Use of HYDAC pressure relay

The HYDAC pressure relay is a critical component in hydraulic systems designed to activate electrical contacts once the fluid pressure hits a specific threshold. Essentially, it transforms hydraulic pressure into an electrical signal, allowing users to customize the pressure settings according to their requirements. By fine-tuning the pressure relay, you can ensure an electrical signal is triggered at a predetermined pressure level. The working principle of a pressure relay involves converting liquid pressure into an electrical signal via a hydraulic-electrical conversion element. Once the system pressure meets the preset value, the pressure relay sends an electrical signal, prompting other electrical components like electromagnets or motors to activate. This leads to the relief or reversal of the oil circuit, ensuring sequential operation of actuators, or halting the motor to stop the system entirely—acting as a safety mechanism. HYDAC pressure relays come in four main types: plunger, diaphragm, spring tube, and bellows. Let’s focus on the plunger-type pressure relay. When liquid enters through the lower inlet and reaches the set pressure, the plunger moves upward. The displacement is then amplified using a lever, which triggers the microswitch. Adjusting the spring's compression allows you to modify the relay's operational pressure. Applications for HYDAC pressure relays include safety protection, sequential actuator control, pump unloading, and pump activation. However, for optimal performance, place the relay where pressure fluctuations are significant. Placing it in the return line won’t work since the direct connection to the tank results in constant low pressure. When using the HYDAC pressure relay, it responds to system pressure changes by sending a switching signal. At a specific pressure, the normally open contact closes while the normally closed contact opens. This functionality can be integrated into various programs. However, users often face challenges, primarily related to product quality: 1. Insensitive response, where the relay fails to send a signal despite reaching the required pressure. This is often due to manufacturing defects. 2. Missing internal microswitches, leading to malfunction—a common issue during assembly. 3. Poor durability, especially with substandard microswitches used by some manufacturers. 4. Leaks caused by improper seals or machining errors. Despite these potential pitfalls, the HYDAC pressure relay remains invaluable for safety purposes. For instance, placing the relay at the clamping hydraulic cylinder ensures workpieces are securely clamped before machining begins. If the pressure doesn't reach the set value, the relay disconnects power to the cutting hydraulic cylinder, preventing accidents. In sequential actuator control, the relay activates after the hydraulic pump fills the left chamber, pushing the piston. Once the limiter is hit, the pressure increases, triggering the relay to send an electrical signal. Depending on further instructions, this could result in fast or slow movement of the hydraulic cylinder. For pump unloading, the pressure relay controls a two-position two-way solenoid valve, redirecting the hydraulic pump’s output back to the reservoir instead of stopping the pump. Lastly, in dual-pump systems, the pressure relay determines when to shut off the high-pressure pump during machining, conserving energy and slowing the cylinder’s movement. Overall, the HYDAC pressure relay plays a vital role in modern hydraulic systems, providing safety, efficiency, and precise control. Proper installation and maintenance are essential to maximize its benefits.

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