Course Polycom Hydraulic Functionality Specification Components PDF

Page 1 PartschW 29 Sep 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROWAL\Training\Presentation\3 Polycom-Hydraulic.
ppt
POLYCOM-Hydraulic
Functionality and Specification of Components
Dipl. Ing.
Wolfgang Partsch
Page 2 PartschW 29 Sep 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROWAL\Training\Presentation\3 Polycom-Hydraulic.ppt
POLYCOM-Hydraulic
Characteristic:
Great reliability
Simple functioning
Few possible faults
Less commissioning work
No additional cooler for

- pressure regulation and
- parallel gap control
POLYCOM-Hydraulic
Components
POLYCOM-Hydraulic
The hydraulic system essentially consists of the following components:
the hydraulic power unit with the hydraulic oil tank, the pump, the return flow filter and the associated controllers and indicators
the valve blocks
the plunger cylinders
the push back cylinders
the piston accumulators with the nitrogen filling devices
and the local control box.
L = looking at the piston accumulators left-hand side of the POLYCOM
R = looking at the piston accumulators right-hand side of the POLYCOM

POLYCOM-Hydraulic
Components
POLYCOM-Hydraulic
POLYCOM-Hydraulic
1.0 Hydraulic oil reservoir
2.0 Drain cock
3.0 Aeration filter
4.0 Oil level indicator
5.0 Heater (if installed)
6.0 Temperature sensor
7.0 Level switch
8.0 Electric motor
9.0 Pump support
10.0 Coupling
11.0 Pump (the stand by pump is not shown
12.0 Return flow filter
13.0 Nonreturn valve
14.0 Hose
15.0 Hose
17.0 Valve block
18.0 Pressure valve with magnetic relief
19.1 Mini-mess connection
19.2 Mini-mess connection
20.1 Mini-mess pressure gauge connection
20.2 Mini-mess pressure gauge connection
21.1 Pressure gauge
21.2 Pressure gauge
22.1 Valve block with non-return valve
22.2 Valve block with non-return valve
23.0 4/2-port directional control valve
24.0 Pressure limiting valve
25.0 Ball valve
POLYCOM-Hydraulic
52.1 Throttle block
52.2 Throttle block
53.1 Piston accumulator
53.2 Piston accumulator
54.1 Nitrogen filling device
54.2 Nitrogen filling device
55.0 Adapter for nitrogen filling
56.0 Nitrogen filling hose
59.1 Pressure monitor
59.2 Pressure monitor
60.1 Plunger cylinder
64.1 Backward travel cylinder
65.1 Ball valve
65.2 Ball valve
70.0 Terminal box
74 Pressure valve
100 Local control box
L = looking at the piston accumulators left-hand side

R = looking at the piston accumulators right-hand side
POLYCOM-Hydraulic
Local control box:
1. Skewing indication 0-20 mm
2. Fast pressure build-up left-hand side
3. Slow pressure build-up left-hand side
4. Opening of roll gap left-hand side
5. Pressure reduction left-hand side
6. Signal lamp, reset button
7. Emergency off button
8. Fast pressure build-up right-hand side
9. Slow pressure build-up right-hand side
10. Opening of roll gap right-hand side
11. Pressure reduction right-hand side

POLYCOM-Hydraulic
Functions of the local control box:
The functions can be performed independently of each other for the left-hand and the right-hand side, but they can also be
simultaneously performed on both sides by simultaneously pressing the corresponding keys left and right.
The skew monitoring system is active for all functions, also in local operating mode, with the exception of the pressure
reduction function.
For example, during forward movement of the floating roll on the right side (by means of slow or fast pressure build-up):
If the floating roll on the right side has been moved to the limit value of skewing, which is 4 mm, further forward movement on
the right side is no longer possible; the floating roll must first be straightened by actuating the key pressure build-up left side.
With the additional function Pressure reduction which activates the solenoid valves y7 to y10, the main pressure cylinders
can be de-aerated in local operating mode. For this purpose, the respective pushbuttons Fast pressure build-up and
Pressure reduction on the left side or on the right side must be simultaneously pressed. This de-aerating mode is very helpful
particularly in the initial phase of commissioning .
POLYCOM-Hydraulic
Functioning
Hydro-pneumatic Spring System
Hydraulic Piston
Accumulator Hydraulic Plunger Adjustable mechanical
Cylinders Stopper
Pneumatic
spring
Floating Roller Fix Roller

Adjustable
throttle valve
Back pressure
valve
Principle of Hydro-pneumatic Spring System
No grinding operation
Hydraulic side is de-pressurised pOil = 0 bar
Setting of initial nitrogen pressure pGas = pPreset pressure
pGas
Piston
Polycom ready for grinding operation

Hydraulic side is set to initial pressure p0 = Hydraulic start-up pressure
Nitrogen is compressed and pressure increases
Nitrogen pressure is equal to hydraulic pressure pOil = p0 = pGas
pOil = p0 = pGas
s0
sa = s0
Pressure absorption by crossbeam with pressure cylinder

Grinding operation
Floating roll is pushed back by feed material
Hydraulic oil is pressed into accumulator
Nitrogen is compressed and pressure increases
Nitrogen pressure is equal to hydraulic pressure pOil = pa = pGas
pOil = pa = pGas
sa > s0
sa
Parts installed at POLYCOM
Parts installed in a separate hydraulic room

underneath the POLYCOM
1. Pressure- free circulation
Conditions:
Electrical motor hydraulic pump is running
All solenoids are de-energized

1. Pressure- free circulation

Electric motor for pump
Pressure free circulation (p < 5 bar)
Pump stage A (75% oil flow)
All solenoids are de-energized
(pressure < 5 bar)
Non- return- valve opens at p > 5 bar
Y1
4/2- way valve Y1
deenergized = open Y2
(return flow pressure < 5 bar)
Non- return- valve

Return flow filter with differential
pressure switch S1
Pump stage B (25% oil flow)
Non- return- valve opens at p> 5 bar

4/2- way valve Y2
Pressure limiting valve 180 bar
2. Flashing of Plunger cylinders
Conditions:
Electric motor for hydraulic pump is running
Y2 is energized
Y5 and Y6 are energized
Y7, Y8, Y9, Y10 are energized

Y10 Y6 energized
Flashing of Plunger cylinders
energized
Pressure filter with p switch
Y2 energized
Y8 energized
Y9 Y5 energized Motor hydraulic pump on

energized
P < 5 bar P > 5 bar

return flow
Pressure filter with p switch
Y7 energized
Valve block
3. Fast pressure increase
Conditions:
Y1 is energized
Y2 is energized
Y5 is energized (left side of POLYCOM)
Y6 is energized (right side of POLYCOM)

Y6 energized
Fast pressure increase
Y1 energized
Y2 energized
Y5 energized
Motor on
4. Slow pressure increase
Conditions:
Y 2 is energized
Y 5 is energized
Y 6 is energized
Y6 energized
Slow pressure increase
Y2 energized
Y5 energized
Motor on
5. Pressure equilisation
Conditions:
Slow pressure increase is finished
Y11 is energized
Pressure equalization
2/2 way valve Y11 energized
Motor on
Nitrogen (N2)
6. Push back hydraulic pressure release
Conditions:
Pump is running

Push back hydraulic - pressure release

Y10
Y7, Y8, Y9 Y10 energized
Y8
Y9
Motor on
Y7
6. Push back hydraulic moving
Conditions:
Y2, Y3, Y4 are energized

Y4 energized
Push back hydraulic - moving
Y2 energized
Y3 energized
Motor on

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Page 1 PartschW 29 Sep 2006 I:\Daten\PartschW\POLYCOM Minerals\Anlagen\CERROWAL\Training\Presentation\3 Polycom-Hydraulic.

Few possible faults

Less commissioning work

No additional cooler for

The hydraulic system essentially consists of the following components:

L = looking at the piston accumulators left-hand side of the POLYCOM

R = looking at the piston accumulators right-hand side of the POLYCOM

L = looking at the piston accumulators left-hand side

Local control box:

1. Skewing indication 0-20 mm

2. Fast pressure build-up left-hand side

3. Slow pressure build-up left-hand side

4. Opening of roll gap left-hand side

5. Pressure reduction left-hand side

6. Signal lamp, reset button

7. Emergency off button

8. Fast pressure build-up right-hand side

9. Slow pressure build-up right-hand side

10. Opening of roll gap right-hand side

11. Pressure reduction right-hand side

Functions of the local control box:

Hydro-pneumatic Spring System

Floating Roller Fix Roller

Principle of Hydro-pneumatic Spring System

Principle of Hydro-pneumatic Spring System

Polycom ready for grinding operation

Pressure absorption by crossbeam with pressure cylinder

Principle of Hydro-pneumatic Spring System

Parts installed at POLYCOM

Parts installed in a separate hydraulic room

1. Pressure- free circulation

Electrical motor hydraulic pump is running

All solenoids are de-energized

1. Pressure- free circulation

Non- return- valve

Pump stage B (25% oil flow)

Non- return- valve opens at p> 5 bar

2. Flashing of Plunger cylinders

Electric motor for hydraulic pump is running

Y5 and Y6 are energized

Y7, Y8, Y9, Y10 are energized

Pressure filter with p switch

Y9 Y5 energized Motor hydraulic pump on

P < 5 bar P > 5 bar

3. Fast pressure increase

Y5 is energized (left side of POLYCOM)

Y6 is energized (right side of POLYCOM)

4. Slow pressure increase

Slow pressure increase is finished

2/2 way valve Y11 energized

6. Push back hydraulic pressure release

Y7, Y8, Y9, Y10 are energized

Push back hydraulic - pressure release

6. Push back hydraulic moving

Y7, Y8, Y9, Y10 are energized

Y2, Y3, Y4 are energized

Push back hydraulic - moving

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