becomes the dynamic seal. The rough mating surface will wear the seal, and the changing gap will erode the edge of the seal.

Option 5: Control oil temperature to prevent deterioration of sealing components:

Premature deterioration of seals may be caused by multiple factors, one of which is high oil temperature. Every 10 ℃ increase in temperature will halve the service life of the sealing element. Therefore, an efficient hydraulic system or a forced cooling device should be reasonably designed to maintain the optimal oil temperature below 65 ℃; Construction machinery shall not exceed 80 ℃; Another factor may be the compatibility issue between the oil used and the sealing material. The type and material of hydraulic oil and sealing components should be selected according to the user manual or relevant manuals to solve the compatibility problem and extend the service life of the sealing components.