丹佛斯51系列变量马达服务培训

Sauer-DanfossSeries51ServiceTraining51系列变量马达服务培训Series51and51-1

BentAxisVariableDisplacementMotors弯轴变量马达Series51Overview纲要MotorsizesandDefinitionFeaturesoftheRotatingGroupFeaturesoftheEndcapControlsPortlocationandGaugeinstallationAdjustmentMinorrepairSeries51&51-1ProductRangeFivedisplacements5种排量:60cc/rev(3.66CIR)*80cc/rev(4.92CIR)**110cc/rev(6.71CIR)**160cc/rev(9.82CIR)250cc/rev(15.26CIR)Speeds速度7000rpm(Max.atmin.disp.)Pressures压力480bar(7000psi)Max.*51-1only**51&51-1圆锥滚柱轴承Taperedrollerbearings支撑盘

Bearingplate配油块Valvesegment最小排量限制器Minimumdisplacementlimiter控制阀ControlvalveSAE法兰flange同步轴Synchronizingshaft柱塞Piston缸体Cylinderblock补油溢流阀Chargepressurereliefvalve伺服活塞Servopiston轴ShaftSeries51Cross-section51马达截面Series51atMinDisplacementSeries51-1Cross-section51-1马达截面ConceptMaximumangle最大摆角:32deg.Highstartingtorque(80%ofrunningtorque).Compactunitenvelope/size/weight.Minimumangle最小摆角:6deg.9pistonsforhighefficiency高效率柱塞Constantvelocitysynchronizingjoint等速同步铰接Displacementratio排量比:5:1.Infinitelyvariable.Highvehiclespeedswithoutgearshifting.Highcornerhorsepower.Series51Nameplate铭牌ModelCode(nomenclature):

51V080RS1NL1B1WB31ADA051AAF0D400ModelNumber: 5084092SerialNumber:

N982211215Series51-1Nameplate铭牌ModelCode(nomenclature):

51D110-1-RD4NE1B1NNU2ADD030AAA30000ModelNumber: 511685SerialNumber:N973212355PICTORIALDIAGRAM

图解示意图SYSTEMCIRCUITDIAGRAM

系统原理图RotatingGroup旋转组件Endcapandrotatingcomponents后盖和旋转组件Pistons柱塞Pistonring Onlyforsealing NosideloadingofpistonsinblockDrilledpistonWeightapproximately1/3ofsolidpistonPressurebalanceBrasssocketspressedintotheshaftNobreakin Higherpower PressurelubricatedScoringonpistonsiscausedbylossoflubrication.Lossoflube.canbecausedby;tolowviscosityoftheoilfromoverheatorjusttothinofoil,improperoil(poorlubricatingqualities),oroverspeed.Thepistonmoviessofastbackandforthinitsborethatitlossesitsoilfilm.Thepistonlandwearsdownenoughtoallowthering(atleast½ofit)tocomeoutofitsgrooveandbreak.Thepiecesoftheringusuallyendupinthemotorcaseorinthedrainline.Butnotalways,somepiecescangointothesystemloopandcausedamage.ScoredPistonScoringintheblockboresisusuallyattheoutersideofthebore.Thisisbecausecentrifugalforceisthrowingthepistonsoutfromcenter.Ifapistonorpistonsarescored,theblockborewillalsobescored.Theroughsurfaceoftheblockboreiswhatscoresthepistonandremovesenoughmaterialtolettheringcomeoutofitsgroove.Scoredblockbores

SynchronizingShaft

同步轴Largesynchronizingshaft&increaseddistancetorollersLongerlifebecauseofreducedcontactstressAllowshighertorsionalaccelerationsLowfrictionlossesintimingcylinderblocktoshaftHighmechanicalefficiency~SpeedSensor

速度传感器SpeedSensorat

CartridgeMotorMagneticring(pressedontotheshaft)ConicalendEndCapAssemblyENDCAP3-POSITION/4-WAYCONTROLVALVETHRESHOLD

SPRINGMODULATINGSPRING(S)LOOPFLUSHINGSHUTTLEEQUALAREASERVOPISTONCHARGERELIEFVALVESETTINGLUGEndCap-LoopFlushingLoopflushingcross-sectionshowingpoppetstylereliefvalveEndCap-OrificedLoopFlushingLoopflushingcross-sectionshowingdefeatedreliefvalveEndCapFeedbackandServoSystem,StandardlogicsleeveEndCapReverselogicsleeveControls

Acompletefamilyofcontrolstofulfillawiderangeofapplications.Threetypesofcontrols.Two-positioncontrolsPressurecompensatorcontrolsProportionaldisplacementcontrolsControlsControls:Two-PositionHZ-Hydraulictwo-positioncontrolMotorbiasedtomax.displacementControlpressureatportX1shiftsmotortomin.displacementCaution:HZcanalsobeproportional;specifycontrolrampspring(moduleS)forproportionalX1Controls:Electric2

Position(E1/E2)Controls:Electric2

Position(F1/F2)Controls:

PressurecompensatingPressureCompensator(PC)FunctionWhenpressureisbelowPCsetting,nofunctionWhenpressurereachesPCsetting,controlbeginstomovemotortowardmax.displacementControladjuststhemotortowhateverdisplacementisnecessarytomaintainthesystempressureatthePCsettingPCOR(PressureCompensatorOverride)functionssameasPC,exceptitisoverridingsomeother“primary”controlfunction(twopositionorproportional)~Controls:

PressurecompensatingBrakePressureDefeat(BPD)FunctionManymachineswilldeceleratetooabruptlyifcontrolledbyaPCorPCORtypecontrol,sincemotorgoestomax.anglewhenbrakingBPDpreventsthePCfromactingduring“dynamicbraking”,onlyallowsPCtofunctionwhensystemdeltapressureis“positive”(asduringacceleration)Resultsinagradual,controlleddecelerationRequiresahydraulicsignaltotellthecontrolwhichwaythemachineistraveling~Controls:PressureCompensating

Pressurecompensatoronly Pressurecompensator+electricorhydraulicoverridetomax.displacementPressurecompensatorpressure+brakepressuredefeatPressurecompensator+BPD+electricorhydraulicoverridetomax.displacementPressurecompensatingcontrolsareavailablewith:PressureCompensatingControlsServopressuresupplyServoPressure&PCORSupplyOptions(ModuleN)C2=Internalsupply,PCavailableonportsA&B,NoBPDControlsC2andC4ControlsServoPressure&PCORSupplyOptions(ModuleN)C0-Internalsupply,PCavailableonportsAorB,(accordingtospoolposition),&BrakePressureDefeat.(BPDshuttlerequirestwoexternalhydraulicsignallinesfromavalvethatisdependentontraveldirection)C0andC3ControlsServoPressureSupplyOptions(ModuleN)(continued)R5-Internalsupply,PressurecompensatoravailableonportAonly.L5-Internalsupply,PressurecompensatoravailableonportBonly,XAXB¾”

L5andL6XAXB¾”R5andR6C1andC3ProportionalDisplacementControlsEP/EQHPHSH1/H2K1/K2HZControls:ElectrohydraulicProportional(EP/EQ)Controls-ElectrohydraulicProportional(EP/EQ)PressureCompensatorOver-Rideoptions:(ModuleN)OverridesproportionaldisplacementcontrolusinghighsystempressurestrokingmotortowardmaximumdisplacementA2-Standardversion,PCORonportsA&Bfunctionswhenmotorisrunninginmotoring(acceleration)&pumping(deceleration)modeControlsPCOR–BelowSetPointPress.PCOR–AboveSetPointPress.PressureCompensatorOverride

Servosupplyoptions

(ModuleN)A1–WithPCOR&BrakePressureDefeat.AshuttlespoolaheadofthePCORvalvedefeatsPCORoperationduringdynamicbreaking.Externalsignalpressureshiftsthespoolaccordingtovehicledirection.R2-PCORonportAonly.L2-PCORonportBonly.ControlsControlBlock(WithPCOR&Defeat)ControlBlock(WithPCOR&Defeat)ControlsPressureCompensatorsettingprocedure

MaximumDisplacementReducedDisplacementStrokingtoMax.Disp.Max.Disp.SystemPressure(M5)Max.Disp.ServoPressure(M4)Min.Disp.ServoPressure(M3)PCORThresholdSettingShiftOPERATORCONTROLSDISPLACEMENTPCORREGULATESDISPLACEMENTChargeCaseSystemPRESSUREControlsL1/L2/L7-ElectricProportionalControldirectactingsolenoiddesign.12or24VDCControlsD7D8-Automotivestylemotorcontrol(ElectrohydraulicProportional,w/PCOR&BPD)Series51Portlocations

51马达油口位置Series51motorsSideport径向油口Series51Portlocations

51马达油口位置Series51motorsAxialport轴向油口Series51-1Portlocations

51-1马达油口位置Series51-1motorsSideport径向油口Series51-1Portlocations

51-1马达油口位置Series51-1motorsAxialport轴向油口Portandgaugeinformation

油口和测压表规格Series51motorsGaugeinformation

测压表规格M1SystempressureportAA口系统压力600bar[10,000psi]9/16-18O-ringfittingM2SystempressureportBB口系统压力600bar[10,000psi]9/16-18O-ringfittingM3Servopressureminimumangle(oncontrol)*最小角度伺服压力600bar[10,000psi]60bar[500psi]*gaugefor2-positioncontrol9/16-18O-ringfittingM4Servosupplypressuremaximumangle600bar[10,000psi]60bar[500psi]*gaugefor2-positioncontrol9/16-18O-ringfittingM5**Servosupplypressure600bar[10,000psi]9/16-18O-ringfitting*51-1only**51

Adjustment-调节补油溢流阀

ChargepressurereliefvalveChargepressurereliefvalveSetthechargepressurereliefvalvetothemodelorderInmostapplications,themotorchargereliefvalveisset2to4barbelowthesettingofthepumpchargereliefvalveChargepressureisreferenced(additive)tocasepressure.MeasuringchargepressureM1,M2L1,L2Adjustingchargepressure最小排量限制器

Adjustment-Minimumdisplacementlimiter调节最小排量限制器流程：1.拆下锥形塑料保护罩(Q120)。2.用5或6mm内六角扳手保持调节螺栓(Y10)不动。3.松开密封锁定螺母(Y20),使用工具：•17mm开口扳手:060cm³及080cm³或•19mm开口扳手:110cm³,160cm³,

250cm³4.旋转排量限制螺栓(Y10)至期望排量(具体调节指导如下页所示),工具：•5mm内六角扳手:060cm³及080cm³。或•6mm内六角扳手:110cm³,160cm³,250cm³。

5.

调节完成后，紧固锁定螺母(Y20)力矩：•51N.m[38lbf.ft]:060cm³或080cm³。•86N.m[63lbf.ft]:110cm³,160cm³,250cm³6.安装新锥形塑料保护罩。Adjustment-最小排量调节器调整Minimumdisplacementlimiter注意：最小排量出厂已设定。每次调节完成后锁紧螺母(Y20)。锥形塑料帽保护调节螺栓，调节完需更换新塑料保护罩(Q120)。最小排量限定设定与马达输出转速成反比。顺时针旋转排量限制螺栓将增加最小排量设定，逆时针将降低最小排量限定。当最小排量限制值改变过大时，可能还需更换不同型号的排量限制螺栓。马达排量Framesize最小排量限定范围Minimumdisplacementrangecm³[in3]调整螺柱尺寸长度Screwsizeandlengthmm[in]调节螺栓每旋转一圈最小排量大致改变值Approximatechangeinminimumdisplacementperrevolutionofadjustingscrewcm³/rev[in3/rev]6012-29[.73-1.77]M10x65[2.56]1.5[.09]30-40[1.83-2.44]M10x80[3.15]8016-35[.98-2.14]M10x65[2.56]2.1[1.3]36-54[2.20-3.20]M10x80[3.15]11022-46[1.34-2.81]M12x70[2.76]3.1[.19]47-74[2.878-4.52]M12x80[3.15]16032-72[1.95-4.39]M12x75[2.95]4.0[.24]73-107[4.45-6.53]M12x90[3.54]25050-90[3.05-5.49]M12x75[2.95]6.2[.38]91-130[5.55-7.93]M12x90[3.54]131-167[7.99-10.19]M12x100[3.94]Adjustmentscrewanddisplacement调整螺柱及调节排量

Adjustment-最大排量限制器

Maximumdisplacementlimiter通过限制伺服控制活塞行程，调节马达最大排量。采用一个限位螺栓及一个套筒，限定马达最大排量。排量限定降低值以最大排量5％为单位。改变最大排量限定值时，需要更换不同长度的螺栓并配合特定长度的套筒。提供一稳定流量，观察处于最大排量下马达输出转速。确认马达最大排量设定是否改变。增加最大排量设定将降低马达输出转速，降低最大排量设定将增加马达输出转速。51系列马达1.用下面工具拆下伺服端盖(G260)4个安装螺栓(G24)：•8mm内六角螺栓(060cm³,080cm³,110cm³,及160cm³马达),或:•10mm内六角螺栓(250cm³马达)。2.拆下伺服端盖(G260)，O型圈(G36)及(G100)。3.用10mm内六角扳手，拆下排量限制器螺栓(F10)及套筒(F20)(如马达已带最大排量限制)。4.针对特定最大排量限定要求，更换合适长度的螺栓及套筒（具体见下页表格）。51系列马达最大排量限制器Series51MaximumdisplacementlimiterAdjustment-最大排量限制器

Maximumdisplacementlimiter51-11系列马达1.用8mm内六角扳手，拆下4个控制模块安装螺栓(M16)。2.拆下控制模块。3.拆下垫圈(G36)及O型圈(G42)或密封垫片。4.加装特定最大排量设定所需长度套筒(F20)及螺栓(具体长度见下页表格)。5.将最大排量限制螺栓(F10)加力矩至:•23N.m[17lbf.ft]：60cm³马达。

•46N.m[34lbf.ft]：80cm³及110cm³马达。6.更换所有O型圈及密封垫，丢弃任何O型圈前，请确认已有正确的替换O型圈。7.安装51系列马达伺服端盖或51-1系列控制模块。8.拧紧伺服端盖螺栓(G24)或控制模块螺栓(M16)。9.给上面安装螺栓(M16)加扭矩至:•78N.m[58lbf.ft]，060cm³,080cm³,110cm³及160cm³马达，工具：8mm内六角扳手。•110N.m[81lbf.ft]，250cm³马达，工具：10mm内六角扳手。51-1系列马达最大排量限制器Series51-1Maximumdisplacementlimiter最大排量限制螺栓(F10)及套筒(F20)

MaximumdisplacementScrewandSpacer增加套筒(F20)长度将减小马达最大排量设定减小套筒(F20)长度将增加马达最大排量设定最大排量限制螺栓(F10)及套筒(F20)

Maximumdisplacementscrew(F10)andspacer(F20)%offulldisp.F10=screwF20=spacer60cm³80cm³110cm³160cm³250cm³100F10NM8x20M10x20M10x20M10x20M10x2095F10AF8x25M10x25M10x25M10x25M10x25F20A3.5mm4.0mm4.0mm4.5mm5.0mm90F10BM8x25M10x25M10x30M10x30M10x30F20B6.5mm7.5mm8.0mm9.0mm10mm85F10CM8x30M10x30M10x30M10x35M10x35F20C9.5mm11mm11.5mm13mm15mm80F10DM8x30M10x35M10x35M10x40M10x40F20D12