ATOS axial piston pump PVPC-C-5090/1D 11 in stock

Brand

ATOS/Italian Atos

Application Areas

Environmental Protection, Chemical Industry, Petroleum, Energy, Comprehensive

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ATOS Gear Pumps, ATOS Axial Piston Pumps, ATOS Vane Pumps, ATOS Cylinders, ATOS Relief Valves, ATOS Proportional Valves

ATOS Piston Pump Working Principle

ATOS piston pumps are an important component of hydraulic systems. They rely on the reciprocating motion of pistons within the cylinder to change the volume of the sealed working chamber, thereby achieving oil suction and pressure. Piston pumps have advantages such as high rated pressure, compact structure, high efficiency, and convenient flow regulation, and are widely used in high-pressure, high-flow, and flow-regulating applications, such as hydraulic presses, construction machinery, and ships.

The Italian ATOS piston pump is a type of reciprocating pump, belonging to the category of positive displacement pumps. Its pistons are driven by the eccentric rotation of the pump shaft, resulting in reciprocating motion. Both its suction and discharge valves are one-way valves. When the piston is pulled outward, the pressure in the working chamber decreases, the outlet valve closes, and when the pressure is lower than the inlet pressure, the inlet valve opens, allowing liquid to enter. When the piston is pushed inward, the pressure in the working chamber increases, the inlet valve closes, and when the pressure is higher than the outlet pressure, the outlet valve opens, allowing liquid to exit. When the drive shaft rotates the cylinder block, the swashplate pulls the piston out of or pushes it back into the cylinder block, completing the oil suction and discharge process. The oil in the working chamber formed by the piston and cylinder bore communicates with the pump's suction and discharge chambers through a distribution plate. A variable displacement mechanism is used to change the swashplate's angle; adjusting the swashplate's angle changes the pump's displacement.

The ATOS axial piston pump is a new type of high-efficiency pump with advanced technology. With the continuous acceleration of domestic production, radial piston pumps will inevitably become an important part of the piston pump application field; for details, please refer to the radial piston pump encyclopedia. The following explanation only uses the axial piston pump as an example.

The ATOS axial piston pump operates by utilizing the volume change generated by the reciprocating motion of a piston parallel to the drive shaft within a piston bore. Because both the piston and the piston bore are circular parts, high precision fitting can be achieved during machining, resulting in advantages such as high volumetric efficiency, smooth operation, good flow uniformity, low noise, and high operating pressure. However, it is more sensitive to hydraulic oil contamination, has a more complex structure, and is more expensive.

The ATOS axial piston pump's pumping mechanism comprises two precision pairs: a plunger and a barrel assembly (Figure 5-11), and a delivery valve assembly (Figure 5-11), consisting of a delivery valve and a delivery valve seat.

The ATOS axial piston pump's plunger and barrel assembly are a precision pair, mated and ground together, and are not interchangeable. They require high precision, a smooth surface finish, and good wear resistance, with a radial clearance of 0.002–0.003 mm.

The plunger head has a beveled groove cut into its cylindrical surface, communicating with the top through radial and axial holes. This serves to alter the circulating oil supply. The barrel sleeve has inlet and outlet oil holes, both communicating with the low-pressure oil chamber within the pump body. After the barrel sleeve is installed in the pump body, it is secured with a locating screw.

The method of altering the oil supply varies depending on the position of the beveled groove on the plunger head.

The delivery valve and delivery valve seat are also a precision pair; they are not interchangeable after mating and grinding, with a clearance of 0.01mm.

The delivery valve is a one-way valve. Under spring pressure, the upper conical surface of the valve fits tightly with the valve seat. Its function is to isolate the high-pressure fuel line from the upper cavity of the plunger when fuel supply stops, preventing fuel from flowing back into the injection pump.

The lower part of the delivery valve has a cross-section, which serves both as a guide and allows diesel fuel to pass through. Below the conical surface of the delivery valve is a small cylindrical surface called a pressure-reducing ring. Its function is to rapidly reduce the fuel pressure in the high-pressure fuel line at the end of fuel supply, preventing dripping at the injection orifice. When the ring falls into the valve seat, the upper volume rapidly increases, the pressure rapidly decreases, and injection stops quickly.

ATOS Axial Plunger Pump Maintenance Types ATOS axial piston pumps generally employ a cylinder block rotation and end-face distribution method. A friction pair consisting of a bimetallic plate and a steel distributor plate is inlaid on the cylinder block end face, and most use a planar distribution method, making maintenance relatively convenient. The distributor plate is one of the key components of the axial piston pump. During pump operation, on the one hand, the high-pressure oil in the working chamber pushes the cylinder block towards the distributor plate; on the other hand, the oil film pressure between the distributor plate and the cylinder block forms a hydraulic counter-thrust force on the cylinder block, causing the cylinder block to move away from the distributor plate. The hydraulic clamping force Fn of the cylinder block on the distributor plate is designed to be slightly greater than the hydraulic counter-thrust force Ff of the distributor plate on the cylinder block, i.e., Fn/Ff = 1.05~1.1, ensuring normal pump operation and maintaining high volumetric efficiency.

ATOS Axial Piston Pump Troubleshooting

ATOS Axial Piston Pump Flow Problems

(1) Insufficient suction volume. The cause is excessive resistance in the suction line or insufficient oil replenishment. For example, excessive pump speed, low oil level in the tank, air leakage in the inlet pipe, or clogged oil filter. (2) Excessive leakage. This is caused by excessive pump clearance and poor sealing. For example, the distributor plate may be scratched by metal fragments or iron filings, causing oil leakage at the end face; the one-way valve sealing surface in the variable mechanism may not fit properly; and there may be sand holes or scratches on the support surfaces of the pump body and distributor plate. The damaged part of the pump can be identified by checking for foreign matter mixed in the hydraulic oil inside the pump body.

(3) The swashplate angle is too small, resulting in a small pump displacement. This requires adjusting the variable piston to increase the swashplate angle.

Discharge is not zero in the neutral position.

The swashplate angle of a variable axial piston pump is called the neutral position when it is zero. At this time, the pump's output flow should be zero. However, sometimes the neutral position deviates from the midpoint of the adjustment mechanism, and there is still flow output at the midpoint. This is caused by the controller's position deviation, loosening, or damage, requiring readjustment, tightening, or replacement. Insufficient pump angle holding force and wear of the swashplate trunnion can also cause this phenomenon.

ATOS Axial Piston Pump Output Flow Fluctuation Fluctuations in the output flow rate of an ATOS axial piston pump are related to many factors. For variable displacement pumps, this can be attributed to poor control of the variable displacement mechanism, such as foreign objects entering the mechanism and causing scratches, wear marks, or damage on the control piston, resulting in unstable piston movement. Insufficient amplifier power, damaged parts, or poor damping efficiency in spring-loaded control pistons can also cause unstable piston movement. Unstable flow rate is often accompanied by pressure fluctuations. These types of faults generally require disassembling the hydraulic pump, replacing damaged parts, increasing damping, improving spring stiffness, and increasing control pressure.

ATOS Axial Piston Pump Output Pressure Abnormalities

The output pressure of an ATOS axial piston pump is determined by the load and is approximately proportional to the input torque. There are two types of abnormal output pressure faults:

(1) Output pressure too low

When the pump is in self-priming mode, if there is air leakage in the inlet pipe or significant leakage in the hydraulic cylinder, check valve, or directional valve in the system, the pressure will not rise. This requires finding the leak, tightening, or replacing the seals to increase the pressure. If the relief valve is faulty or the adjusted pressure is too low, the system pressure will also not rise; the pressure should be readjusted or the relief valve repaired. If the hydraulic pump cylinder body and distributor plate deviate, causing significant leakage, the cylinder body may crack in severe cases; in this case, the mating surfaces should be re-ground or the hydraulic pump replaced.

(2) Excessive Output Pressure

If the circuit load continues to increase, the pump pressure will also continue to increase, which is normal. If the load is constant and the pump pressure exceeds the required load value, the hydraulic components other than the pump, such as the directional valve, pressure valve, transmission device, and return oil pipe, should be checked. If the maximum pressure is too high, the relief valve should be adjusted.

ATOS Axial Piston Pump Vibration and Noise

ATOS axial piston pump vibration and noise occur simultaneously. They not only harm the machine operator but also pollute the environment.

(1) Mechanical Vibration and Noise

Noise can be generated by misalignment or jamming of the pump shaft and motor shaft, damage to bearings and couplings of the rotating shaft, broken elastic pads, and loose assembly bolts. For pumps operating at high speeds or transmitting large amounts of energy, regular inspections are necessary to record the amplitude, frequency, and noise of each component. If the pump's rotational frequency is the same as the natural frequency of the pressure valve, resonance will occur; the pump's speed can be changed to eliminate resonance.

(2) Noise generated by fluid flow in the pipeline

Noise can be generated by a narrow inlet pipe, insufficient flow capacity or blockage of the inlet filter, air intake in the inlet pipe, excessively high oil level, insufficient oil suction due to low oil level, and liquid hammer in high-pressure pipelines. Therefore, it is essential to design the oil tank correctly and select the appropriate filter, oil pipe, and directional valve.

ATOS Axial Piston Pump Overheating There are two main reasons for excessive heat generation in ATOS axial piston pumps: First, mechanical friction generates heat. Due to dry or semi-dry friction on the moving surfaces, heat is generated through friction between moving parts. Second, fluid friction generates heat. High-pressure oil leaks into the low-pressure chamber through various gaps, resulting in a significant loss of hydraulic energy as heat. Therefore, correctly selecting the clearance between moving parts, the tank volume, and the cooler can prevent excessive pump overheating and high oil temperature. Additionally, a clogged return oil filter causing excessive back pressure can also lead to high oil temperature and pump overheating.

The main causes of oil leakage in ATOS axial piston pumps are as follows:

(1) Damaged spindle oil seal or defects/scratches on the shaft;

(2) Excessive internal leakage increases pressure at the oil seal, damaging or dislodging it;

(3) The drain pipe is too thin or too long, causing leakage at the seal;

(4) Loose external oil pipes, damaged pipe joints, aged or cracked gaskets;

(5) Loose bolts in the variable displacement adjustment mechanism, resulting in a damaged seal; (6) Cast iron pump casing has sand holes or poor welding.

Key Features of ATOS (Italy)

**Dual-plunger structure, low pressure pulsation, long sapphire ball life;**

**Imported sapphire plungers and balls ensure accurate flow;**

**Communicates with a computer via RS232 interface for direct computer control;**

**Materials in contact with the medium are resistant to organic solvent corrosion;**

**Built-in overpressure protection and flow correction system;**

**Large LCD display;**

**Carefully designed venting device effectively removes air bubbles from the pumped liquid;**

**Flow and pressure settings can be memorized;**

**Communication with PLC (customizable)**

**Software Functions:**

**Real-time display of current pressure, set pressure, and set flow rate;**

**Real-time curve display of pump operating pressure;**

**Flow and pressure can be set in two ways, quick and practical;**

**Timer function for convenient pump operating time setting;**

**Saves current operating pressure for easy viewing;**

**Prints important parameters such as current pressure.** Horizontal flow pumps (plunger pumps) are widely used in petroleum exploration and development evaluation experiments, catalytic reactions in petrochemicals, polymerization reactions, food processing, pharmaceuticals, liquid chromatography analysis, supercritical extraction, separation, atomic energy science, environmental science, process equipment, experimental equipment, and micro-volume delivery of various liquids. The TBP series horizontal flow pumps (plunger pumps) meet the performance requirements for oilfield fluid seepage and rheological characteristic research, filling a gap in my country's equipment manufacturing capabilities in related experimental technologies and reaching the level of similar instruments.

(ATOS Italian Plunger Pump Mechanical Maintenance)

(ATOS Italian Plunger Pump Mechanical Maintenance) For piston pumps supplied with hydraulic fluid by a make-up pump, operators should inspect the pump 1-2 times daily after 3000 hours of use, checking for normal operating noise. If a decrease in hydraulic cylinder speed or stalling is observed, the make-up pump should be disassembled and inspected for scratches on the impeller edges and excessive clearance in the internal gear pump. For self-priming piston pumps, the hydraulic fluid level in the tank must not fall below the lower limit indicated on the gauge; a sufficient quantity of hydraulic fluid must be maintained. Higher hydraulic fluid cleanliness results in a longer pump lifespan.

The most critical component of a piston pump is the bearing. If the bearing has clearance, the normal clearance of the three pairs of friction surfaces inside the hydraulic pump cannot be guaranteed. This also damages the hydrostatic support oil film thickness of each friction surface, reducing the service life of the piston pump bearing. According to data provided by hydraulic pump manufacturers, the average service life of a bearing is 10,000 hours; exceeding this value requires replacement. Without professional testing equipment, the clearance of a disassembled bearing cannot be detected; it can only be visually inspected. If scratches or discoloration are found on the roller surface, the bearing must be replaced.

When replacing bearings, pay attention to the letters and model number of the original bearing. Piston pump bearings are mostly high-load-capacity bearings; it is best to purchase products from the original manufacturer and of the original specifications. If replacing with a different brand, consult an experienced bearing specialist to refer to a table for the correct replacement, in order to maintain the bearing's precision grade and load capacity.

The lifespan of a plunger pump is related to routine maintenance, the quantity and quality of hydraulic oil, and oil cleanliness. Preventing particles in the hydraulic oil from causing wear on the plunger pump's friction pairs is also an effective way to extend its lifespan. When replacing parts during maintenance, original manufacturer parts should be used whenever possible. These parts are sometimes more expensive than imitations, but their quality and stability are better. Purchasing cheaper imitations may seem cost-effective in the short term, but it introduces hidden dangers and may cause greater damage to the plunger pump.

Distributor plates come in two forms: planar and spherical. For spherical distributor plates, if the scratches on the cylinder block's distributor surface are shallow, they can be repaired by grinding. If the grooves on the cylinder block's distributor surface are deep, surface engineering techniques should be used to fill the grooves before grinding. Blind grinding should be avoided to prevent thinning of the copper layer or oil leakage through the steel base.

Plunger pumps can also save energy using frequency converters. Engineers at Shanghai Zhengyi point out that in actual production, plunger pumps typically regulate their operating state based on pressure or flow rate. When the actual pressure exceeds the required pressure, an overflow valve is used to stabilize the operating pressure, releasing the excess. Meanwhile, the motor runs at full speed repeatedly, resulting in constant power consumption.

When using overflow to regulate pressure and flow, some excess flow returns to the original system, causing wasted power and low efficiency in the plunger pump. However, with the use of Chuangjie energy-saving frequency converters, the overflow valve can be permanently closed, and the frequency converter itself automatically adjusts the operating pressure to maintain stability and track the equipment's pressure. This achieves automated control, thus saving energy. This adjustment method reduces the operating energy consumption of the plunger pump, achieving energy savings of over 30%.

Main Features and Functions

1. Energy saving effect of 30-70%.

2. Soft start of the motor, reducing mechanical shock.

3. No high-pressure throttling energy loss.

4. Features automatic protection against undervoltage, overvoltage, overload, short circuit, and phase loss.

5. Replaces the original system, reducing product procurement costs (new equipment purchase).

6. Reduces mechanical maintenance costs.

7. Simple operation and remote control capability.

ATOS Italy - Maintenance

(1) Check the plunger for scratches and corrosion; replace with a new one if necessary.

(2) Check the plunger assembly fit. Insert the plunger end into the plunger sleeve at approximately 60°. If the plunger slides down slowly under its own force, the fit is good.

(3) Check the plunger assembly seal. Hold the plunger sleeve with one hand, and block the oil inlet at the top and side of the plunger with two fingers. Pull out the plunger with the other hand; if a strong suction is felt and the plunger immediately retracts to its original position, the plunger assembly seal is good. Otherwise, replace the plunger assembly.

(4) Check the pressure reducing ring of the delivery valve assembly for wear, steps, or scratches; replace if necessary. (5) Check the fit of the delivery valve assembly. Block the lower hole of the delivery valve with one finger, and gently press the delivery valve downwards with another finger. If it automatically springs back to its original position when the finger is removed from the upper end of the delivery valve, it indicates that the delivery valve assembly is sealing well; otherwise, the delivery valve assembly should be replaced.

(6) Check the tappet. The standard clearance between the injection pump body and the tappet is 0–0.03 mm. If it exceeds 0.2 mm, the part should be replaced.

(7) Check the clearance between the plunger flange and the groove of the control sleeve. It should be 0.02–0.08 mm. If it exceeds 0.12 mm, the control sleeve must be replaced.

ATOS Axial Piston Pump

The company primarily deals in European and American products, and can source brands from any European country. For example, key German brands include: BURKERT, DEMAG, HAWE, REXROTH, HYDAC, PILZ relays, FESTO, IFM sensors, E+H, HEIDENHAIN, P+F sensors, SICK, TURCK, HIRSCHMANN industrial switches, Henschler, MURR, SCHMERSAL, SAMSON, and EPRO (a subsidiary of Emerson).

American brands include MOOG, ASCO solenoid valves, MAC solenoid valves, NUMATICS, PARKER pneumatics and hydraulics, VICKERS, and ROSS.

British brands include Norgren. Italian brands OMAL, ATOS, CAMOZZI, UNIVER, and KEMOL

Rexroth solenoid valves, Rexroth piston pumps, Rexroth relief valves, Rexroth proportional valves, and Rexroth vane pumps