How to properly repair a hydraulic piston (hydraulic pump) that exceeds the stroke limit

The hydraulic pump is the heart of the hydraulic system of the busbar processing machine. Its normal working state directly affects the efficiency and reliability of the entire system. The over-limit problem, that is, the hydraulic pump exceeds its designed stroke range during operation, is one of the common faults of hydraulic pumps. This article will discuss how to repair the over-limit problem of the busbar machine hydraulic pump, in order to provide theoretical reference and practical guidance for relevant technicians.

In our daily after-sales service of busbar machines, the hydraulic pump of the punching unit cannot automatically return to the initial position due to exceeding the limit. This is often caused by the operator’s unfamiliarity with the equipment and misoperation: the operator repeatedly presses the manual operation button downward. Generally, this problem mainly occurs when customers install new busbar machine equipment.

Generally speaking, there are two ways to control the operation of the busbar machine unit, one is the foot pedal switch, and the other is the push button switch. Push button switches are often used for fine-tuning of equipment, while foot pedal switches are commonly used for daily operations. When the motor of the punching unit (or bending unit or cutting unit) of the equipment is powered on for the first time, the first press of the switch button or the foot pedal switch starts the working unit motor, and the second press of the switch button or the foot pedal switch is to operate the working unit action.

Working principle of the push button switch: When you press the button and do not release it, the working unit will automatically move up and down or forward and backward; when you press the button and release it quickly, the working unit will move forward once and stop. When you press the button continuously, the working unit will continue to move forward until it exceeds the limit and cannot automatically return to the initial position. This is mainly related to the Siemens PLC program.

Working principle of the foot pedal switch: When you press the button and do not release it, the working unit will automatically move up and down or forward and backward; when you press the button and release it quickly, the working unit will stop immediately and return to its initial position

So how to fix the problem that the hydraulic pump exceeds the limit and cannot be restored to the initial position due to misoperation of the button switch?

Let’s take the busbar machine punching unit hydraulic pump as an example:

Step 1: Power on the equipment and turn off the power to the punching unit motor.

Step 2: Find the punching unit hydraulic solenoid valve, and one person pokes the middle part of the solenoid valve with a screwdriver or iron rod;

Step 3: At this time, use the crane to pull the punching unit hydraulic pump upward to the hydraulic pump stroke range: 10-50mm. If the hydraulic pump cannot be pulled upward, use a screwdriver or iron rod to poke the middle part of the opposite side of the solenoid valve.

Step 4: Start the punching unit motor, release the crane, and one person presses the “UP” button, and the repair is complete.

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