16/09/2025
Guide to Operation and Performance Testing
1. Components and Functions of
1.1 Components
: Converts mechanical energy into hydraulic energy, providing the required flow and pressure for the system. Common types include gear pumps, vane pumps, and piston pumps.
: Powers the hydraulic pump.
1.2 Control Components
Directional Control Valve: Controls the direction of fluid flow to start, stop, or change the direction of actuators.
Pressure Control Valve: Regulates system pressure, such as relief valves and pressure-reducing valves.
Flow Control Valve: Adjusts fluid flow to control the speed of actuators.
1.3 Actuators
: Converts hydraulic energy into linear motion.
: Converts hydraulic energy into rotational motion.
1.4 Auxiliary Components
Reservoir: Stores hydraulic fluid and dissipates heat.
Filter: Removes contaminants from the hydraulic fluid.
Cooler/Heater: Maintains the fluid temperature within an optimal range.
Pipes & Fittings: Connect components and transport fluid.
1.5 Working Fluid
Hydraulic Oil: Transmits energy, lubricates components, and prevents corrosion. Regular testing of viscosity, cleanliness, and water content is required.
2. Operation Steps
2.1 Pre-Startup Checks
Check if the oil level is within the range indicated on the tank gauge.
Ensure filters are clean and all connections are tight.
Verify the electrical system is functional (e.g., motor wiring, fuses).
2.2 Startup Procedure
Jog the motor to confirm the correct rotation direction of the pump.
Run the system without load for 5-10 minutes to check for abnormal noises or leaks.
Gradually increase the load to the operating level.
2.3 Runtime Monitoring
Monitor pressure gauge readings to ensure they are within the rated range.
Check fluid temperature (recommended range: 30-60°C).
Observe whether actuator movements are smooth and free of jitter.
2.4 Shutdown Procedure
Release system load and return actuators to their initial positions.
Turn off the motor and disconnect the power supply.
Clean the system surface and record operational data.
3. Performance Testing Methods
3.1 Pressure Test
Method: Use pressure gauges or sensors to measure the maximum working pressure and stability.
Standard: Refer to ISO 4413 or GB/T 3766; pressure fluctuations should be less than ±5%.
3.2 Flow Test
Method: Use a flow meter to measure the pump’s output flow and the flow requirements of actuators.
Standard: Flow deviation should be less than ±10% of the rated value.
3.3 Leakage Test
Internal Leakage: Measure leakage rates of valves and actuators under pressure-holding conditions.
External Leakage: Check for fluid seepage at pipe connections and fittings.
3.4 Temperature Test
Method: Monitor fluid temperature using infrared thermometers or temperature sensors.
Standard: Fluid temperature should not exceed 60°C during continuous operation.
3.5 Efficiency Test
Volumetric Efficiency: Compare theoretical flow rate to actual flow rate (≥90% is acceptable).
Overall Efficiency: Measure the ratio of output power to input power (≥80% is acceptable).
3.6 Reliability Test
Run the system continuously for over 24 hours and record failure frequency and performance degradation.
4. Safety Precautions
Wear protective equipment (gloves, safety goggles) before operation.
Never loosen pipes or components while the system is pressurized.
Dispose of waste hydraulic oil according to environmental regulations.
5. Common Issues and Solutions
SymptomPossible CauseSolutionLow System PressurePump wear or relief valve faultReplace pump or adjust/replace valveSlow Actuator SpeedInsufficient flow or internal leakageCheck pump flow and component sealsHigh Fluid TemperatureInadequate cooling or low efficiencyClean cooler or replace hydraulic fluid
By following standardized operations and systematic testing, can operate efficiently and reliably, extending equipment service life.
