é ve C- A on BASIC INDUSTRIAL HYDRAULICS [Fitna Port Plug) Contact for HYDRAULICS TRAINING Email: training@yukenindia.comHandouts on BASIC INDUSTRIAL HYDRAULICS INTRODUCTION Hydraulics plays a very important part in almost all sections of Industry whether it is related to manufacturing, travel, healthcare, hospitality or any other sector. The uses of Hydraulics are innumerable and its applications are visible in almost all walks of life. In science and engineering applications, it occupies a prominent place in under water (submarines), in ships, on land, in air travel & space. The knowledge of hydraulics technology therefore is very useful for not only science & engineering graduates but also for others who use these applications. This handout gives a clear sectionised picture about the components that go to make a hydraulic system, with brief notes. Please observe that most of the diagrams depict initial condition and also the operated condition. This will help you in recollecting what you were taught in the class. To derive the most benefit from this handout, please synchronize what is being taught in the class to what is being shown in the handouts and make relevant notes in the handouts for your future reference. Also please relate to the legend below for colour coding in the handouts. Legend ME RED Operating or System Pressure MEE ORANGE Reduced Pressure, Pilot Pressure or Charging Pressure ME BLUE Suction or Exhaust or Drain Flow ME GREEN Intake or Drain (lm YELLOW Measured (Metered) Flow ‘Contact for: HYDRAULICS TRAINING Email: training@yukenindia.comSL.No. 10 " 12 13 14 15 16 TABLE OF CONTENTS Subject Basics of Hydraulics Hydraulic Pumps Hydraulic Valves Logic Valves Electro-Proportional Valves Servo Valves Mobile Valves Hydraulic Cylinders Hydraulic Motors Hydraulic Accessories Hydraulic Circuits Hyd. Oils, Contamination & Filtration Maintenance & Trouble shooting of Hydraulic systems Graphical Symbols Pipe Selection (Nomograph for choosing Pipe ID) Solution to Exercises Page No. 15 35 39 45 51 55 63 nm 83 99 107 111 133 135) Basics of Hydraulics 1, Definition The study of Hydraulics deals with the use and characteristics of liquids. The term “Hydraulics” has been derived from 2 Greek words “Hydor” — meaning Water , = “Aulos” — meaning Pipe Therefore the term “Hydraulics” can be broadly defined as the work done by fluids in pipes. 2, Classification Hydraulics is broadly classified into 2 types - 2.1. HYDROSTATICS 2.2. HYDRODYNAMICS 3. Hydrostatics With ref, to Fig.l, when a force F; is applied on the smaller piston, the bigger piston moves. This is because one of the properties of hydraulic oil is that it is incompressible. The study of the confined fluid transmitting power, modifying motion and multiplying forces is called Hydrostatics. 4. Hydrodynamics A jet of water at high velocity impinging on the turbine blades causing the turbine shaft to rotate is an example of Hydrodynamics. Fig.l 5. Pressure Pressure is defined as the force exerted over an unit area of cross section. Pressure = Force Force in — Kilograms (kgs ) Area Area in — Sq.Cms (cm?) . Pressure is in —> Kilogram / Sq. Cms (kg/cm? )® Basics of Hydraulics Atmospheric air exerts an uniform pressure all around us. At sea level the atmospheric air exerts a pressure of 1.03322 kgf/cm? Force 6. Pascal’s Law Pressure applied on a confined fluid is transmitted undiminished in all directions and acts with equal force on equal areas and at right angles to them. (Fig. 2) Pascal was a French Scientist. who discovered this in the 17th Century. 7. Bramah’s Press During the industrial revolution a British mechanic by name Joseph Bramah, thought about the above law, and how to apply it in real life - if a small force on a small area would give a bigger force on a bigger area, then the only restriction to the force a machine can exert is the area on which the pressure is acting. This was the basic idea on which he designed the Hydraulic Press. ( Bramah’s Press ) ( Fig. 3 ) Pressure developed throughout is 10 Kg/cm? A10 kg load is acting on 1cm* area, and the pressure developed will be 10 kg/cm? . At the other end the area is 10 cm? and therefore it can balance a load of 100 kgs. XA = 10 kg/cm? X 10 cm? = 100 Kgs.® Basics of Hydraulics 7.1. Law of Conservation of Ene The law of conservation of energy states that energy can neither be created nor destroyed, Here we are seeing a load of 10 kgs balancing a load of 100 kgs. * Suppose, the 10 kgs load is moved by say 10 cms. © The volume of fluid displaced will be Area X Distance = 1 X 10 = 10 cm? = The same 10 cm’ will be displaced at the other end «To displace 10 cm? the bigger piston has to move by only 1 cm. Therefore, what is gained by the force is sacrificed by the distance moved. 8. Hydraulic Power Transmission The source of power for the hydraulic system is the prime mover, which may be an electric motor or an engine, which will drive the Pump. The pump is called the input component in a hydraulic system. The output component in a hydraulic system is called the actuator. There are 2 types of actuators - 8.1. Linear Actuators - ( Cylinders ) which give linear motion along with force 8.2. Rotary Actuators- ( Hyd. Motors) which give rotary motion along with torque 9. Advantages Of Hydraulics 9.1. Variable Speeds - ( Can be run at various speeds with ease by using a flow Control valve ) 9.2. Hydraulic drives are Reversible - ( Instantaneous change in direction by using a Directional Valve ) 3. Overload protection (Relief W. protects the system from being overloaded) 9.4, Compact in size - (Considering high speed & pressure capabilities and power outputs, hyd. systems are compact ) 9.5. Can be stalled - ( Without damage ) Ta aN 10. Pressure in a fluid column » 14cm? ( 1cc ) of Oil weighs about 0.85 gms. (Fig. 4) +. Pressure at the bottom of 1cc of oil will be 0.85 gms/cm* |= A2.Cm of Oil column weighs 0.85 X 2 = 1.7 gms. -- Pressure at the bottom of 2c of oil column will be 1.7 gms/cm? \ —_ A 300 Cm of oil column weighs 0.85 X 300 = 255 gms = 0.255 Kgs. Fig - Pressure at the bottom of 300cc of oil column will be 0.255 kg/cm? Thus to estimate the pressure at the bottom of any column of oil simply multiply the height by 0.85| ®@ Basics of Hydraulics 10.1.Pump_inlet_locations One of the important effect of the oil’s weight is the effect on the pump inlet. When the pump is below the oil reservoir, a positive pressure is available to force the oil into the pump inlet. When the pump is above the oil reservoir, a vacuum is required to lift the oil to the pump inlet. 11, Characteristics of fluids 11.1, How pressure is developed When the faucet is wide open, the delivery from the pump goes unrestricted and there is no reading in the pressure gauge. When the faucet is gradually closed, the resistance to the flow increases and causes pressure to build up in the upstream. If the restriction is still increased, it takes increasingly more pressure to flow through the restriction. (Fig. 5) Without the relief valve there would be no limit to the build up of pressure. In that case the weakest component would snap. When the pressure builds up to the setting of the Relief valve, it opens thereby diverting the oil from the pump to the tank through the relief valve and hence protects the system from excess build up of pressure. Pressure is developed whenever there is a resistance to the flow !® Basics of Hydraulics 11.2. Parallel Flow paths 10 bar Check valves opens at A 10 Bar B= 20 Bar C — 30 Bar Oil takes the path of least resistance 11.3.Series Flow paths Series resistances add pressure. ( Fig. 7) When the same 3 check valves are connected in series, the pressure at the pump outlet will be the sum of the individual pressures of the 3 check valves. To Tank S=10BAR j| 108aR =ort0 S=20BAR ‘S= Spring Tension 3 = P2420 S=30BAR j) conan =30+30® Basics of Hydraulics 12. Orifice An orifice is a restricted passage in a hydraulic line or component, used to control flow or create pressure differential ( Pressure Drop ) Q=KxAxVAP Where Q— Flow through an orifice. (1 / min ) K — Constant. ( Depends on Coefficient of discharge, viscosity of oil ) A Area of Orifice (Cm 2 ) AP —> Pressure drop across the Orifice ( Kg/Cm? ) 13. Principles of Flow 13.1. Velocity The average distance the fluid particles travel per unit of time. Unit: cm/sec or cm/min or m/min 13.2. Flow Rate It is the volume of fluid passing a point in a given time Unit: m/min or — L/min (lpm) 13.3. Speed of an Actuator Depends upon the size and the rate of flow into it. Q=AXxv Where Q = Flow in cm?/min A = Area in cm? V = Velocity in cm/min 14, Bernoulli’s Principle The sum of the pressure energy and kinetic energy at various points in a system is constant if flow rate is constant. When the cross-sectional area of a flow path increases, the velocity (kinetic energy) decreases, and results in the increase of pressure energy ie., pressure. This transformation of energy from one type to the other keeps the sum of the two energies constant. (Fig. 8) Venturi effect in a gasoline engine carburetor is an application of the Bernoulli’s principle.® Basics of Hydraulics Velocity decreases in larger pipe. Ki energy loss made up by increase in pressure. Velocity is high, pressure is low CARBURETOR BARREL ~~ |] J BUTTERFLY VALVE “A ud Tunoat. a) 1 etic Ignoring friction loss pressure again becomes same as that of “A” when velocity becomes that of “A”. Fig.9 FUEL BOWL Venturi effect in a gasoline engine carburetor is an application of Bernoulli’s principle.i essen een enn rn RR EU nu nut u tet e teu uu EEE ® Basics _of HydraulicsQ@ Hydraulic Pumps 1. Principle The function of a Hydraulic Pump is to convert mechanical energy into hydraulic energy. This is achieved by generating an increased volume during intake and decreased volume during delivery. Piston ) (Naive During Suction Piston ) Valve ) During Delivery leo J net 2. Characteristics 2.1. Flow Rating Specified usually by cc/rev. and then converted to lpm based on the rpm of the prime mover 2.2. Pressure Rating Function of the pump is to create flow. Pressure is developed when there is a resistance to the flow. The maximum pressure, which the pump can withstand, is called as the pressure rating. 2.3. Volumetric Efficiency Qa St x100 Qn Where Qact — Actual Flow Qt, — Theoretical (Geometric ) Flow 2.4. Noise Level Measured in Decibels ( db ) 2.5. Contamination level allowed Degree of oil contamination allowed is specified. Eg. by NAS classificationTT @ Hydraulic Pumps 3. Types of Pumps 3.1. Non Positive displacement pumps 3.2. Positive displacement pum) 3.2.1. Rotary 2211. Gear Pump 3.2.1.2. Vane Pump Reciprocator Axial Piston Pump Radial Piston Pump 4 Non Positive displacement pumps No positive seal between outlet and the inlet. Eg. : Centrifugal Pumps 5 Vane Pumps | Suction MEM Discharge leet Drain ischarge Port (ide Plate baci oncrae Port | 1] fi 5) od oE¢ — & | 4 \ Suction Port nari bot © Cartridge kit type of construction * Fixed displacement * Displacement range determined by Cam geometry - throw of the vanes, Cam width * Balanced vane pump@ Hydraulic Pumps 5.1 Double Vane Pumps * Single suction , 2 deliveries - High flow * 2 cartridge - 1 small cartridge, 1 bigger cartridge mounted on same shaft * Typ. Application - Hi-low circuits of Press applications 5.2 Variable displacement Vane Pumps * Can set the flow in the pump within a range by the flow adj. screw (fig.3 ) (By varying the amount of eccentricity between the ring and the rotor ) © Maximum Pressure can be limited by the pressure adj. screw. When the set pressure is reached, flow is cut off and the pressure is maintained. This helps in saving a lot of power. 8 Suction MEMMEDischarge Sill Drain yf ' + discharge L Discharge Port Port ‘Suction Port Drain Port GRAPHIC SYMBOL rN Fig3 n uw 6.1 External Gear Pump * Gears mesh externally inside a housing. * One is the drive gear and the other is the driven gear. * Pumping action takes place by the unmeshing - (Suction) and meshing - (Delivery) of the gears. * Oil is taken from the gap between the gear teeth and the housing * Unbalanced types of pumpsCC @® Hydraulic Pumps Outlet External Gear Pump Driven Gear 6.2 Internal Gear Pump Inner Gear| [Pumping Chamber] (Outer Gear] Lr re _} \[crescent Seal db Pump Housing| * An inner gear meshes onto the insides of a larger (outer) gear. Pumping chambers are formed between the gear teeth. Acrescent seal ensures the separation of the suction and the delivery ports. 7. Variable displacement Piston Pumps * Cylinder block assembly type of construction © Can set the flow in the pump within a range by the flow adj. screw (fig.6 ) by adjusting the angle of the yoke and hence the reciprocating length of the pistons. 12@ Hydraulic Pumps * Maximum Pressure can be limited by the pressure adj. screw. When the set pressure is reached, flow is cut off ( by making the yoke vertical ) and the pressure is maintained. © This helps in saving a lot of power. | Suction MEMMEDischarge amet Drain [Filling Port Plug} ‘(Drain Port) © At Full Cut-off®@ Hydraulic Pumps 8 Comparison of Pumps Type Vane Pump Gear Pump Piston Pump Working Varying volume. Shifting volume Varying volume by Principle between camring | surrounded by gear | reciprocating and vane grooves & casing _| pistons Low Highest ‘Average . Efficiency High Except for pr. Among three Loading type types. Efficiency does not | Efficiency Efficiency Wear & Efficiency | decrease as wear | decreases with decreases with ‘is compensated wear out wear out Sensitivity to dust Less sensitive compared to Piston Pumps Less sensitive than piston pump and vane pumps Most sensitive to dust. Applicability of variable displacement type Possible Not possible Possible Life of bearings Balanced vane pumps. life of bearings is long Life of bearings is short since large amount of side loads Large amount of side loads. 2 bearings are used Noise In the range of 60 - 80 db 90 db and above Tn the range of 50 - 70 db 9 Pump Motor combination - (PVEM/ AREM Series ) - Characteristics © Pump shaft is hollow, Electric motor’s shaft matches with the hollow pump. shaft. © Vibration free © Compact * Concealed rotating parts © Easy replacement of pumps © No bell housing / coupling © Nil coupling loss 10 Pal Pumps - Characteristics * Low Noise © Compact © Intelligent * Motor Integrated@ Hydraulic Valves HYDRAULIC ELEMENTS VALVES ACTUATORS PRESSURE FLOW DIRECTION CONTROLS] | CONTROLS] | CONTROLS [MODULAR a & LOGIC ELEMENTS 1 Classification 2. Principle 2.1 Force Balance * Spring Force > F = K. X Where F = Force ( kgs ) K = Spring Constant ( Kgf/mm ) X = Compression length (mm ) © Hydraulic Force > F =P. A 2.2. Flow & Pressure drop across an orifice Qa AVP-P, Q= Flow A= Area of Orifice P; - Pz = Pressure difference across the orifice 2.3 Heat Generation from, flow through an orifice H=1.41xPxQ_ Keal/ Hr. ( 860 Keal/hr = 1 KW ) P = Differential Pressure across the Orifice ( Kg/cm? ) Q= Flow ( Lpm ) 3 Pressure control valves 3.1. Relief valves 3.2 Pressure reducing valves 3.3 Sequence / Counter balance valve 3.4 Pressure switchCe _ eee @ Hydraulic Valves 4 Relief valves Relief valves protect the hydraulic system from excess pressure build up and maintain a constant pressure in the hydraulic system. It is a normally closed type valve connected between the pressure line (Pump outlet) and the reservoir. 4.1 Remote control relief valve / Direct acting relief valve «These valves are used for pressure control for tow flow rates. «When the set pressure is reached the Poppet opens to relieve the oil from Pressure port to Tank port. Pressure Tank 1 Hydraulic pressure BELOW set pressure Pressure Tank 7 Hydraulic pressure REACHES set pressure Port Port 4.2 Pilot operated relief valve © Balanced Piston type relief valve © Pilot valve on top. © Normally closed type «The Pilot Poppet opens at the set pressure causing decay of pressure in the top chamber of the main piston and opening of the main piston. 16® Hydraulic Valves 1 Hydraulic pressure REACHES set pressure (Relieving)6) Hydraulic Valves T Vent port OPEN to tank. x Relief Valve operating at minimum Pressure. (Unloading) 5 Pressure reducing valves Pilot Poppet) (Plunger (Remote Control Port > cy =) (Photon) (Pitot Spring ) Spring GRAPHIC SYMBOL fs = {( spoot r L Primary Pressure + Secondary pressure BELOW set pressure (Normally Open) 18(6) Hydraulic Valves T Secondary pressure REACHES set pressure (Closes) Normally open type The relief valve regulates maximum pressure, and the reducer valve is used when pressure of a lower value is required in a part of the circuit. Limits secondary pressure to something lower than the preset relief valve pressure by adjustment of the pilot valve The opening of the Pilot Poppet at the set pressure causes decay of pressure in the top chamber of the main spool, thus lifting it up and closing the secondary pressure port from the primary pressure port. 6 Counter balance valve Internal Pilot - Internal Drain - Counter balance valve External Pilot - Internal Drain - Counter balance valve The Spool opens at set pressure, thus connecting the Primary pressure port to the Secondary pressure port 19@ Hydraulic Valves Set Pressure = 60 Kg/Cm* T Primary pressure BELOW set pressure Set Pressure = 60 Kg/Cm? 7 Primary pressure REACHES set pressure 20® Hydraulic Valves 7 Sequence valve Internal Pilot - External Drain - Sequence valve External Pilot - External Drain - Sequence valve 1 Primary pressure BELOW set pressure 7 Primary pressure REACHES set pressure 2@ Hydraulic Valves 8 Pressure Switches Pressure Adj. Screw Low Pressure High Pressure Pressure switches open or close electrical circuits at selected pressures, actuating solenoid-operated valves or other devices used in the system. Turning the adjusting screw to increase or decrease the spring force alters the operating pressure of each switch. Figure shows the condition of the sensitive switches when pressure is above the low-pressure setting and below high pressure setting. 9. Flow Control Valve 9.1. Throttle valve / (Throttle & Check valve) 9.1. Flow control valve( Pressure & Temperature compensated ) 9.1. Deceleration valve 9.1. Feed control valve 22® Hydraulic Valves 10 Throttle & Check valve Flow Adj. Handle Piston + Spool Controlled Flow Outlet <= = Controlled Flow Inlet or or Free Flow Inlet > => Free Flow Outlet GRAPHIC SYMBOL ei * Simple in structure, easy to operate and perform a wide range of flow control. * Flow rate through the valve varies with the variation of differential pressure between the primary pressure and the secondary pressure, even if its opening is constant. * Due to the above reason, these valves are not used where there are load fluctuations and fine speed control is demanded. * Throttle and check valves allow reversed free flow to the primary side through the check valve, whereas flow to the secondary side is controlled. * Figure shows the controlled flow going from controlled flow Inlet port to the controlled flow Outlet port depending on the opening set by the flow adjusting handle. 11 Flow control valve These valves are pressure and temperature compensating type valves and maintain ‘a constant flow rate independent of change in system pressure (load) and temperature (viscosity of the fluid). They control flow rate of the hydraulic circuit and eventually control speed of the actuator precisely. 23@ Hydraulic Valves Valves with an integral check valve allow a controlled flow, and a reverse free 12 Deceleration valves ‘Spool Port A => Eaiaemae GRAPHIC SYMBOL eee Normally Open Type oe© Hydraulic Valves These valves are used for reduction of the flow rate from the valve, to decelerate the actuator speed by movement of the valve piston by a cam or by other methods. ‘As the piston is depressed, the flow is decreased in a normally open type of the yalve, while the flow is increased in a normally closed type of valve. 13 Feed control valve TA Ti INN Flow Adj. Dial These valves are the combination of flow control valve, a deceleration valve, and a check valve and used mainly for controlling rapid traverse and feed cycles in machine tools. Rapid traverse to feed is made by the cam operation of the deceleration piston, and fine feed control is accomplished by flow control. Figure shows flow from Port ‘A’ to Port ‘B’. Flow is changing from Rapid (through Deceleration valve) to Feed (through flow control valve) by the actuation of the roller and spool by the cam arrangement. 14 Direction control valves 14.1 Check valves 14.2 Solenoid operated valves 14.3 Solenoid controlled pilot operated valves 14.4 Manually operated valves 14.5 Mechanically operated valves 25® Hydraulic Valves 15 Check Valves 15.1 INLINE CHECK VALVE ones) Carina) Outlet Port Outlot Port o Ke Inlet Port Inlet Port 1 Free Flow T Non return from inlet to outlet outlet to inlet 15.2 RIGHT ANGLE CHECK VALVE ‘onaPwe syMBOL Seat Inlet Port 15.3 Pilot Controlled Check Valves ‘These valves allow free flow in one direction and prevent flow in the reverse direction. Cracking pressure specified is the pressure required to open the valve and allow free flow. In case of pilot controlled check valves it allows free flow in the reverse direction also, when operated by pilot pressure. 26yo @ Hydraulic Valves Goin) ae GRI SYMBOL Gat) I Free flow Free flow Inet ‘Outlet, (Cimon tea) frre Gerng Fotos) ~ “+ Pilot Port 1 Free Flow from inlet to outlet Reverse Flow Outlet. —— <— Pilot Port 7 Non return outlet to inlet 216) Hydraulic Valves Reverse Reverse Flow Outlet Flow Inlet <— Pilot Port 1 Reverse Free Flow from outlet to inlet. with pilot pressure applied 16 Directional valves - Classification 16.1 - by the number of ports 2 ports, 3 ports, 4 ports, multi ports 16.2 - by the number of control positions 2 Positions, 3 Positions, Multi positions by the operating methods ‘Manual operated, Mechanically operated, Pilot Pressure, Solenoid 16.4 - by the type of spring Spring offset, Spring Center, No Spring 16.5 - by the condition of flow in the center position Closed Center - All Ports Open Center - All Ports, A, B & T, A, B & T Restricted flow, P,A & T etc.,, 16.3 - 28@ Hydraulic Valves 17 Directional valve - Solenoid operated * At Center position ees) co) == (=) c= INN oD SOL b sOLa > ‘SOL b@) Hydraulic Valves 18 Directional valve - Solenoid controlled pilot operated * At Center position * Sola is Energized sole sot» 30 |® Hydraulic Valves ¢ Sol b is Energized soa sob YT A PB 19 Directional valve - Manually operated (Detented Type) Lever Spoot A Pp Detent aS i Cl GRAPHIC SYMBOL No - Spring Detented Hr 2 8 oy a<— TE ot at 31® Hydraulic Valves | | joy J °FF _— @ Hydraulic Valves 21 Modular valves - Characteristics Stackable units Installation and mounting space minimised Piping eliminated No special skill required for assembly, and any addition or alteration of the circuit can be made quickly and easily 33® Hydraulic Valves 22 Modular Relief Valve@® Logic Valves 1, Introduction Logic valves are poppet - type elements that are normally controlled by another valve to provide a complete hydraulic function (such as direction, pressure, or flow control). This is especially used in high-speed equipments with high flow hydraulic circuits. The modern day logic element is a cartridge poppet, which must be mounted, in a manifold block. A logic valve is inserted into a standardised cavity in a manifold block and held in place with either self contained screw threads or a cover secured with bolts to complete the logic valve design concept. 2. Construction Logic valves are similar to poppet Check valves and consists of an Insert assembly that slips into a cavity machined into a manifold block. A control cover bolted to the manifold secures the insert within the cavity. ‘As shown in Fig.1, the insert includes a sleeve, a poppet, a spring, and seals. Logic valve has two main flow ports “A” & “B”. (Fig. 1) Drilled passages in the manifold connect the “A” and “B” ports to other logic valves or to the operating hydraulic system. Similarly, a drilled pilot passage in the manifold connects the control port “x” 3. Working 3.1 Closed operation Pressure working over the top area of the Poppet creates a force, which tends to seat the poppet and block the flow path from A to B. Opening forces, are established by pressure working over the bottom area of the Poppet. In Fig. 2, the pilot line acting on the top of the poppet is through the Direction control valve. 35@ Logic Valves 3.2 Open Operation When the direction control valve is energised (Fig.3) the pilot line gets connected to the tank. Asa result, the pressure on the top chamber of the poppet decays. Now the pressure acting on the bottom of the poppet lifts the poppet. As a result flow starts to occur from Port “A” to Port “B”. When the direction control valve is again de-energised, the pilot line gets connected to the pressure Port A, Fig. 3 rt, Fig. 3 which makes the poppet to seat back, thus stopping the flow from Port. ” to Port “B”. Depending on the method of piloting, the elements can be used to perform check, directional and flow control function. In addition, some forms of pressure control can be obtained. 4. Direction & Flow control Logic valve Port X = 36i) Logic Valves 5. SOLENOID OPERATED DIR. LOGIC VALVE * Solenoid OFF * Solenoid ON X (Pilot Port ) 1 Port A > Port B is OPEN T Port A ¢> Port B is CLOSE 6. RELIEF LOGIC VALVE Y¥ (Drain Port ) B(“T” Port ) ACP Pot A(“P” Port ) | 1 Hydraulic pressure 1 Hydraulic pressure if i BELOW set pressure “~F1-S —_REACHES set pressure t * 37® Logic Valves 7. SOLENOID CONTROLLED RELIEF LOGIC VALVE ACP oPon) T si Relief Valve erating at minimum Pressure. (Unloadins X Port. Y (Drain Port ) B(“T” Port) } } A (*P" Port) einem T Solenoid ON i u Stent ON neon Hydraulic pressure REACHES Hupdeaue pressure BELOW set pressure(Relieving) | 38© Electro-Proportional Valves Comparison between Conventional and Proportional Valves Description — Conventional Proportional 1__|Setting ‘Mechanical Electrical 2__ | Stage control Single Multiple 3___| Slope control In steps [Smooth slope 4 _| Circuit ‘Complex Simple 5 _| Size of blocks, pipes _| Large Small 6 _ | Power saving circuit | Complicated Simple 7__| Feedback Not available Available 2. Devices for the proportional control 2.1 Setting Device - Generates command signal 2.2 Power Amplifier - converts command signal to DC current for solenoid drive 2.3. Proportional Valve - receives current, converts it to hydraulic pressure or flow rate according to the magnitude of the received current. 2.4 Sensor - detects the controlled hydraulic energy - Pressure, flow rate, speed and converts it to electrical current. 3 Principle of operation The proportional control valve is derived by replacing the manual operating control (handle ) of a conventional control valve by a DC solenoid section. Proper operation is assured as the solenoid offers a great driving force. Plunger ® 100 % current | 70% 50 % Coil g 30% +— Stroke 4 Characteristics 4.1 Step response 100 A response made when the input signal suddenly ® changes from a given value to another given 3 50 value. Fig. Shows the valve requires 80 ms to go from0 to 100 % stroke and 70 ms to fully close. fa ., 150 ms is required to complete one cycle. TIME (ms) 39® Electro-Proportional Valves 4,2 Erequency Response | Frequency Frequency is the number of times any action occurs in a given measure of time. Unit is Hertz(Hz) or (Cycles per second). 4.2.1 Phase Lag The time required for the output to recreate the input command. Measured in degrees. Cyclic Input 90° Phase Lag Degrees 4.2.2 Amplitude Ratio ( Gain It is the ratio of the output change to the input change. Measured in dB (Decibels). Frequency { Hz) 01 0.2 040.71 2 4 710 20 40 70 9 -20 44 Gain] 100 “120 140 “160 “180 Phase (deg.) Flow Rate 2. Limin Pressure +: 80416 Keffem* Trapped Oil Volume — : 30 cm’ Viscocity £30 St For EDG-01 (Prop. Electro-Hydraulic Pilot Relief valve) 40® Electro-Proportional Valves 5. Proportional Electro-hydraulic Pilot Relief valve Pre. Adj. Screw for safety valve 5.1 Step Response 5.2 Control Pressure Vs. Input Current Kottom? EDG-01-B KgtiCm* 260 % een a 200 | a Bs 180 20 Sep Signa ~ 10 : — Tam 100 | ba eDG-016 50 + Zr lien 7200 aod ode T000 Inpat mA Current 4l® Electro-Proportional Valves | 6 Proportional Electro-hydraulic Flow control valve Pr. Compensator Piston <= Inlet Port GRAPHIC SYMBOL E ~~ Drain Port ===> Outlet Port 4 7 Proportional Electro-hydraulic Relief and Flow control valve ‘low Control Solenoid Orifice Sleeve, Proportional Pilot Relief Valve with Saftey Valve a he GRAPHIC SYMBOL i Inlet Port Tank Port Drain Port Outlet Port 42© Electro-Proportional Valves 8 Proportional Electro-hydraulic Directional and Flow control valve (Proportional Solenoid [ GRAPHIC SYMBOL ey a- pe uv ae These valves incorporate two control functions - flow and direction - which simplify the hydraulic circuit composition and therefore the cost of the system is reduced. 9 Hybrid series proportional valves f—Geoiiied ce Pressure Senso?) Pressure Sensor Port 4Bpo r ® Electro-Proportional_ Valves 10 Typical Applications * Elevators © Rolling mills Planers ® Injection moulding machines * Presses © Surface grinding machines.© Servo Valves 1. Definition A Servo valve is a directional valve that may be infinitely positioned to provide control of both the amount and the direction of fluid flow. Aservo valve coupled with the proper feedback sensing devices provides very accurate control of the position, velocity, or acceleration of an actuator. 2 Comparison_between a Proportional valve and a Servo valve 2.1 Based on control method In both proportional and servo valve, Pressure, Flow, Direction control is by the electrical signal. Both use a controller and an amplifier 2 R Based on Application Proportional Valve: Used for general electrical control system Servo Valve : Used for high accuracy, high frequency applications. Proportional Valve : Used in Open loop or Closed loop circuit Servo Valve : Used in Closed loop circuit only. 3 Control method - Proportional valve Proportional Solenoid Flow Stroke Current Fig. 1 By providing spool between the magnetic proportional solenoid and the spring it is possible to control the hydraulic energy. 45© Servo Valves 4 Electro-Hydraulic two stage Servo valve 4.1 No Signal To Valve ‘* Torque Motor and Bushing & Spool Assembly. * Low energy electrical signal to high level hydraulic power * Electro-hydraulic 3 stage servo valves (For higher flows) © Torque Motor, Pilot stage valve, Main valve © Servo valves with LVDT feedback In this the main spool is positioned by the feedback system with the differential transformer, which detects the position of the spool and gives a feedback to the amplifier (Position sensor). Any error is corrected by giving an error signal again to the torque motor and the correction is done. 46© Servo Valves 4.2 Signal applied to Torque Motor & Spool about to move. 4.3 Equilibrium condition with Signal applied.© Servo Valves 5 Types of Proportional /_ Servo Valves 5.1. Proportional Valves : According to required function many type of valves are available. © Prop. Pressure control valve * Prop. Flow control valve * Prop. Pr. and Flow control valve © Prop. Direction and Flow control valve 5.2 Servo Valves : Construction is same as a directional valve. Based upon the type of feedback sensor, function of the servo valve is determined. For example, if we use pressure sensor and give feedback, then it becomes a pressure control servo valve. To get high frequency response, high pressure response should be given. Generally 70 Kg/Cm? pressure difference is given. Care to be taken care about power loss and heat generation. Hysterisis : Less than 1% Repeatability : Less than 0.5 % Frequency Response Gain at -3db: 70 ~ 150 Hz. Phase at 90 ° : 150 ~ 170 Hz. 6 Features : Servo valves | FREQUENCY RESPONSE — 38 L/min Amplitude Ratio (Gain ) (dB ) 488 © Servo Valves Applications * High frequency Applications Eg,, Fatigue testing machines, Spring testing © High accuracy applications Eg., Aircraft applications, Industrial Applications - Thickness of sheets in rolling mills if it is very critical. High accuracy presses. * Closed loop applications Eg., Satellites ( Solar panel controls ), satellite launch etc., Care in use Cil cleanliness level should be NAS 7. Filter of specification 5 1 absolute should be used. 49© Servo Valves 50si@ Mobile Valves 1 Introduction Mobile valves are basically Direction Control Valves. As the name suggests it is used in mobile applications. Directional valves, Priority valves, Joystick valves are all mobile valves. 2 Features of a Mobile Valve A single mobile valve can be used to operate multiple actuators, by having multiple spool assemblies. Mobile valves are very compact. a al 3 Types of Mobile Direction Control Valves 3.1 Monoblock Type ( Fig.1,3) 3.2 Sectional Type (Fig.2) 3.1 Monoblock Type Direction Control Valve © Single Block with inbuilt Relief valve and Check Valve with single spool, assembly. © Standard features - Handle with Rubber grip and bellows. * 3 Spool positions. © Relief valve Range 30 Kg/Cm? to 320 Kg/Cm* 51@ Mobile Valves ¢ Neutral Position (Unloading) * Lever activated on one side Pressure Port -°P* * Lever activated on other side Pressure Port -°P* “Tank Port “7 52®M Mobile Valves 3.2 Sectional Type Direction Control Valve = Multiple blocks, namely a) Input Section with relief assembly (Fig. 4) b) Spool assembly ( Fig. 5) ©) End cover assembly ( Fig. 6) Combined together to form 1 Sectional Valve = No. of Spool assemblies allowed in a bank = 1 to 10 = Standard - Spring centered, Detent type also available. 3.2.1 Input Section with relief assembh Fig. 4 3.2.2 Spool Assembly Neutral Position (Unloadin, | (a on) g | O\T/® ‘ORAPHIG SYMBOL, Gon") (Trkon="T) YA ove 53@ Mobile Valves mma) Lil Gert) | wre) @ o\Yje GeareF) (roe) (uren-"F) ; ig Gere) | ore) @ o\Y7o (oarot) Gat) Gatto) 3.2.3 End Cover Assembly 4. Applications Used in mobile cranes, Fork Lifts, Loaders, Dumpers, Excavators, Bore drillers, tractors, tillers, hydraulic trolleys etc. 54Hydraulic Cylinders 4, Hydraulic power transmission Source of Input Control Actuators Power component Elements Hyd, Motors Hyd. Cylinders Electric Motor or an Engine Pressure ctrl. Vvs. Flow ctrl. Vvs. Dir. ctrl. Vvs. Drives the pump Creates flow. Controls the hyd, Give motion Pr. develops when energy — Pressure, Rotary - Motors flow, direction Reciprocatory ~ to flow Cylinders 2 Actuators - Classification ACTING SINGLE ACTING RAM SPRING ELESCOPIC INGLE \) (DOUBLE TYPE & TYPE TYPE ROD ROD 3 Cylinders - Definition A device that receives hydraulic energy and converts it into mechanical force and linear motion of the piston. 3.1 Applications © Lifting © Pushing © Tilting * Clamping etc., 55Hydraulic Cylinders 3.2 Advantages * Large force generation * Flexibility and remote control operation * Quick response and precise position control Minimum service requirement. 4 Construction 5 Classification 5.1 Based on Action 5.1.1. Single acting cylinder 5.1.2, Double acting cylinder 5.1.3 Telescoping cylinder 5.2. Based on Construction 5.2.1 Tie rod type 5.2.2 Threaded type 5.2.3 Mill type 5.2.4 Welded type 5.3 Based on Mounting Style 5.3.1 Trunnion Mounting 5.3.2 Flange Mounting 5.3.3 Lug Mounting 5.3.4 Angle Mounting 5.3.5. Clevis Mounting 5.3.6 Tie rod extension 5.3.7. Tapped MountingHydraulic Cylinders 6 Single Acting Cylinders 6.1 Ram type cylinders GRAPHIC SYMBOL 6.2 Spring return cylinders GRAPHIC SYMBOL [fee — 6.3 Telescopic cylinders GRAPHIC SYMBOL = 57Hydraulic Cylinders 7 Double Acting Cylinders 7.1 Single rod cylinders GRAPHIC SYMBOL [_ 4 These are the most common type of cylinders in use. These are also called as the differential cylinders. This is because of the difference in area at the cap end and the rod end. The area at the rod end of the piston is less because the piston rod blocks a part of the piston area. As a result of this the following phenomenon occurs. EXTENDIGN | _HIGH A _| RETRACTING | _LessY _| (F =PxA) and (V=Q7A) 7.2 Double rod cylinders GRAPHIC SYMBOL This consists of rods on both ends of the piston. These are called as the non- differential cylinders. Force acting on both ends of the piston is equal because of equal areas on both sides. The speed of movement of the piston in both directions is also the same. These cylinders are used where equal force and velocity are required in both directions or when 2 loads have to be moved through equal distance simultaneously. 58Hydraulic Cylinders 7.3 Tandem cylinders GRAPHIC SYMBOL Higher forces can be developed since the pressure is acting on double the area at the same time. 8 Cushioning Cushioning of cylinder is the slowing down of the piston near the end of the stroke by restricting the exhaust flow of the fluid. This will prevent the pistons from hitting the end caps with a high force and thus prevents vibration and damage to the components. 8.1 Velocity curve \ Cushioning Piston Velocity | Cushioning stroke 59Hydraulic Cylinders 9 Seals 9.1 Types of Seals 9.4.1. Piston seals 9.4.2. Rod seals 9.1.3 Wiper seals 9.1.4 Static seals 9.2. Material of seals * Leather * Natural rubber * synthetic rubber * Viton * Teflon * Piston Rings ‘SPEED & TEM M/min[ “Cc 1_| LEATHER (WAX IMP.) 10-12 | 40 2_| LEATHER (RUBBER IMP.) Ww (<°C) 10-12 | 50 3 | NATURAL RUBBER Brake fluid, Non Petr. 20 = | 40-50 is 4 | BUNA S W, Water Glycol 20 70 5 | BUNA N A,O,W, W / Glycol 20 70 6 | SILICONE W,O, Phos, Ester 20 250 7 | NEOPRENE W, W / Glycol 20-25 | 65 8 | VITON A,O,W, W/g, Ph./E. 25 200 9 | POLYURETHANE ° 25 90 10 | TEFLON 0,W, Ph./ E,W/glycol 60 250 A-Air, O- Oil, W- Water 9.3 Types of packings Packings are classified Based on the shape of the packing as L packing, V packing, U J packing, X ring, O ring, S - combined seals P - Piston ring etc., packing, “YeHydraulic Cylinders 10 Formulae 10.1 Output Force of a cylinder AREA A, OF, area a, ‘OUTPUT FORCE = PRESSURE x EFFECTIVE PISTON AREA FeP ox A (Kg) (Kgs Cm?) (Cm?) FyPxA, = PxaxDD ......., (While Extending ) 4 Fy=PxA, = Pxxx (Did) ..... ( While Retracting ) 4 10.2 Speed of a cylinder ILO AREA Ay AREA A, SPEED = FLOW RATE V=_Q > (em?/min) EFFECTIVE PISTON AREA A (em?) Vie a= a Viz a= a RK, xp axa) 4 4 ees (White Extending ) || ........ ( While Retracting ) 11.1 Piston speed Tube bore (mm) 80 to 125 140 to 200 ‘Minimum (mm / sec) ‘Maximum (mm / sec) 61Minimum operating pressure Shape of Piston Packing packing Packing other than “V” Hydraulic Cylinders Shape of rod Packing “Vv” packing 2 7.5 4.5 11 Cylinder selection criteria 11.1 Pressure 11.2 Load 11.3 Stroke 11.4 Rod end 11.5 Cylinder action 11.6 Duty cycle 11.7 Shock loading 11.8 Cushioning 11.9 Piston velocity 11.10 Fluid medium 11.11 Cylinder life 11.12. Available mounting 11.13 Porting connections 11.14 Size & weight 11.15. Efficiency 11.16 Special features 11.17 Initial cost 11.18 Serviceability 11.19 Availability and compatibility 1.5 62® Hydraulic Motors 1 Different forms of ener * Electrical energy (Ex) * Thermal energy (En) * Mechanical energy produced by an electric motor or an oil engine ( Ey ) * Hydraulic energy from hydraulic pump in the system ( Enyo ) * Mechanical energy from hydraulic actuator. ( Hydraulic Motor )( Ey ) Ee./ Etu— En — Enyo > Em 2. Basic arrangement of a hydraulic system * Prime mover - Electric motor or engine © Fluid reservoir - Hydraulic tank Energy transfer medium - Hydraulic oil Fluid transfer unit - Hydrautic pump ‘Fluid transfer medium - Hoses and pipes © Controls - Pressure controls, Flow controls, Direction controls © ACTUATORS - Hydraulic motors, Cylinders 3 Types of Actuators 3.1. Linear Actuators - Hydraulic Cylinders 3.2 Oscillatory Actuators - Restricted rotation motors 3.3. Rotary Actuators - Hydraulic Motors 4 Hydraulic power transmission MOTOR OSCILLATORY LINEAR ‘ACTUATOR ACTUATOR G) ae ——e a VALVING Pump (* PRIME MOVER uu 5 Definition Hydraulic Motor is a device, which converts the hydraulic energy (power) generated by a pump into mechanical energy (power) in the form of torque and rotation (rpm) 6@ Hydraulic Motors 6 Graphical Symbols Envelope "“)* ws Dotted Line Uni - Directional Ww for Drain Hyd. Motor Solid Fixed Displacement Triangle (Hydraulic ) 7 Salient features of hydraulic motor © Extreme range of speed is possible CO 5 1 Ww Bi-Directional Hyd. Motor Fixed Displacement © Torque control throughout the operating speeds * Low inertia © Compactness of space © The fact that they can be stalled indefinitely without damage ‘© Instant reversal of the motor shaft possible. * Dynamic braking easily accomplished. 8 Classification of Hydraulic Motors » GEOMETRY OF THE ACTUATING MECHANISM > SPEED AND TORQUE RATING HIGH TORQUE LOW SPEED MOTORS (HTLS) RADIAL PISTON MOTORS: |-— CRANKSHAFT L— cam - LOBE = ORBIT MOTORS | GeRoTor (_ GEROLLER % AXIAL PISTON MOTORS | SWASH PLATE L_ BENT Axis ™ GEAR MOTORS = VANE MOTORS: 64® Hydraulic Motors 9) Gear Motors Compact * Low cost = Low efficiency (60 ~ 70% ) = Speed range ( 500 ~ 3000 rpm ) = Cannot be used for low speed Pressurised fluid enters the inlet and follows the path around the periphery and causes the gears to rotate. The fluid then exits at low pressure at the outlet. 10 Gear ring motors ( Orbit Motors = Higher power output for a given outer dimension = Overall efficiency is low = Volumetric efficiency is low * Rotation at low speeds not smooth * Higher heat generation (loss of energy is more) Geroller Motor 65® Hydraulic Motors The outer gear has one tooth more than the inner gear. The outer gear is stationary and the inner gear is the rotating gear. When pressurised fluid enters the motor, the inner gear rotates with its teeth meshing with the outer gear. "1 Vane Motors = Complicated design * Manufacturing complicated = High cost = Medium torque * Medium Speed * Change of speed with change of torque possible ‘Axial Piston Motors = Low Torque. + High speed. + Complicated Design. = Manufacturing difficult. = High cost. = Reversing shaft output easy. = Speed control possible. = Torque control possible. 13 Radial Piston Motors = High starting torque = High running torque * Compact in size. ( Specific torque is high ) * Bi-directional * Low speed possible ( <10 rpm ) * Torque variation possible * Low noise * Vibration very low + High mechanical efficiency = High volumetric efficiency + Instant reversing possible. 66®@ Hydraulic Motors 14 Motor ratings The rating of hydraulic motors are done based on the following operating parameters : © Displacement ® Torque capacity © Speed © Operating Pressure 14.1 Displacement : of a hydraulic motor is defined as the amount of fluid required to turn the motor shaft by one revolution. 14.2 Torque _: Torque is the turning force developed at the motor shaft due to its rotation. The value of Torque increases with an increase in operating pressure, and decreases when the pressure decreases. 14.3 Speed _: The speed of a hydraulic motor depends on its displacement and the flow rate to it. 14.4 Operating Pressure : The pressure required by a hydraulic motor depends on the torque requirement and its displacement. 67® Hydraulic Motors 15 Motor Selection OUTPUT PARAMETERS : > SPEED (RPM) > TORQUE (KG-M) MOTOR PARAMETER : > DISPLACEMENT ( CC / REV. ) HYD. PARAMETERS : > FLOW (LPM) > PRESSURE ( BAR ) TORQUE : > DISPLACEMENT X PR. X Tim 628 SPEED : > FLOW X 1000 X ny DISPLACEMENT 16 Effect on hydraulic motor during change in hydraulic settings under constant load condition CHANGE SPEED | OPERATING | 4 FORQUE PRESSURE Increase pressure setting No Effect No Effect Increases Decrease pressure setting No Effect No Effect Decreases Increase flow “Increases No Effect No Effect Decrease flow Decreases No Effect No Effect Increase displacement (Size) - Decreases Decreases Increases Decrease displacement (Size) | Increases Increases Decreases 68® Hydraulic Motors 17 Case Study Application: Hydraulic Motor Drive For Conveyor EXISTING DRIVE Electric Motor : 10HP @ 1440 rpm Gear Box : 1:30 ratio The conveyor is driven in one direction continuously 24 hrs a day. DETAILED CALCULATION Power (H.P ) 2m N (rpm) xT (kgm) 4500 Torque (kgm) : _ 10x 4500 = 4.97 = 5 kgm 2x mx 1440 Considering the gearbox, the output torque of gear box : 5x30= 150 kgm Considering the efficiency of a gearbox, output torque: 150 x 0.9 = 135 km (mechanical efficiency of gearbox considered at 90 % ) Output speed of the gearbox : 1440 = 48rpm 30 TORQUE = DISPLACEMENT X PR. X Mim 628 Since it is a continuous application, it is better to consider an operating pressure of 100 bar . ©. DISPLACEMENT = Tx 628 = 135x628 PR. X Tn 100 x 0.95 ( Assuming mech. Eff. 1, = 95%) = 892cc /rev Considering the standard displacement available from M4 series of hydro motor and selecting M4-900, the operating conditions are : 0@ Hydraulic Motors From Catalogue: f14-SERZES NoMa conTinuous enusour eneSSune tis por minute NOMINAL DISPLACEMENT] seo [ 660 [ ©00 | e20 | o=5 | vo | soo | 000 | 1000] 1100 Displacement [ormirev | «07 | esa | oor | eve | ese | 711 | 70a wo22 [1116 sa | so| sa] ea | eo] so| es | 7 | 70 Cont. torque [kom jos | 220 | a0 272 | 202 | sve | seo | «07 | aa5 " HP 75 | eo | eo 304 | 108 | +10 | 110 | 110 | 130 peek power Taw. se | eo| ee| 75 | 7e| 7e| o2| e2| e2| o2 Peak speod [rom ‘300 | s00 | soo | a0 | «50 | 50 | a0 | 200 | oso | oso Saseor Ma Series “ro te frome 810972 kame TORQUE = DISPLACEMENT X PR. X Tim 628 Operating Pressure PR. = TORQUE x 628 DISPLACEMENT x in, = 135 x 628 = 99 bar 904 x 0.95 Considering the starting torque of about 150 %, (Torque = 135 x 1.5 = 202.5 kgm ), Operating Pressure PR. = 202.5 x 628 = 148 bar 904 x 0.95 The main relief valve to be set based on the starting torque value. SPEED = FLOW x 1000 x ny DISPLACEMENT Flow Required = SPEED x DISPLACEMENT 1000 x ny = 48x 904 = 44.7 lpm 1000 x 0.97 70 i@ Hydraulic Accessories 1 Tank Top Accessories 1.1 Reservoir 1.2 Breather Filler 1.3 Fluid level gauge 1.4 Drive coupling 1.5 Pressure gauge 1.6 Pulsation dampner 1.7 Gauge Isolator 1.8 Temperature gauge 1.9 Temperature switch 1.10 Magnetic tank cleaner 1.11 Float switch 1.12. Pressure switch 1.13. Castor wheels 2 Reservoir 2.1. Sunk welded type 2.2 Bolted type 3 Breather Filler 3.1 Tank top ~~ 3.2 Side mounted@ Hydraulic Accessories GRAPHIC SYMBOL 5 Drive Coupling Cal 5.1 Spider coupling 5.2 Geared coupling \@ i @: 6 Pressure Gauges =0= 6.1 Surface mounted bottom entry (SB ) 6.2 Face mounted back entry ( FB ) Gear Driven Pointer 100 — Mechanical Linkage 500 Bourdon Tube Gauge 2@ Hydraulic Accessories Pulsation dampner Protects gauges against - GRAPHIC SYMBOL Line pressure surges Pointer vibrations © Fluid hammer 8 Gauge Isolator 8.1. Single station gauge isolator 8.2 Multi station gauge isolator S38 7 2 © Ee a 1 i HINGRS : I 5 { B " cl ' E 28 | 26 | ie Single Station Gauge 7 Isolator Multi Station Gauge Isolator GRAPHIC SYMBOL GRAPHIC SYMBOL @ ‘i select 1-6 | ao wade 9 Temperature Gauge GRAPHIC SYMBOL B@ Hydraulic Accessories 10 Temperature Switches GRAPHIC SYMBOL © Temperature range © Capillary tength * Differential (Min. & Max. ) 11. Magnetic tank cleaner 2 Float Switches 12.1 Two level float switches 12.2 Multi level float switches GRAPHIC SYMBOL, Float@ Hydraulic Accessories 13 Pressure Switch Low Pressure Indicator High Pressure indicator “Sensitive Switch GRAPHIC SYMBOL. - uw Pressure Port e =< ‘Spring Prossure Adj. Scrow, Low Pressure High Pressure Pressure switches open or close electrical circuits at selected pressures, actuating solenoid-operated valves or other devices used in the system. Turning the adjusting screw to increase or decrease the spring force, alters the operating pressure of each switch. 14 Castor Wheels me _— v 15 In-line Accessories 15.1 Suction Strainer 15@ Hydraulic Accessories 15.2 Filters 15.2.1. Pressure line filters 15.2.2 Return line fitters 15.3 Diffusers 15.4 Coolers 15.4.1 Air coolers 15.4.2 Water coolers 15.4.3 Refrigeration coolers 15.5 Accumulators. 16 Suction Strainer an = 17 Filters 17.1 Pressure line filters NS iv] 1 U i i N N Ny iy i H i N H H H H H H \ i \ H RF) N a) IS ISS@ Hydraulic Accessories 17.2 Return line filters ‘ered emer | 19 Coolers 19.1 Air coolers | oF , Hot Air LL Inlet Outlet Air Blast Oil Coolers nN@ Hydraulic Accessories Specifications: Capacity in Kcal/hr © Working pressure and Maximum pressure In bar © Delivery in lpm * Fan diameter in inches * Overall, mounting Dimensions & port size * Input power supply 19.2 Water Coolers Specifications * Heat dissipation capacity In Keal / Hr * Oilinlet & outlet temp. in °C * Oil flow & cooling water, flow in lpm, Water inlet temp. °C Shell & Tube type Oil cooler 20 Accumulators An accumulator is used in a hydraulic system to Store hydraulic fluid under pressure. 20.1 Types of Accumulators 20.1.1 Weight loaded accumulator 20.1.2 Piston Accumulator 20.1.3 Bladder Accumulator @ ~ 78@ Hydraulic Accessories 20.2 Bladder Accumulator GRAPHIC SYMBOL 6 20.2.1 Accumulator - Functioning * After Precharging * Oil entry * Discharging20.3.1 Energy storage 20.3.2 Shock dampening 20.3.3 Pulsation dampening 20.3.4 Counter balance : 20.3.5 Shock absorption 20.3.6 Transfer barrier @ Hydraulic Accessories 20.3 Accumulators - ications | 20.3.7 Compensator for thermal expansion 24. Anti -Vibration Accessories 24.1 Rubber Gromet 24.2. Expansion joint 24.3 Anti - Vibration pads 21.4 Hoses and Tubes Pipe Dia. 22 Rubber Gromet le They prevent the contact between the | 1 Pipe and the top plate of the reservoir = thus reducing the vibrations. J rep Plate or ' 3. Expansion joint a = a <6. tit ct} 80Hydraulic Accessories 24 Anti-vibration pads | Sane 25 Hoses Hoses are used when hydraulic lines are subjected to movement, flexing, and/or vibration. A standard hose has 100R numbers that control construction, dimension, pressure, fluid compatibility and temperature requirements. TUBE REINFORCEMENT BRAID (WIRE/TEXTILE) COVER 81Hydraulic Accessories@ Hydraulic Circuits 1 Hydraulic System requirements * Satisfy the specifications of the operation with safety * Perform smooth operation * Low energy consumption - Low heat generation ‘* Reduce initial cost and the running cost * Make maintenance easy. 2 Basic Hydrauli suits 2.1. Speed control circuits 2.2 Pressure control circuits 2.3 Unloading circuits 2.4 Filter circuits 2.5. Synchronizing circuits 2.6 Regenerative circuits 2.7 Locking circuits 2.8 Sequence circuits 2.9 Accumulator circuits 2.10 Motor circuits 3 Speed control circuits 3.1 Meter-in circuit In this circuit, the flow control valve is installed on the inlet side of the actuator. ( Fig. 1 ) This circuit is used when the load is positive. 3.2. Meter-out circuit In this circuit, the speed of the actuator is controlled by installing the flow control valve on the outlet side of the actuator. (Fig. 2) 83@ Hydraulic Circuits 3.3 Bleed off circuit In this circuit, the flow control valve is installed between the pump and the actuator as a bypass circuit, and the speed of the actuator is controlled db by controlling the flow rate bypassed from the pump. ) (Fig.3) 3.4 Speed reduction circuit [ This type of circuit is used to decelerate the fast moving cylinder from a certain position. (Fig. 4) x 7 4 Pressure control circuits sa Koicnt eae 70 Kglom? 4.1. Remote control circuit =a 5- rear This circuit remote controls the w TI CT aw discharge pressure of the pump. When the solenoid is not operated, AUX circuit pressure is 100 kg/Cm?. otherwise, pilot operated relief valve has 70 kg/Cm? or 50 kg/Cm?, ie., the Vent pressure depending on the position of the direction control valve. 4.2 Two operating pressure circuit 2 kinds of pressures are applied to the circuit by using 2 relief valves. Low-pressure relief valve @ is used In the upward stroke of cylinder, While the high pressure relief valve © operates in the downward stroke. 84@ Hydraulic Circuits 4.3 Decompression circuit Decompression circuit is used to gradually return hydraulic oil of high pressure and large volumeto f=. the reservoir, after completion fa) of the pressurised stage, while cin\h reducing its pressure. ( Fig. 7) ab > Fig. 7 5 Unloading circuits The unloading circuit is used to operate a pump under the no-load condition by returning the discharge from the pump to the reservoir at low pressure while the hydraulic circuit in operation does not require flow. 5.1 Open centre circuit —— PR connecting directional control valve is used in this circuit. When directional control valve is in the neutral position, load is blocked and all of the discharge from the pump is returned to the reservoir ai] and the pump operates in the no-load condition, (Fig. 8) 5.2 Circuit using Accumulator = When circuit pressure reaches the set level, the directional valve operates to return the discharge from the pump to the reservoir directly. At this time, the circuit pressure is maintained by the accumulator. (Fig. 9) 85iii @ Hydraulic Circuits 5.3 Hi-Low (2 pump ) circuit This circuit generates high flow low pressure and low flow high pressure. When high flow, low pressure is required, the discharge from both the pumps are combined and supplied to the circuit. When low flow, high pressure is required, the discharge of (pump A) low pressure , high flow is directly returned to the reservoir by ‘opening the unloading valve C. ( Fig. 10 ) Fig. 10 6 Filter circuits There are various kinds of filter circuits depending on the installation position of the filter in the circuit. 6.1 Suction line filter circuit (Fig. 11) 6.2 Pressure line filter circuit (Fig. 12) 6.3 Return line bypass filter circuit (Fig. 13) To System 7 Toon 2 Fig. 1 Fig. 12 7 Synchronizing circuits 7.1 Mechanical connection The synchronization of the two cylinders is done by connecting the piston rods mechanically. ( Fig. 14) Fig. 14 CF ‘L 86 |@ Hydraulic Circuits 7.2 Circuit using two flow control valve Cylinders are synchronized by equalizing the amount of hydraulic fluid flow into or discharged from each cylinder by means of flow control valves. (Fig. 15) Fig. 15 : 4 d 8 Regenerative circuit - In this the extension speed rons oe of the cylinder is increased oa by directing the fluid from Colinder the rod end to the cap end. 7 5 Idle condition -sol, off Regenerative advance Da - energised Retraction Db - energised (Fig. 16) Reliof Valve C rl ‘Db 9 Locking circuit This is used to prevent the cylinder from moving due to large load or pressure drop in the circuit, when The cylinder is to be locked at a specified position. (Fig. 17) 87@ Hydraulic Circuits 10 Sequence circuits 10.1 Electrically controlled circuit cylinder 1 — cylinder2. >? 3 eigecig <4 oe ist us 1s3 a fn b e {x]| {Fu a “hg ty any Seat | Operation | Signal] Moversrt [+ [Pusn—On] Soa [oy 1—> Ls-20Nn | Sole [one >| OO A [is-a0n | sole [owt | ts-10N | sod [ow2 <<] U Fig. 18 In the electric control circuit, the solenoid operated directional control valve is operated by the limit switches. The sequence of signalling and the operations will be as shown in the table above. (Fig. 18 ) 10.2. Clamping and Sequencing circuit Sequence circuits are designed to control the sequence of cylinder operations by circuit pressure, and are made up of sequence valves. (Fig. 19) Sequence of operations: as seit Extending clamp cylinder © Extending work cylinder © Limiting max. force of clamp cyl. * Retracting work cylinder * Retracting clamp cylinder CF ct 88@ Hydraulic Circuits 11 Accumulator 11.1 Accumulator unloading circuit This circuit shows one method of unloading the pump when the accumulator is fully charged. here the use of the accumulator is to maintain the system pressure When the accumulator is fully charged, and the pressure reaches the high pressure setting of the pressure switch, it de-energises Dir. Valve and the pump start unloading. elt Vato A — ‘Sequence of operation: * Charging * Unloading © Supply from Accumulator 11.2 Pressure holding ( Leakage com} In this type of circuit, accumulators are used to retain pressure, compensate for leakage and save power. ‘As shown in figure, when a vice is at tightening position, pressure in the cylinder is retained by the accumulator. Since the accumulator retains the pressure and compensates for leakage, the pump operates intermittently. ( Fig. 21) sation circuit Vice 89@ Hydraulic Circuits 11.3 Surge pressure reducing circuit Accumulator is used to reduce surge | Pressure, which is generated in a high- pressure circuit when high-speed hydraulic fluid flow is changed rapidly. (Fig. 22) 12 Motor circuit 12.1 Brake circuit When stopping a rotating hydrautic motor by operating the directional control valve or turning off the pump, the motor continues to rotate by inertia as well as the load and operates as a pump. In this circuit the relief valve operates as a brake. (Fig. 23 ) 13 Normal working pressures for various systems FIELD OF APPLICATION Pressure (Kg / Cm?) AVERAGE 150 SHIPS (MARINE ) 4-250 | 9 | MACHINE TOOL FORGES INJECTION MOULDING M/c INDUSTRIAL ROBOT 907 @ Hydraulic Circuits 14 Selection of a cylinder oD - OUTPUT FORCE RI —_—__ PRESSURE = EFFECTIVEPISTON AREA - F kg “Ser mx D? A= 4 15 To calculate the flow “Q” Q=AxV A= Area in Cm? V = Velocity in Cm/min 16 To calculate the Motor Power PxQ MOTOR POWER (KW) = ———~_ Po ou 612xn, P = Pressure in Kg/Cm* Q= Flow in LPM To = Pump overall efficiency (Eg., if 85% — 0.85) Q = Flow in Cm? /min (divide by 1000 get flow In LPM)@ Hydraulic Circuits 17 Heat in a hydraulic system 17.1 Heat generation in a hydraulic system 17.1.1 Heat generated from the pum, Hy = Heat generated from the pump (Kcal / Hr ) 4 100 =n Hy = L,x oo Me x 860 L = Pump input power (KW) ‘no = Pump overall efficiency (%) 17.1.2 Heat generated from the flow through orifice When pressurised fluid flows through throttle parts at a certain pressure, the pressure drop is converted into heat. _ 10 x60 xPxQ 427 H, Hz = Heat generated ( Kcal / Hr ) P = Differential pressure across orifice (Kg / Cm?) (In case of relief valve the set pressure shall be the differential pressure ) Q= Flow through the orifice ( Lpm ) 17.2 Heat dissipation from a hydraulic system Heat dissipation from the surface of the reservoir: Hy= Kx Ax (tty) Hs = Heat dissipated from the surface of the reservoir ( Kcal / Hr ) K = Coefficient of heat dissipation (7-9 Kcal / Hr. °C. m?) A = Effective area of the Reservoir ( m? ) t= Oil temperature (°C) tz = Room temperature (°C ) 92@ Hydraulic Circuits 17.3 Qil temperature 17.3.1 Oil temperature at equilibrium condition The oil temperature accelerates the heat transfer as it rises, and reaches an equilibrium state of thermal relationship H; + Hz = Hs The equilibrium oil temperature - _H,xH, t ‘ KA +t, 17.3.2 Oil temperature when the temperature is rising The thermal relationship H; + Hy > H3 then the oil temperature “t” at a time “T” is given by - KAT. to eta (1-e c Jee C = Heat capacity of the reservoir (Cm?) C=vxrxS Where v = Reservoir capacity (Cm? ) specific gravity of oil ( 0.86 x 10° Kef / Cm?) pecific heat of oil ( 0.45 Kcal / Kg °C) T= Time (Hr. ) 93@ Hydraulic Circuits 18 Case Study 1__ Preparation of hydraulic circuit for a 50 tonne C-frame Hydraulic press machine. Apress manufacturer wants to make a hydraulic system for his press has given the following particulars : ° Cylinder Specification : 200 x 160 x 250 mm stroke ¢ Load or Force required during pressing : 50,000 Kef * Speeds of the actuator: » Rapid approach —- 68 mm/sec ® Pressing = 40 mm/sec = Rapid return + 100 mm/sec Task to do: o You as the hydraulic system designer have been given the task of designing the circuit diagram for this application. o Please make a suitable basic circuit diagram remembering the following points - > Make use of proper graphical symbols for each element. > The first step should be to write down the sequence of operation. » Calculate pressure and flow for each operation. > Prepare Bill of Materials for major items to be used. > Then go to the control system of different valves (For different configuration of elements, please refer Yuken Catalogue (“Hydraulic Equipment Catalogue”) v For this exercise use minimum necessary Accessories. > Consider the safety features wherever required. > Also make the chart for pressure settings required for tonnage of 5,10,15,20,25,30,35,40, and 45 tonnes force.@ Hydraulic Circuits us [yousars wnanoanoa] [) wnoutg 407003 -F Buidweig jueuoduioy@ Hydraulic Circuits O/W ONTOS FIOH ASVO YNVED SNIHOVA 3SOduNd WiIdddS = be © ie jaa | sATHIRS 96@ Hydraulic Circuits 8 2NIHOWN SOdaifig 77 J@ Hydraulic Circuits 98,- @® Hyd. Oils, Contamination & Filtration Hydraulic Oils 1 Definition Hydraulic oil is a medium to convert hydraulic energy to mechanical energy 2 Purpose of a hydraulic fluid 2.1 To transmit power 2.2 To lubricate moving parts 2.3 To dissipate heat 2.4 To seal clearances between parts 3 Types of hydraulic fluids “WATER GiveoLs - Typ 40% 860% ‘OLN WATER EMULSION Typ. 5% & 4 Fluid properties 4.1 Viscosity Viscosity is the measure of fluid’s resistance to flow. If a fluid flows easily, its viscosity is low. If the fluid flows with difficulty its viscosity is high. 4.11 Defining viscosity 4.111 Absolute viscosity Absolute viscosity is the resistance encountered when moving one layer of liquid over another. Absolute viscosity hear Stress Unit is Centi Poise (cP ) Rate of Shear 4,112. Kinematic viscosity Kinematic viscosity is defined as the time needed for a fixed volume of oil to flow through a capillary tube. Kinematic viscosity = Absolute Viscosity Unit is Centi Stokes ( cSt ) Density 99@®) Hyd. Oils, Contamination & Filtration 4.113 Relative viscosity - Saybolts Relative viscosity The time taken for 60 ml of fluid to flow through an orifice of a particular size. Viscosity is measured in Saybolts Universal Seconds ( SUS or SSU ) at a particular temperature. ( cSt = SUS x 0.220 ) 4.2 Viscosity _Index ka Is the measure of change in viscosity { 450 with temperature. an Higher the viscosity index value, 2 lower the variation of viscosity 2 350 with temperature and vice versa = 300 Mineral oil - VI is around 95 - 100 250 40 60 80 100 Temp°C —> 4.3 Pour point It is the temperature at which oil stops flowing due to freezing, The pour point of the selected oil should be min. 7°. lower than the minimum temperature encountered. 4.4 Flash point It is the minimum temperature at which the i saturated oil vapour catches fire instantaneously in the presence of a spark. 4.5 Specific heat Itis the ratio of the heat required to raise the temperature of a given weight of fluid to that required to raise the temperature of the same weight of water by the same temperature difference. Higher the specific heat of fluid, higher is it’s capacity to absorb and dissipate heat. Specific heat of Mineral oil - 0.45 cal/gm.° c, water - 1.0 cal/gm. °c 100® Hyd. Oils, Contamination & Filtration 4.6 Compressibility It is the property of a hydraulic fluid which defines the volume reduction at pressure. 4.7 Demulsibility It is the ability of a fluid to separate out water. 0.03% by volume can saturate a hydraulic oil, Contamination 5 Definition It is defined as any foreign substance that causes harm to the hydraulic fluid. It harms the system or parts of the system to which the fluid is exposed. Nearly 70 - 75 % of the problems that occur in a hydraulic system is due to contamination. ‘ion 5.1 Types of contamination 5.11 Particulate 1. Particulate 5.111 Silt (0-5 um ) none 5.112 Chips (5 pm +) ae tree & Dissolved) 5.12 Water 6 Free or dissolved é 6 5.13 Air 5.2. Sources of contamination 5.2.1 Built-in contamination 5.2.2. External Ingression 5.2.3 Internally generated contamination 5.2.3.1 Abrasive wear 5.2.3.2 Adhesive wear 5.2.3.3 Erosive wear 5.2.3.4 Fatigue wear 5.2.3.5 Cavitations wear 5.2.3.6 Corrosive wear 5.2.3.7 Aeration wear 5.2.4 Contaminated new oil 101@® Hyd. Oils, Contamination & Filtration 5.3 Water as a contaminant Water is in * Dissolved state * Free state or emulsified state — This is water above saturation point . Noticeable as a “milky” discolouration. 5.3.1 Damage caused by water and other contaminants during operation * Corrosion Accelerated abrasive wear Additive breakdown Increased acid level Viscosity variance 5.4 Entrainment of Air Increase in free air causes increase in compressibility of hydraulic fluid creating cavitation and high pressure fluctuations resulting in noise. 6 Fluid Cleanliness Standards NAS Standards ‘Maximum number of dirt particles in 100ml hydraulic fluid at particle Size Size CLASS # joojotat2;3;4[5fel7] sf 9] wl] 12 5-15 | 125] 250 | 500 | 1000] 2000] 4000 | 8000 |16000| 32000|64000) 128000 | 256000 | 12000 | cza000 1525 | 22 | 44 | 89 | 178 | 356 | 712 | 1425] 2850] 5700 |11400|22800| 45600] 9120082400 2550[ 4 | 8 | 16 | 32 | 63 | 126 | 253 | S06 | 1012| 2025] 4050| 8100] 16200 32400] so-100/ 1 | 2 | 3 | 6 | 11 | 22 | 45 | 90 | 180 | 360 | 720 | 1440| 2880| 5760 >toofo | oj] 142i 4 {8 | | 32 | 64 | 128] 256) 512 | 1024 Electro -hydraulic Servo Systems Small Flow Control Systems Electro -hydraulic Proportional Systems Hyd. Systems exceeding 210 Kgf / Cm? Hyd. Systems exceeding 140 Kgf / Cm? General Low Pressure Systems 1027" ® Hyd. Oils, Contamination & Filtration 1SO Standards 5 Eg. ISO Code : 18/16/13 » Particles 2 2 microns 7 Particles 2 5 microns Particles 2 15 microns The ISO code will have 3 numbers **/**/** These numbers are called as the range nos. Referring to the table on the left, for ISO : 18/16/13 Size of 2 microns particles and above are 1300 ~ 2500 numbers Size of 5 micron particles & above are 320 ~ 640 numbers and Size of 15 micron particles & above are 40 ~ 80 numbers per ml of oil Lower the range numbers, less contaminated is the oil. Filtration 7 Fluid Filtration Filters are used in a hydraulic system for contamination control. A filter consists of a porous media which traps contaminants above a particular size in the system fluid. 7.1 Types of filter media 7.1.4 Surface media - Eg. Wire mesh 7.1.2 Depth media - Eg. Cellulose ( Paper ) , Fibre glass 7.2 Types of filters 7.2.1 Strainers - Coarse filters with pores generally larger than 50 microns 7.2.2 Filters - Generally smaller than 50 microns 7.3 Specifications of filters 7.3.1 Mesh Number For wire mesh strainers , higher the mesh no. or sieve no. finer is the screen 103® Hyd. Oils, Contamination & Filtration ‘Mesh Number Opening size ( Microns ) — 60 238 200 700 149 Md veh 200 74 Number 325 4 | 7.3.2. Nominal Ratings | A nominal rating of 10 microns means some particles of 10 microns size or bigger | will be trapped by the filter 7.3.3 Absolute Ratings An absolute rating of 25 microns means that the largest hard, spherically shaped \ particle passing through the filter will be 25 microns in diameter. A filter of 10 microns nominal rating can have a 25 micron absolute rating. 7.3.4 Beta Ratio (Filtration Ratio It is the measure of the particle capture efficiency of a filter element. Bx = Number of particles > x in upstream Number of particles > x in downstream A)— Be = 5000 = 50 “Beta Six = 50” 100 100 particles 5000 particles > 6 jum downstream, upstream Capture efficiency = (1 - 1) x 100 B (1-4) x 100 = 98% (In this example ) 50— COI OE: @® Hyd. Oils, Contamination & Filtra 8 Filter types based on location 8.1. Suction Filters ( Strainers ) 8.2 Pressure Filters 8.3 Component Isolation Filters 8.4 Return line Filters 8.5 Duplex Filters 8.6 Off-line Filters PRESSURE INGRESS UNE FILTER ROM CYLINDER, ROD SEALS PUMP TENDS TO GRIND EXISTING DIRT AND GENERATE MORE AS A RESULT INGRESS FROM AIR BREATHER, INGRESS FROM ‘OIL FILLING on 105® Hyd. Oils, Contamination & FiltrationEEE ’“SOg OO ® Maintenance & Trouble shooting of Hydraulic systems 1 Standard Maintenance Practices = Periodic checking of oil level in the reservoir. Periodic cleaning of suction strainer. = Return line filter element to be changed after initial 100 hours and at 500 hours there after. = Periodic analysis of oil sample to check the contamination level. = Flushing of the system after major break down and restart. = Ensure proper type and quantity of spare items and proper storage. = Mounting of magnets in reservoir to prevent entry of ferrous particles. * Do not return to the system any fluid that has leaked out. = Do not mix two different grades / makes of oil. = Use clean containers, hoses and funnels for filling the oil in to the reservoir. Use of portable filtration unit is recommended. * Use only cloth for cleaning or wiping of hydraulic components. 2 Trouble shooting 2.1 Shutting down machine for Service LOWER OR [MECHANICALLY ‘SECURE ALL 2.2 Checking faults ‘© Actuator Force ==> is controlled by Pressure * Actuator Velocity =p is controlled by Flow ‘* Actuator Direction ==> is controlled by Direction of Flow Therefore the factors that transmit and control power in a hydraulic system are : Pressure, Flow and Direction of Flow. Therefore ask questions that identify the problems in terms of Pressure, Flow & Direction of flow. 107® Maintenance & Trouble shooting of Hydraulic systems 2.3 Required pressure not developin; PROBABLE CAUSE REMEDY Preset Pressure of Relief valve too low. + Reset the Relief Valve pressure with the help of a pressure gauge. Relief Valve is opened + Open the Relief Valve, check for smoothness in movement of piston * Check for Seating area is proper ( Poppet and Seat ) + Clean the Orifice hole in the piston if it is blocked Excessive Internal Leakage + Check actuator / valves for excess Internal Leakage. System oil flows back to reservoir = Check the valves for mal-function Dir. Valve , Relief Valve, Check Valve, Shut off Valve + Incorrect spool function of Dir. Valve Change to correct spool function Incorrect adjustment or Malfunctioning of flow regulator Valve + Make setting again. Or eliminate the malfunction 2.4 No flow from the Pump PROBABLE CAUSE REMEDY Wrong Direction of Pump Rotation + Run in the specified direction of rotation Pump shaft not rotating + Key not fitted or coupling is loose. Large air entry from suction port * Tighten all suction fittings, fill with hydraulic oil or cover with grease Insufficient revolution + Run at atleast minimum specified RPM ( Run inbetween specified RPM range ) Failure of vanes to come out of Slots ina Vane Pump + Disassemble, clean and remove dust in slots. Delivery rate set at O with a variable displacement pump + Readjust the delivery rate High mounting position + Height of pump inlet port to be within one meter from the oil level in reservoir Excessive Oil Viscosity + Choose oil with suitable viscosity grade If required preheat oil with a heater Worn out or damaged parts + Repair or replace the parts 108® Maintenance & Trouble shooting of Hydraulic systems 25 Excessive Temperature PROBABLE CAUSE REMEDY Reduced Efficiency of oil cooler + Check Temp. of cooling media - Air/Water + Check for choking of cooling area - Tubes / Fins + Check for Quantity of supply of cooling Media - Fan angle damage / Water supply Reservoir Fluid level low + Top up the Reservoir Correct fluid not used + Drain and re-fill with correct fluid The pump output pressure is too high. + Readjust the set pressure of the Relief valve to meet with required system load. Increased Internal Drain in pump (Wear Out ) + Measure Drain amount - Piston Pump + Measure Flow at set Pr. - Vane Pump & Gear Pump ( Volumetric Efficiency ) Reservoir surrounding not clear 2.6 Excessive Noise PROBABLE CAUSE + Clear the area for Natural cooling REMEDY Pump Noisy - Air in the System + Tighten all connecting parts of Pipe& Pump inlet port. (Apply Grease / Fill with oil ) Air entry through pump shaft seal + Replace pump shaft seal if worn out. Air Bubbles in Reservoir + Return line Pipe should terminate below Oil surface in Reservoir at any time. + Location of Return Pipe with respect to Suction Pipe to be proper and also flow path Small Size of the Suction Strainer (Increased suction flow resistance) + Change to larger size Suction Strainer. Clogged Strainer / Filter reased suction flow resistance) Pump speed is too high. + Clean or Replace the Strainer / element + Reduce the pump speed below the rated maximum speed recommended in manual Coupling Misalignment * Re-align Pump and motor accurately. Align fowithin 0.1 mm TIR and angular tolerance Relief Valve Noisy - Settling too low or too close to another valve setting + Adjust to correct Pressure 109® Maintenance & Trouble shooting of Hydraulic systems 2.7 Oil Leakage PROBABLE CAUSE REMEDY The line pressure is out of the rated Pressure range of the seals + Check the seal if it meets with the Use for the line pressure. If not Replace it Seal is not compatible with the oil + Either swelling or shrinkage can Occur due to chemical reaction. Change the seals to the particular type of oil used. Deformation due to shelf life of seals + Flatness or Hardness may change or degradation can occur since the seals have a specific shelf life The finish of the surface which interfaces with the seal is improper Misalignment of Piping and fitting + Check the surface for roughness, burrs and contaminant particles on the area. Refinish the surface, get rid of burrs, clean the surface area. + Open the nut, correct the eccentricity between pipe ferrule and fitting Improper tightening torque for Bite type fitting * Check for the ferrule movement. + Deformation inside the pipe Improper usage of thread Combination + Use correct thread combination Parallel to Parallel Parallel to Taper Damaged Sealing Material + Damaged Dowty Seal + Damaged “0” Ring 110| @ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS HYDRAULIC PUMPS Fixed Displacement Pumps Name New Old Single Pump Same as New Two Stage Pump ~ Single - Suction { i Same as New Double Pump |___ Dual - : Suction 1 Pan Same as New Single SO 7 a ! Same as New Triple Pump | Sap = -- smn | gama as New Combination |__ Pump Type Me poate ED Ob- ot Motor Pump Same as New ut@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves Pressure Control Valves _Name New a Old on Remote Control L Relief Valve 7 aL rt rh U Ch “a Direct Type a L Relief Valve Using Vent Port | Using Vent Port = 4 Solenoid Controlled Relief Valve 112@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves Pressure Control Valves Sequence& Check Valve ‘Sequence& Check Valve Counter balance Valve (€xt Pilot. rain) | Name New Old ‘Area ratio where auxiliary pilot HC Type Pressure works on itis 1 to 8 Pressure Control fats omenenee enn nn, Valve With Auxiliary 1 Pilot Pr Counter balance i fal i Pressure Reducing Valve Unloading Relief Valve Pressure Reducing & ‘Check Valve Pressure | Reducing & a) i os 1 Relic ' = ' i le | +h Pressure Switch i"@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS % _ Control Valves Flow Conirol Valves Name | New _ _Old For eterout TTth (PL tO a : = Throttle and J __ ret Check Module For Meter-in ca tap 4 L J Wormaly Open Deceleration . | va ‘Normally Closed Normally Open Deceleration & ‘Check Valve Normally Closed 114@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves Directional Control Valves Name Spool Type of Direetional Control Valve aes New. Old atts & 4 atta gS8 88 ‘Spool Type. =: say se pee 115@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves Directional Control Valves i Name New | Old@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves Directional Control Valves Name New Old it Operated em = ph sath Pad ‘ x Xai é Tae ee aera str Dr 2 AB cen Datla are aw et, etree, 117@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS ___Control Valves Directional Control Valves Name New Old Manually Operated Directional Vale@ GRAPHIC SYMBOLS FOR Directional Valve FLUID POWER SYSTEMS Control Valves Directional Control Valves Name New Old tit “eft | oT ( eau wh - —_ | same UX» ( -cuny || —tikh [ emits | 4 AB x! Lhe ~ah Cam Operated “ath [ oath | Units ~t2it> —ii$ [ xb | ‘Note: Graphic Symbols [ ] indicates a transitional position ¢ + $ Check Valve Not: Symbol of pings wd only when here isto noe Taemal Day Pilot Controlled _ Check Valve ~ gaan 119@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves 01 & 03 Series Modular Valves Name New Old me “5 4 Relief Modular |_| A eT 8 A Valve u : | oy a 1 Fi * Al C= FS LJ Reducing Modular Valve 120@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS 01 & 03 Series Modular Valves Control Valves. Name New Reducing Modular Valve Reducing Modular Valve for Low Pressure Setting Brake Modular Valve Sequence Modular Valve Counterbalance Modular Valve “a7@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves Pressure ‘Switch Modular | Valve Flow Control Modular Valve | Flow Control and Check Modular Valve 122@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves 01 & 03 Series Modular Valves Name New Old TT If iL] fi SHE Temperature - Compensated | fk y! TaTr Throttle and i le ‘Check Modular tet Fe Valve = —— lee | THe t ud Throttle TTT Modular Valve Check and Throttle Modular Valve Throttle and Check Modular Valve tt Te J Uae |. ORB OB gf UB 123@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves 01 & 03 Series Modular Valves Old@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS >—_____________________ Control valves 01 & 03 Series Modular Valves __Name New Anti-Cavitation Modular Valve oe a LITT i PTB A End Plate a oo — — inaell | Ut tt PTBA cE PTAA ATER A P TBA Connecting - : _| Plate + Base Plate a | 125@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Control Valves “E” Series Proportional Electro-Hydraulic Control Valves Name | New Old Proportional Pilot Relief Valve Proportional Relief Valve Proportional Relieving & Reducing Valve Proportional Flow Control 100 Series: Pit Valve a Aa wy Operated Type a Internal Pilot | External Pilot Internal Pilot | External Pilot 400 Series: Direct Drive Type Proportional Flow Control & Check Valve Internal Pilot | Externali ————_—____ @ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Actuators Hydraulic Motors | Name New Old | ixed Displacement Type | Qe Same as New Hydraulic Motor Note: The figures inthe graphie symbols IMlustrate displacement code Two Speed Type (An example of the hydraulic circuit control valve) Lit MVH Series. ye ALi (An example circuit) At full Torque (High Torque, Low Speed) a Soares At 2/8 Torque (Medium Torque, Middle Speed)@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS ee - Actuators Rotary Oscillating Torque Actuators & Hydraulic Cylinder | Name New old Rotary _ te Oscillating L Torque _ Actuator opt > No Cushion ~ au Cop [E+ Boh Sides Cushion | au i (at e— Double Acting = Cylinder Single Rod Side Cushion ~ Rod Type eu ~ Head Side Cushion a Note: The figures inthe graphic symbol illustrate sre ratios ‘No Cashion —— mt fal ‘oth Sides Cashion Double Acting He Cylinder : Double Rod Rod Side Cishion Type — _ we | aa 2 Head Side Cushion ~ | i Et HF} Double Acting fae Cylinder with Proximity ‘Switch ‘ACCylinder with two switches is shown above 128i ——— @ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Accessories Hand Pump & Valves ‘Shut-off Valve with restrictor Name New Old Hand Pump oH Aa YL Shut-off Valve bt Sunes Nee Shut-off & alee = - Check Valve b+ Same as New ‘Same as New Shut-off Valve for Accumulator Note: If either valve is always shut, represent that valve by solid black fl a ‘Same as New Solenoid Valve for Water 8 Same as New Automatic Feed Water valve : Flow Divider id Same as New Flow Dividing and Combining Same as New Valve Air Bleed Valve a - hm $f 129@ GRAPHIC SYMBOLS FOR ELUID POWER SYSTEMS — oo. Accessories Hand Pump & Valves Name New = Old Air Breather & ~ Filler 2 Y , } a Filler Breather by Filter without By-Pass Valv © Without Clogging Indicator <> * With Clogging Indicator o ‘= Without Housing (Swaine) < fe | ® With Clogging Indicator & Coniact point | + With Contact Point for cogaing = With Housing <> Filter with By. Pass Valve Same as New Filter with Reverse Flow valve Same as New Filter with Magnet Filter with Shut- off Valve Same as New Duplex Filter Same as New * Clogging indicators and contacts points use the same symbols as Filters wit ithout by — pass valves Magnet cs 1307 | @ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Accessories a Hand Pump & Valves | Name New Old Accumulator 0 ‘Same as New Water Cooler & Same as New Air Cooler $9 &} Coupling Cooler (An example Cireuit) ore Electric Heater Same as New Steam Type iiearee Same as New | Prossure Gauge Same as New Differential Pressure Instrument Pressure Indicator Pressure Gauge with Contact Point Y) Q\-2) @/o| #4), Pressure Switch | Pressure | Transducer } Push Type a 7 ) FAN=) Same as New Rotary Type | Gauge Isolator SIHe ott Same as New | as } wo | ° | 131@ GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS Thermometer, Liquid Level Gauge & Fiow Meter Name Thermometer Thermometer with Contact Point tH Thermostat Liquid Level Gauge Liquid Level Gauge with contact point Liquid Level Gauge with Thermometer Liquid Level ‘Switch — 8 Se Flow Switch ot = Flow inoter ©- Same as New Integrating ®& samoas New ae | i | |cr eae eee ruanntt e000 eerste ye renrng ane errr: a) ® Pipe Selection (Nomograph for choosing Pipe ID Lmin Flow (pump) 800 600. 500. 400. 300. % 180 1100: % 80: 60 50: UE an 30 20. as; 10) 1000 PIPE / TUBE VELOCITY SELECTION FOR DIFFERENT PRESSURE, Pressure Line 25 bar—3 mtr / sec 40 bar — 3.3 mtr/ sec 64 bar — 3.6 mtr/ sec 100 bar ~ 4 mtr/ sec 160 bar ~ 5 mtr / sec 250 bar - 6 mtr / sec avaeye Return Line — 1.5 to 2 mtr/ sec Suction Line — 0.5 to | mtr / sec s-1.5 10 0.8 0 0.5 0.4 0.3 0.2 0.15, oa 0:08 0.06 0.05 133, ee @® Solution to Exercises Solution to case study 1 of - @ Hydraulic Circuits (Page no. 94) 18 Case Study 1__ Preparation of hydraulic circuit for a 50 tonne C-frame Hydraulic press machine. ® Available data : * Cylinder Specification : = Boredia = 200mm = Piston dia - 160mm "Stroke = 250mm * Pressing Force / Load: 50,000 Kgf. * Speeds of the actuator: = Rapid approach - 68 mm/sec = Pressing - 10 mm/sec = Rapidreturn —- 100 mm/sec axe F, d " @ F, Area Full area of cylinder: Ay = x x D? = mx20 = 314,16. Cm? 4 4 Piston rod area of cylinder: = mx 16 4 Annular area of cylinder: Az = (Al - a) = 314.16 - 201.06 = 113.1. Cm? ® Flow Flow required for rapid approach: Q=AxV = 314.16 x 68 x 60 10 x 1000 128.17 lpm 135Solution to Exercises Flow required for pressing: Q=AxV 14.16 x 10 x 60 410 x 1000 = 18.85 ipm Flow required for rapid return: Q=A x V = 113.1 x 100 x 60 40 x 1000 = 67.86 lpm @ Pressure Pressure required for rapid approach: 10 Kg/Cm* Pressure required for pressing: P = F = 50,000 = 160 Kg/Cm* A 314.16 Pressures required for pressing at different forces: Force _ in Pressure Setting (Kg/cm’) —_5,000 | 16 70,000 32 = 75,000 48 | 20,000 7 64 25,000 | 8 30,000 96. | 35,000 ee 12! 40,000 7 128 45,000 7 144 © Motor Capacity Maximum Flow: 129 lpm Maximum Pressure: 160 Kg/Cm?* Motor Capacity = PxQ = 160x129 = (39.67 KW( 53 HP) 612x no 612 x 0.85 To save power use Double pump and energy saving circuit Pump which can give 19 lpm at 160 Kg/Cm? 110 lpm at 15 Kg/Cm* Theoretically 5 HP motor can be used. (0.54 KW + 3.17 KW)@® Solution to Exercises Considering the efficiency of the pump and motor, 10 HP motor is selected. Tank capacity General thumb rule is 3 - 4 times of system flow. (Vane pump circuit) Max. system flow = 129 lpm Tank capacity = 129 x 3 = 387 ltrs say 400 Itrs. e0ose160x250 STROKE. 16 | segs | rast are. ~ somm/see. | Presse fomm/ase | rerum — rast Hydraulic Circuit for 50 Tonne Hydraulic Press Machine feononact: [si [sal sa) se [rst aovnocn | + sinc [be couPnass * mrp reve | le] [x ‘ati Fp DENTE Hc PRONE. 137@ Solution to Exercises BILL OF MATERIALS Part] Part No. Description No. Deseription 1 | Oil Reservoir 29. | Bolt kit Suction Strainer 30. | Bolt kit | | 3. | Electric Motor 31_| Bolt kit ual ionvetcouriing eae : ote | nol eee oo 5 | Double pump 33._| Pressure gauge 6,8 | Check valve 7 | Pressure relief valve 9 | Solenoid operated relief valve Solenoid controlled pilot operated directional valve 11 | Remote control relief valve 12. | Gauge Isolator 13 | Pressure gauge 14 | Pilot operated check valve 15 | Counter Balance valve 16 | Hydraulic cylinder 17 | Sol operated directional valve 18 | Modular Bolt Kit 19 | Pressure gauge panel 20 | Manifold 21. | Mod Bolt Kit 22_| Bell housing 23. | Return Line filter 24 | Filler / Breather 25 | Oillevel gauge 26 | Modular throttle valve 27 | Bolt kit 28 | Boltkit 138Seeesreeeeeereeseees eee sese eee este creer eee eee eee ee eee ereeseees ® Solution to Exercises Bill of Materials for Component Clamping & Ejector Circuit of - @ Hydraulic Circuits Description ae Description 1 | Oil Reservoir 27_| Pulsation Dampener 2 | Oil Level Indicator 28 | Pressure Gauge - 3 | Breather filler [ 29 | Pressure indication plate | 4 | Float Switch 30 | Pressure gauge panel 5 | Flexible Drive Coupling 31,32 Name plate 6 | Suction flange 33. | Circuit Plate ~7_| Variable Displacement Pump 38 | Air Bleed Valve ai 8 | Suction Strainer 9. | 3 Phase Electric Motor 10 | Coupling Cooler 11_| Return Line Filter Tank Top Type 12 | Check Valve 13. | Modular Pressure Reducing Valve 14 | Modular Bypass Plate 15 | Pumping Unit Mounting Plate 16,17] Modular Throttle and Check Valve 18. | Modular Pilot-operated Check Valve Solenoid Operated Direction Control Valve 21 | Bolt Kit 22,23| Bolt Kits 24 | Pressure switch 25. | Manifold 19,20 26 | Multi Station Gauge Isolator 139@ Solution to Exercises Bill of Materials for Special Purpose Machine Crank Case Hole Boring Machine of ~ @ Hydraulic Circuits (Page no. 96) Part) Ne Description Description 1 | Oil Reservoir 48 Pressure Gauge Panel 2 | Breather filler 49 Pressure indication plate 3 | Suction Strainer 50 | Shut off valve 5 | Oil Level Indicator with Temperature 51,52 | 3 Phase Electric Motor Indicator 6 | Return Line Filter Tank Top Type 7,8 | Variable Displacement Pump 53,54 | Flexible Drive Coupling 55,56 | Bell housing 57,58 | Suction Flange 9 | Multi Station Gauge Isolator 10,11) Check Valve 12. | Pressure Gauge 13,14| Pressure Switches ‘Solenoid Operated Direction Control Valve ‘Solenoid Operated Direction Control Valve ~ Detent type 20,21] Modular Pressure Reducing Valve 16,17 18,19 22,23| Modular Connector Plate 24,25] Modular Throttle and Check Valve 26 ~ 29. '30,31| Modular Counterbalance Valve 32,33} Mod Bolt Kit 34,35] Mod Bolt Kit 36,37) Flow Control & Check Valve Solenoid Operated Direction Control Valve '40,41| Bolt Kit 42,43] Bolt Kit 44 | Drain Plug 45,46| Manifold 47 | Anodised Circuit Plate Modular Pilot-operated Check Valve 38,39| 140Bill of Materials for Special Put @® Solution to Exercises (Page no. 97) Machine (W) of - @ Hydraulic Circuits Part Ay Part a aa Description No. |___Deseription 1_| Oil Reservoir 36,37 | Modular Bolt Kit 2 | Breather filler ~ Side mounting 38 | Modular Bolt Kit 3. | Suction Strainer 39. | Modular Bolt Kit 4 | Drain Plug 40~43 | Name Plate 5 _| Return Line Filter Tank Top Type 44 | Manifold 6 | 3 Phase Electric Motor 45,46 Modular Pressure Reducing a lve 7__| Flexible Drive Coupling 47,48 | Modular Pilot-operated Check 8 | Multi Station Gauge Isolator Valve all pears Ca 49,50 | Modular Throttle Valve 51,53 | Solenoid Operated Direction 10 | Pressure Gauge Panel 53 | Control Valve 11 | Pressure Indication Plate 52,54 | Ditection Control Solenoid 2 |P it Me Plat Spersied Cee 55,56 | Modular Bolt Kit se eee Blesdvalie 57,58 | Modular Bolt Kit ~ itch 14~16] Pressure Switel aallnceene 17 | Coupling Cooler <1 | Manifota 18 | Check Valve 62,63 | Flow Control Valve 19 | Pulsation Dampener erealllsaren 20 | Variable Displacement Piston Pump G6 | Modular Throwle Valve 21_| Suction Flange 67 | Solenoid Operated Direction 22_ | Oil Level Indicator Control Valve 23. | Manifold ese Bok Et Solenoid Operated Direction 24 | Modular Pressure Reducing Valve 69 | Conmol Vane 25. | Modular Pilot-operated Check Valve 70 _| Direct Type Relief Valve 26-28| Modular Throttle and Check Valve 71 | Bolt Kit 29,30 | Modular Check Valve 72.73 | Bolt Kit 31_ | Modular Connector Plate 74__| Solenoid Operated Direction 432-34] Solenoid Operated Direction Control Control Valve valve - Detent type 45 | Solenoid Operated Direction Control Valve 141BASIC HYDRAULIC AND COMPONENTS YUKEN INDIA LTD., (Leading Manufacturers of Oil Hydraulic Eqiupments in collaboration with YUKEN KOGO CO.,, LTD., Japan) Whitefield Road, Whitefield, BANGALORE 560 066 - INDIA Ph: 91-080-2845 5007 Fax. No.91-080-28452261