I. Product Overview
The V30D160 + 160 dual variable displacement plunger pump is a dual-pump system that integrates two V30D160 variable displacement plunger pumps. This design is intended to meet the requirements of industrial applications that demand high flow rates and pressures and require a compact and efficient system to perform multiple functions. Variable displacement plunger pumps have the characteristic of automatically adjusting the displacement according to load requirements, which can effectively improve system efficiency and reduce energy consumption.
II. Structural Features
(A) Dual-Pump Integrated Structure
1. Compact Layout: The two V30D160 pumps are integrated into a single pump body through a well-designed mechanical layout, sharing some common basic structures and connecting components. This design significantly reduces the overall space occupied, making installation more convenient, especially for mechanical equipment with limited space, such as small machine tools and compact equipment on automated production lines.
2. High-Strength Pump Body: The pump body is made of high-strength alloy materials and manufactured through precise casting and machining processes. It has good rigidity and sealability, enabling it to withstand various stresses in high-pressure and harsh working environments, such as high temperatures, high pressures, and vibrations, ensuring long-term stable operation and reducing failures caused by pump body deformation or damage.
(B) Displacement Adjustment Mechanism
1. Advanced Control Principle: Each V30D160 pump is equipped with an advanced displacement adjustment mechanism. It achieves stepless displacement adjustment by changing the swash plate inclination angle or the plunger stroke. For example, when the system load is small, the displacement adjustment mechanism automatically reduces the pump's displacement and output flow, thereby reducing energy consumption. When the load increases, it can quickly increase the displacement to provide sufficient power.
2. Diverse Control Methods: There are various displacement control methods available, which can be selected according to different application scenarios, including manual control, hydraulic control, and electro-hydraulic proportional control. Manual control is suitable for simple applications with low control accuracy requirements. Hydraulic control uses hydraulic signals in the system to adjust the displacement, featuring a fast response speed. Electro-hydraulic proportional control combines the precision of electrical signals with the power of hydraulic systems, enabling high-precision displacement control and is widely used in equipment with high automation levels.
(C) Plunger and Port Plate Design
1. High-Quality Plunger Material: The plungers are made of high-quality stainless steel or hard alloy materials and undergo precise machining and heat treatment. These materials have high hardness, wear resistance, and good dimensional stability, allowing them to operate for a long time under high-speed and high-pressure working conditions without significant wear. This ensures the matching accuracy between the plungers and the cylinders, effectively reducing leakage and improving volumetric efficiency.
2. Precision Port Plate: The port plate is reasonably designed, and its surface is specially treated, such as through hard chrome plating or laser quenching, to have good wear resistance and corrosion resistance. The port plate has excellent sealability between it and the cylinder, accurately separating the high-pressure oil and the low-pressure oil to ensure the normal oil suction and discharge processes of the pump. Meanwhile, the oil port layout on the port plate is optimized to reduce hydraulic shock and noise.
III. Performance Parameters
(A) Flow Rate Range
1. Single-Pump Flow Rate: Each V30D160 pump can reach a maximum flow rate of 160 L/min at the rated speed, and the minimum flow rate can be adjusted to nearly zero (the specific minimum flow rate depends on the control accuracy of the displacement adjustment mechanism). By changing the speed and displacement, it can meet the flow rate requirements under different working conditions.
2. Dual-Pump Combined Flow Rate: After the combination of the two pumps, the flow rate can be flexibly distributed according to system requirements. When both pumps operate at the maximum displacement, the total system flow rate can reach 320 L/min, providing sufficient power for large hydraulic equipment. Additionally, the two pumps can output different flow rates through displacement control to meet various flow rate requirements in complex working conditions.
(B) Pressure Ratings
1. Rated Pressure: The dual-pump system has a relatively high rated working pressure, generally 31.5 MPa. Under this pressure, the pump can operate stably for a long time, providing reliable power support for the hydraulic system.
2. Peak Pressure: In a short period, the system can withstand a higher peak pressure, for example, up to 35 MPa, to cope with sudden load increases and ensure system safety and reliability.
(C) Speed Range
The pump has a wide speed range and can generally operate stably between 600 and 2000 r/min. At a low speed, the pump can maintain good volumetric and mechanical efficiencies, reducing wear and noise. At a high speed, it can provide a larger flow rate output to meet the requirements of rapid movements.
IV. Application Fields
(A) Construction Machinery
1. Excavators: In excavators, the V30D160 + 160 dual variable displacement plunger pump can provide a stable and adjustable power source for the hydraulic system. By precisely controlling the flow rate and pressure of the two pumps, it enables smooth and efficient operation of the excavator's slewing, traveling, and digging movements. For example, during excavation, the pump's output flow rate and pressure can be adjusted according to the soil hardness and excavation depth to improve work efficiency and accuracy.
2. Cranes: For large cranes, the dual-pump system can meet the synchronous or independent movement requirements of multiple actuators, such as hoisting, luffing, and slewing. When hoisting heavy objects, the pump's displacement and pressure can be increased to provide sufficient power. During slewing and luffing, the flow rate can be precisely adjusted according to actual needs to ensure safe and reliable crane operations.
(B) Industrial Equipment
1. Plastic Injection Molding Machines: In plastic injection molding machines, this dual-pump system can provide precise pressure and flow rate control for injection, clamping, and ejection movements. By adjusting the pump's displacement, it can accurately control the injection speed and pressure, improving the quality and production efficiency of plastic products. For example, when injecting thin-walled products, a higher injection speed and pressure are required, which can be achieved by increasing the pump's displacement. When injecting thick-walled products, the displacement and pressure can be appropriately reduced to avoid product defects.
2. Die Casting Machines: In die casting machines, the dual-pump system can provide sufficient high-pressure oil to ensure that the molten metal quickly fills the mold cavity under high pressure. Meanwhile, it can flexibly adjust the flow rate and pressure according to different die casting process requirements. For example, when die casting aluminum alloy products, a higher pressure is required to ensure product density. When die casting zinc alloy products, the pressure can be appropriately reduced to reduce mold wear.
(C) Shipbuilding and Ocean Engineering
1. Steering Gear Systems: In ship steering gear systems, the V30D160 + 160 dual variable displacement plunger pump can provide a stable and reliable power source for the rotation of the rudder blades, ensuring the ship's maneuverability during navigation. Through displacement control, the running speed and torque of the steering gear can be precisely adjusted according to the ship's navigation status and steering requirements. For example, when the ship is sailing at high speed, a larger steering gear torque is required to quickly change the course. When sailing at low speed, the torque can be appropriately reduced to improve steering flexibility.
2. Drilling Equipment on Offshore Platforms: In drilling equipment on offshore platforms, this dual-pump system can meet the power requirements of mud pumps, top drives, and other equipment, adapting to the high-pressure and large-flow requirements in complex working conditions such as deep-sea drilling. For example, during drilling, the flow rate and pressure of the mud pump need to be adjusted according to the formation conditions to carry drill cuttings and cool the drill bit. The top drive also requires stable power support for rotating and lifting the drill string.
V. Maintenance and Upkeep
(A) Regular Inspections
1. Appearance Inspection: Regularly inspect the pump's appearance to check for oil leakage. Check whether the bolts at various connecting parts are loose, and tighten them promptly if loose to prevent failures caused by leakage and loosening. Also, check the pump body for cracks, deformation, or other damage.
2. Oil Level and Quality Inspection: Check the hydraulic oil level to ensure it is within the specified range. Regularly sample and inspect the quality of the hydraulic oil, observing its color, odor, and transparency. If the oil turns black, has an odor, or becomes turbid, it indicates that the oil has deteriorated, and the hydraulic oil should be replaced promptly.
(B) Cleaning and Filtration
1. Pump Body Cleaning: Keep the pump body and its surrounding environment clean to prevent dust, impurities, etc., from entering the pump. Regularly wipe the pump body surface with a clean cloth to remove dust and oil stains.
2. Filter Maintenance: Regularly clean or replace the hydraulic oil filters to ensure that the hydraulic oil entering the pump is clean. Filter blockage can cause poor hydraulic oil flow, increasing pump wear and energy consumption. Generally, clean or replace the filters according to the time intervals or operating hours specified in the equipment operation manual.
(C) Displacement Adjustment Mechanism Maintenance
1. Control Valve Inspection: For the displacement adjustment mechanism, regularly inspect the working status of the control valves. Check whether the valve cores are flexible and free from sticking, and whether the valve seats are well-sealed without leakage. Replace the control valves promptly if they are damaged or malfunctioning.
2. Sensor Calibration: If the electro-hydraulic proportional control method is used, regularly calibrate the sensors to ensure that their output signals are accurate and reliable. Sensor errors can lead to inaccurate control of the displacement adjustment mechanism, affecting pump performance.
3. Lubrication Maintenance: Pay attention to the lubrication of the displacement adjustment mechanism and add an appropriate amount of lubricating grease according to the regulations to ensure the flexible operation of its moving parts. Regularly check whether there is lubricating grease leakage at the lubrication points and deal with it promptly if there is.
(D) Long-Term Storage Handling
If the equipment is to be stored for a long time, drain the hydraulic oil from the pump and take anti-rust measures, such as applying anti-rust oil. Before putting it back into use, conduct a comprehensive inspection and commissioning of the pump, including checking the appearance, connecting parts, and displacement adjustment mechanism of the pump for normal operation. Then, perform no-load and loaded operation tests to ensure its normal performance
