As the equipment is used for a longer time, the hydraulic system may have a slow response problem, which will not only reduce work efficiency, but also affect the operating accuracy. There are many reasons for the slow response of the hydraulic system, usually involving performance problems of multiple components such as hydraulic pumps, hydraulic oil, valves, and cylinders. Taking appropriate solutions to these possible faults can effectively improve the system's response speed and ensure the normal operation of the equipment.
1. Common Causes of Slow Response in Hydraulic Systems
The root causes of slow response in hydraulic systems can usually be attributed to the following categories: reduced fluid transmission efficiency, reduced performance of mechanical components, control component failure, etc. Specifically, common causes include:
(1) Hydraulic pump performance degradation
As the power source of the system, the hydraulic pump is responsible for converting mechanical energy into hydraulic energy. If the performance of the pump deteriorates, the hydraulic system cannot provide sufficient pressure and flow, resulting in a slow response. Pump wear, internal leakage or increased clearance will reduce the volumetric efficiency of the pump, thereby affecting the overall operating speed of the system. In particular, after long-term operation, the internal components of gear pumps and vane pumps will wear out more, which can easily lead to insufficient or fluctuating flow.
(2) Hydraulic oil quality issues
Hydraulic oil is the medium for transmitting power. The viscosity, purity and cleanliness of the oil have an important impact on the response speed of the system. If the hydraulic oil is contaminated, oxidized or mixed with air, it will affect the fluidity of the system. In particular, oil with too high or too low viscosity may increase the flow resistance and reduce the transmission efficiency of the system. The mixing of air will also cause cavitation, which will affect the normal operation of hydraulic components.
(3) Hydraulic valve failure
Hydraulic valves are responsible for regulating the flow direction and volume of fluids. If the valve core is stuck, blocked or the solenoid valve fails, the fluid flow in the hydraulic system will be affected, causing the actuator to move slowly. Wear, corrosion or oil contamination inside the valve will cause the valve to respond untimely, thereby delaying the action of the hydraulic cylinder or motor. In addition, failure of the electronic components of the proportional valve or solenoid control valve may also affect the precise adjustment of the valve.
(4) The presence of air inside the system
During the operation of the hydraulic system, air may enter the system due to poor sealing or improper maintenance. Air is compressible, which will reduce the transmission efficiency of the hydraulic system and cause cavitation. Cavitation will not only cause slow system response, but also damage important components such as hydraulic pumps and valves.
(5) Internal leakage of hydraulic cylinders
The hydraulic cylinder is the actuator of the hydraulic system. Wear or leakage of its internal seals will affect the ability of the oil to push the piston. If the seals are aged or damaged, the oil may leak inside the cylinder, causing the piston to move slowly. Internal leakage of the hydraulic cylinder may also cause the system oil temperature to rise, aggravating the wear and aging of other components.
(6) Load exceeds carrying capacity
The design of the hydraulic system needs to match the actual load. If the actual load exceeds the designed carrying capacity of the system, the response speed of the system will be greatly reduced, and even the task cannot be completed. Long-term operation under overload will also aggravate the wear of hydraulic system components, resulting in a decrease in the overall performance of the system.
2. Troubleshooting steps and solutions
In view of the above reasons for the slow response of the hydraulic system, the following specific steps can be used to troubleshoot and solve the problem and ensure that the system returns to normal response speed.
(1) Whether the load exceeds the system range
Ensure that the system's workload operates within the design range. If the load exceeds the system's design capacity, consider reducing the load or upgrading the system configuration to avoid slow response caused by overload operation. For operating conditions where overload occurs frequently, it is recommended to reserve a higher load margin during the design phase to ensure that the system can operate stably under various operating conditions.
(2) Adjust the system pressure setting
Check the setting value of the relief valve to ensure that it meets the system's operating requirements. If the pressure setting value is too low, it should be adjusted appropriately to improve the system's response speed. At the same time, check whether there are any leaks in the system and repair the leaks to restore the system pressure. In addition, use tools such as a pressure gauge to regularly check the system's pressure status to ensure that the system operates within the normal pressure range.
(3) Replace or purify hydraulic oil
Check the degree of oil contamination and replace the oil if necessary. Use hydraulic oil that meets the system requirements to avoid oil with too high or too low viscosity affecting system performance. When replacing the oil, the oil tank, pipes and filters should be thoroughly cleaned to prevent impurities or bubbles from remaining in the system. For high-precision equipment, it is recommended to use a high-efficiency filter to ensure that the hydraulic oil is always kept clean.
(4) Remove air from the system
The presence of air will significantly affect the transmission efficiency of the hydraulic system. During system maintenance, the oil system should be sealed and appropriate air exhaust devices should be installed. In particular, after replacing the hydraulic oil or when the system is overhauled, the air should be fully exhausted to prevent air from mixing into the system. In addition, check the status of the seals to ensure that there is no oil or air leakage at the interfaces of the system.
(5) Check the hydraulic valve
Clogged or stuck valve core or solenoid valve coil failure will affect the flow of hydraulic oil. Clean the valve to ensure that the valve core operates flexibly and avoid accumulation of oil or impurities. For solenoid control valves, check whether the circuit system is working properly. If the valve is severely damaged or excessively worn, it is recommended to replace the valve assembly with a new one to ensure the flow control accuracy of the system.
(6) Check the hydraulic cylinder and seals
Wear or internal leakage of the hydraulic cylinder seals will significantly reduce the response speed of the system. Check whether the hydraulic cylinder seals are aged, worn or cracked, and replace them in time if necessary. If the cylinder barrel of the hydraulic cylinder is severely worn or there is obvious leakage, consider repairing or replacing the hydraulic cylinder to ensure the normal operation of the system.
(7) Check the performance of the hydraulic pump
The performance of the hydraulic pump directly affects the working efficiency of the entire system. Check the output flow and pressure of the pump. If the pump flow rate drops significantly or the output pressure is insufficient, it may be caused by wear or leakage inside the pump. In case of severe wear, it is recommended to overhaul or replace the hydraulic pump. In addition, regularly lubricate the rotating parts of the pump to ensure its normal operation.
