German MAPLE pump MAPLE model MAPLE price

MAPLE pump is an important device in hydraulic systems. It relies on the reciprocating motion of plungers in the cylinder block to change the volume of the sealed working chamber, thereby achieving oil suction and pressure discharge. Plunger pumps have advantages such as high rated pressure, compact structure, high efficiency, and convenient flow regulation. Plunger pumps are widely used in applications requiring high pressure, large flow, and flow regulation, such as hydraulic presses, construction machinery, and ships.

MAPLE pump structural form

Plunger pumps are divided into two representative structural forms: axial plunger pumps and radial plunger pumps; since radial plunger pumps belong to a new type of high-efficiency pump with high technical content, with the acceleration of localization, radial plunger pumps will inevitably become an important part of the plunger pump application field; a radial plunger pump is a plunger pump where the reciprocating motion direction of the piston or plunger is perpendicular to the drive shaft. Radial plunger pump working principle: Drive torque is transmitted from the drive shaft through a cross coupling to the star-shaped hydraulic cylinder block rotor, and the stator is not subject to other lateral forces. The rotor is mounted on the distribution shaft. The radially arranged plungers located in the rotor press tightly against the eccentric stroke stator via hydrostatically balanced slippers. The plunger is connected to the slipper by a ball joint and locked by a retaining ring. Two retaining rings hold the slippers against the stroke stator. When the pump rotates, it presses against the inner surface of the stator by centrifugal force and hydraulic pressure. When the rotor rotates, due to the eccentricity of the stator, the plunger performs reciprocating motion, and its stroke is 2 times the stator eccentricity. The stator eccentricity can be adjusted by two plungers positioned radially opposite each other on the pump body. Oil inlet and outlet pass through flow channels on the pump body and distribution shaft, and are controlled by the suction port on the distribution shaft; the hydraulic pressure generated in the pump body is absorbed by the hydrostatically balanced surface. The hydrostatic balance of the friction pair adopts an over-balance pressure compensation method, forming open-loop control. The bearings supporting the drive shaft only serve a supporting role and are not subject to other external forces. In hydraulic systems: Axial plunger pumps operate by utilizing the volume change produced by the reciprocating motion of plungers parallel to the transmission shaft within the plunger holes. Since the plungers and plunger holes of plunger pumps are circular parts, they can achieve very high precision fits during machining.

MAPLE pump classification

Plunger pumps are generally divided into single plunger pumps, horizontal plunger pumps, axial plunger pumps, and radial plunger pumps. 1) Single plunger pump: The structural composition mainly includes an eccentric wheel, plunger, spring, cylinder block, and two check valves. A sealed volume is formed between the plunger and the cylinder block hole. One rotation of the eccentric wheel causes the plunger to reciprocate once; downward motion sucks oil, and upward motion discharges oil. The volume of oil discharged per revolution of the pump is called displacement, which is related only to the structural parameters of the pump. 2) Horizontal plunger pump: A horizontal plunger pump consists of several plungers (generally 3 or 6) installed in parallel, using 1 crankshaft(s) to directly push the plungers via connecting rod sliders or an eccentric shaft to perform reciprocating motion, realizing a hydraulic pump for suction and discharge of liquids. They all adopt valve-type distribution devices, and most are fixed-displacement pumps. Emulsion pumps in coal mine hydraulic support systems are generally horizontal plunger pumps. Emulsion pumps are used at coal mining faces to provide emulsion for hydraulic supports; the working principle relies on the rotation of the crankshaft to drive the Piston to perform reciprocating motion, realizing liquid suction and discharge. 3) Axial type: Axial plunger pump (English name: Piston pump) is a plunger pump where the reciprocating motion direction of the piston or plunger is parallel to the central axis of the cylinder block. Axial plunger pumps operate by utilizing the volume change produced by the reciprocating motion of plungers parallel to the transmission shaft within the plunger holes. Since the plunger and plunger hole are both circular parts, they can achieve very high precision fits, resulting in high volumetric efficiency. 4) Straight-axis swashplate type: Straight-axis swashplate plunger pumps are divided into pressure-supply type and self-priming type. Pressure-supply type hydraulic pumps mostly use pressurized oil tanks; for hydraulic tanks relying on air pressure for oil supply, after each machine start-up, operation must wait until the hydraulic oil tank reaches the operating air pressure. If the machine is started when the air pressure in the hydraulic oil tank is insufficient, it will cause detachment of the slippers inside the hydraulic pump, leading to abnormal wear between the return plate and the pressure plate in the pump body. 5) Radial type: Radial plunger pumps can be divided into two categories: valve distribution and shaft distribution. Valve-distribution radial plunger pumps have disadvantages such as high failure rate and low efficiency. Shaft-distribution radial plunger pumps developed internationally in the 70s and 80s overcame the shortcomings of valve-distribution radial plunger pumps. Due to the structural characteristics of radial pumps, shaft-distribution radial plunger pumps are more impact-resistant, have longer service life, and higher control precision than axial plunger pumps. For pumps with short variable strokes, variation is achieved by changing the stator eccentricity under the action of the variable plunger and limit plunger, and the maximum stator eccentricity is 5—9mm (depending on displacement size), with a very short variable stroke. Moreover, the variable mechanism is designed for high-pressure operation and controlled by a control valve. Therefore, the pump has a fast response speed. The radial structural design overcomes problems such as uneven slipper wear in axial plunger pumps, significantly improving its impact resistance. 6) Hydraulic type: For hydraulic plunger pumps relying on pressurized oil tanks for oil supply, after each machine start-up, operation must wait until the hydraulic oil tank reaches the operating air pressure. Straight-axis swashplate plunger pumps are divided into pressure-supply type and self-priming type. Pressure-supply type hydraulic pumps mostly use pressurized oil tanks, and some hydraulic pumps themselves have a boost pump to provide pressure oil to the hydraulic pump inlet. Self-priming type hydraulic pumps have strong self-priming capability and do not require external oil supply.

MAPLE pump mechanical maintenance

For plunger pumps supplied with oil by a boost pump, after 3000h of use, operators need to inspect the plunger pump 1-2 time(s) daily to check whether the hydraulic pump operating sound is normal. If a decrease in hydraulic cylinder speed or stalling is found, the boost pump should be disassembled for inspection to check for scratches on the impeller edge and whether the internal gear pump clearance is excessive. For self-priming plunger pumps, the oil level in the hydraulic tank must not be lower than the lower limit of the oil gauge; sufficient hydraulic oil must be maintained. The higher the cleanliness of the hydraulic oil, the longer the service life of the hydraulic pump. The most important component of a plunger pump is the bearing. If bearing clearance occurs, the normal clearance of the three pairs of friction pairs inside the hydraulic pump cannot be guaranteed, and the thickness of the static hydraulic support oil film of each friction pair will be damaged, reducing the service life of the plunger pump bearing. According to data provided by hydraulic pump manufacturers, the average service life of bearings is 10000h; exceeding this value requires replacement with new ones. Removed bearings cannot be tested for clearance without professional detection instruments; only visual inspection is possible. If scratches or discoloration are found on the roller surface, they must be replaced. When replacing bearings, note the English letters and model of the original bearing. Plunger pump bearings mostly adopt high-load capacity bearings; purchase products from the original manufacturer with original specifications. If switching to another brand, consult personnel experienced with bearings to check tables for equivalents, with the aim of maintaining the bearing's precision grade and load capacity. The service life of a plunger pump is related to routine maintenance, the quantity and quality of hydraulic oil, and oil cleanliness. Avoiding wear on the plunger pump friction pairs caused by particles in the oil is also an effective way to extend plunger pump life. During maintenance, try to use original manufacturer parts when replacing components. These parts are sometimes more expensive than other counterfeit parts, but their quality and stability are better. Purchasing cheap counterfeit parts may seem to save costs in the short term, but brings hidden dangers and may cause greater harm to the use of the plunger pump. Distribution plates have two forms: flat distribution and spherical distribution. For spherical distribution friction pairs, if scratches on the cylinder block distribution surface are relatively shallow, they can be repaired by grinding; if grooves on the cylinder block distribution surface are deeper, "surface engineering technology" methods should first be used to fill the grooves before grinding. Blind grinding should be avoided to prevent thinning of the copper layer or exposure of the steel base causing oil leakage. Plunger pumps can also use frequency converters to save energy. Engineers from Shanghai Zhengyi point out: In actual production processes, plunger pumps usually regulate their working state by pressure or flow. When the actual pressure is greater than the required pressure, it is regulated by a relief valve to keep the working pressure stable, allowing the relief valve to release the excess. The motor always runs at full speed with repeated actions, and power consumption remains unchanged. When using overflow to regulate pressure and flow, part of the surplus flows back to the original system, resulting in useless power in the plunger pump and low work efficiency. If using Chuangjie energy-saving frequency converters, the relief valve can be set to close, and the working pressure is automatically adjusted by the energy-saving frequency converter itself to maintain stable working pressure and automatically track equipment pressure. This achieves automated control, thereby saving energy consumption. The biggest advantage of this regulation method is that it can reduce the operating energy consumption of the plunger pump, with power saving effects reaching 30% or more.

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