German PERMA pump PERMA model PERMA price

PERMA pumps are an important component in hydraulic systems. They rely on the reciprocating motion of plungers within the cylinder block to change the volume of the sealed working chamber, thereby achieving oil suction and pressure discharge. Plunger pumps offer 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 rates, and flow adjustment, such as hydraulic presses, construction machinery, and ships.

PERMA pump usage instructions

For plunger pump cylinder blocks fitted with copper bushings, installation can be performed by replacing the copper bushings. First, trim the outer diameters of a set of plunger rods to a uniform size, then polish the outer diameter using sandpaper of 1000# grit or higher. Three methods for installing copper bushings in the cylinder block: a) Heat the cylinder block for hot fitting or cryogenically freeze the copper bushing for press-fitting, achieving an interference fit; b) Use Loctite adhesive for bonding assembly; this method requires grooves on the outer surface of the copper sleeve; c) Tap threads into the cylinder bore, machine threads onto the outer diameter of the copper bushing, apply Loctite adhesive, and screw it into place. Installation methods for cylinder blocks and copper bushings joined by sintering are as follows: a) Use a lapping bar to manually or mechanically lap and repair the cylinder bore; b) Use a coordinate boring machine to re-bore the cylinder block holes; c) Use a reamer to repair the cylinder block holes. Methods using "surface engineering technology" are as follows: a) Electroplating technology: Plate a layer of hard chrome on the plunger surface; b) Brush plating technology: Brush plate wear-resistant materials onto the plunger surface; c) Thermal spraying, arc spraying, or electric spraying: Spray high-carbon martensitic wear-resistant materials; d) Laser cladding: Clad high-hardness wear-resistant alloy powder onto the plunger surface. e) For cylinder blocks without copper bushings, the material is mostly nodular cast iron, with an amorphous film or coating prepared on the inner wall of the cylinder block. Because of this special material on the inner wall of the cylinder bore, a hard-to-hard friction pair can be formed.

PERMA pump mechanical principle

The total stroke L of the plunger's reciprocating motion is constant and determined by the cam lift. The fuel supply volume per plunger cycle depends on the fuel supply stroke; the fuel supply stroke is variable and not controlled by the camshaft. The start of fuel supply does not change with variations in the fuel supply stroke. Rotating the plunger changes the end of fuel supply timing, thereby altering the fuel supply volume. When the plunger pump is operating, the cam on the fuel injection pump camshaft and the plunger spring force the plunger to move up and down reciprocally, thus completing the pumping task. The pumping process can be divided into the following two stages. 1) Oil intake process: After the cam lobe rotates past, under the force of the spring, the plunger moves downward, creating a vacuum in the space above the plunger (called the pump chamber). When the upper end face of the plunger opens the inlet port on the plunger sleeve, diesel fuel filling the oil passage in the upper body of the oil pump enters the pump chamber through the oil port. The plunger moves to the bottom dead center, and the oil intake ends. 2) Oil return process: The plunger supplies oil upward. When it moves up to the point where the helical groove (cut-off edge) on the plunger aligns with the return oil port on the sleeve, the low-pressure oil circuit in the pump chamber communicates with the central hole, radial holes, and helical groove at the plunger head. The oil pressure drops suddenly, and the delivery valve closes rapidly under the force of the spring, stopping oil supply. The plunger continues to move upward. After the cam lobe rotates past, the plunger moves downward again under the action of the spring. This begins the next cycle. The plunger pump is described here using a single plunger as an example. A plunger pump has two check valves with opposite directions. When the plunger moves in one direction, negative pressure occurs in the cylinder, opening one check valve and drawing liquid into the cylinder. When the plunger moves in the other direction, the liquid is compressed, opening the other check valve, and the liquid drawn into the cylinder is discharged. This continuous operation results in continuous oil supply.

PERMA pump mechanical maintenance

For plunger pumps supplied with oil by a boost pump, after 3000h of use, operators must inspect the plunger pump 1-2 times daily to check whether the hydraulic pump operating noise is normal. If a decrease in hydraulic cylinder speed or stalling is observed, the boost pump should be disassembled for inspection. Check for scoring on the impeller edges and whether the internal gear pump clearance is excessive. For self-priming plunger pumps, the oil level in the hydraulic tank must not fall below the lower limit of the oil gauge; maintain a sufficient quantity of hydraulic oil. 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 hydrostatic support oil film of each friction pair will be damaged, reducing the service life of the plunger pump bearings. According to data provided by hydraulic pump manufacturers, the average service life of bearings is 10000h; beyond this value, new bearings must be replaced. Removed bearings cannot have their clearance detected without professional testing instruments; only visual inspection is possible. If scratches or discoloration are found on the roller surfaces, they must be replaced. When replacing bearings, note the English letters and model numbers of the original bearings. Plunger pump bearings mostly use high-load capacity bearings. Purchase products from the original manufacturer and with original specifications. If switching to another brand, consult personnel experienced with bearings to check tables for equivalents, aiming to maintain 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 may sometimes be more expensive than counterfeit alternatives, but their quality and stability are better. Purchasing cheap counterfeit parts may seem to save costs in the short term, but it introduces hidden dangers and may cause greater harm to the use of the plunger pump. The distribution plate has two forms: flat distribution and spherical distribution. For spherical distribution friction pairs, if scratches on the cylinder block distribution surface are shallow, they can be repaired by lapping. If grooves on the cylinder block distribution surface are deep, "surface engineering technology" methods should first be used to fill the grooves, followed by lapping. Blind lapping should be avoided to prevent thinning of the copper layer or exposing the steel base, which could lead to oil leakage. Plunger pumps can also use frequency converters to save energy. Engineers from Shanghai Zhengyi point out that in actual production processes, plunger pumps usually regulate their operating status by pressure or flow. When the actual pressure exceeds the required pressure, it is regulated by a relief valve to maintain stable working pressure, with the relief valve releasing the excess. However, 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 a Chuangjie energy-saving frequency converter is used, the relief valve can be set to close, and the frequency converter itself automatically adjusts the working pressure to maintain stability and automatically track the equipment pressure. This achieves automated control, thereby saving energy consumption. The greatest 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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