Pileco Diesel Hammers

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29 Νοε 2013 (πριν από 3 χρόνια και 9 μήνες)

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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 can’t
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, 900.00
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

2
mm

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

3
mm

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 0.008 ~ 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 0.015 ~ 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
H
ammer


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


L
ead
is free hanging at a 3 line crane
boom


L
ines
for lead, hammer and pile)


L
ead
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
:


L
ead
is attached with a boom point connector to the crane boom tip and at the lower


E
nd
supported by a hydraulic adjustable spotter


E
xact
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:



L
ead
is attached with a boom point connector to the crane boom tip and at the lower
end
supported by a hydraulic adjustable
spotter


E
xact
positioning to ram point possible while also adjusting to the exact batter


W
ide
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


U
pgrade 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