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Company Synthesis TMK. offers services for overhaul of industrial hydraulic presses.
Types of Press
In the broadest sense of the word, an industrial hydraulic press is a mechanism designed to process anything with the pressure created by a liquid. The principle of operation of such a press is based on one of the basic laws of physics, namely Pascal’s law, which states that the pressure exerted on a liquid in one place is evenly distributed throughout its volume. That is, schematically, the work of almost any industrial hydraulic press is to transfer through the hydraulic cylinder to the part or workpiece pressure generated by the hydraulic unit.
Industrial hydraulic presses are currently represented by a wide range of products of foreign and domestic production (including those of the USSR). They are used for stamping parts from blanks (including in the automotive industry), calibration, hooding, bending, editing, firmware, pressing and some other operations. Among the industrial hydraulic presses there are real giants, whose height exceeds 10 meters, and the weight is estimated in tens of tons. Such specific equipment is usually used in mechanical engineering, as well as for the repair of railway equipment.
By design type, industrial hydraulic presses are divided into vertical and horizontal. As the name suggests, a vertical hydraulic press is a tall column in which the piston goes up and down. Accordingly, the horizontal press the main size is its length, and the piston in it goes perpendicular to the vertical plane.
Preparatory stage of work
The preparatory stage of the overhaul of industrial hydraulic presses is to study the drawings of industrial facilities, passports of press equipment, instructions and technical specifications. Also, before the start of work, our specialists develop PPR for the installation of the press.
Since there are real giants among industrial hydraulic presses and, given the high vibration load of this equipment, all work on overhaul, subsequent installation and commissioning is carried out exclusively in accordance with the technical documentation of the press manufacturer, TU for connection to intra-factory networks, projects for their placement, and in addition: updated versions of regulatory documents (GOST, SNIP, SP, etc.).
Remont of Hydraulic Presses
The most responsible and, as a consequence, the most loaded hydraulic press unit is the hydraulic cylinder, the performance of which determines the performance characteristics of the entire press. Failure and forced downtime of presses is most often due to the occurrence of cracks or ruptures of metal in the most loaded sections of the cylinder, and as a result: due to leaks of oil and working fluids, including from under the rod and from under the plunger. Often, a high-pressure hydraulic pump also requires repair.
The timing and cost of the repairs we offer to customers are 100% reasonable and realistic.
Analysis of a large number of damages allows us to say with confidence that the main causes of malfunctions of the hydraulic press and subsequent emergency stops are, as a rule, errors in calculations, the presence of internal defects of the metal, design defects, improper machining, the action of reactive forces, as well as neglect and non-compliance with maintenance technologies and scheduled preventive repairs. In the absence of the necessary technical documentation, our specialists are able to quickly restore or re-develop it. The timing and cost of the repairs we offer to our customers are 100% reasonable and realistic.
The procedure of overhaul of the hydraulic press includes a whole range of mandatory and even wider list of recommended works. The first thing that the specialists of our company do is carefully examine the unit and make a defective list. Then there is the maximum possible dismantling of the press. Removed nodes are cleaned, washed, a new lubricant is laid in them. The next stage of work is a defect, during which our engineers decide what will be more expedient and profitable for the client: restore a particular part during repair or replace it with a new one. Often (this primarily concerns equipment produced in the years of the existence of the USSR) press parts that require replacement are made according to individual drawings, which are also performed by specialists of our company.
The surfaces of the slider, flywheel, wall, tables and other basic elements of the industrial hydraulic press are necessarily treated accordingly. In the process of overhaul of the nodes, bronze liners and bushings are used, new bearings are installed.
In the process of repairing hydraulic cylinders, the specialists of our company replace the glands and cuffs, and in special cases – rods and transition bushings. During the repair of control valves, the efficiency of electromagnetic starters is restored, restored or changed to new spools. If necessary, the pneumatic equipment is replaced, the state of the oil plant is audited, as well as the oil pipes are repaired.
Synthesis TMK. perform work on the overhaul of hydraulic presses qualitatively, in a short time and at an adequate price
After completion of the overhaul, the industrial hydraulic press is installed on the old or new place with connection to the air, oil and other highways, as well as to the power grid. After that, our specialists set standards for the accuracy of the slider. At the final stage of commissioning tests, a test run-in of the press is carried out with the control of the accuracy of its operation. After that, the unit is painted and handed over to operation services.
FUNDAMENT FOR HYDRAVLIC PRESS
In the process of overhaul of the hydraulic press, the condition of its foundation is also studied. If it has lost its structural integrity and its further use is not possible, our company can provide a service for dismantling the old foundation and installing a new foundation from reinforced concrete of high grades with the necessary number of press mounting points.
Equipment and equipment for installation
The efficiency and speed of installation of industrial hydraulic presses depends not only on the qualifications of the personnel who carry out these works, but also on the used equipment and means of mechanization: portal systems, mounting cranes, lifting mechanisms, etc. The final choice of equipment and its parameters is fixed in the PPR.
Why are we?
Our company has extensive experience in the field of overhaul of large-sized and large-tonnage equipment, in particular, such as industrial hydraulic presses in a short time and, including, in tight conditions without stopping production processes. By ordering the service of overhaul of your hydraulic press in our company, you are guaranteed to receive high-quality service, and save yourself from the undesirable consequences of poorly carried out, repairs, errors in the installation of the press and connecting it to communications, and, accordingly, financial losses caused by improper operation of the equipment.
Normative documents
GOST 31733-2012 “Hydraulic Presses”. Safety requirements”.
GOST 12.2.017-93 “Forge-press equipment”.
GOST 12.1.003-83 General requirements for noise safety.
GOST 12.1.004-91 General requirements of fire safety.
GOST 12.1.012-90 General requirements of vibration safety.
GOST 12.1.019-79 General requirements for electrical safety.
GOST 12.2.003-91 “Production equipment”.
GOST 12.2.007.1-75 “Electric rotating machines”. Safety requirements”.
GOST 26583-85 System of maintenance and repair of technological equipment of machine-building enterprises.
GOST 27487-87 Electrical equipment of production machines. General technical requirements and test methods.”
SNIP 3.03.01-87 “Carrying and enclosing structures”.
SNIP II-23-81 “Steel Structures”.
SNIP III-18-75 “Metal structures”.
SNIP 52-01-2003 “Concrete and reinforced concrete structures”.
SNIP II-90-81 “Production buildings of industrial enterprises”.