High Quality DYW Series Explosion-Protected Electro-Hydraulic Thrusters

 

 

1. Series Overview & Core Function

The DYW Series (D = Heavy-Duty, Y = Hydraulic, W = Explosion-Protected) is classified as a multi-environment explosion-safe actuation unit, bridging electrical control systems and mechanical load-bearing mechanisms. Its core functions are tailored to the safety and performance needs of offshore, marine, and mining industries:

Heavy-Duty Brake Actuation: Generating linear thrust to release spring-engaged brakes (e.g., for offshore crane wheels, mining conveyor drums) during operation, and ceasing thrust to enable emergency braking or static load holding.

Precision Positioning: Driving clutches or linkage mechanisms for equipment positioning-such as offshore platform winches, chemical tanker cargo handlers, or mining crusher feeders-ensuring stable motion without ignition risks.

Fail-Safe Emergency Response: Instantly stopping thrust output upon power loss, system leaks, or overpressure, allowing brakes/mechanisms to return to safe states and preventing explosions in flammable gas/dust atmospheres.

With compliance to marine classification society standards (e.g., DNV GL, ABS) and mining safety norms, the series supports continuous (S1) and intermittent (S3-60%) duty cycles, adapting to 24/7 offshore operations or cyclic mining tasks.

2. Working Principle

The DYW Series operates on a sealed, pressure-stabilized electro-hydraulic conversion principle, integrating explosion-proof components to eliminate ignition sources while delivering high thrust. Its working cycle includes three key states, optimized for harsh environmental resilience:

2.1 1. Thrust Generation (Actuation)

When activated, the explosion-proof electric motor (housed in a flameproof enclosure) drives a high-efficiency gear or vane pump. The pump draws marine-grade hydraulic oil from the sealed, corrosion-resistant reservoir and pressurizes it (12–25 MPa, model-dependent).

Pressurized oil flows through explosion-proof control valves to a double-acting hydraulic cylinder (for bidirectional thrust) or single-acting cylinder (for unidirectional thrust). This pushes the piston and hard-chrome plated output rod outward, generating linear thrust (1.4–80 kN) to actuate brakes, clutches, or positioning mechanisms.

2.2 2. Thrust Retention (Sustained Operation)

Once the output rod reaches the maximum stroke (customized to 50–300 mm based on application), a pressure relief valve diverts excess oil back to the reservoir. This maintains stable cylinder pressure, keeping the thruster in the extended/retracted position without overloading the motor-critical for continuous offshore crane operations or mining conveyor holding.

A built-in check valve prevents oil backflow, ensuring thrust retention even if minor leaks occur, avoiding unexpected mechanism movement.

2.3 3. Thrust Cessation (Emergency/Reset)

In power loss, emergency shutdown, or detection of explosive gas concentrations (via external sensors), the motor and pump stop immediately. Hydraulic pressure dissipates, and the target mechanism's return force (e.g., brake spring tension, gravity) retracts the output rod. Oil flows back to the reservoir, resetting the thruster and engaging safety brakes.

The flameproof enclosure and sealed hydraulic system contain any internal sparks or heat, preventing ignition of external flammable gases (e.g., methane in mines, hydrocarbon vapors offshore).

3. Core Structure & Explosion-Protected Components

The DYW Series features a rugged, multi-environment adaptive design with five critical subsystems, all compliant with strict explosion and corrosion resistance standards:

3.1 1. Marine/Mining-Grade Explosion-Protected Motor (Power Input)

A three-phase AC induction motor with Exd IIB T4 Ga/Exd I Mb explosion-proof marks (compliant with GB 3836-2010, ATEX 2014/34/EU, and IECEx):

Offshore/onshore industrial zones: Exd IIB T4 Ga for Class IIB explosive gas atmospheres (hydrocarbons, solvents) with temperature class T4 (≤ 135°C).

Underground mining: Exd I Mb for methane-rich coal mine environments.

Motor power ranges from 0.75–15 kW, with dual-voltage options (380V/660V, 660V/1140V AC, 50/60Hz) to match mining and marine power systems. Insulation class is Class H (heat resistance up to 180°C) for high-temperature tolerance in engine rooms or mining tunnels.

3.2 2. Sealed Hydraulic Power Unit (Energy Conversion)

Explosion-Safe Pump: A low-noise, high-pressure gear/vane pump (pressure up to 25 MPa) with non-sparking copper-alloy components. It is enclosed in a flameproof housing to avoid friction-induced sparks.

Corrosion-Resistant Reservoir: A 316L stainless steel or marine-grade aluminum reservoir (capacity: 2–15 L) with a sealed lid and flameproof breather valve. It resists saltwater corrosion (offshore) and mine water/chemical erosion, while an integrated 5μm oil filter maintains oil cleanliness.

Explosion-Proof Valve Block: Houses solenoid valves (24V DC explosion-proof coils), pressure relief valves, and check valves-all with flameproof seals to maintain the enclosure's integrity and prevent oil leakage.

3.3 3. Heavy-Duty Hydraulic Cylinder (Force Output)

A single/double-acting cylinder with a hard chrome-plated 316L stainless steel output rod (diameter: 30–100 mm) for extreme corrosion resistance and wear reduction. The cylinder bore (50–150 mm) and stroke are customized to match thrust and mechanism travel requirements.

Marine-Grade Seals: Fluoropolymer (FKM) or perfluoroelastomer (FFKM) seals (standard) resist oil leakage, saltwater, and chemicals, ensuring reliable performance in temperatures from -30°C to 150°C (suitable for LNG carrier low-temperature environments).

3.4 4. Flameproof & Marine-Protected Enclosure (Safety Core)

Dual-Material Housing: A combination of cast steel (for impact resistance) and 316L stainless steel (for corrosion resistance) with flameproof joints (gap ≤ 0.12 mm). It contains and cools internal explosions, preventing flame propagation to external atmospheres.

IP67 Protection: The enclosure is dust-tight, waterproof, and submersible for short periods (up to 1m depth for 30 minutes), adapting to offshore wave splashes or mining flood risks.

Marine-Grade Cable Glands: Armored cable entries with brass or stainless steel glands, compatible with offshore/mine armored cables to prevent gas ingress and ensure spark-free wiring.

3.5 5. Installation & Adaptation Components

Universal Mounting: A rotatable trunnion or flange base (180° adjustment) and 360° swiveling rod head allow vertical, horizontal, or inclined installation on offshore cranes, mining conveyors, or tanker decks.

Anti-Vibration Mounts: Rubber isolators with stainless steel brackets reduce vibration transfer from marine engines or mining machinery, protecting hydraulic components and extending service life.

4. Key Features & Advantages

The DYW Series is distinguished by its dual-environment (marine/mining) adaptability, explosion safety, and heavy-duty performance, with core benefits for high-risk industries:

4.1 1. Multi-Standard Compliance

Meets global explosion standards (GB 3836-2010, ATEX, IECEx) and marine classification society certifications (DNV GL, ABS, Lloyd's Register), ensuring legal compliance in offshore, chemical, and mining sectors.

4.2 2. Extreme Corrosion & Temperature Resistance

Marine-grade stainless steel, FKM/FFKM seals, and IP67 protection resist saltwater, mine chemicals, and temperature extremes (-30°C to 150°C), suitable for LNG carriers, offshore oil rigs, and underground mines.

Class H motor insulation tolerates high temperatures in engine rooms or mining tunnels, avoiding overheating during continuous operation.

4.3 3. High Thrust & Load Capacity

Delivers 1.4–80 kN of thrust (corresponding to 140–8,000 N・m braking torque) and 适配 wheel diameters of 200–710 mm, making it suitable for heavy-duty equipment like offshore crane wheels, mining conveyor drums, and chemical tanker cargo handlers.

4.4 4. Low Maintenance & Long Service Life

Sealed hydraulic systems and corrosion-resistant materials reduce maintenance frequency; oil changes are only required every 12–24 months (twice as long as standard thrusters).

Heavy-duty components (stainless steel rods, FKM seals) ensure a service life of ≥ 12,000 working hours under continuous offshore/mining operation.

4.5 5. Fast Response & Emergency Safety

Thrust build-up time (startup to full stroke) is ≤ 0.6–1.2 seconds, enabling quick brake release for offshore crane positioning or mining conveyor emergency stops.

Integrated pressure sensors and external gas detection compatibility trigger automatic shutdown in hazardous conditions, enhancing operational safety.

5. Typical Applications

The DYW Series is purpose-built for extreme hazardous environments across marine, offshore, and mining industries:

Offshore Oil/Gas: Actuating brakes for offshore crane wheels, drill rig winches, and platform conveyor drums; driving clutches for subsea equipment launch/recovery systems.

Marine Vessels: Controlling brakes for chemical tanker cargo handlers, LNG carrier cryogenic pump drives, and offshore supply vessel winches.

Underground Mining: Driving brakes for mine hoists, conveyor drums, and crusher feed mechanisms; positioning linkages for ore transfer chutes (methane-rich zones).

Chemical/Petrochemical: Operating emergency brakes for solvent storage tank conveyors, gas pipeline pumps, and chemical reactor agitators (Class IIB explosive zones).

 

 

 

 

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