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Causes of hydraulic pump failure

Imagine yourself working in an industrial environment, when suddenly a shrill alarm sounds. You rush to the source of the noise and are stunned to discover a hydraulic pump essential to your production process, pinned to the floor, powerless. Your work rate is interrupted, deadlines are compromised, and you're faced with an unexpected loss of productivity. But what has really happened? What are the insidious causes of these common failures of hydraulic pumps, can they bring an entire business to a standstill? In this article, we're going to delve into the depths of these mysterious breakdowns and reveal the keys to avoiding these disruptions.

How do hydraulic pumps work ?

The operating mechanism may vary depending on the type of pump used.

For example, in a gear pump, two gears interact to draw hydraulic fluid through the inlet port. Then, when the gear teeth meet, they compress the fluid and push it through the outlet port, generating the desired hydraulic flow.

In a piston pump, the pistons move in cylinders by means of an eccentric cam or a swash plate. When the pistons move backwards, they create a vacuum that draws hydraulic fluid into the pump. Then, as the pistons move forward, they compress the fluid and propel it through the pump.

Vane pumps use an eccentric rotor with moving vanes. As the rotor rotates, the vanes move along the rotor, creating chambers of varying volume. Hydraulic fluid is drawn into these chambers as the vanes move away from the centre and is then compressed and expelled as the vanes move closer together.

By understanding how hydraulic pumps work and the specific characteristics of each type of pump, you'll be better able to identify potential causes of failure and take appropriate measures to ensure their smooth operation and durability.

What factors are responsible for hydraulic pump failure ?

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From overload and excessive pressure to inadequate lubrication, hydraulic leaks and component wear, hydraulic pump failures can be attributed to a number of common causes.

- Overloading and excessive pressure

Hydraulic pumps are often subjected to heavy loads and high pressures in industrial environments. When a pump is overloaded or regularly operates at pressure levels above its maximum capacity, this can lead to excessive wear, deformation of internal components and premature fatigue.

The consequences of this overload can include loss of performance, internal leakage, excessive vibration and eventually total pump failure.

It is therefore vital to comply with the load and pressure specifications recommended by the manufacturer to ensure reliable operation of the pump.

- Lubrication problems

Adequate lubrication is essential for the correct operation of hydraulic pumps. Insufficient lubrication or the use of a poor quality lubricant can lead to excessive friction between the pump's moving parts. This can lead to premature component wear, overheating and a general deterioration in pump performance.

In addition, contamination of the lubricant by foreign particles can clog the pump's internal channels and affect its operation.

It is therefore important to follow the manufacturer's recommendations on lubrication and to use high-quality lubricants that are compatible with the hydraulic pump.

- Hydraulic leaks

Hydraulic leaks are a common cause of hydraulic pump failure. They can be caused by faulty seals, loose connections, cracks or damage to the pump casing. Leaks reduce system pressure, lead to loss of pump performance and can cause further damage to other components in the hydraulic system.

It is important to check the pump regularly for leaks, replace faulty seals and ensure that all connections are properly tightened to prevent unwanted leaks.

- Component wear

Parts such as gears, pistons, vanes and seals undergo normal wear over time due to loads, repeated movements and internal friction. However, premature wear can be caused by inadequate lubrication, contaminants in the hydraulic fluid, abnormal operating conditions or poor quality materials.

Regular monitoring of component wear and timely replacement are essential to maintain pump performance.

What is the impact of hydraulic pump failure ?

CAUSES DE PANNES SUR LES COMPOSANTS HYDRAULIQUE - simitma

Hydraulic pump failures can have a significant impact on industrial operations and the performance of hydraulic systems. This can result in repercussions such as:

- Stopping production

When a hydraulic pump breaks down, it can bring production to a complete or partial halt. This can lead to delays, disruption and additional costs for the company.

- Loss of productivity

A faulty pump can lead to a reduction in the productivity of machines and equipment that depend on the hydraulic system. Operations may slow down or be unable to function properly, resulting in lost time and reduced overall efficiency.

- Repair and replacement costs

Repairs to hydraulic pumps can be costly, particularly if internal components have to be replaced or if the entire pump has to be replaced. In addition, the costs associated with stopping production during repairs can be significant.

- Increased operating costs

A faulty hydraulic pump can lead to increased energy consumption, leaks of hydraulic fluids or further damage to other system components. These problems can lead to increased operating costs, including the cost of maintenance, fluid replacement and additional repairs.

- Insecurity for workers

Hydraulic pump failure can create dangerous situations for workers. For example, a sudden loss of pressure can cause heavy loads to fall or move unexpectedly, endangering the safety of operators and surrounding personnel.

It is therefore crucial to take preventive measures to avoid hydraulic pump failure.

Likeow can hydraulic pump failures be prevented ?

Symptômes pompe hydraulique HS - Experthydraulique

To prevent hydraulic pump failure, it is essential to implement appropriate solutions and good practices. These include :

- Preventive programme

Establish a preventive maintenance programme that includes regular inspections, cleaning, lubrication and scheduled replacement of wearing parts. By following a preventive maintenance schedule, you can identify and resolve potential problems before they become major failures.

- Contamination control

Install appropriate filtration systems to keep the hydraulic fluid clean. Filters should be regularly maintained and replaced in accordance with the manufacturer's recommendations. Minimising contamination protects pump components and extends their life.

- Condition monitoring

Use condition monitoring techniques such as vibration analysis, infrared thermography and oil analysis to detect early signs of failure. These tools enable you to identify anomalies and take corrective action before problems escalate.

- Adequate lubrication

Be sure to use the lubricants recommended by the manufacturer and to observe the appropriate lubrication intervals. Proper lubrication reduces friction, wear and the risk of overheating, thereby prolonging pump life.

- Compliance with specifications and load limits

Adhere to the manufacturer's specifications regarding maximum loads and pressure limits. Avoid overloads and excessive pressures, as these can lead to premature wear and pump failure.

- Staff training

Ensure that operators and maintenance personnel are trained and competent in the operation and maintenance of hydraulic pumps. Proper training ensures correct use, handling and maintenance practices, reducing the risk of failure.

By implementing these solutions and following these best practices, you can minimise the risk of hydraulic pump failure, optimise performance and extend pump life.

Still on the same theme

- How should hydraulic pumps be maintained to prevent failure ?

- Symptoms of hydraulic valve failure

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