ABB 57310256-A DSBB 102 总线背板

　　在这种尺寸的铝挤压机中，液压元件会受到严重且持续的磨损。在生产各种零件数十年之后，液压系统维护（尤其是液压泵）变得更加频繁，从而减少了印刷机的正常运行时间和生产力。

　　与许多使用类似型号泵的客户一样，零件变得几乎不可能获得，合格的技术人员变得更难找到。泵老化的一个主要后果是液压油泄漏增加。Superior 开始每年记录 65 到 70 小时的停机时间来修复泄漏，以及内部维修和制造管道和其他部件的成本。

　　嵌入式液压泵升级解决方案

　　Superior 找到博世力士乐帮助开发解决方案，因为他们过去曾在其他液压项目上合作过，包括新系统和设备升级。“博世力士乐已经存在多年，他们在质量和服务方面享有盛誉。这对我们来说很重要，因为在挤压行业，当零件出现故障时，您不能只跑到五金店购买现成的新零件，”Superior 总裁兼执行官 Bradley Couture 说。

　　据 Bosch Rexroth 的冲压应用工程师 Michael Kramer 介绍，传统泵位于油箱顶部，从油箱中抽出油，并通过两个供油口将油供给系统。大多数现代泵仅使用一个供应端口运行，因此安装新泵需要重新配置系统。

　　此外，Superior 和 Bosch Rexroth 需要设计一个相对简单的升级。

　　在与 Superior 合作之前，博世力士乐团队认识到这种泵样式已经过时了。作为回应，他们在宾夕法尼亚州伯利恒的工程团队与德国的同事合作设计和设计了一个泵/歧管/控制装置的替代品。

　　在伯利恒工厂进行了 150 小时的测试并在力士乐客户的 2,400 吨挤压机上进行了超过 2,000 小时的生产测试后，该团队验证了新的嵌入式解决方案符合公司的性能和可靠性标准。

　　Superior 的项目是次有机会应用经过测试的插入式概念。解决方案的核心是 Rexroth A4VSO 500 轴向柱塞泵。“通过在吸入管底部添加一个止回阀并将部分填充量注入管道，我们可以确保管道入口在启动时或在最小流量条件下是满的，”克莱默说。

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　　In an aluminum extrusion press of this size, hydraulic components are under significant and constant wear and tear. After decades producing a wide range of parts, hydraulics maintenance — especially on the hydraulic pump — had become more frequent, reducing press uptime and productivity.

　　As with many customers using similar model pumps, parts became nearly impossible to obtain and qualified technicians became harder to find. One major consequence of the pump’s aging condition was increases in hydraulic fluid leaks. Superior began logging 65 to 70 hours of downtime every year to repair leaks, along with the costs of repair and fabricating piping and other parts in-house.

　　THE DROP-IN HYDRAULIC PUMP UPGRADE SOLUTION

　　Superior approached Bosch Rexroth to help develop the solution, since they had worked together on other hydraulic projects in the past, both for new systems and equipment upgrades. “Bosch Rexroth has been around for years, and they have a reputation for quality and service. That was important to us because in the extrusion industry, when a part goes down, you can’t just run to the hardware store to buy a new one off the shelf,” said Superior’s President and CEO Bradley Couture.

　　According to Michael Kramer, Press Application Engineer at Bosch Rexroth, the legacy pump sat on top of the tank, drawing oil up from the reservoir and supplying it to the system through two supply ports. Most modern pumps operate with just one supply port, so installing a new pump required system reconfiguration.

　　In addition, Superior and Bosch Rexroth needed to design a relatively straightforward upgrade.

　　Prior to working with Superior, the Bosch Rexroth team recognized that this pump style was becoming obsolete. In response, their engineering team in Bethlehem, PA, collaborated with associates in Germany to design and engineer a pump/manifold/controls replacement.

　　After 150 hours of testing at the Bethlehem facility and over 2,000 testing hours in production on a Rexroth customer’s 2,400-ton extrusion press, the team validated that the new drop-in solution met the company’s performance and reliability standards.

　　Superior’s project was the first opportunity to apply the tested drop-in concept. At the solution’s heart was a Rexroth A4VSO 500 axial piston pump. “By adding a check valve at the bottom of the suction pipe and injecting a partial filling volume into the pipe, we could ensure that the pipe inlet was full upon start-up or under minimal flow conditions,” Kramer said.