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Mobile Hydraulics: Workbook TP 800
Mobile Hydraulics: Workbook TP 800
Workbook
TP 800
With CD-ROM
C (X1) D (X2) A B
LS
P
T
B A
T T
D
P
LS
LS2
LS1
Festo Didactic
574166 en
Order no. 574166
Revision level: 03/2013
Authors: Ulrich Schedel, Levent Unan
Editor: Christine Löffler
Graphics: Doris Schwarzenberger
Layout: 03/2013, Susanne Durz, Christine Löffler
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges
and training centres, the right of use shall also include use by school and college students and trainees at
the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this available
for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a
wide variety of users, including those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic GmbH & Co. KG.
Contents
Exercises and solutions: Mobile hydraulics, basic level working hydraulics (TP 801)
Exercise 1-1: Examining performance for a controller using constant displacement pump
and fixed pressure limitation ____________________________________________________3
Exercise 1-2: Examining performance for a controller using constant displacement pump
and adjusted pressure limitation using open-centre load-sensing pressure balance _____ 13
Exercise 1-3: Examining performance of speed control using a 6/3-way proportional valve ___________ 23
Exercise 1-4: Examining energy efficiency of speed control in an open-centre load-sensing system ____ 31
Exercise 1-5: Moving and holding a load with a 6/3-way proportional valve _______________________ 41
Exercise 1-6: Moving and holding a load with a piloted non-return valve __________________________ 51
Exercise 1-7: Moving and holding a load with a pressure-relief valve as counter pressure ____________ 59
Exercise 1-8: Moving and holding a load with a counterbalancing valve___________________________ 69
Exercise 1-9: Examining parallel, series and tandem configurations ______________________________ 79
Exercises and solutions: Mobile hydraulics, advanced level steering system (TP 802)
Exercise 2-1: Examining the steering valve in a hydrostatic steering system _______________________ 91
Exercise 2-2: Examining steering when external forces are exerted ______________________________ 99
Exercise 2-3: Examining overload protection for steering _____________________________________ 107
Exercise 2-4: Examining a steering system with priority function _______________________________ 115
Exercise 2-5: Designing a steering system for centre-pivot steering _____________________________ 123
Exercise 3-1: Examining a hydraulic system with load-sensing-controlled variable displacement pump 133
Exercise 3-2: Examining the load hold function _____________________________________________ 143
Exercise 3-3: Remotely controlling proportional directionalcontrol valves using a hydraulic joystick __ 151
Exercise 3-4: Setting a (volumetric) flow rate independent of load ______________________________ 159
Exercise 3-5: Setting the volumetric flow rate using a load-sensing-controlled pump unit ___________ 169
Exercise 3-6: Examining a load-sensing system with upstream pressure balance __________________ 179
Exercise 3-7: Examining a load-sensing system with downstream pressure balance ________________ 191
Exercises and worksheets: Mobile hydraulics, basic level working hydraulics (TP 801)
Exercise 1-1: Examining performance for a controller using constant displacement pump
and fixed pressure limitation ____________________________________________________3
Exercise 1-2: Examining performance for a controller using constant displacement pump
and adjusted pressure limitation using open-centre load-sensing pressure balance _____ 13
Exercise 1-3: Examining performance of speed control using a 6/3-way proportional valve ___________ 23
Exercise 1-4: Examining energy efficiency of speed control in an open-centre load-sensing system ____ 31
Exercise 1-5: Moving and holding a load with a 6/3-way proportional valve _______________________ 41
Exercise 1-6: Moving and holding a load with a piloted non-return valve __________________________ 51
Exercise 1-7: Moving and holding a load with a pressure-relief valve as counter pressure ____________ 59
Exercise 1-8: Moving and holding a load with a counterbalancing valve___________________________ 69
Exercise 1-9: Examining parallel, series and tandem configurations ______________________________ 79
Exercises and worksheets: Mobile hydraulics, advanced level steering system (TP 802)
Exercise 2-1: Examining the steering valve in a hydrostatic steering system _______________________ 91
Exercise 2-2: Examining steering when external forces are exerted ______________________________ 99
Exercise 2-3: Examining overload protection for steering _____________________________________ 107
Exercise 2-4: Examining a steering system with priority function _______________________________ 115
Exercise 2-5: Designing a steering system for centre-pivot steering _____________________________ 123
Exercises and worksheets: Mobile hydraulics, advanced level working hydraulics (TP 803)
Exercise 3-1: Examining a hydraulic system with load-sensing-controlled variable displacement pump 133
Exercise 3-2: Examining the load hold function _____________________________________________ 143
Exercise 3-3: Remotely controlling proportional directional control valves using a hydraulic joystick __ 151
Exercise 3-4: Setting a (volumetric) flow rate independent of load ______________________________ 159
Exercise 3-5: Setting the volumetric flow rate using a load-sensing-controlled pump unit ___________ 169
Exercise 3-6: Examining a load-sensing system with upstream pressure balance __________________ 179
Exercise 3-7: Examining a load-sensing system with downstream pressure balance ________________ 191
The mobile hydraulics basic and advanced level training packages are only to be used:
for the intended purpose in teaching and training applications
when their safety functions are in flawless condition
The components in the training packages are designed in accordance with the latest technology as well as
recognised safety rules. However, life and limb of the user and third parties may be endangered, and the
components may be impaired, if they are used incorrectly.
The learning system from Festo Didactic has been developed and produced exclusively for training and
continuing vocational education in the field of automation technology. The training companies and/or
trainers must ensure that all trainees observe the safety instructions described in this workbook.
Festo Didactic hereby excludes all liability for damage suffered by the trainee, the training company and/or
any other third parties as a result of use of these equipment sets outside a purely training situation, unless
Festo Didactic has caused this damage wilfully or through gross negligence.
Festo Didactic’s training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. The learning system is therefore broken down as follows:
Technology oriented training packages
Mechatronics and factory automation
Process automation and control technology
Mobile robotics
Hybrid learning factories
The training system for automation and technology is continuously updated and expanded in accordance
with developments in the field of education, as well as actual professional practice.
The training packages deal with various technologies including pneumatics, electro-pneumatics,
servopneumatics, hydraulics, electro-hydraulics, proportional hydraulics, servohydraulics, mobile
hydraulics, programmable logic controllers, sensor technology, electrical engineering, electronics and
electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual training packages. For example, PLC actuation of pneumatic, hydraulic and
electric drives is possible.
Hardware
The hardware in the training packages is comprised of industrial components and systems that are specially
designed for training purposes. The components contained in the training packages are specifically
designed and selected for the projects in the accompanying media.
Media
The media provided for the individual topics consist of a mixture of teachware and software. The teachware
includes:
Technical literature and textbooks (standard works for teaching basic knowledge)
Workbooks (practical exercises with supplementary instructions and sample solutions)
Lexicons, manuals and technical books
(which provide technical information on groups of topics for further exploration)
Transparencies and videos (for easy-to-follow, dynamic instruction)
Posters (for presenting information in a clear-cut way)
The teaching and learning media are available in several languages. They are intended for use in classroom
instruction, but are also suitable for self-study.
Seminars
A wide range of seminars covering the contents of the training packages round off the system for training
and vocational education.
This workbook is part of the training system for automation technology from Festo Didactic GmbH & Co. KG.
The system provides a solid basis for practice oriented training and vocational education. The mobile
hydraulics workbook communicates the basics and fundamental knowledge on the hydraulic systems of
mobile work machines.
The contents of the workbook are project exercises on the basic level of working hydraulics (TP 801),
advanced level steering systems (TP 802) and advanced level working hydraulics (TP 803). The workbook
also contains a basic information section on mobile hydraulics.
The basic level working hydraulics (TP 801) is suitable for basic training in mobile hydraulics.
Using practice-related problem descriptions, the energy balances of different hydraulic systems (also while
loaded) will be examined and evaluated. Control systems with multiple consuming devices are set up in
parallel, tandem and series connections and examined in relation to priority, flow rate distribution, and
pressure dependency. Further course topics are the behaviour of consuming devices while under loads and
the options for safely holding and lowering a load. Basic knowledge of hydraulic device technology is a
prerequisite.
The advanced level steering system (TP 802) communicates the basics of hydrostatic steering systems with
suitable hydraulic controls. The controllers contain typical components of a steering system like steering
valve, shock and anti-cavitation valve, steering cylinder and, if required, a secondary consuming device.
In the project exercises for advanced level working hydraulics (TP 803), details of the working hydraulics are
expanded upon and hydraulic controls with load-sensing controlled variable displacement pump will be set
up and examined.
The practical execution of the nine project exercises for TP 801 requires a TP 801 equipment set. One TP 801
and TP 802 equipment set is required for the practical execution of each of the five project exercises for
TP 802. An additional TP 803 equipment set is necessary for the practical execution of the seven project
exercises for TP 803.
The theoretical fundamentals for understanding these exercises can be found in the following textbooks:
Hydraulics, basic level
Electro-hydraulics, basic level
as well as in the appendix to this workbook.
Data sheets for the individual components are also available (cylinders, valves, sensors etc.).
General
Trainees should only work with the circuits under the supervision of a trainer.
Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in laboratory rooms which are equipped with residual current devices (RCDs).
Observe specifications included in the technical data for the individual components, and in particular all
safety instructions!
Malfunctions which may impair safety must not be generated in the training environment, and must be
eliminated immediately.
Wear personal safety gear (safety glasses, safety shoes) when working on circuits.
Mechanical system
Only reach into the setup when it is at a complete standstill.
Mount all of the components securely onto the slotted profile plate.
Limit switches may not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Set all components up so that activation of switches and disconnectors is not made difficult.
Adhere to the instructions regarding positioning of the components.
Always set up cylinders together with the appropriate cover.
Electrical functions
Use extra-low voltage only (max. 24 V DC).
Establish or interrupt electrical connections only in the absence of voltage!
Use only connecting cables with safety plugs for electrical connections.
When disconnecting connector cables, only pull by the plug, never by the cable.
Hydraulics
Limit system pressure to 6 MPa (60 bar).
Maximum permissible pressure for all devices included in the training package is 12 MPa (120 bar).
In the case of double-acting cylinders, pressure could be increased relative to the surface area ratio due
to pressure boosting. With a surface area ratio of 1:1.7 and a system pressure of 6 MPa (60 bar), it may
amount to more than 10 MPa (100 bar).
Danger of injury due to oil temperatures of greater than 50° C!
Hydraulic fluid with an oil temperature of greater than 50° C may result in burns or scalding.
Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
Variant A, snap-in system
Lightweight devices which cannot be subjected to loads (e.g. directional control valves and sensors).
Simply clip the components into the slots on the slotted profile plate. Release the components from the
slots by actuating the blue lever.
Variant B, rotary system
Components with medium load capacity (e.g. hydraulic cylinders). These components are clamped to
the slotted profile plate with T-head bolts. The blue knurled nut is used for clamping and loosening.
Make sure that the T-head bolts have been turned 90° after tightening.
Variant C, screw system
For devices with high load capacity and devices which are seldom removed from the slotted profile plate
(e.g. the hydraulic power unit). These devices are fastened with socket head screws and T-head nuts.
Required accessories
Two digital multimeters are required to evaluate exercises which make use of the flow sensor.
The output voltage of the flow sensor is measured with the multimeter.
The TP 800 training package consists of a multitude of individual training materials. This package refers to
components and basic circuits of the hydraulic systems of working machines. Individual components from
training package TP 800 may also be included in other packages.
Media
The teachware for the training package TP 800 consists of one workbook. The contents of the workbook are
the project exercises on the basic level of working hydraulics (TP 801), advanced level steering systems
(TP 802) and advanced level working hydraulics (TP 803). The theoretical fundamentals for understanding
the exercises are described in the textbook attachment.
The workbook includes the exercise sheets and worksheets for the project exercise, the solutions to each
individual worksheet and a CD-ROM. A set of ready-to-use exercise sheets and worksheets is included in
each workbook for all of the exercises.
Data sheets for the hardware components are made available along with the equipment set.
Media
The media are offered in several languages. Further training materials can be found in our catalogues and on
the Internet.
Exercise 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9
Learning objective
Learning objective
Learning objective
Learning objective
To know how valve manifolds in mobile hydraulics work and how to use
•
them.
To know the relationship between load changes and speed changes when
•
using a flow control valve.
The equipment sets TP 801, TP 802 and TP 803 are compiled for the basic and advanced level mobile
hydraulics. Equipment set TP 801 includes all of the components which are necessary for mastering the
learning objectives for TP 801. To master the learning objectives for TP 802, you will require the components
of the three equipment sets TP 801 and TP 802. For the setup of the control units for TP 803, you will require
the components of the three equipment sets TP 801, TP 802 and TP 803. The equipment sets can be
supplemented with other equipment sets as desired.
Equipment set: Mobile hydraulics, basic level working hydraulics (TP 801), order no. 574161
6/3-way proportional hand lever valve, mid-position with tank recirculation 572141 2
T-distributor 152847 3
P2 P1 T2
P T
Shut-off valve
A1 B1
Pressure-relief valve
P
X X
T T
2 RD (1)
BK1 (4), SP1
p
p BK2 (5), SP2
WH (2)
U
BU (3)
q 0 – 10V
(BK)
0V (BU)
Hydraulic motor
1 0 2
P T
X (1:3)
T-distributor
Shuttle valve
B
A1 A2
Equipment set: Mobile hydraulics, advanced level steering system (TP 802), order no. 574162
4/3-way hand lever valve, working lines relieved in mid-position, detenting 544344 1
P T
P T E
A1 T B1
T-distributor 152847 1
P 35 kPa
P
A A
0.55 MPa 0.55 MPa
X X
P P
LS
P
T
T-distributor
P
T
Equipment set: Mobile hydraulics, basic level working hydraulics (TP 801)
Exercise 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9
Component
Shut-off valve 1 1 1 1 1 1 1 1 1
Pressure-relief valve 2 1 2 2 1 2
Pressure gauge 1 1
Flow sensor 2 2 2 2 1 1 1 2
Hydraulic motor 2 2 2 2 1 1 1 2
T-distributor 1 2 1 2 2 3 2
Shuttle valve 1
Required accessories
Exercise 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9
Component
Digital multimeter 2 2 2 2 1 1 1 2
Power pack, 24 V DC 1 1 1 1 1 1 1 1 1
Tubing line 9 10 13 15 12 15 16 16 16
Component
Shut-off valve 1 1 1 1 1
Pressure gauge 1 1 1
Flow sensor 1
Hydraulic motor 1
T-distributor 1 2 2
Required accessories
Component
Digital multimeter 1
Power pack, 24 V DC 1 1 1 1
Tubing line 8 13 16 15 9
Component
T-distributor 1
Shut-off valve 1
Pressure-relief valve 1 2 2 2
Pressure gauge 1 1
Flow sensor 1 1 2 2 2
Hydraulic motor 1 1 1 2 2
T-distributor 1 2 3 3
Shuttle valve 1 1
*) Components with light grey background are components from the equipment set TP 802
**) Components with dark grey background are components from the equipment set TP 801
Required accessories
Component
Digital multimeter 1 1 2 2 2
Power pack, 24 V DC 1 1 1 1 1 1 1
Tubing line 10 10 9 8 9 15 16
Learning objectives
The basic learning objective of this workbook is to understand, set up, safely commission and analyse using
measurement technology the basic hydraulic circuits of mobile work machines. This knowledge is gained by
means of theoretical questions and by actually setting up the circuits on the slotted profile plate. Direct
interplay of theory and practice ensures fast progress and long-lasting learning. The more specific learning
objectives are documented in the matrix. Concrete, individual learning objectives are assigned to each
exercise.
Required time
The time required for working through the exercises depends on the learner’s previous knowledge of the
subject matter. Each exercise should take approximately 1 to 1½ hours.
Standards
The following standards are applied in this workbook:
DIN ISO 1219-1 Fluid power systems and components – Graphic symbols and
circuit diagrams
EN 60617-2 to EN 60617-8 Graphic symbols for diagrams
EN 81346-2 Industrial systems, installations and equipment and industrial products;
structuring principles and reference designations
All of the project exercises of the basic level TP 801 and the two advanced levels TP 802 and TP 803 have the
same methodical structure. The tasks and are broken down into:
Title
Learning objectives
Problem description
Positional sketch
Project assignments
Work aids
Worksheets
The workbook includes the solutions for all of the worksheets for all exercises.
Component designations
Components are designated in circuit diagrams in accordance with DIN ISO 1219-2. All of the components
included in any given circuit have the same primary identifying number. Letters are assigned depending on
each respective type of component. Consecutive numbers are assigned if several components of the same
type are included within a single circuit.
CD-ROM contents
The workbook is included on the CD-ROM as a PDF file. The CD-ROM also provides you with additional
media.
Illustrations
Photos and graphics of components and industrial applications are made available. These can be used to
illustrate individual tasks or to supplement project presentations.
Data sheets
The data sheets for the components included in the training package are supplied along with the equipment
set, and are additionally available as PDF files.
Exercises and solutions: Mobile hydraulics, basic level working hydraulics (TP 801)
Exercise 1-1: Examining performance for a controller using constant displacement pump
and fixed pressure limitation ____________________________________________________3
Exercise 1-2: Examining performance for a controller using constant displacement pump
and adjusted pressure limitation using open-centre load-sensing pressure balance ______ 13
Exercise 1-3: Examining performance of speed control using a 6/3-way proportional valve ___________ 23
Exercise 1-4: Examining energy efficiency of speed control in an open-centre load-sensing system _____ 31
Exercise 1-5: Moving and holding a load with a 6/3-way proportional valve________________________ 41
Exercise 1-6: Moving and holding a load with a piloted non-return valve __________________________ 51
Exercise 1-7: Moving and holding a load with a pressure-relief valve as counter pressure ____________ 59
Exercise 1-8: Moving and holding a load with a counterbalancing valve ___________________________ 69
Exercise 1-9: Examining parallel, series and tandem configurations ______________________________ 79
Learning objectives
After completing this exercise:
you will be familiar with the relationship between pressure, flow rate and power output.
you will be able to calculate the power consumption of a hydraulic system.
you will know that flow division can lead to energy losses in a hydraulic system.
you will know that when using a constant displacement pump, non-decreasing volume flow leads to
energy loss.
Problem description
The motor speed of a wheel milling cutter is controlled using a flow control valve. The rotation of the motor
is only in one direction. The load acting on the motor changes depending on the soil conditions.
Examine how different load requirements affect the energy balance of the controls.
Positional sketch
Parameters
When the hydraulic power unit is switched on, the motor will turn.
The load on the motor should be simulated using a proportional pressure-relief valve.
Project assignments
1. Set up the controller.
2. Familiarise yourself with the commissioning procedure.
3. Find out about the procedure when taking measurements in the electrical circuit.
4. Double check the controller configuration.
5. Measure the pressure and flow rate at different load pressures.
6. Calculate the power output of the pump unit; the effective power and the power loss based on the
measured values. Depict the calculated power output in the bar chart and evaluate the results.
Visual inspection
Continuous visual inspection for defects in tubing and hydraulic devices is an essential part of
hydraulic safety standards.
Work aids
Data sheets, operating instructions
Hydraulics textbook
Basics of mobile hydraulics (see attachment)
1B4
p2
1V4 P
1V3 B
A
1B3
p1 T
q1 q2
T
0Z1 LS P1 P2 T T L L LA LA
60 bar
Circuit diagram
If the hydraulic motor is only used in connection with a flow sensor, the combination of the two will
be given the equipment designation B for a sensor. If the hydraulic motor is an independent driving
component of the control system, it will be given its own designation A (also only in connection with
a flow sensor).
Note
The pressure-relief valve 1V4 is used to set load pressures.
9 — Tubing line
Equipment list
Note
You will need the following in order to perform the measurements.
• 1 power pack 24 V DC
• 2 digital multimeters
Information
During practice operation and for industrial maintenance purposes, safe commissioning is
undertaken at low pressure which is then increased up to the maximum value. This is possible with
either a pressure-relief valve or a pump recirculation circuit. At low pressure, leaks can be safely
detected after device replacement, for example.
3. Finding out about the procedure when taking measurements in the electrical circuit
Safety instructions
• Before measuring, make sure that the section of the controller in which you intend to take
measurements only works with an electrical voltage of no greater than 24 V DC!
• Measurements within sections of the controller which function with higher voltages (e.g. 230 V)
may only be performed by persons who have received appropriate training or instruction.
• Incorrect performance of this measurement is life endangering!
• Observe the safety precautions for working with electrical power!
Information
Procedure for performing measurements in the electrical circuit
1. Switch off supply power to the electrical circuit.
2. Select the desired operating mode at the multimeter (e.g. direct current measurement).
3. Connect the measuring instrument with correct polarity when measuring direct current/
direct voltage.
4. Select the largest measuring range.
5. Switch supply power to the electrical circuit back on.
6. Watch the display and switch to increasingly smaller measuring ranges step-by-step.
7. Read the value from the display after arriving at the smallest possible measuring range.
Note
You will find information on the sensors in the operating instructions.
When using the analogue output of the pressure switch, make sure it is set to between 0-10 V.
Execution
Set the pressure-relief valve 1V1 to 45 bar. Set the values indicated in the table for the flow control
valve 1V3 and the pressure-relief valve 1V4. Measure the pressure and flow rate for these values.
– Set the values indicated in the table. Enter the measured pressure and flow rate values into the table.
Load case Valve specifications Pump pressure Flow rate Load pressure Flow rate
p1 [bar] q1 [l/min] p2 [bar] q2 [l/min]
1V3: open
a 15.8 4.14 12.4 4.22
1V4: Minimum pressure
e — 40.6 4.06 25 2
f — 45 4.06 1 0
Measurement log
Notes
Fully open the flow control valve 1V3 before dismantling the controller.
Fully open the pressure-relief valves 1V1 and 1V4 before dismantling.
Information
The formula for calculating the power in the hydraulic system when using the indicated physical
units is:
q p
P
600
P Power [kW]
q Flow rate [l/min]
p Pressure [bar]
Power loss: PV
PV PP PL
PV Power loss [kW]
a) Calculate the pumping power, effective power and power loss for the load cases a to f (see workbook 4).
Enter the values to the table.
f 0.305 0 0.305
0.35
P
kW
0.25
0.2
0.15
0.1
PP
0.05
PL
PV
0
PP PL PV PP PL PV PP PL PV PP PL PV PP PL PV PP PL PV
a b c d e f
PP Pumping power
PL Effective power
PV Power loss
Performance of the system with constant displacement pump and pressure limitation with different load cases a to f
c) When is power loss PV particularly high? Give reasons for your answer.
Power loss (PV) is particularly high when the flow rate of the consuming device (q2) is low. In this case,
almost the entire delivery rate of the pump unit must discharge at maximum pressure through the
pressure-relief valve.
Exercises and worksheets: Mobile hydraulics, basic level working hydraulics (TP 801)
Exercise 1-1: Examining performance for a controller using constant displacement pump
and fixed pressure limitation ____________________________________________________3
Exercise 1-2: Examining performance for a controller using constant displacement pump
and adjusted pressure limitation using open-centre load-sensing pressure balance _____ 13
Exercise 1-3: Examining performance of speed control using a 6/3-way proportional valve ___________ 23
Exercise 1-4: Examining energy efficiency of speed control in an open-centre load-sensing system ____ 31
Exercise 1-5: Moving and holding a load with a 6/3-way proportional valve _______________________ 41
Exercise 1-6: Moving and holding a load with a piloted non-return valve __________________________ 51
Exercise 1-7: Moving and holding a load with a pressure-relief valve as counter pressure ____________ 59
Exercise 1-8: Moving and holding a load with a counterbalancing valve___________________________ 69
Exercise 1-9: Examining parallel, series and tandem configurations ______________________________ 79
Exercises and worksheets: Mobile hydraulics, advanced level steering system (TP 802)
Exercise 2-1: Examining the steering valve in a hydrostatic steering system _______________________ 91
Exercise 2-2: Examining steering when external forces are exerted ______________________________ 99
Exercise 2-3: Examining overload protection for steering _____________________________________ 107
Exercise 2-4: Examining a steering system with priority function _______________________________ 115
Exercise 2-5: Designing a steering system for centre-pivot steering _____________________________ 123
Exercises and worksheets: Mobile hydraulics, advanced level working hydraulics (TP 803)
Exercise 3-1: Examining a hydraulic system with load-sensing-controlled variable displacement pump 133
Exercise 3-2: Examining the load hold function _____________________________________________ 143
Exercise 3-3: Remotely controlling proportional directional control valves using a hydraulic joystick __ 151
Exercise 3-4: Setting a (volumetric) flow rate independent of load ______________________________ 159
Exercise 3-5: Setting the volumetric flow rate using a load-sensing-controlled pump unit ___________ 169
Exercise 3-6: Examining a load-sensing system with upstream pressure balance __________________ 179
Exercise 3-7: Examining a load-sensing system with downstream pressure balance ________________ 191
Learning objectives
After completing this exercise:
you will be familiar with the relationship between pressure, flow rate and power output.
you will be able to calculate the power consumption of a hydraulic system.
you will know that flow division can lead to energy losses in a hydraulic system.
you will know that when using a constant displacement pump, non-decreasing volume flow leads to
energy loss.
Problem description
The motor speed of a wheel milling cutter is controlled using a flow control valve. The rotation of the motor
is only in one direction. The load acting on the motor changes depending on the soil conditions.
Examine how different load requirements affect the energy balance of the controls.
Positional sketch
Parameters
When the hydraulic power unit is switched on, the motor will turn.
The load on the motor should be simulated using a proportional pressure-relief valve.
Project assignments
1. Set up the controller.
2. Familiarise yourself with the commissioning procedure.
3. Find out about the procedure when taking measurements in the electrical circuit.
4. Double check the controller configuration.
5. Measure the pressure and flow rate at different load pressures.
6. Calculate the power output of the pump unit; the effective power and the power loss based on the
measured values. Depict the calculated power output in the bar chart and evaluate the results.
Visual inspection
Continuous visual inspection for defects in tubing and hydraulic devices is an essential part of
hydraulic safety standards.
Work aids
Data sheets, operating instructions
Hydraulics textbook
Basics of mobile hydraulics (see attachment)
4 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 574166
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
1B4
p2
1V4 P
1V3 B
A
1B3
p1 T
q1 q2
T
0Z1 LS P1 P2 T T L L LA LA
60 bar
Circuit diagram
Note
The pressure-relief valve 1V4 is used to set load pressures.
© Festo Didactic GmbH & Co. KG 574166 Name: __________________________________ Date: ____________ 5
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
9 — Tubing line
Equipment list
Note
You will need the following in order to perform the measurements.
• 1 power pack 24 V DC
• 2 digital multimeters
6 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 574166
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
Information
During practice operation and for industrial maintenance purposes, safe commissioning is
undertaken at low pressure which is then increased up to the maximum value. This is possible with
either a pressure-relief valve or a pump recirculation circuit. At low pressure, leaks can be safely
detected after device replacement, for example.
3. Finding out about the procedure when taking measurements in the electrical circuit
Safety instructions
• Before measuring, make sure that the section of the controller in which you intend to take
measurements only works with an electrical voltage of no greater than 24 V DC!
• Measurements within sections of the controller which function with higher voltages (e.g. 230 V)
may only be performed by persons who have received appropriate training or instruction.
• Incorrect performance of this measurement is life endangering!
• Observe the safety precautions for working with electrical power!
© Festo Didactic GmbH & Co. KG 574166 Name: __________________________________ Date: ____________ 7
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
Information
Procedure for performing measurements in the electrical circuit
1. Switch off supply power to the electrical circuit.
2. Select the desired operating mode at the multimeter (e.g. direct current measurement).
3. Connect the measuring instrument with correct polarity when measuring direct current/
direct voltage.
4. Select the largest measuring range.
5. Switch supply power to the electrical circuit back on.
6. Watch the display and switch to increasingly smaller measuring ranges step-by-step.
7. Read the value from the display after arriving at the smallest possible measuring range.
Note
You will find information on the sensors in the operating instructions.
When using the analogue output of the pressure switch, make sure it is set to between 0-10 V.
Execution
Set the pressure-relief valve 1V1 to 45 bar. Set the values indicated in the table for the flow control
valve 1V3 and the pressure-relief valve 1V4. Measure the pressure and flow rate for these values.
8 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 574166
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
– Set the values indicated in the table. Enter the measured pressure and flow rate values into the table.
Load case Valve specifications Pump pressure Flow rate Load pressure Flow rate
p1 [bar] q1 [l/min] p2 [bar] q2 [l/min]
1V3: open
a
1V4: Minimum pressure
b 1V3: open 30
d — 30 0.5
e — 25 2
f — 1 0
Measurement log
Notes
Fully open the flow control valve 1V3 before dismantling the controller.
Fully open the pressure-relief valves 1V1 and 1V4 before dismantling.
Information
The formula for calculating the power in the hydraulic system when using the indicated physical
units is:
q p
P
600
P Power [kW]
q Flow rate [l/min]
p Pressure [bar]
© Festo Didactic GmbH & Co. KG 574166 Name: __________________________________ Date: ____________ 9
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
Power loss: PV
PV PP PL
PV Power loss [kW]
a) Calculate the pumping power, effective power and power loss for the load cases a to f (see workbook 4).
Enter the values to the table.
10 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 574166
Exercise 1-1 – Examining performance for a controller using constant displacement pump and fixed pressure limitation
0.35
P
kW
0.25
0.2
0.15
0.1
PP
0.05
PL
PV
0
PP PL PV PP PL PV PP PL PV PP PL PV PP PL PV PP PL PV
a b c d e f
PP Pumping power
PL Effective power
PV Power loss
Performance of the system with constant displacement pump and pressure limitation with different load cases a to f
c) When is power loss PV particularly high? Give reasons for your answer.
© Festo Didactic GmbH & Co. KG 574166 Name: __________________________________ Date: ____________ 11
Contents
There are a number of special conditions which occur in mobile hydraulics but not in industrial hydraulics:
No regular working cycle
In industrial hydraulic systems, the force acting on the drive is normally constant. With mobile systems,
on the other hand, the operative force is extremely variable. For hydraulic applications with variable
force and speed, the use of a constant-displacement pump and a maximum pressure safety valve is not
an economic solution.·
Generally no external energy supply
Harsh environmental conditions
These may include large temperature differences, dust and impacts.
Limited installation space
Limited weight
From the above we derive the requirements for mobile hydraulic systems:
Efficiency in energy consumption
The most important consideration in mobile systems is efficiency: As mobile machines generally move
independently from any power source, the power supply is limited. In most cases, the only power
source is an internal combustion engine with a limited fuel supply.
Compact design
The individual components of mobile machines, such as tanks, pumps, motors, cylinders and valves
should be kept as small and light as possible. In order to achieve the desired performance with small
components, it is necessary to increase the pressure. Higher pressure in turn demands valves with close
tolerances in order to minimise leakage losses. Close-tolerance valves and the high performance
density make it necessary to pay more attention to filtering and cooling the hydraulic fluid.
Robust design
The components are subjected to wide temperature fluctuations. Moreover, the drives are frequently
subject to wide and rapid fluctuations in force. External drives and supply-line hoses are directly
exposed to dirt and collisions, for example with excavated material. This means that the hydraulic
components must be of robust design.
There are of course also combinations of the two types of circuit within one machine. In these cases, the
vehicle engine drives several pumps. The main pump in this case is the pump for the closed drive circuit,
while the auxiliary pumps operate with open circuits and supply the working hydraulic systems.