BS-7198-2-1989 ISO-7241-2-1986.pdf

BRITISH STANDARD BS 7198-2: 1989 ISO 7241-2: 1986 Hydraulic fluid power quick-action couplings Part 2: Methods of test Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 11:28:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7198-2:1989 This British Standard, having been prepared under the direction of the Machinery and Components Standards Policy Committee, was published under the authority of the Board of BSI and comes into effect on 29 September 1989 © BSI 11-1999 The following BSI references relate to the work on this standard: Committee reference MCE/18 Draft for comment 84/70507 DC ISBN 0 580 17552 9 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Machinery and Components Standards Policy Committee (MCE/-) to Technical Committee MCE/18, upon which the following bodies were represented: Advanced Manufacturing Technology Research Institute Association of British Mining Equipment Companies Bath University Library British Compressed Air Society British Fluid Power Association British Hydromechanics Research Association British Steel Industry British Telecommunications plc Department of Trade and Industry (National Engineering Laboratory) Electricity Supply Industry in England and Wales Federation of Manufacturers of Construction Equipment and Cranes Institution of Mechanical Engineers Ministry of Defence The following bodies were also represented in the drafting of the standard, through subcommittees and panels: British Industrial Truck Association British Rubber Manufacturers Association Engineering Equipment and Materials Users Association Amendments issued since publication Amd. No.Date of issueComments Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 11:28:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7198-2:1989 © BSI 11-1999i Contents Page Committees responsibleInside front cover National forewordii 0Introduction1 1Scope and field of application1 2References1 3Definitions1 4Selection and examination of test samples1 5Test apparatus1 6Test conditions1 7Connect force test1 8Disconnect force test1 9Leakage test1 10Extreme temperature test2 11Pressure impulse test3 12Endurance test3 13Pressure drop test3 14Vacuum test3 15Air inclusion test4 16Spillage test4 17Static pressure test4 18Burst test4 19Data accuracy4 20Test report and data presentation5 21Summary of information to be supplied5 22Test/production similarity5 23Identification statement5 Figure 1 Low-pressure leakage test apparatus (coupled)9 Figure 2 Low-pressure leakage test apparatus (uncoupled half)10 Figure 3 Pressure impulse test11 Figure 4 Pressure drop test12 Figure 5 Vacuum leakage test13 Figure 6 Air inclusion test14 Figure 7 Spillage test15 Table 1 Data accuracy4 Table 2 Typical format for presenting test data6 Publications referred toInside back cover Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 11:28:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7198-2:1989 ii © BSI 11-1999 National foreword This Part of BS 7198 has been prepared under the direction of the Machinery and Components Standards Policy Committee and is the first of a two Part standard for hydraulic fluid power quick-action couplings. It is identical with ISO 7241-2:1986 “Hydraulic fluid power Quick-action couplings. Part 2: Test methods” published by the International Organization for Standardization (ISO). The other Part of the standard is BS 7198-1, “Specification for dimensions and performance” (implementing ISO 7241-1:1987). The Technical Committee has reviewed the provisions of ISO 4411:1986 to which reference is made in the text, and has decided that they are acceptable for use in conjunction with this standard. The related British Standard is BS 4062-1:1982 “Valves for hydraulic fluid power systems. Part 1: Methods for determining pressure differential/flow characteristics”. There is no corresponding British Standard for ISO 5598. Additional information. For the purposes of this British Standard, the identification statement specified in clause 23 should read as follows. “The method of obtaining and presenting the coupling performance data complies with BS 7198-2:1989.” A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Cross-references International StandardCorresponding British Standard ISO 3448:1975BS 4231:1982 Classification for viscosity grades of industrial liquid lubricants (Identical) ISO 7241-1:1987BS 7198 Hydraulic fluid power quick-action couplings Part 1:1989 Specification for dimensions and performance (Identical) Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 16, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 11:28:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7198-2:1989 © BSI 11-19991 0 Introduction In hydraulic fluid power systems, power is transmitted and controlled through a liquid under pressure within an enclosed circuit. Quick-action couplings are used to join or separate quickly fluid conducting lines, without the use of tools or special devices. 1 Scope and field of application This part of ISO 7241 specifies different test methods which could be applied to quick-action couplings. This part of ISO 7241 applies to male and female coupling halves, complete couplings, couplings with and without sealing means when uncoupled, and couplings that are connected and disconnected by a linear and/or rotational motion. The user of this part of ISO 7241 may select only the tests applicable to his needs. It is not intended that all tests be carried out for every application. 2 References ISO 3448, Industrial liquid lubricants ISO viscosity classification. ISO 4411, Hydraulic fluid power Valves Determination of pressure/differential flow characteristics. ISO 5598, Fluid power systems and components Vocabulary. ISO 7241-1, Hydraulic fluid power Quick-action couplings Part 1: Dimensions and requirements. 3 Definitions For the purposes of this part of ISO 7241, the definitions given in ISO 5598 apply. 4 Selection and examination of test samples Coupling assemblies selected shall constitute a representative sample of a production lot in all respects: design, material, surface treatment, process, etc. 5 Test apparatus 5.1 The apparatus shown in Figure 1 to Figure 7 shall be used. 5.2 Apparatus capable of providing test result data accuracy in accordance with clause 19 shall be used. 6 Test conditions 6.1 Tests shall be carried out at an ambient temperature of 20 to 35 °C, unless otherwise specified. 6.2 Tests shall be carried out using a fluid of ISO VG 32, in accordance with ISO 3448 (28,8 to 35,2 mm2/s viscosity at 40 °C). 7 Connect force test Lubricate the coupling interfaces with the test fluid. Insert the coupling in a test fixture. Maintain the internal test pressure, i.e. the maximum internal pressure as specified in ISO 7241-1. Apply a linear force and/or torque to the coupling half until complete connection occurs. NOTEDuring this operation, the locking mechanism may be operated manually, if necessary, to permit normal coupling of the halves. Measure the connecting force and/or torque, as appropriate. Repeat the test a total of five times on the same test coupling. Average the results of the five tests to determine the connect force or torque. Report the average connect force or torque in the test report (see clause 20). Report any conditions of damage or malfunction in the test report (see clause 20). 8 Disconnect force test Lubricate the coupling interfaces with the test fluid. Insert the coupling in a test fixture. Maintain the internal test pressure, i.e. the maximum operating pressure specified in ISO 7241-1, and/or the prevailing flow conditions. Apply a linear force and/or torque to the retaining mechanism of the coupling, until disconnection occurs. Measure the disconnect force and/or torque. Repeat the test for five disconnections on the same test coupling. Average the test results of the five tests to determine the disconnect force and/or torque. Report the average results in the test report (see clause 20). Report any condition of damage or malfunction in the test report (see clause 20). 9 Leakage test 9.1 Low pressure, coupled Insert the coupling assembly in a test apparatus. Fill the test apparatus with test fluid (see 6.2) to a fluid column height of 750 mm. Apply a 50 N load perpendicular to the coupling centreline at a distance of 10 D from the axis of the gauge balls of the locking device (see Figure 1). Measure the drop in column height over a minimum test period of 30 min. Calculate the leakage rate, in millilitres per hour. Report the leakage rate in the test report (see clause 20). Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 11:28:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7198-2:1989 2 © BSI 11-1999 9.2 Low pressure, uncoupled (valved only) Insert each coupling half in a test apparatus. Fill the test apparatus with test fluid (see 6.2) to a fluid column height of 750 mm (see Figure 2). Measure the drop in column height over a test period of 30 min. Calculate the leakage rate, in millilitres per hour. Report the leakage rate in the test report (see clause 20). 9.3 Maximum operating pressure, coupled Purge internal air from the circuit. Pressurize the coupling assembly, with the test fluid, at maximum operating pressure as specified in ISO 7241-1. Observe leakage over a test period of 30 min, while maintaining maximum operating pressure. Collect and measure the leakage in a graduated measuring flask. Calculate the leakage rate, in millilitres per hour. Report the leakage rate in the test report (see clause 20). 9.4 Maximum operating pressure, uncoupled (valved only) Purge internal air from the circuit. Pressurize each coupling half, with the test fluid, at maximum operating pressure as specified in ISO 7241-1. Observe leakage over a test period of 30 min, while maintaining maximum operating pressure. Collect and measure the leakage for each coupling half in a graduated measuring flask. Calculate the leakage rate, in millilitres per hour. Report the leakage rate in the test report (see clause 20). 10 Extreme temperature test 10.1 Maximum operating temperature exposure, coupled Fill the coupling assembly with test fluid and subject the assembly to the maximum operating temperature for at least 6 h. The coupling shall be internally vented to atmosphere during temperature adjustment. Allow the coupling to cool to ambient temperature. Disconnect and reconnect the coupling. Determine the leakage rate in accordance with 9.1 and 9.3. Report the leakage rate in the test report (see clause 20). 10.2 Maximum operating temperature exposure, uncoupled (valved only) Fill the coupling halves with test fluid and subject the halves to the maximum operating temperature for at least 6 h. Allow the coupling half to cool to ambient temperature and actuate the valves five times manually to separate the valve seal from the sealing surface. Determine the leakage rate in accordance with 9.2 and 9.4. Report the leakage rate in the test report (see clause 20). 10.3 Maximum operating temperature service, coupled1) Fill the coupling assembly with test fluid and subject the assembly to the maximum operating temperature for at least 6 h. The coupling shall be internally vented to atmosphere during temperature adjustment. Determine the leakage rate at maximum operating temperature in accordance with 9.1 and 9.3. Report the leakage rate in the test report (see clause 20). 10.4 Maximum operating temperature service, uncoupled (valved only)1) Fill the coupling halves with test fluid and subject the halves to the maximum operating temperature for at least 6 h. Determine the leakage rate at maximum operating temperature in accordance with 9.2 and 9.4. Report the leakage rate in the test report (see clause 20). 10.5 Minimum operating temperature, coupled Fill the coupling assembly with test fluid and subject the assembly to the minimum operating temperature for at least 4 h. Determine the leakage rate at minimum operating temperature in accordance with 9.1 and 9.3. Report the leakage rate in the test report (see clause 20). 10.6 Minimum operating temperature, uncoupled (valved only) Fill the coupling halves with the test fluid and subject the halves to the minimum operating temperature for at least 4 h. Actuate the valves five times manually to separate the valve seal from the sealing surface. Determine the leakage rate at minimum operating temperature in accordance with 9.2 and 9.4. 1) This procedure requires testing at the maximum operating temperatures. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 11:28:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7198-2:1989 © BSI 11-19993 Report the leakage rate in the test report (see clause 20). 11 Pressure impulse test As the pressure impulse test is a destructive test, a new coupling shall be used; the coupling tested shall not be used for any further testing. 11.1 Coupled test Connect the coupling assembly to a test apparatus capable of producing pressure impulses, as shown in Figure 3. Adjust the test apparatus so that a pressure-time cycle corresponding to the curve shown within the shaded area of Figure 3 is obtained. Conduct the specified number of test cycles at a uniform cycle rate of 0,5 to 1,0 Hz. Uncouple and couple the test coupling assembly 10 times at intervals of 10 000 cycles throughout the test. Record any evidence of binding or malfunction. Determine the leakage rate in accordance with 9.1 and 9.3. Report the leakage rate and the number of test cycles in the test report (see clause 20). 11.2 Uncoupled test (valved only) Connect each coupling half to a test apparatus, capable of producing pressure impulses, as shown in Figure 3. Adjust the test apparatus so that a pressure-time cycle corresponding to the curve shown within the shaded area of Figure 3 is obtained. Conduct the specified number of pressure impulse cycles. Determine the leakage rate in accordance with 9.2 and 9.4. Report the leakage rate and the number of test cycles in the test report (see clause 20). 12 Endurance test As the endurance test is a destructive test, a new coupling shall be used; the coupling tested shall not be used for any further testing. Connect the coupling assembly to a pressure source, capable of providing 1 bar (100 kPa)2