1. Introduction
Concrete pumps are essential construction equipment that use pressure to transport concrete through pipelines. The hydraulic system in a concrete pump is typically a high-pressure and high-flow system. According to field observations, many types of concrete pumps operate for about 40 minutes, during which the hydraulic oil temperature can rise to 60°C. After approximately 2 hours, the system reaches a thermal equilibrium temperature above 70°C, whereas the normal operating temperature should be around 50°C. This excessive heating of the hydraulic system is a common issue that affects performance and longevity.2. Hazards of Hydraulic System Heating in Concrete Pumps
Excessive heating of the hydraulic system can significantly impact the performance and reliability of concrete pumps. The main hazards include: (1) Increased fluid temperature reduces viscosity, leading to higher internal leakage and reduced pump flow. (2) High temperatures cause seals to degrade, reducing their effectiveness and potentially leading to leaks. (3) Thermal expansion differences between valve components may cause jamming, preventing the pump from functioning properly. (4) Lower viscosity decreases lubrication efficiency, accelerating wear on hydraulic components and shortening their lifespan. To prevent these issues, some pumps must be shut down periodically to cool down, which reduces operational efficiency and delays construction progress. Therefore, it is crucial to identify and address the root causes of overheating to maintain optimal performance and extend the life of the hydraulic system.3. Main Causes of Hydraulic System Heating and Solutions
Heating in the hydraulic system can be attributed to two main categories: design flaws or component failure and improper usage. Each cause requires different diagnostic and corrective approaches.3.1 Design-Related Issues Leading to Overheating
(1) Incorrect hydraulic oil selection can lead to overheating. If the oil has too low a viscosity at high temperatures, it increases internal leakage, which in turn raises the oil temperature further. The solution is to select oil with appropriate viscosity based on the system's load and operating conditions. (2) An improperly designed fuel tank can reduce cooling efficiency. A small tank volume or poor layout (such as close proximity of suction and return lines) limits the oil’s ability to cool and separate contaminants. Increasing the tank size and adding a baffle between the inlet and outlet pipes can improve cooling performance. (3) Inadequate cooler placement or insufficient cooling capacity can also contribute to overheating. Air-cooled systems are more common, but if the cooler is installed on a low-flow line, its effectiveness is limited. Installing an independent cooling circuit or placing the cooler on the main return line can enhance cooling. Additionally, ensuring proper fan speed and pressure regulation helps maintain efficient operation. (4) Improperly sized hydraulic components, such as valves and pumps, can cause excessive pressure loss and heat generation. Selecting components that match the system’s maximum pressure and flow requirements minimizes energy loss and reduces overheating risks. (5) Poor pipeline design, including small diameters or sharp bends, increases pressure drop and heat generation. Proper pipe sizing and installation help maintain smooth flow and minimize heat buildup.3.2 Component Failure or Improper Usage Causing Overheating
(1) Low oil levels in the reservoir reduce cooling efficiency. Maintaining the correct oil level ensures proper heat dissipation and prevents overheating. (2) A clogged or dirty cooler can reduce its effectiveness. Regular cleaning and inspection of the cooler, along with adjusting safety valve settings, ensure optimal performance. (3) Incorrect pressure settings on relief or sequence valves can lead to excessive heat. Adjusting these valves to match system requirements helps maintain stable pressure and prevent overheating. (4) Increased internal leakage from damaged components raises oil temperature and reduces system efficiency. Regular maintenance and replacement of worn parts are essential to prevent this.In conclusion, overheating in concrete pump hydraulic systems is a critical issue that affects performance, safety, and longevity. Manufacturers should focus on optimizing design to minimize heat generation, while users must follow proper maintenance procedures to ensure reliable operation. By addressing the root causes of overheating, both parties can improve efficiency, reduce downtime, and extend the life of the equipment.
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