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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic Functionality and Specification of Components
Dipl. Ing. Wolfgang Partsch
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic
Characteristic:
•
Great reliability
•
Simple functioning
•
Few possible faults
•
Less commissioning work
•
No additional cooler for - pressure pressure regulati regulation on and and - parallel parallel gap gap contro controll
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic
Components
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic The hydraulic system essentially consists c onsists of the following components: • • • • • •
the hydraulic power power unit with the hydraulic oil tank, the pump, the return flow filter and the associated 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
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic
Components
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.1 19.2 20.1 20.2 21.1 21.2 22.1 22.2 23.0 24.0 25.0
Hydraulic oil reservoir Drain cock Aeration filter Oil level indicator Heater (if installed) Temperature sensor Level switch Electric motor Pump support Coupling Pump (the stand by pump is not shown Return flow filter Non –return –return valve Hose Hose Non –return –return valve Valve block Pressure valve with magnetic relief Mini-mess connection Mini-mess connection Mini-mess pressure gauge connection Mini-mess pressure gauge connection Pressure gauge Pressure gauge Valve block with non-return valve Valve block with non-return valve 4/2-port directional control valve Pressure limiting valve Ball valve
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic 51.1 51.2 52.1 52.2 53.1 53.2 54.1 54.2 55.0 56.0 59.1 59.2 60.1 60.2 60.3 60.4 64.1 64.2 64.3 64.4 65.1 65.2 70.0 74 100
Non –return –return valve Non –return –return valve Throttle block Throttle block Piston accumulator Piston accumulator Nitrogen filling device Nitrogen filling device Adapter for nitrogen filling Nitrogen filling hose Pressure monitor Pressure monitor Plunger cylinder Plunger cylinder Plunger cylinder Plunger cylinder Backward travel cylinder Backward travel cylinder Backward travel cylinder Backward travel cylinder Ball valve Ball valve Terminal box Pressure valve Local control box
L = looking at t he piston accumulators left-hand side R = looking at the piston accumulators right-hand side
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic Local control box:
1. Skewing Skewing indicat indication ion 0-20 0-20 mm 2. Fast pressure pressure build-u build-up p left-hand left-hand side side 3. Slow pressur pressure e build-up build-up left-han left-hand d side 4. Opening Opening of roll roll gap left-hand left-hand side side 5. Pressure Pressure reducti reduction on left-han left-hand d side side 6. Signal Signal lamp, lamp, reset reset butto button n 7. Emergency Emergency off butto button n 8. Fast pressure pressure build-u build-up p right-hand right-hand side 9. Slow pressur pressure e build-up build-up right-han right-hand d side 10. Opening of roll gap right-hand side 11. Pressure reduction right-hand side
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic Functions of the local control box:
The The func functi tion ons s can can be perf perfor orme med d inde indepe pend nden entl tly y of each each othe otherr for for the the leftleft-ha hand nd and and the the righ right-h t-han and d side side,, but but they they can can also also be simult simultane aneous ously ly perfor performed med on both both sides sides by simult simultane aneou ously sly pressi pressing ng the corres correspon pondin ding g keys keys left left and right. right. The The skew skew moni monito tori ring ng syst system em is acti active ve for for all all func functi tion ons, s, also also in loca locall oper operat atin ing g mode mode,, with with the the exce except ptio ion n of the the pres pressu sure re reduction reduction function. function.
For example, during forward movement of the floating roll on the right side (by means of slow or fast pressure build-up): 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 With the additi additiona onall functi function on “Pressure “Pressure reduction reduction”” whic which h acti activa vate tes s the the sole soleno noid id valv valves es y7 to y10, y10, the the main main pres pressu sure re cyli cylind nder ers s can can be de-a de-aer erat ated ed in loca locall oper operat atin ing g mode mode.. For For this this purp purpos ose, e, the the resp respec ecti tive ve push pushbu butto ttons ns “Fast pressure pressure buildbuild-up” up” and the left left side side or on the the righ rightt side side must must be sim simulta ultane neou ousl sly y pres presse sed. d. This This de-a de-aer erat atin ing g mode mode is very very help helpfu full “Pressure “Pressure reduction reduction”” on the part partic icul ular arly ly in the the init initia iall phas phase e of comm commis issi sion onin ing g.
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
POLYCOM-Hydraulic
Functioning
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Hydro-pneumatic Hydro-pneuma tic Spring System
Hydraulic Piston Accumulator
Hydraulic Plunger Cylinders
Adjustable mechanical Stopper
Pneumatic spring
Adjustable throttle valve
Back pressure valve
Floating Roller
Fix Roller
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Principle of Hydro-pneumatic Spring System
No grinding operation • Hydraulic side is de-pressurised de-pressurised
pOil = 0 bar
• Setting of initial nitrogen pressure
pGas = pPreset pressure
pGas
Piston
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Principle of Hydro-pneumatic Spring System
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
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Principle of Hydro-pneumatic Spring System
Grinding operation • Floating roll is pushed back by feed material • Hydraulic oil is pressed into accumulator • Nitrogen is compressed and pressure increases pOil = pa = pGas
• Nitrogen pressure is equal to hydraulic pressure
pOil = pa = pGas
sa > s0
sa
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Part Partsc schW hW
29 Sep Sep 2006 2006
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Parts installed at POLYCOM
Parts installed in a separate hydraulic room underneath the POLYCOM
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
1. Pressure Pressure-- free circul circulatio ation n
Conditions: • Electrical motor hydraulic pump is running • All solenoids are de-energized
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
1. Pressure Pressure-- free circul circulatio ation n Electric motor for pump
Pressure free circulation (p < 5 bar) All solenoids are de-energized
Pump stage A (75% oil flow) (pressure < 5 bar)
Non- return return-- valve valve opens opens at p > 5 bar bar 4/2- way valve valve Y1 Y1 deenergized = open (return flow pressure < 5 bar)
NonNon- retur returnn- valve valve Return flow filter with differential pressure switch S1
Pump stage B (25% oil flow) Non- return return-- valve valve opens opens at p> p> 5 bar 4/2- way valve valve Y2 Y2 Pressure limiting valve 180 bar
Y1 Y2
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
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 energized
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Part Partsc schW hW
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Y10 energized
I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Y6 energized energized
Flashing of Plunger cylinders
Pressure filter with p switch
Y2 energized energized
Y8 energized energized
Y9 energized
Y5 energized energized
Motor hydraulic pump on
P < 5 bar return flow Pressure filter with p switch
Y7 energized energized Valve block
P > 5 bar
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
3. Fast pressure increase
Conditions: • Y1 is energized • Y2 is energized • Y5 is energized (left (left side of POLYCOM) POLYCOM) • Y6 is energized (right (right side of POLYCOM) POLYCOM)
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Y6 energized energized
Fast pressure increase
Y1 energized energized Y2 energized energized
Y5 energized energized
Motor on
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
4. Slow pressure increase
Conditions: • Y 2 is energized energized • Y 5 is energized energized • Y 6 is energized energized
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Y6 energized energized
Slow pressure increase
Y2 energized energized
Y5 energized energized
Motor on
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
5. Pressure equilisation
Conditions:
• Slow pressure increase is finished • Y11 Y11 is energized energized
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Pressure equalization
2/2 way valve Y11 energized energized
Motor on
Nitrogen (N2)
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
6. Push back hydraulic – pressure release
Conditions: • Pump is running • Y7, Y8, Y9, Y10 are energized energized
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Push back back hydraulic hydraulic - pressure pressure release Y10 Y7, Y8, Y9 Y10 energized energized
Y8
Y9 Motor on
Y7
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
6. Push back hydraulic – moving
Conditions: • Y7, Y8, Y9, Y10 are energized energized • Y2, Y3, Y4 are energized
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Part Partsc schW hW
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I:\D I:\Dat aten en\P \Par arts tsch chW\ W\PO POLY LYCO COM M Mine Minera rals ls\A \Anl nlag agen en\C \CER ERRO ROWAL WAL\T \Tra rain inin ing\ g\Pr Pres esen enta tati tion on\3 \3 Poly Polyco comm-Hy Hydr drau auli lic. c.pp pptt
Y4 energized energized
Push back hydraulic hydraulic - moving
Y2 energized energized
Y3 energized energized
Motor on
