1 挑战水深每增加 10 米，压力增加 1 巴设备处于海水腐蚀环境防腐蚀措施必不可少电子液压元件无法在海水环境中使用防渗水的措施极其重要

1

挑战

水深每增加 10 米，压力增加 1 巴

设备处于海水腐蚀环境

防腐蚀措施必不可少

电子液压元件无法在海水环境中使用

防渗水的措施极其重要

使用工况很难监测诊断

| 2011-08-11 | | DC-IA/MKT32 | | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

深海液压系统– 挑战博世力士乐深海液压系统

2 | 2011-08-11 | | DC-IA/MKT32 | | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

博世力士乐深海液压系统

工程案例：深海履带挖掘机 23 个控制阀块 27 根油缸 7 个液压马达


液压油箱海水

弹簧使内外压差为 1 巴

液压油与海水分离油箱里的绝对压力为 1 巴

压力补偿的优点 :

设计压力仅为液压系统压力，而不是静态压力密封不需要太复杂


压力解决方案：压力补偿器


防腐蚀解决方案使用防海水元器件不锈钢配件和测量头特定喷涂 :

第一层 =亚美隆 400 铝层 100 - 120µ

第二层 =亚美隆 400 面漆 100 - 120µ



电气解决方案密封的阀块 , 充满液压油并有压力补偿盖板有防海水密封空气已完全排出专门设计的开关和比例阀，比例阀带有特制的电磁线圈及接线插头深海电气插头



用焊接代替螺纹联接设计以防海水渗入油缸高压位移传感器，带有外壳保护按超高压设计油缸结构（可承载 600 bar ）深海电气插头特殊表面处理

油缸防渗水解决方案 1



活塞杆密封压力补偿特殊的防尘圈主密封件不与海水直接接触高强度螺栓用盖板和密封圈保护以防海水渗入

压力补偿

油缸防渗水解决方案 2



液压系统故障监测诊断解决方案所有油缸配备接近开关或位移传感器

主泵配备摆角位移传感器

马达配备速度传感器以监控运行状况

堵塞指示灯监控压力和回油过滤器

回油路配备污染度检测仪

特殊深海压力传感器监控系统主要功能

压力补偿器配备液位开关

油箱配备水分检测传感器和温度传感器



深海动力站系统博世力士乐深海液压系统

控制阀块控制阀块

轴向柱塞马达轴向柱塞马达

油箱油箱

油缸油缸

过滤器过滤器

泵泵

补偿器 I补偿器 I

深海电控马达深海电控马达

补偿器 II补偿器 II


深海动力站系统–压力测试

测试结果显示：在模拟海底 6000 米环境 ( 周围压力 600 bar) 下，动力站仍然能正常工作


11 | 2011-08-11 | | DC-IA/MKT32 | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Challenges

ambient pressure 1 bar per 10 m water depth

equipment located in salt water

corrosion protection is indispensable

electro hydraulics does not work in salt water

avoid water penetration at all costs

diagnosis of operating conditions

Deep water hydraulics – challenges and solutions

Bosch Rexroth Deep Water Hydraulics



Deep sea crawler 23 control manifolds 27 cylinder axes 7 hydraulic motors



Hydraulic oil reservoirSea water

Spring ensure pressure difference to 1 bar

medium separation absolute pressure in the reservoir is 1 bar

Benefits of pressure compensation: design pressure is ‘‘only‘‘ the hydraulic

pressure, not the static pressure seals are less complicated



Solutions – corrosion protection use of sea water protected components stainless steel fittings and minimess special paint:

1st layer =Amerlock 400 aluminum 100 - 120µ

2nd layer =Amerlock 400 color 100 - 120µ



Solutions – electro hydraulics encapsulated manifold, oil filled and pressure compensated sea water resistant seal for cover air has to be vented completely specially developed on-off and prop. valves

with modified solenoids and terminal strips sub sea electrical connector



welded instead of threaded design to avoid water penetration high pressure position transducer, encapsulated extra heavy design for cylinder bottom and thread for position

encoder (600 bar at bottom and thread) sub sea electrical connector special paint

Solutions – deep water cylinder



rod seals pressure compensated special wiper ring main seal not in contact with sea water high-strength bolts protected with cover

and seals in order to avoid water penetration

Pressure compensation

Solutions – deep water cylinder



Solutions – diagnosis of hydraulic system

all cylinders equipped either with proximity switches or position encoders

main pump fitted with swivel angle transducer

speed sensors for track drive motors

clogging indicator for pressure and return filters

particle counter in return line

special sub sea pressure sensors for all main functions

compensators equipped with level indicators

oil reservoir with water ingress and temperature sensors



Deep sea power unit



Deep sea power unit – test in pressure chamber

test up to 6,000 m water depth (ambient pressure 600 bar) have been successful



Summary and prospects deep water hydraulics is feasible but expensive breakthrough for the profitability is not far away raising energy costs and increasing consumption are driving the need for sub sea

solutions but there are still some open points:

electric energy supply in great water depth maintenance of filters and pressure medium long service life

years ago, Bosch Rexroth already started to develop special solutions for underwater

applications. Nowadays we are concentrating on sub sea in future, hydraulic systems for sub sea applications will be lighter, even more accurate

and easier to control

Documents

1 挑战 水深每增加 10 米，压力增加 1 巴 设备处于海水腐蚀环境 防腐蚀措施必不可少 电子液压元件无法在海水环境中使用 防渗水的措施极其重要

1 挑战水深每增加 10 米，压力增加 1 巴设备处于海水腐蚀环境防腐蚀措施必不可少电子液压元件无法在海水环境中使用防渗水的措施极其重要