Pilot-type relief valve fault diagnosis and troubleshooting
With the injection molding machine's hydraulic system operating under high pressure, pilot relief valves are commonly used in the control circuits of these systems. In practice, to ensure maximum efficiency and protect the control system, it is essential to perform accurate and timely diagnosis and troubleshooting of the pilot relief valve. A failure in the pilot-type relief valve can lead to the injection molding machine being unable to function properly. Based on observed symptoms, potential causes include a broken pilot spool spring, a blocked or damaged orifice, poor sealing at the pilot valve port, or a stuck main spool. To address these issues, the following measures can be taken: replace or flatten the damaged washer for emergency use, clean and clear the blockage, grind or break the oil passage as an emergency fix, and clean and regrind the affected parts.
Pressure-limiting instability is another common issue with pilot-type relief valves. This instability may manifest as either excessively low or high pressure in the hydraulic system, leading to weak actuation, pipe leakage, pump body damage, or even rupture of the system components. The causes of such failures typically include incorrect pressure adjustment, a bent or softened pilot spool spring, or contaminated oil with poor flow characteristics. To resolve these problems, the pressure should be readjusted, the faulty spring replaced, and the system cleaned thoroughly.
Pilot-type relief valve pressure instability is often a progressive failure, whereas valve failure itself tends to occur suddenly. After troubleshooting and resolving the fault, it is important to re-adjust the pressure limit on the pilot-operated relief valve to ensure the system operates safely and efficiently. Regular maintenance and monitoring of the hydraulic system can help prevent such issues and extend the life of the equipment.
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