Hydraulics IOE 2010

Satya Narayan Shah
B.Sc.MechanicalEngineering(India) MSinManufacturingEngineering&Management(UK)
BasicsofHydraulics MajorapplicationsinEarthMovingEquipment
j p y y MajorComponentsofHydraulicSystem
HydraulicSystemDesign
BasicsofHydraulics
LIQUIDSHAVENOSHAPEOFTHEIROWN.
Theyacquiretheshapeofanycontainer.Becauseofthis,oilinahydraulicsystem willflowinanydirectionandintoapassageofanysizeorshape.
SIMPLEHYDRAULICCIRCUIT
LOAD RESERVOIR
LIQUIDSTRANSMITAPPLIEDPRESSUREINALL DIRECTIONS. LIQUIDSAREPRACTICALLYINCOMPRESSIBLE. LIQUIDSPROVIDEGREATINCREASESINWORK FORCE.

Thisprinciplehelpsyoutostopalargemachinebypressingabrakepedal.
RELIEF VALVE PUMP
CONTROL VALVE
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ACTUATOR
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HOWAHYDRAULICSYSTEMWORKS
1.
ThePUMP whichmovestheoil.
2. TheCYLINDER whichusesthemovingoiltodowork. 3. CHECKVALVES toholdtheoilflow. 4. ARESERVOIR (anditsAncillaries)tostoretheoil. 5. TheCONTROLVALVE directstheoilflow. 5 directstheoilflow 6. TheRELIEFVALVE protectsthesystemfromhigh 7. 8. 9. 10.
pressures. Gaugesshowflowandpressureatvariouspoints. Accumulator (iffitted)smoothenstheperformance. Filterstoseparatethecontamination. Primemovertodrivethepump.

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ADVANTAGES Driveunit
Hydraulicsystemsaredrivenbymotors(electrical motors,combustionengines). Electricalmotorsgenerallyprovidethe mechanicalpowerforthepumpinstationary hydraulicsystem. Combustionenginesaregenerallyusedinmobile hydraulicsystem.
FLEXIBILITYUnlikethemechanicalmethodofpowertransmissionwhere therelativepositionsoftheengineandworksitemustremainrelatively constantwiththeflexibilityofhydrauliclines,powercanbemovedtoalmost anylocation. MULTIPLICATIONOFFORCEsmallforcescanbeusedtomovelarge loads. SIMPLICITYThehydraulicsystemhasfewermovingparts,fewerpointsof wear.Anditlubricatesitself. COMPACTNESS Thehydraulicsystemcanhandlemorehorsepowerforits COMPACTNESSThehydraulicsystemcanhandlemorehorsepowerforits sizethaneitheroftheothersystems. ECONOMYThisisthenaturalresultofthesimplicityandcompactness whichproviderelativelylowcostforthepowertransmitted.Also,powerand frictionallossesarecomparativelysmall. SAFETYfewermovingpartssuchasgears,chains,beltandelectrical contactsthaninothersystems.Overloadscanbemoreeasilycontrolledby usingreliefvalvesthanispossiblewiththeoverloaddevicesontheother systems.
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DISADVANTAGES
EFFICIENCYWhiletheefficiencyofthehydraulic systemismuchbetterthantheelectricalsystem,itis lowerthanforthemechanicaltransmissionofpower. NEEDFORCLEANLINESSHydraulicsystemscanbe damagedbyrust,corrosion,dirt,heatandbreakdown offluids.Cleanlinessandpropermaintenancearemore criticalinthehydraulicsystemthanintheother methodsoftransmission. FIREHAZARD Duetoneglegence.
APPLICATIONS
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MajorComponentsofHydraulicSystem
Reservoir
Tank Filters
Hydraulicreservoir
Thereservoirinahydraulicsystemfulfilsseveral tasks.
Itactsasanintakeandstoragereservoirforthe hydraulicfluidrequiredforoperationofthe system; Itdissipatesheat; Itseparatesair,waterandsolidmaterials; It t i t d lid t i l Itsupportsabuiltinorbuiltonpumpanddrive motorandotherhydrauliccomponents,suchas valves,accumulators,etc.
Pumps Valves
CheckValves DirectionalValves ReliefValves
Hydraulicaccumulators Cylinders/Motors
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Hydraulicreservoir
Thereservoirconsistsof
Reservoirbody Intakeandreturnlines Baffleandseparatingplate Ventilationandexhaust Magneticplug
Reservoir
Return Connection Filler Breather with filter
Volume of Reservoir 2 - 3 times delivery of pump in 1 minute
Pump
Return line
Thesizeofthereservoirdependson
Pumpdelivery Theheatresultingfromoperation Thevolumeofliquid Theplaceofapplication Thecirculationtime Thesizeofthereservoirisnotclassifiedbyitsphysical dimensionsbutitsliquidcapacity Reservoirsize(litres)=pump(litres/min)x3
Access panel
Level indicator
Suction line Strainer Drain Plug Baffles

ReservoirAccessories
Hydraulic filter
The task of the filter is to reduce the contamination in the system to an acceptable level in order to protect the various components from excessive wear.
Baffleplate
Itislocatedlengthwisethroughthecentreofthetank andis2/3theheightoftheoillevel. Itisusedtoseparatetheoutlettopumpfromthereturn line.Thisensuresacircuitousflowinsteadofthesame fluidbeingrecirculated. Thebafflepreventslocalturbulenceinthetank,allows foreignmaterialtosettle,getridofentrappedairand g ,g pp increasesheatdissipation.
Filler cap (breather cap)

Itshouldbeairtightwhenclosed,butmaycontaintheairventwhich filtersairenteringthereservoirtoprovideagravitypushforproperoil flow.
Oil level gauge

It shows the level of oil in the reservoir without having to open the reservoir.
Intake filter
It is usually a screen that is attached to the suction pipe to filter the hydraulic oil.
Suctionandreturnlines
Theyaredesignedtoenterthereservoiratpointswhere airturbulenceareleast. Theycanenterthereservoiratthetoporatthesides,but theirendsshouldbenearthebottomofthetank. Ifthereturnlineisabovetheoillevel,thereturningoil canfoamanddrawinair.
Drain plug
Itallowsalloiltobedrainedfromthereservoir. Somedrainplugsaremagnetictohelpremovemetalchipsfromthe oil.
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Suctionandreturnlines
Suction line Return line
Hydraulic filters Thetaskofthefilteristoreducethecontamination inthesystemtoanacceptablelevelinorderto protectthevariouscomponentsfromexcessivewear. Coolers Inhydraulicsystems,frictioncausesenergylosses whenthehydraulicfluidflowsthroughthelinesand components. Thiscausesthehydraulicfluidtoheatup. Toacertainextent,thisheatisgivenofftothe Toacertainextent thisheatisgivenofftothe environmentviatheoilreservoir,linesandother components Thefollowingcoolingdevicesareavailable: Aircooler:differenceintemperatureofupto25C possible. Watercooler:differenceintemperatureofupto35c possible. Oilcoolingbymeansofairfancooler:whenlarge quantitiesofheatmustbedissipated.
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Heaters
Heatingelementsorflowpreheatersare usedforheatingandpreheatinghydraulic fluid. Heatersareoftenrequiredtoensurethat optimumoperatingtemperatureisquickly attained. attained Thisistoensurethatoncethesystemis startedup,thehydraulicfluidquickly reachestheoptimumviscosity. Iftheviscosityistoohigh,theincreased frictionandcavitationsleadtogreater wear.
HydraulicPumps
Thepumpbasicallyperformstwofunctions:
Itcreatesapartialvacuumatthepumpinletport.The vacuumenablestheatmosphericpressuretoforcefluidfrom thereservoirintothepump. Themechanicalactionofthepumptrapsthisfluidwithin thepumpcavities,transportsitthroughthepump,and forcesitintothehydraulicsystem.
Hydraulicpumps
Threebasictypesofhydraulicpumpscanbe distinguishedonthebasisofthedisplacement volume: Constantpumps
Fixeddisplacementvolume
Itisoftenassumedthatpumpscreatepressure,butthe solepurposeofpumpsistocreateflow. Pressureiscreatedbyresistancetoflow. Apumpisamechanismdesignedtoproducetheflow necessaryforthedevelopmentofpressure. Itcannotitselfproducepressure,sinceitcannotprovide resistancetoitsownflow.

Adjustablepumps
Adjustabledisplacementvolume
Variablecapacitypumps
Regulationofflowrate.
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HYDRAULIC PUMP FAMILY

HYDRAULIC PUMPS
GEAR VANE PISTON
Hydraulicpumps
Pumprating
Ratedbytheamountoffluidthatcanbedisplacedforeach revolutionofthepumpshaft Specifiedincubicinchesorcubiccentimeterperrevolution
FIXED
VARIABLE
Displacementisdefinedasthevolumeofoilmovedor displacedduringeachcycleofapump. Therearetwoformsofdisplacement:

Nonpositivedisplacement Positivedisplacement
EXTERNAL
INTERNAL
FIXED
VARIABLE
AXIAL BENTAXIS
AXIAL BENTAXIS RADIAL
Positivedisplacementpump
Deliverstothesystemaspecificamountoffluidperstroke, revolutionorcycle
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Hydraulicpumps
Besides being positive displacement pumps, they are also categorized as either:
Fixed displacement pumps Variable displacement pumps

Fixed displacement pumps move the same volume of oil with every cycle. This volume is only changed when the speed of the pump is changed. Variable displacement pumps can vary the volume of oil they move with each cycle - even at the same speed. These pumps have an internal mechanism which varies the output of oil. 6/14/2011 Satya Narayan Shah
The centrifugal pump is an example of the nonpositive aspect, it simply moves the fluid and allows for back flow.
Fixed&Variabledisplacementpumps
Fixed
Fixeddisplacementpumpsmovethesame volumeofoilwitheverycycle. Thisvolumeisonlychangedwhenthespeedof thepumpischanged.
Variable
Variabledisplacementpumpscanvarythe volumeofoiltheymovewitheachcycle even atthesamespeed. Thesepumpshaveaninternalmechanism whichvariestheoutputofoil.
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Gearpumps Typesofhydraulicpumps
Mostpumpsusedontodayssystemsareofthree basicdesigns:
Gearpumps Vanepumps V Pistonpumps
Theyarewidelyusedbecausetheyaresimpleand economical. Whilenotcapableofavariabledisplacement, theycanproducethevolumeneededbymost systemsusingfixeddisplacement. Often,theyareusedaschargingpumpsforlarger Of h d h i f l systempumpsofothertypes.
Allthreedesignsworkontherotaryprinciple;a rotatingunitinsidethepumpmovesthefluid
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EXTERNAL GEAR PUMP
Externalgearpump
Gearpumpsarefixed displacementpumps sincethedisplaced volumewhichis determinedbythe toothgapisnot adjustable.
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EXTERNAL GEAR PUMP CHARACTERISTICS

Typicaldisplacementsto250cm3/r Typicalpressuresto250bar Fixeddisplacementonly Goodspeedrange,simplemultiple assemblies Generallynoisy Goodcontaminationsensitivity Poorserviceability Compact,lowweight Lowcost.
Internalgearpumps
Theinternalgearpumpalsousestwogears,butnow aspurgearismountedinsidealargergear. Thespurgearisinmeshwithonesideofthelarger gearandbothgearsaredividedontheothersidebya crescentshapedseparator. Thedriveshaftturnsthespurgear,whichdrivesthe largergear.
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INTERNAL GEAR PUMP
INTERNAL GEAR PUMP CHARACTERISTICS

Typicaldisplacementsto250cm3/r Typicalpressuresto250bar Fixeddisplacementonly Goodspeedrange Simplemultipleassemblies Lownoise Goodcontaminationsensitivity Poorserviceability Goodfluidcompatibility.
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VANE PUMPS
Vane pumps are fairly versatile pumps and can be designed as single, double, or even triple units. All vane pumps move oil using a rotating slotted rotor with vanes fitted into the slots.
VANE PUMP PRINCIPLE
Two types of vane pumps are most often used:

The unbalanced vane pump uses the basic principle of a turning rotor with vanes working inside a fixed rotor ring. However, the operating cycle only happens once each revolution. So this pump has only one inlet and one outlet port. Also, the slotted rotor is now set offside in a circular ring.
Unbalanced Vane Pumps-
Balanced Vane Pumps-The rotor is driven by the drive shaft and

turns inside an oval rotor ring. The vanes are fitted into the rotor slots and are free to move in or out. The pump has two inlet ports, located opposite each other. And it has two outlet ports, also on opposite sides of the pump. Both sets are connected to a central inlet and outlet.
Unbalancedvanepump
Theunbalancedvanepumpcanhaveafixedora variabledisplacement. Itusesthesamebasicprincipleofaturningrotor withvanesworkinginsideafixedrotorring. However,theoperatingcycleonlyhappensonce eachrevolution. Sothispumphasonlyoneinletandoneouter port. Also,theslottedrotorisnowsetoffsideina circularring.
Unbalancedvanepump
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Unbalancedvanepump
Balancedvanepumps
Thebalancedvanepumpisstrictlyafixeddisplacement typepump. Inthebalancedvanepump,therotorisdrivenbythedrive shaftandturnsinsideanovalrotorring. Thevanesarefittedintotherotorslotsandarefreeto moveinandout. Typicaldisplacementsto200cm3/r Typicalpressuresto280bar Fixeddisplacementonly Providesprimemoversoftstart Simpledoubleassemblies Lownoise Goodserviceability
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Balancedvanepumps
BALANCED VANE PUMP
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VARIABLE VANE PUMP PRINCIPLE
Unbalancedvariablevanepump
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VARIABLE VANE PUMP
MULTIPLE VARIABLE VANE PUMP
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FIXED VANE PUMP CHARACTERISTICS
VARIABLE VANE PUMP CHARACTERISTICS

Typicaldisplacementsto100 cm3/r Typicalpressuresto280bar Fixeddisplacementonly Providesprimemoversoftstart Simpledoubleassemblies Lownoise Goodserviceability. Typicalpressuresto160bar Simplemultipleassemblies Rangeofpumpcontrols Lownoise Lowcost.
Typicaldisplacementsto200cm3/r
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Pistonpumps
Pistonpumpsareoftenfavouredonmodernhydraulic systemswhichusehighspeedsandhighpressures. However,pistonpumpsaremorecomplexandmore expensivethantheothertwotypes. Theycanbedesignedforeitherfixedorvariable displacement. Mostpistonpumpsareeither: p p p Axialpistonpumps Radialpistonpumps Axialpistonmeansthatthepistonsaremountedinlines parallelwiththepump'saxis(alinedownthecentre). Radialpistonmeansthatthepistonsareset perpendiculartothepump'scentrelikethesun'srays.
Pistonpumps introduction
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Axialpistonpump
Axialpistonpump
Axialpistonpump
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Axialpistonpump
Axialpistonpump
Axialpistonpump
Axialpistonpump
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Axialpistonpump
Axialpistonpump
Axialpistonpump
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FIXED AXIAL PISTON PUMP CHARACTERISTICS
Axialpistonpump
Typicaldisplacementsto 500cm3/r
Typicalpressuresto350 bar
Multipleassemblies possible
Highoverallefficiency
Compactpackage.
FIXED DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PUMP - MAX FLOW

STROKE
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VARIABLE DISPLACEMENT PUMP - REDUCED FLOW

STROKE
VARIABLE DISPLACEMENT PUMP - REDUCED FLOW

STROKE
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VARIABLE DISPLACEMENT PUMP - ZERO FLOW

STROKE
VARIABLE DISPLACEMENT PUMP - ZERO FLOW

STROKE
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VARIABLE DISPLACEMENT PUMP - REVERSED FLOW
VARIABLE DISPLACEMENT AXIAL PISTON
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FIXED AXIAL PISTON PUMP CHARACTERISTICS

Typicaldisplacementsto 500cm3/r
Bentaxisaxialpistonpumps
Theswashplatedoesnotturnbutitcanbetilted backandforth. Theangleoftheswashplatecontrolsthedistance thatthepistonscanmovebackandforthintheir bores. Thegreatertheangle,thefartherthepistons travelandthemoreoilthatisdisplacedbythe pump.
Typicalpressuresto350 bar
Multipleassemblies possible
Highoverallefficiency
Compactpackage.
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Radialpistonpump
Inaradialpistonpump,thecylinderblockrotatesinsideacircular rotor. Astheblockrotates,centrifugalforce,chargingpressure,or mechanicalactioncausesthepistontofollowtheinnersurfaceofthe ring,whichisoffsetfromthecentrelineofthecylinderblock. Thepistonstakesinfluidastheymoveoutwardanddischargeitas theymovein. Displacementsto750+cm3/r Pressurecapabilitiesto350/400bar Highnoiselevel Sensitivetopoorinletconditions&contamination Highoverallefficiency Goodlifeexpectancy Large,bulkyunits Goodfluidcompatibility Highcost.
VARIABLE DISPLACEMENT RADIAL PISTON PUMP
Pistonpumps introduction
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CYLINDERS
PistonTypeCylindersgivestraightmovement.
SINGLEACTINGCYLINDERS giveforceonlyoneway. Pressureoilisadmittedtoonlyoneendofthecylinder, raisingtheload.Anoutsideforcesuchasgravityora springmustreturnthecylindertoitsstartingpoint. DOUBLEACTINGCYLINDERS giveforceinboth directions.Pressureoilisadmittedfirstatoneendofthe directions Pressureoilisadmittedfirstatoneendofthe cylinder,thenattheother,givingtwowaypower.
VaneTypeCylindersgiverotarymovement
Inaroundbarrel,theshaftandvanerotateaspressureoil enters.Oilisdischargedthroughtheoutletholeinthe othersideofthecylinder.
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Hydraulicaccumulators
Hydraulicaccumulatorsareusedfor: Storingenergy Absorbingshock Buildingpressureregularly Maintainingconstantpressure
Typesofhydraulicaccumulators: Gasloadedaccumulator Weightloadedaccumulator Springloadedaccumulator
TypesHydraulicAccumulators
Weightloadedaccumulators Gasloadedaccumulators Spring loadedaccumulators
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Characteristicsofhydraulicaccumulators
Weightloadedaccumulator Constantpressureisobtained Springloadedaccumulator Canbemountedinanyposition Gasloadedaccumulators theselectionanduseofthis accumulatordependsuponthe pressureandvolumeneedsofthe system
PNEUMATIC ACCUMULATORS
UsesinertgaseslikedryNitrogen Oilandgaschambersareseparatedby piston,bladderordiaphragm Gasiscompressedwhileexcessoilistaken duringoffloadperiodandexpandswhen d i ffl d i d d d h supplyingoiltothesystem Failureofpackingsealcausesmixingofgas andoil
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Precautions for Pneumatic Accumulators

NEVER FILL AN ACCUMULATOR WITH OXYGEN! An explosion could result if oil and oxygen mix under pressure. Never fill an accumulator with air. When air is compressed, water vapor in the air condenses and can cause rust. This in turn may damage seals and ruin the accumulator. Also, once air leaks into the oil, the oil becomes oxidized and breaks down. Always fill an accumulator with an inert gas such as dry g p yg gas nitrogen. This g is free of both water vapor and oxygen; this makes it harmless to parts and safe to use. Never charge an accumulator to a pressure more than that recommended by the manufacturer. Read the label and observe the "working pressure." Before removing an accumulator from a hydraulic system, release all hydraulic pressure. To disassemble, release both gas and hydraulic pressures. To disassemble, make sure that dirt and abrasive material does not enter any of the openings
SPRING-LOADED ACCUMULATORS
In operation, pressure oil loads the piston by compressing the spring .When pressure drops, the spring forces oil into the system. The accumulator can be used as a gradual pressure builder for an automatic transmission. When the transmission is shifted, pressure drops and the accumulator sends a "surge" of oil in to "take up slack." This fills the chamber behind the clutch pistons. Then pressure builds gradually for a smooth engagement of the clutch. By controlling the flow of oil to the accumulator, the time needed to charge it can also be controlled
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SPRING-LOADED ACCUMULATORS
Theoperationofspringloadedaccumulatorscanbe variedbychanging1)thestrengthofthespring,2)the lengthofthespring,3)thepreloadonthespring,4) thesizeofthepistonor,5)thelengthofthepiston stroke.
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HydraulicValves
Hydraulicvalvesregulate
Pressure Direction Volume
PressureControlValves(PCV)
PCVareusedtolimitorreduce systempressure Unloadapump Setthepressure
Typesofvalve
Pressurecontrolvalves Directionalcontrolvalves Volumecontrolvalves
ExamplesofPCVare
Reliefvalves Pressurereducingvalves Pressuresequencevalvesetc
ReliefValves
Usedassafetyvalves Preventstheincreaseofsystempressure fromthespecifiedpressurerange Crackingpressureisthepressureatwhich thereliefvalvesfirstbegintoopen Fullflowpressureisthepressureatwhich thevalvepassesitsfullquantityofoil
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PressureReducingValves
Tokeepthepressureinonebranchof circuitbelowthanthatofmaincircuit Whennotoperatingthisvalveisopen Thespringtensioncanbeadjustedusing screw Thisvalvewilllimitmaximumpressurein thesecondarycircuitirrespectiveof pressurechangesinthemaincircuit
PressuresequenceValves
Tocontrolthesequenceofflowtovarious branchesofcircuit Valvesallowflowtoasecondfunction onlyafterafirsthasbeenfullysatisfied Whenclosed,thevalvedirectsoilfreely totheprimarycircuit Whenopened,thevalvedivertsoiltoa secondarycircuit Thesecondcylinderbeginsitsstroke oncefirstcompletesitsstroke
Directionalcontrolvalves
Directstheflowofoilinhydraulic system
Types Checkvalves Spoolvalves S l l
SpoolDirectionalvalve
Directsoiltostart,operateandstop theactuatingunitsonmodern hydraulicsystem Spoolvalvecanbecategorizedbyits p g y positionandwayofdirectingtheoil line Forexamplethreepositionandfour wayvalve
Checkvalves:
o Onewayvalve o Opentoallowflowinonedirectionbutcloseto
preventflowintheoppositedirection
o Mostlyusedtostopreverseflow
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Volumecontrolvalves
Controlsthevolumeorflowofoil usuallybythrottlingordiverting Speedofcylinderormotoris g y regulatedbythisvalve Mostlyusedinfixeddisplacement typeofvalve
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Hydraulicfilter
Filtersthecontaminationfromtheoil Itcanbetakenfromthemachineand cleanedduringservicingperiod.If cloggedbypassvalvecomesinaction Isgenerallycartridgetype Hydraulicfiltergenerallyisinbetween returnlineandtank
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Hydraulichoses
Carrieshydraulicoilfromone componenttotheanotherinhydraulic system Areofhighpressureandlowasperthe oilflowline Flexibleinnature Canbeconnectedwithanotherpipe throughcoupling Sometimessteelpipescanbeusedfor connectingtwocomponentsiftheyare closedtoother
Hydraulic hoses
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Hydraulicfluid
Thehydraulicfluidisthetransmittingmediumofthe hydraulicsystem.Itperformsvarioustasks:
Transmissionofhydraulicenergy Preventionofcorrosionofmovinginternalparts Removalofdirt,abrasivematter,etc Dissipationofheat Lubrication Sealing
Hydraulicfluidrequirements
Mustnotboil,vaporizeorfreezewithinthe temperaturelimitsofthesystem Mustnotcorrodetheinternalparts Viscositymustremainstable Mustbechemicallystable Capableofresistingfoaming p g g Capableofseparatingfromwater Compatiblewithsealsandgaskets Lubricatingability Oxidationresistance Loadcarryingcapacity
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Toohighaviscosityincreasesfriction,resultingin:
Highresistancetoflow. Increasedpowerconsumptionduetofrictionalloss. Hightemperaturecausedbyfriction. Increasedpressuredropbecauseoftheresistance. Possibilityofsluggishorslowoperation. Difficultyinseparatingairfromoilinreservoir. Greatervacuumatthepumpinlet,causingcavitation. p p , g Highersystemnoiselevel.
Typesofhydraulicfluids
Petroleumoil Fireresistantfluids Waterglycols Wateroilemulsion Syntheticoil
Andshouldtheviscositybetoolow:
Internalleakageincreases. Excessivewear. Pumpefficiencymaydecrease,causingsloweroperationoftheactuator. Increasedtemperatureresultfromleakagelosses
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Typicalhydrauliccircuit
.
Control valve
GeneralMaintenanceofhydraulicsystem
Criteriaforgeneralmaintenance Changingoffilter: Normally500hoursof operation Changeofoil: 2000hoursofoperation Problemarisesfromfailureofhoses Replacementofseals,oringsincylinderpiston R l t f l i i li d i t Testingofpressureatdifferenttestpointsliketest ofreliefvalvepressure Internalleakagetestofpump RefertheElectroniccontrollererrorcodeand followtheinstruction
L.H. Cylinder
Pressure Relief P R li f Valve
R.H. Cylinder
Main pump Hydraulic filter
Tank
GeneralMaintenanceofhydraulicsystem
ForHitachiEX300excavator Faultcode : 05 Trouble: SignalfromPVCisnottransmittedtoEC Correctiveaction: Checkwireharness,replacePVCor ECifautoidleisabnormal Faultcode: 22 Trouble: Abnormalpumpcontrol Correctiveaction: Harnesscheck,checkpump displacementsolenoidvalve,checkanglesensor,check PVC
Testingofleakage anexample
Leakageofoilinsystemdueto
Internalleakagefrompumpandvalve Internalleakagefrompistoncylinder
Testingprocedure
Raisethebucketwithload.Keepthebucketin holdingposition.Observethepositionofbucket holdingposition Observethepositionofbucket Ifbucketlowerscompletely,leakagefrompumpand valve Ifnotcompletelyretracted,leakagefromthepiston andcylindergap
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Generalprecautiontobecarriedout
Reliefvalvepressureifitistobe resetrefertotherecommended valuesfrommanufacturer Ifmetallicchipsfoundinoil,the wholeoiltobeflushedand replacedbynewonewithfilter Recommendedoiltofilled Oilissensitivetothedust

Theanaloguemechanicalsignalsarecaptured bytransducerscommonlycalledsensors Electroniccircuitstransformtheanalogue signaltodigitalsignalifrequired. Relayshelpthesignalstoactivatethesolenoid valves Solenoidvalvesonceactivatestheinputsignal goestoElectronicControlUnit(ECU) Thentothecorrespondingcomponentasper thesystemrequirement
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Designofasimplehydraulicsystem
Whendesigningasimplehydraulicsystem,we needtocalculatethefollowing: Pressure,forceandarea Speedofanactuator S d f Flowvelocityinpipes Pipesizerequirements Work,horsepowerandtorque Reservoirsizing
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Pressureindicatesworkload
Resistanceofaloadgeneratespressure. Pressureequalstotheforceoftheloaddivided bythepistonarea. Wecanexpressthisrelationshipbythegeneral formula: P=pressure;f=forceanda=area p ;
Forceisproportionaltopressure andarea
When a hydraulic cylinder is used to clamp or press, its output force can be computed as follows: F=pxa
P =
F A
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Computingpistonarea
The area of a piston can be computed by this formula
Speedofanactuator
Howfastapistontravelsoramotorrotates dependsonitssizeandtherateofoilflowintoit. Torelateflowratetospeed,considerthevolume thatmustbefilledintheactuatortocauseagiven amountoftravel. f l
A= A
x d2
Volume
Time
= Speed x Area
Speed
Volume Area
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Time
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Velocityinpipes
Thevelocityatwhichthehydraulicfluidflows throughthelinesisanimportantdesign considerationbecauseoftheeffectofvelocityon friction. friction Generallytherecommendedvelocityrangesare:
Pumpinletline=0.61 1.22metrespersecond Workinglines=2.13 6.10metrespersecond
Pipesizerequirements
IftheLPManddesiredvelocityareknown,use thisrelationshiptofindthecrosssectionalarea:
Area(mm2 ) =
LPMx 16667 Velocity(in mmper second)
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When the LPM and size of pipe is given, use this formula to find what the velocity will be:
Selecttheproper conductorinternal diameteriftheflow rateisknown. Determineexactlywhat thevelocitywillbeif theconductorsizeand flowrateareknown.
Velocity (mm per second ) =
LPM x 16667 Area (mm 2 )
Alternatively, the area can be obtained from the selection chart.
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Workandpower
Workandpower
Whenaforceisexertedthroughadistance,work isdone. Work=forcexdistance W k f di Workisusuallyexpressedinjoules. Forexample,ifa50nweightislifted3m,thework doneis150nmorj.
Thepreviousformuladoesnottakeinto considerationhowfasttheworkisdone. Therateofdoingworkiscalledpower.

Power = Forcex Distance Work or Time Time
Theusualunitofpoweristhehorsepower (watt),abbreviatedhp(w).(1hp=746watts) Onewattisequivalentto1newtonliftedone metreinonesecond)
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Horsepowerinahydraulicsystem
Inthehydraulicsystem,speedanddistanceare indicatedbytheLPMflowandforceisindicated bypressure. Thus,wemightexpresshydraulicpowerthisway:
Bychangingtheunits,weget
kW =
LPM x bar 600
Power =
Litres Newtons x Minutes Square Metres
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Thesehorsepowerformulastelltheexactpower beingusedinthesystem. Thehorsepowerrequiredtodrivethepumpwill besomewhathigherthanthissincethesystemis not100%efficient. % ffi i Theformulaischangedwhentheaverage efficiency()istakenintoaccount.
Horsepowerandtorque
The following are general torquepower formulas for any rotating equipment:
Torque
9550 x kW rpm
kW =
LPM x bar 600 x

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kW =
Torque x rpm 9550
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Marginoferror
Whenworkingontheformulas,wemusttakeinto considerationthemarginoferrorifitisgiven. Workingpressure,p=operatingpressure W ki i marginoferror
Reservoirsizing
Forindustrialuse,ageneralsizingruleisused: Tanksize(litres)=pumplpmx3
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Areaofpiston
Giventhefollowing:
Load=35000N Distance=0.5m Operatingpressure=60bar O i 6 b Marginoferror=10% Rateofraisingload=0.15m/sec Flowvelocity=2.5m/sec Systemefficiency=90%
Loadis35000N Pressureis60bar
Area =
Force 35 000 = = 0.0065 m2 Pressure 54 x 105
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Velocity
Rateatwhichloadistoberaised =15cm/sec=0.15m/sec Whichisequalto9m/min h h l
Rateofoilflow
Rateofoilflow = = = litres/min = = travelratexarea 9x0.0065 0.0585m3/min 0.0585x1000 58.5litres/min
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Wattageofmotor
Insidediameterofpipe
Todeterminetheinsidediameterofthepipeifa flowvelocityof2.5m/secistobemaintained. Usingthenomogram,for6.5LPMand2.5m/sec, weget: Areaoffluidconductor=4cm2
kW = kW =
LPM x bar 600 x 58.5 x 60 = 6.5kW 600 x 0.9

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Diameterofhydraulichose
Withtheareaoffluidconductorbeing4cm2 Thediameterofthehydraulichosecanbeobtained:
Reservoirsizing
Reservoirsize Reservoirsize =58.5x3
4 d d
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x = =
= x
4 4 cm
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=175.5litres
4 2.26
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Hydraulics IOE 2010

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Satya Narayan Shah

LIQUIDSTRANSMITAPPLIEDPRESSUREINALL DIRECTIONS. LIQUIDSAREPRACTICALLYINCOMPRESSIBLE. LIQUIDSPROVIDEGREATINCREASESINWORK FORCE.

RELIEF VALVE PUMP

pressures. Gaugesshowflowandpressureatvariouspoints. Accumulator (iffitted)smoothenstheperformance. Filterstoseparatethecontamination. Primemovertodrivethepump.

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Volume of Reservoir 2 - 3 times delivery of pump in 1 minute

Suction line Strainer Drain Plug Baffles

Filler cap (breather cap)

Oil level gauge

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Itisoftenassumedthatpumpscreatepressure,butthe solepurposeofpumpsistocreateflow. Pressureiscreatedbyresistancetoflow. Apumpisamechanismdesignedtoproducetheflow necessaryforthedevelopmentofpressure. Itcannotitselfproducepressure,sinceitcannotprovide resistancetoitsownflow.

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HYDRAULIC PUMP FAMILY

Displacementisdefinedasthevolumeofoilmovedor displacedduringeachcycleofapump. Therearetwoformsofdisplacement:

AXIAL BENTAXIS RADIAL

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Fixed displacement pumps Variable displacement pumps

Theyarewidelyusedbecausetheyaresimpleand economical. Whilenotcapableofavariabledisplacement, theycanproducethevolumeneededbymost systemsusingfixeddisplacement. Often,theyareusedaschargingpumpsforlarger Of h d h i f l systempumpsofothertypes.

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EXTERNAL GEAR PUMP

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EXTERNAL GEAR PUMP CHARACTERISTICS

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INTERNAL GEAR PUMP

INTERNAL GEAR PUMP CHARACTERISTICS

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VANE PUMP PRINCIPLE

Two types of vane pumps are most often used:

Unbalanced Vane Pumps-

Balanced Vane Pumps-The rotor is driven by the drive shaft and

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BALANCED VANE PUMP

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VARIABLE VANE PUMP PRINCIPLE

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VARIABLE VANE PUMP PRINCIPLE

VARIABLE VANE PUMP PRINCIPLE

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VARIABLE VANE PUMP

MULTIPLE VARIABLE VANE PUMP

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