Excavator accessories - hydraulic flat compactor
1、 Definition and advantages of hydraulic flat compactor
Flat compactor is an engineering equipment used to compact materials such as sand, gravel, asphalt, etc. with low adhesion and friction between particles. It is divided into three categories: internal combustion, electric, and hydraulic drive.
1. The construction effect is good. The impact force of hydraulic compactor can reach several hundred tons or even thousands of tons, and the compaction depth can reach 10 meters. When used for roadbed reinforcement and compaction, it can cause the roadbed to settle more than 10cm in advance to meet the compaction standards.
2. High construction efficiency. Compared to traditional compaction methods, hydraulic compaction machines can achieve automated operation and improve work efficiency. Moreover, hydraulic compactors have the characteristics of large amplitude and high compaction frequency, which can quickly complete work tasks and improve work efficiency.
3. Stronger adaptability. The hydraulic compactor has three working modes: strong, medium, and weak. It can not only adjust the magnitude of the impact force but also change the compaction frequency. At the same time, the high-speed hydraulic compactor can switch between the two working modes of "high vibration amplitude and low frequency" and "high frequency and low amplitude" at any time, which can meet a wider range of construction needs.
4. More economical and applicable. Hydraulic compactors not only have a high degree of automation, but also do not require a large amount of manpower and material resources, which can reduce the reuse of conventional compactors and manpower, thereby reducing the labor intensity of workers and engineering production costs.
5. The construction safety is high. The hammer foot of the vertical hydraulic compactor is always directly grounded, which has the characteristics of preventing detachment, dust and splashing, and can ensure the safety between the construction site workers and adjacent machinery and equipment.
6. Strong stability and durability. Compared to mechanical compactors, hydraulic compactors have the advantages of strong durability and long service life.
The hydraulic system of the hydraulic compactor can effectively reduce mechanical wear and prolong the service life of the machine. Hydraulic compactors can eliminate the inherent and artificial defects of layered compaction of roadbeds, as well as the possible post construction settlement that may occur during the foundation's use. This can solve the common problems of bridge head jumping, uneven settlement at the junction of old and new roadbeds, and the boundary between roadbed filling and excavation in China.
2、 Material Upgrade: High Wear Resistant Alloy and Composite Shock Absorbent System
Rammed plate substrate: Made of NM400 high-strength wear-resistant steel, the surface is laser coated with tungsten carbide coating (hardness ≥ 58HRC), which improves the wear resistance by three times compared to traditional Q345 steel. When matched with a 6-ton excavator for operation, the asphalt compaction life exceeds 2000 hours, which is 40% longer than conventional models.
Shock absorption module: multi-layer rubber spring composite structure, built-in polyurethane buffer pad, reducing vibration transmission rate to below 15%. After being loaded onto a 7.5 ton excavator, the vibration amplitude of the cab is ≤ 2.5m/s ², and the operational fatigue is reduced by 50%.
Hydraulic cylinder: The surface of the piston rod is coated with hard chromium and ceramic coating, and the salt spray test can withstand 1200 hours. Suitable for crawler excavators in coastal areas, with a corrosion failure rate reduced by 80%.
3、 Technological breakthrough in precise matching of adaptive flow and tonnage
Intelligent hydraulic system
Dual mode pressure control: The electronic proportional valve automatically switches between high-frequency/strong vibration modes based on the packing density. When compacting sand with a 6-ton excavator, use high-frequency mode (12Hz) and fuel consumption ≤ 5L/h; When a 7.5 ton excavator processes gravel, it triggers a strong vibration mode (with an amplitude of 8mm), resulting in a 30% increase in efficiency.
Tonnage adaptation technology:
6 ton crawler excavator: equipped with HPC60 ramming plate with a flow rate of 60L/min and an excitation force of 16kN, specializing in trench backfilling and slope compaction.
7.5 ton model: matched with HPC80 system (flow rate of 120L/min, excitation force of 24kN), with a single compaction width of 800mm, and a 25% increase in the compliance rate of roadbed bearing capacity.
Structural optimization and innovation
Quick change interface integration: Hydraulic self-locking joint enables 30 second switching between the ramming plate and the digging bucket. The actual measurement of Yunnan municipal projects shows that crawler excavators can complete the entire process of compaction, excavation, and backfilling in a single day, and the equipment utilization rate is increased by 40%.
Temperature control protection system: The oil circuit is equipped with a temperature sensor, which automatically reduces the frequency when the hydraulic oil temperature is ≥ 85 ℃. Solve the problem of oil overheating during continuous compaction of asphalt with a 7.5 ton excavator.
4、 Development process
1. In the era of mechanical transmission (before 2015): gear pumps drive ramming plates, and 6-ton excavators require additional hydraulic valve groups, resulting in an oil leakage failure rate of over 35%.
2. Hydraulic Integration Period (2016-2020):
Popularization of independent hydraulic circuits to reduce power interference
The 7.5 ton crawler excavator comes standard with the LUDV load sensing system, which compresses the response time of the ramming plate start stop to 0.5 seconds.
3. In the era of intelligence (2021 present):
5G remote compaction (such as Sany SY75C) achieves unmanned construction
The AI compaction analysis system automatically generates quality reports, and the construction acceptance rate of crawler excavators reaches 98%.
5、 Maintenance points: Full cycle operation and maintenance strategy
Hydraulic system maintenance
Oil management: HV46 low-temperature oil (starting at 30 ℃) is used in cold regions, and HM68 anti-wear oil is used in tropical regions. The oil should be changed for 150 hours for the first time and every 1000 hours thereafter.
Filter element monitoring: If the 10 μ m fine filter is clogged and the pressure difference is greater than 0.3MPa, it should be replaced immediately - a 6 ton excavator at a certain construction site suffered from a stuck main valve due to filter element failure, resulting in a repair loss of over 80000 yuan.
Mechanical component protection
Vibration bearing: Inject lithium based grease every 50 hours, and during oil injection, press the plate to the ground to reduce pressure. The high load operation of a 7.5 ton excavator needs to be shortened to 30 hours per operation.
Storage standard: When idle for a long time, the tamper plate should be suspended to prevent deformation, and the oil cylinder piston rod should be retracted and coated with anti rust paste.
Future vision: Electrification and digital twin operation and maintenance
Hydrogen energy adaptation: The XCMG XE75E electric 7.5 ton excavator is matched with a silent hydraulic ram, reducing noise to 72dB and providing a range of up to 6 hours.
Predictive maintenance: The vibration sensor monitors the bearing wear deviation of 0.1mm for warning, and the monthly failure time of the 6-ton crawler excavator is reduced from 18 hours to 4 hours.
From NM400 wear-resistant steel plate to AI compaction algorithm, hydraulic flat compactors have evolved from auxiliary attachments to "efficiency multipliers" for 6 ton and 7.5 ton crawler excavators. When no one compacts on the dangerous cliff slope, when electric compactors silently construct in residential areas at night - this technological revolution that began with steel hardness will ultimately reshape the compaction standards for every inch of land.
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