Hydraulic system debugging is a key link to ensure the normal operation of the system and the best performance. Through debugging, problems in the system can be detected and solved, ensuring that the flow, pressure and other parameters of the system under normal working conditions meet the design requirements, thereby improving the performance and reliability of the system.

The following are the debugging methods, steps and precautions of the hydraulic system. Have you done them all correctly?

1.Debugging Methods

(1) No-load debugging: After the hydraulic system is installed, start the system without adding load, let the hydraulic pump run idle for a while, check whether the operating sound, temperature, pressure, etc. of the hydraulic pump are normal, and check whether there are leaks in the pipelines and joints.

(2) Load debugging: After the no-load debugging is normal, gradually increase the load and observe the operation of the system under different loads, including whether the parameters such as pressure, flow, speed meet the design requirements, and check whether the actuators (such as hydraulic cylinders, hydraulic motors) move smoothly and accurately, and whether there are abnormal phenomena such as creeping and jamming.

(3) Pressure debugging: By adjusting the pressure control elements such as the overflow valve, the system pressure reaches the set value, and the pressure stability and pressure fluctuation range are checked. At the same time, check whether the pressure of each branch meets the requirements and whether the pressure is too high or too low.

(4) Flow debugging: Use instruments such as flow meters to measure the flow of each branch of the system and adjust the flow control elements such as throttle valves to make the flow meet the working requirements of the actuator and ensure that the movement speed of the actuator meets the design requirements.

2.Pre-commissioning inspection

(1) Check whether the hydraulic system is installed correctly, whether the connections between various components and pipelines are firm, and whether there is any loss, leakage, etc.

(2) Check whether the oil quality and oil level of the hydraulic oil meet the requirements, whether the oil is clean, and filter or replace it if necessary.

(3) Check whether the wiring of the electrical system is correct, whether the operation of each control component is flexible and reliable, and whether the safety protection devices are complete and effective.

3. No-load start and operation

(1) Start the hydraulic pump motor to check whether the motor is in the correct direction. After confirming that it is correct, start the hydraulic pump for no-load operation.

(2) Observe the operating status of the hydraulic pump, including sound, vibration, temperature, etc. If there is any abnormality, stop the machine immediately for inspection.

(3) Run the hydraulic system in a no-load state for a period to allow the oil to circulate fully and remove the air in the system.

4. Pressure debugging

(1) Adjust the overflow valve to gradually increase the system pressure. The pressure increases in amplitude should not be too large each time. Observe the reading of the pressure gauge until the set working pressure is reached.

(2) During the pressure increase process, check whether there are leaks in each pipeline, joint, component, etc. If there is a leak, it should be handled in time.

(3) Adjust the pressure control components such as the pressure reducing valve and sequence valve of each branch to make the pressure of each branch meet the design requirements.

5. Flow debugging

(1) Move the actuator (such as a hydraulic cylinder) to the middle position of the stroke, adjust the throttle valve and other flow control elements, observe the movement speed of the actuator, measure the flow rate through a flow meter, and make the flow rate reach the design value.

(2) For systems with multiple actuators, debug the flow of each actuator separately to ensure that their movement speed and synchronization meet the requirements.

6. Debugging Load

(1) After no-load debugging and pressure and flow debugging are normal, gradually increasing the load and perform load debugging.

(2) Observe the operation of the system under different loads, including whether the action of the actuator is smooth and accurate, and whether there is creeping, jamming, impact and other phenomena.

(3) Check whether the system’s pressure, flow and other parameters are stable and within the allowable range. If there is any abnormality, it should be adjusted in time.

7. Performance testing and adjustment

(1) Test various performance indicators of the system, such as system efficiency, response time, positioning accuracy, etc., and make necessary adjustments based on the test results.

(2) Check whether the system’s safety protection devices are reliable, such as whether overload protection, pressure relays, etc. can work properly.

8. Final inspection and cleaning

(1) After debugging is completed, check again whether the connections of each part of the system are firm and whether there are any leakage problems.

(2) Clean up the debris, oil stains, etc. generated during the debugging process to keep the system clean.

9. Precautions

(1) The commissioning personnel should be familiar with the working principle, operating procedures and safety precautions of the hydraulic system, and strictly follow the commissioning steps.

(2) During the commissioning process, the operating status of the system should be closely observed. If any abnormality is found, the system should be stopped for inspection immediately. The commissioning can be continued after the fault is eliminated.

(3) During pressure commissioning, attention should be paid to the pressure rise rate to avoid damage to components or safety accidents caused by sudden pressure increase.

(4) During flow commissioning, the flow should be reasonably adjusted according to the working requirements of the actuator and the actual situation of the system to avoid excessive or insufficient flow affecting system performance.

(5) During load commissioning, the load should be gradually increased to avoid sudden loading causing system shock and damage.

(5) During the commissioning process, data records should be kept, including parameters such as pressure, flow, temperature, and the movement speed of the actuator, to analyze and judge the operation of the system.

(6) After commissioning, the system should be fully inspected and cleaned to ensure that there is no leakage or debris in the system, and then the system should be properly maintained.