The cleanliness of hydraulic oil in excavators is crucial for the longevity and efficiency of the hydraulic system. To maintain the purity of hydraulic oil, various filtration and purification methods are employed, each with its unique features and effects.
Firstly, the three-stage cartridge filtration system is designed to meet the high-volume filtration requirements of construction machinery. This system achieves thorough cleaning of hydraulic oil through a sequential filtration process. It includes a three-stage cartridge and a pipeline filtration system, using quick-change couplings to connect seamlessly to the excavator's hydraulic oil tank. By utilizing this method, the contamination level of the hydraulic oil can be significantly reduced, often exceeding industry standards. This filtration system is particularly effective at removing larger particles and debris, thus extending the service life of hydraulic components and improving overall system performance.
High-precision cartridge filtration technology is another critical method, specifically designed to remove microscopic contaminants from hydraulic oil. This technology can filter out particles smaller than 3 micrometers (µm), with some systems achieving filtration accuracies as fine as 1 µm. The filters used in this method come in various materials, including mesh, paper, sintered metal, steel wire, and magnetic materials. By eliminating extremely fine particles, this method significantly enhances the cleanliness of hydraulic oil, reducing wear and tear on hydraulic components, thereby extending operational life and lowering maintenance costs.
Additionally, the electric heating + multi-stage filtration + oil and gas separation method combines several advanced processes to achieve comprehensive purification of hydraulic oil. Initially, the hydraulic oil is heated to 60°C through an electric heating system to reduce viscosity, enhancing the effectiveness of subsequent filtration stages. Primary filtration uses a high-gradient electromagnetic cartridge to remove ferromagnetic corrosion products and large oxidation macromolecules. Intermediate filtration targets larger solid particles, while the final three-stage filtration employs high-precision filters in parallel to ensure redundancy. An exhaust valve then removes gaseous impurities and air bubbles formed during filtration, while an oil-water separation system eliminates water from the oil.
A contamination particle counter monitors oil cleanliness in real-time, and the oil return pipe’s solenoid valve closes once the required purification level is reached. This method provides a comprehensive purification solution, significantly improving the cleanliness of the hydraulic oil by effectively removing a wide range of contaminants, including solid particles, gases, and water, ensuring optimal performance and reliability of the hydraulic system.
Moreover, the centrifugal separator offers a dynamic purification solution by leveraging centrifugal force to clean hydraulic oil. This method involves a pretreatment oil circuit and a centrifugal separator, which spins at high speeds to generate centrifugal force that separates water, air, and solid particles from the hydraulic oil. The centrifugal separator is highly effective at removing contaminants of various sizes and types, continuously eliminating impurities and maintaining the hydraulic system’s integrity and operational efficiency.
Finally, by improving the manufacturing process of the hydraulic tank, including structural enhancements and the development of new pre-treatment, drying, and dust-free assembly techniques, the ingress of solid particles can be effectively prevented. This approach reduces the adverse impact of contaminants on the hydraulic system’s lifespan, ensuring long-term cleanliness of the hydraulic system and thereby extending the service life of hydraulic components and improving system reliability.
In conclusion, these filtration and purification methods each have their advantages and are suitable for different operational needs and scenarios. By selecting the appropriate method or combination of methods, the contamination levels in hydraulic oil can be significantly reduced, ensuring smooth and efficient operation of excavators. This not only enhances the performance and reliability of the hydraulic system but also extends the machinery's lifespan, reducing downtime and maintenance costs.
