1. Equipment Structure and Components
1.1 Core Components
【表格】
Component Functional Description Typical Material
Piston Pump Achieves fluid suction, compression, and discharge through reciprocating piston motion, providing high-pressure output. Pump body: Cast iron/stainless steel; Piston: Ceramic-coated
Drive Motor Supplies power to the piston pump, typically an electric motor (AC/DC) or hydraulic motor. Motor housing: Aluminum alloy; Stator: Copper winding
Reducer (Gearbox) Reduces motor speed and increases output torque to match the piston pump's operating requirements. Gears: Alloy steel; Housing: Cast aluminum
Coupling Connects the motor output shaft to the reducer input shaft, transmitting torque while compensating for misalignment. Elastomer: Polyurethane; Metal parts: Steel
Control System Regulates pump speed, pressure, and flow rate; optional PLC or frequency inverter for automation. Controller: Industrial PLC; Sensors: Pressure/flow meters
1.2 Integration Forms
• Integrated Design: Motor, reducer, and pump body are directly connected via flanges for compactness (e.g.,PPR-100 Series).
• Modular Design: Motor and reducer are connected via a coupling, with the pump body installed separately (suitable for space-constrained applications).
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2. Working Principle
2.1 Fluid Transfer Process
1. Suction Phase:
• The motor drives the reducer, moving the piston backward to expand the pump chamber volume, creating negative pressure.
• The inlet check valve opens, drawing fluid into the pump chamber.
2. Compression Phase:
• The piston moves forward, reducing the pump chamber volume and increasing pressure.
• The outlet check valve opens, discharging fluid into the system pipeline.
3. Cycle Repetition:
• Continuous reciprocating motion ensures steady fluid delivery, with flow rate proportional to piston stroke and frequency.
2.2 Power Transmission Path
Motor Output Shaft → Reducer (Gear/Planetary Gear) → Coupling → Piston Pump Crankshaft/Cam → Reciprocating Piston Motion
• Reduction Ratio: Typically 5:1 to 50:1, adjusted based on pump speed requirements (e.g., for a pump speed of 500 rpm, select a motor speed of 2500 rpm with a 5:1 ratio).
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3. Key Technical Parameters
【表格】
Parameter Category Parameter Range Typical Value (PPR-100 Example)
Flow Rate 0.1–1000 L/min (varies by pump type) 100 L/min (water-based medium)
Pressure 1–500 bar (high-pressure models up to 1000 bar) 250 bar (hydraulic oil medium)
Speed 50–3000 rpm (motor speed) 1500 rpm (reduced to 300 rpm output)
Power 0.75–300 kW (motor power) 15 kW (4-pole asynchronous motor)
Efficiency Mechanical: 85–95%; Volumetric: 90–98% Total: ~90%
Noise Level ≤75 dB (at 1 m distance) 68 dB (with soundproof enclosure)
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4. Typical Applications
4.1 Industrial Hydraulic Systems
• Case Example: Injection molding machine hydraulic stations, die-casting machine clamping units.
• Requirements: High pressure (200–350 bar), large flow (200–500 L/min), continuous operation.
• Equipment Selection:
• Pump Type: Axial piston pump (swashplate design).
• Reducer: Planetary gearbox (high torque density).
• Motor: Variable-frequency drive motor (adaptable to varying loads).
4.2 Petroleum and Chemical Industry
• Case Example: Oil well water injection, polymer transfer.
• Requirements: Corrosion resistance (H₂S/CO₂ environments), explosion-proof (Ex dIIB T4).
• Equipment Selection:
• Pump Body: Duplex stainless steel (2205/2507).
• Motor: Explosion-proof asynchronous motor (IP55 protection).
• Reducer: Hardened gearbox (lifespan ≥5 years).
4.3 Environmental Water Treatment
• Case Example: Sludge dewatering, reverse osmosis pressurization.
• Requirements: Low pulsation, frequency control.
• Equipment Selection:
• Pump Type: Radial piston pump (low flow fluctuation).
• Reducer: Harmonic drive (high precision).
• Motor: Servo motor (±0.1% speed accuracy).
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5. Selection and Maintenance Guide
5.1 Selection Steps
1. Determine Operating Parameters:
• Flow demand (L/min), pressure demand (bar), medium viscosity (cSt).
2. Calculate Power Requirements:
P=Q⋅ΔP600⋅ηP = \frac{Q \cdot \Delta P}{600 \cdot \eta}P=600⋅ηQ⋅ΔP
WhereQ Q Q= flow rate (L/min),ΔP \Delta P ΔP= pressure differential (bar),η \eta η= total efficiency (0.85–0.95).
3. Match Reduction Ratio:
• Select ratioi=nmotornpump i = \frac{n_{\text{motor}}}{n_{\text{pump}}} i=npumpnmotorbased on pump speed (npump n_{\text{pump}} npump) and motor speed (nmotor n_{\text{motor}} nmotor).
4. Verify Installation Dimensions:
• Check flange interfaces, shaft diameters, and spatial compatibility with existing systems.
5.2 Common Faults and Solutions
【表格】
Fault Symptom Possible Causes Solutions
Insufficient Flow Suction line leakage, worn piston rings Inspect seals, replace piston rings
Pressure Fluctuation Stuck check valve, excessive reducer backlash Clean valves, adjust gear clearance
Excessive Noise Poor coupling alignment, worn gears Realign coupling, replace gears
Motor Overheating Frequent starts/stops, poor cooling Add soft starter, clean cooling ducts
5.3 Maintenance Schedule
• Daily Checks: Oil level, temperature, noise (per shift).
• Monthly Maintenance: Replace lubricant, inspect seals.
• Annual Overhaul: Replace gears, bearings, and wear parts.
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6. Industry Certifications and Standards
• International Standards:
• ISO 4401 (hydraulic valve interfaces), ISO 9906 (pump efficiency testing).
• Domestic Standards:
• GB/T 7935 (general technical conditions for hydraulic pumps), JB/T 8098 (reducer testing methods).
• Certification Requirements:
• CE (EU safety), ATEX (explosion-proof), UL (North America).
