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Technical Measures to Improve HBT60 Concrete Pump
The original HBT60 gate valve concrete pump has several limitations that make it unsuitable for modern construction demands. It features low power, insufficient outlet pressure, outdated structural design, and long-term wear and tear due to extended usage. The transmission cylinder is severely worn, the hydraulic system suffers from leaks, and overall efficiency is very poor. Even after replacing the damaged components, its technical performance remains inadequate, failing to meet current construction requirements. Therefore, an upgrade was necessary—improving the pump’s performance parameters while redesigning its structure to create a more advanced model: the HBT60G.
To enhance pumping performance, the design parameters were brought up to the level of similar models. The original HBT60 was equipped with a main pump A7VO160, constant power control, a system pressure of 28MPa, a main cylinder bore of φ80mm, a concrete delivery cylinder of φ195mm, a stroke of 1400mm, a motor Y250M-4 with 55kW and 1480r/min, an outlet pressure of 4.7MPa, and a delivery capacity of 50m³/h. However, these parameters are relatively low compared to industry standards. To improve this, the upgraded HBT60G now uses a dual-pump system (A8VO107), maintains the same system pressure of 28MPa, but increases the main cylinder bore to φ100mm, keeps the delivery cylinder at φ195mm, and extends the motor to Y280S-4 with 75kW and 1480r/min. The outlet pressure rises to 7.36MPa, and the delivery volume increases to 65m³/h, significantly improving overall performance.
Here are the pump performance curves for both HBT60 and HBT60G:
**Performance Analysis:**
1. The HBT60 enters constant power at around 1.5MPa, but due to internal pressure losses, actual performance declines as delivery distance or height increases. In contrast, the HBT60G enters constant power at about 2.5MPa, achieving a theoretical delivery of 62m³/h, compared to 45m³/h for the HBT60 at the same pressure—an increase of 17m³/h.
2. The maximum outlet pressure of the HBT60 is 4.7MPa, with a delivery volume of 25m³/h. For the HBT60G, the maximum pressure reaches 7.36MPa, and the delivery volume increases to 37m³/h, indicating that the HBT60G can pump concrete nearly twice as far or high as the HBT60.
3. At the same pumping distance or height, the HBT60G operates at a lower system pressure than the HBT60, resulting in higher reliability. For example, at an outlet pressure of 3MPa, the HBT60G system pressure is 11.5MPa, while the HBT60 system pressure is 18MPa.
**2. Configuration and Structural Improvements to Enhance Reliability**
To ensure better machine reliability, significant upgrades were made to the hydraulic system and other components:
1. The hydraulic system was improved by replacing the gear pump with a dual-gear pump for mixing and cleaning, creating independent circuits. This increases the pressure in the stirring and washing systems, reduces the load on the main system, and improves the lifespan of hydraulic components.
2. The mixing drive system was simplified by connecting the motor directly to the drive shaft, eliminating the need for chains and reducing potential failure points.
3. The slide valve cylinder assembly was enhanced with added buffer systems and piston guide sleeves, extending the service life of the spool valve cylinder.
4. The electrical control system was upgraded with additional protection features, making the control more rational and ensuring stable operation and improved safety.
In summary, after the improvements, the HBT60G concrete pump shows a significant enhancement in overall performance. It meets modern construction needs effectively, proving its value in real-world applications. Compared to its predecessor, the HBT60G represents a qualitative leap forward and is well-suited for today's demanding construction environments.