乳化液泵站回液断路阀失效分析与结构优化研究

Failure Analysis and Structural Optimization Research on the Return Liquid Circuit Breaker of the Emulsion Pump Station

摘要: 本文论述了回液断路阀在乳化液泵站系统中的作用，乳化液泵站回液系统中的回液断路阀是保障供液系统正常工作的关键元件，其阀芯卡滞、断裂及阀座气蚀等故障会严重影响整个泵站的可靠性与寿命。本文针对上述问题，首先深入分析了回液断路阀定向泄流、防倒灌和真空阻断三大核心作用及其失效后果。在此基础上，进行了关键参数的设计计算，包括基于背压需求和压力脉动的开启压力设定、阀口通径与流阻计算、以及针对冲击载荷的阀芯强度校核，提升阀的耐久性；采用二级节流结构，有效控制了节流压降，从根本上抑制了气蚀的产生，降低了泵站因该部件引发的故障停机时间，经济效益与安全效益显著，本研究为矿山高压液压系统设计和优化提供了参考。

Abstract: This paper discusses the role of the hydraulic check valve in the emulsion pump station system. As a critical component in the return circuit, the check valve ensures the normal operation of the fluid supply system. Failures such as spool sticking, fracture, and seat cavitation can severely affect the reliability and service life of the entire pump station. To address these issues, this study first provides an in-depth analysis of the three core functions of the check valve: directional drainage, backflow prevention, and vacuum blocking, along with the consequences of their failure. On this basis, key parameters are designed and calculated, including the cracking pressure setting based on backpressure requirements and pressure pulsation, the flow diameter and flow resistance calculation of the valve orifice, and the strength verification of the spool under impact loads to enhance durability. By adopting a two-stage throttling structure, the pressure drop across the throttle is effectively controlled, fundamentally suppressing cavitation and reducing pump station downtime caused by related failures. This improvement offers significant economic and safety benefits. The study provides a valuable reference for the design and optimization of high-pressure hydraulic systems in mining applications.