Presentation on theme: "Pileco Diesel Hammers. Pileco Diesel Hammer The Pileco Diesel hammer is a time proven design using the impact atomization principle. The Diesel pile hammers."— Presentation transcript:
Pileco Diesel Hammers
Pileco Diesel Hammer The Pileco Diesel hammer is a time proven design using the impact atomization principle. The Diesel pile hammers are self contained and do not require an additional power source. PILECO Diesel Hammers are reliable and always ready to operate Air-cooled; extreme heat and cold are not a problem The capacity of the Diesel oil and lubricant tank allows several hours of constant pile driving. PILECO Diesel Hammers are adjustable The adjustable fuel pump serves to regulate the jumping height, and thereby the impact energy. The PILECO Diesel Hammer is environmentally friendly Following alternate fuels can be used without any pump or valve conversion to reduce pollution - soybean oil refined or oilseed rape (colza oil) - estherized soybean oil or oil serape oilseed rape - kerosene and JP-8 fuel
Where the Pileco Diesel Hammers come from? The main factory A hammer cylinder being Machined in a lathe Hammers are built to Pileco specifications using the time proven design along with many additional improvements Hammers are produced by Wuxi Xinren Universal Machinery Co. Ltd. – a manufacturer that has more than nine years experience in building D62 size hammers and larger (i.e. D80, D100, D125, D160, D180, D225, D250 and the D280)
The new factory opened in May 2004, using modern machining methods to produce high quality equipment. The hammer cylinder in a mill. Hammers ready for shipment The foundry A hammer being tested Where the Pileco Diesel Hammers come from?
The Single Acting Pileco Diesel Hammer
Function of a Pileco Diesel Pile Hammer
Functional operation of a Pileco Diesel Hammer Raising of piston (starting)
Functional operation of a Pileco Diesel Hammer Raising of piston (starting) For starting the Diesel hammer, the piston (ram) is raised by means of a mechanical tripping device and is automatically released at a given height.
Functional Operation of a Pileco Diesel Hammer Injection of Diesel fuel and compression
Functional operation of a Pileco Diesel Hammer Injection of diesel fuel and compression As the piston falls through the cylinders it activates a lever on the back of the fuel pump, which injects a measured amount of diesel fuel onto the top of the impact block. Shortly after this, the exhaust ports are closed.
Functional operation of a Pileco Diesel Hammer 3. Impact and atomization
Functional operation of a Pileco Diesel Hammer Compressing all the air between the exhaust ports and the top of the impact block, the piston continues falling until it strikes the top of the impact block. The heat generated by the compression of air in the presence of atomized fuel, causes an explosion of the fuel, throwing the piston upward and forcing the impact block downward against the pile Impact and atomization
Functional operation of a Pileco Diesel Hammer Exhaust
Functional operation of a Pileco Diesel Hammer Exhaust While moving upwards, the piston will pass and open the exhaust ports. Exhaust gases will escape and the pressure in the cylinder will equalize
Functional operation of a Pileco Diesel Hammer Scavenging
Functional operation of a Pileco Diesel Hammer Scavenging The piston continues its upward momentum which draws in fresh air for the next cycle, cools the cylinders, and releases the pump lever. The pump lever returns to its starting position, so that the pump will again be charged with fuel. Gravity stops the upward motion of the piston and it starts falling through the cylinders once again.
Pileco Diesel Hammers This is a comparison of the quality and materials used for the diesel hammers made by Pileco and the competition.
Others The piston is cast with simple casting technique --- cast from the top, which causes the piston have more impurities and unstable performances. There are not any special metal elements added. The toughness and wear resistance properties are bad. Less part of the gating (sprue) and feeder are removed, which cant guarantee the quality of the part of the piston that can be used. So, the cost of the piston is 25% lower than the piston made by Pileco. Pileco The piston is cast with the most advanced special casting technique in the world ---cast from the bottom, which creates a piston with less impurities and a higher density of 7.2T/M 3. Special metal elements are also added for additional strength. The gating (sprue) and the feeder of the piston are longer so that more part of the gating (sprue) and feeder are removed. This ensures the quality of the part of the piston that can be used. The piston has stable and reliable quality, but its cost is RMB3, higher than the piston made in Guangdong. The Piston Pileco Others
Impact Block Pileco The impact block is precision forged with the material 50CRMoA. It is finish machined after being heat treated twice after which it is sent to a heat treatment factory for nitrogen treatment. The impact block has reliable quality, stable property and longer service life. The cost of nitrogen treatment is USD1.00/kg, which is more expensive. Nitrogen treating increases the toughness of the steel providing a longer life of the block. Others The impact block is ordinary forged. The material used for it is 50CRMo, which is not purified steel/ virgin steel. The impact block is not nitrogen treated after the heat treatment of quenching and tempering and finish machining. The cost of the impact block is 22% lower than the impact block made by Pileco. Pileco Impact Block
Upper Cylinder The metal used to fabricate all tanks of upper cylinder is 2 ~ 3mm thinner than the metal used to fabricate the tanks of Wuxi hammers. The inside wall of tanks is not spayed with stainless steel. All welding seams are weld by hand. Fillet welding seams are not welded on the rolling table / welding manipulator. There is oxide on the inside wall of fuel and oil tanks due to heat treatment. Other factories needs to clean up the oxide after heat treatment and weld again. There is always a welding seam left finally that is not heat treated to eliminate welding stress and it will crack easily after long-term use. The cost of the upper cylinder is 32% higher than Pileco 8mm
Upper Cylinder The thickness of metal used to fabricate the fuel and oil tanks of upper cylinder for small hammer is 2mm thicker than that of the hammers made by others. The thickness of the metal used to fabricate fuel and oil tank of the upper cylinder for large hammer is 3mm thicker than that of the hammers made by others. The inside wall of the tanks all are hot spayed with a metal powder of stainless steel. The purpose of spaying stainless steel is to prevent any oxide. This will provide a smooth fuel and oil passage ways thus ensuring that the fuel and oil systems are not blocked. All seams are welded using an argon arc weld. This is to ensure that they are welded thoroughly. All seams are heat treated after they all are welded. This ensures the welded width and strength. They are welded on rolling table. The surface is then given a shot blasting after heat treatment to ensure the quality. This ensures a stable and reliable weld. The welded seams of tanks will not crack easily after long term use. 10mm
Lower Cylinder Pileco Special metal elements are added to the material of the lower cylinder. This is to create a dense material. The weight of the casting feeder is 1/5 of the weight of lower cylinder roughcast. The material of cylinder sleeve is #60 special steel, which is a hard metal and has good wear resistance after it is forged and heat treated. Others The casting feeder of the lower cylinder is very small (saving material), so the roughcasts of lower cylinder all are loose and have small defects. There are not sleeves for the hammers sold in China. For the lower cylinders sold to foreign countries, one section of cylinder sleeve is used with standard material of #45 steel, and the other section of sleeve is used with common material of 16mm steel pipe which is not wear resistant.
Piston Ring Pileco The casting is the special roughcasting shell of piston ring cast by Shanghai Hudong Foundry. The material quality is controlled by the foundry and engineer Xu Zu Liang, and then it is sent to the appointed piston ring factory to be machined in secrecy. The surface of the piston ring is coated with hard chrome. The piston ring is a better quality product. Others The material of piston ring is very common, and it is cast and machined by small factory. Its surface is not coated with hard chrome. The piston ring has low cost and is not serviceable.
Inner Endring Pileco The material of the inner endring is #60 special steel. It is machined after heat treatment (two times) and eliminating stress (one time). It is then sent to the special heat treatment factory for nitrogen treatment. This is to ensure accuracy and hardness. The inner endring is wearable and serviceable and is a better quality item. Other The inner endring is made of common composition brass and is not heat treated. It is not wearable and serviceable. It is low cost and not serviceable
Pumps The fuel pump body and cover as well as the oil pump body are made by Shanghai Hudong Foundry. The casting quality of them is controlled by the foundry. The material quality is very reliable. The pump element used for fuel pump and the cylinder used for oil pump all are precision ground, the clearance is ~ 0.011mm. All the hoses used for pumps are Parker hoses. The injective valves are machined using special machine tool to ensure the accuracy and exchangeability. Pileco Fuel Pump Pileco Oil Pump
Pumps The fuel pump body and cover as well as the oil pump body are cast by common small foundry. They are loose fitting. The pump element in fuel pump and cylinder in oil pump are not precision ground and the accuracy of them is ~ 0.02mm. All the hoses used for pumps are common rubber hoses. The injective valves are machined using common machine tool, which have poor exchangeability and stability.
Honing of the upper & Lower Cylinders Pileco Others Precision honing of the inside walls of upper and lower cylinders all are done on the special vertical honing machine we own. The honing time is very long and the honing accuracy is very high. Precision honing of the inside walls of upper and lower cylinders all are made on the common horizontal honing machine. This is done in an outside factory. Because the honing machine is horizontal, the orientation is not uniform and the accuracy is poor. Pileco Vertical Honing Machine
Presentation Quality Others The appearance of hammers is rougher due to various reasons such as casting and welding.
Presentation Quality The presentational quality is much better. We have made a higher standard of quality in our product. The presentational quality of all future hammers is constantly being improved.
Pile Driving Systems with A Diesel Hammer Swinging lead Swinging lead spotter supported Fixed lead spotter supported Fixed lead with three axis boom point connector and vertical travel Caisson type lead Large diameter lead systems for vertical piles
Swinging Leads Characteristics: Most economical onshore pile driving Lead is free hanging at a 3 line crane boom Lines for lead, hammer and pile) Lead steps in the ground allow to swing the upper end in every direction
Characteristics: Lead is free hanging at a 3 line crane boom ( lines for lead, hammer and pile) Hydraulic spotter allows to swing the lead more exactly and quicker to the ram point Lead steps can set in the ground allow to swing the upper end in every direction Swinging Leads Spotter Supported
Characteristics: Lead is attached with a boom point connector to the crane boom tip and at the lower End supported by a hydraulic adjustable spotter Exact positioning to ram point possible while also adjusting to the exact batter 2 line head block for hammer and pile line Upgrade the system with additional pile line and auger drilling equipment possible Fixed Extended Leads – Spotter Supported
Characteristics: Lead is attached with a boom point connector to the crane boom tip and at the lower end supported by a hydraulic adjustable spotter Exact positioning to ram point possible while also adjusting to the exact batter Wide range of batter piling possible, because the lead can lowered down to the ground and below 2 line head block for hammer and pile line as minimum version Upgrade the system with additional pile line and auger drilling equipment possible Vertical Travel Leads Spotter Supported
Characteristics: Lead and hammer with helmet are one unit hanging at crane or derrick Lead is supported by the pile only while driving, batter piling is possible Pile adaptors can be used for large diameter piles Caisson Type Leads
Characteristics: Special lead frames for large pipe piles up to 120 diameter Lead is supported by the pile only while driving Large Diameter Lead Systems for Vertical Piles
Characteristics: Adapter sled for Telescopic Lead – Mobilram Systems are useful in case where pile driving with vibratory hammers is not anymore efficient or where restrictions are given Telescopic Lead Mobilram System