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    36 views90 pages

    NFPC L1 Hydraulics

    Uploaded by

    Deividas B

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    © All Rights Reserved
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    of 90
    National Fluid Power Centre Sparrows Brea wish emetic FLUID POWER ‘The LEVEL 4 Hydraulics Programme is designed to provide a foundation of knowledge ‘and understanding at a down to earth level. Itis a pre-requisite course for the LEVEL 2 programmes (normally machine/system specific) Itis not intended in any way to take a theoretical view of the subject, but a more practical approach based upon function and operation of the component parts that make up a hydraulic system. The programme touches on the subject of control at an introductory but useful level : (On completion of this course YOU will Know the fundamental principles that underpin all hydraulic system operations - *Be able to identify hydraulic symbols and better interpret a circuit diagram Know the function and operation of the key component parts Realise the need for goad contamination management at all times Be aware of the need to carryout safe-working practices at all times Self Assessment Questionnaire Page 4 Why use Hydraulics? Page 6 Risk Management /Safety Page 9 Your Role Page 11 Hydraulic Symbols and Circuitry Page 12 Basic Hydraulic Principles Page 21 Fs oe Page 36 Energy Losses Page 44 Direction Control plus Proportional / Servo Control Page 55 Load Holding and Motion Control Page 65 Pumps and Control (inc Accumulators) Page 67 | . Fault Finding Page 90, Contaminetion Management (ine Flushing) Page 91 Hydraulic “luid Management Page 92 Appendices Page 95 * General Safety + Basic Electrical Theory + Hydraulic Hose and Fittings + Offshore — Depth Compensation + Basic Formulae and Calculations + PRACTICAL HYDRAULIC EXERCISES 3 AANHRAAAAARAAAAA AAR AA ANARAAAARAARARARARA AA 0¢ 4B Ud “puayxe |IIM pos uoysid ayy ‘sSpULJAS poppoi-e|6uls Buyoe-ejqnop e jo apis seyj!9 0} palidde exe soinssaud jenbo 41 ‘pL asrwaGrd “swio|qoid wioysks asneo pinos Yyotym ‘sjUeUILUE;UOD pIjOs ULe;UOD S|1O MON-EL astvwaanul Gaabipaien “seat? oe ay} Seyoeal ainssaid wa}sAs ayy |IJUN [10 ssed pue uedo jou Op SeAjeA Jol10y ZL asrwafsnu) ‘duind e jo @pis uopons ay uo suna20 Aju UoHeWAES“LL asTv4anuL, dosp insseid ayuyep e ayeas9 JsNW anjeA Jarja1 2Be}S-Omy e U! 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CYAMOd INT SILWHM. Y3MOd GINS smo.iieds —" ANRNHNNHNAHKHNAHRAHRARANRARANKRAKRARAKRARKRANRARAAARARARARN _—— Fd sparrows FLUID POWER | Why Use H Once Bernoulli came on the scene pressure was very much seen as units of vital energy, that is to say, the magnitude of pressure at the actuator would determine the force transmitted However, Bernoulli discovered that to move the fluid within the pipe work would required energy even before it reached the actuator and therefore this would result in less than 100% at the output end of the system. Suddenly EFFICIENCY and LOSSES were being talked about. Pressure Gradient Factors affecting Pressure Drop + Flow rate + Pipe dimehsions /configuration + Pipe roughness + Type of and condition of fluid + Nature of the flow. Once this was discovered and the factors affecting the pressure losses then it could be accounted for and in some cases kept to 2 minimum, but it existed wherever a flow of fluid occurred. It represented a loss of useful pressure and would be converted in to other forms of energy such as heat and noise resulting in a reduction in overall transmission efficiency. Its worth remembering at this stage that this represent a LOST COST. GENERAL OVER VIEW Why Use Hydraulics? + It is one of the most flexible and controllable means of transmitting power + It offers a high power density (A visible small unit can in fact transmit a large power) + With the interface of electricallelectronic control its application is now extensive involving both mobile and static applications, offshore, marine, steel production, plastic moulding, transport, leisure, food gathering and packaging, pressing and forming, civil and aerospace THE LIST IS ENDLESS. HYDRAULICS IS AN ENABLING TECHNOLOGY SPECIFIC FEATURES * Actuator speed control (system output) can be controlled over a wide operating range, acceleration and deceleration can be applied effectively + Reversibility is easily dealt with and actuators can be reversed instantly without damage. + Overload protection can be installed and strategically positioned to safeguard both the system and individual components + Pressure control devices can be used to limit actuator torque and forces transmitted + Will handle an extensive range of loads and demand changes and can stall without damage to the system or components. + Systems are self lubricating + Can be employed with a range of special fluids to accommodate health and safety issues. + Can operate in a range of environments and ambient temperatures... + Operation and control by the operator can be effortless. + A system can be readily extended and modified to accommodate additional services and can in most instance fit the space provided S 7 2008 National F conte ci ARNRARARARARARARARRARARARARARARARAARARARARARAR aera a sparrows FLUID POWER CONTINUED + In general fluid power systems use less moving parts than comparable electrical or mechanical systems and in most instances ‘simpler to maintain and operate. SOUNDS TOO GOOD TO BE TRUE? Hydraulic systems do have some inherent problems, such as LEAKAGE. However, lets put the record straight in your mind at this point. HYDRAULIC SYSTEMS DO NOT HAVE TO LEAK. The use of compatible seals, pipes, hoses and connectors together with installation Procedures all play a vital part in overcoming this stigmatism that hydraulic systems leak Contamination control is in many instances the vital ingredient that assures the success and longevity of a hydraulic system and this will in some case result in a change in current working practices with a greater around emphasis on ingression prevention. The skills. knowledge and competence levels of maintenance staff are very important when it comes to fluid power systems. Taking a proactive approach to managing systems is correct and ensuring that installation, commissioning, testing, modifications and adjustments are made by people who understand the system in question. There is no room for the HIT and MISS approach. Even the best designed system can be defeated by poor maintenance. Hydraulic systems can be dangerous and pressure must be treated with respect The effect of a leak under pressure can be devastating to human flesh NEVER WORK ON SYSTEMS: * without personal protective clothing. + before ensuring that all trapped pressures are dissipated. Sorry to be so GRUESOME at this early stage but you only have one chance. opyrigh — a sparrows FLUID POWER The HSE has identified 5 STEPS to RISK ASSESSMENT and they are as follows: 1. LOOK FOR THE HAZARDS ~ your experience and knowledge of the system is critical at this stage together with the nature of the work to be carried out 2. DECIDE WHO MIGHT BE HARMED AND HOW- at this stage consideration must be given to the safety of all those involved and nearby the work being carried out. Good communications are important throughout. 3 EVALUATE THE RISK — decide whether existing precautions are adequate or more should be done. As everything been done to reduce risks as far as reasonable practicable, » together with instructions and adequate procedures put in place RECORD YOUR 4 RECORD YOUR FINDINGS - write down your findings, the hazards identified, actions taken and conclusions made to reduce alll possible risks to personnel At this stage a suitable checklist / chart should be produced and there are many different styles in use shown is a typical example fiesaice | tecers, eereons [Raines] Control Measures | Residual Risk identified] Effects | at Risk iM “| Actions Required 41. Probability 1-6 2 Severity 1-6 = Revised Probability multiplied by Revised Risk Rating a cath see control _ procedures have been applied 5. | sREVIEW AND ASSESSMENT AND REVISE AS NECESSARY — Periodic review against current practices or if modifications or new equipment has been installed. This will require an action Putting in place to update the RISK ASSESSMENT PROFILE Regular review of the present systems identify their effectiveness against current practices. 10 —— a sparrows FLUID POWER Your role is to manage and maintain fluid power systems, keep them operational and productive. Your role involves regular checks and inspections for abnormalities against what is considered to be the NORM. You will be involved in : + Visual inspections + Checking the condition of pipes and hoses for leakage, abrasive wear, damage and movement around the hose connection. + Checking noise levels, * Checking for vibration * Cheeking for abnormal levels of heat + Chécking filter indicators + Checking machine operation ( time/speed/sequence/performance.) + Recognising symptoms associated with changes in performance and understanding the cause. + Adjusting the controls associated with machine performance and knowing the outcome. + Checking the security and position of guards + Checking exterior cleanliness of system and work area * Writing accurate reports on all actions taken and planning work accordingly + Communicating with other staff over a range of technical levels, WHAT DO YOU SEE WHEN YOU LOOK AT A HYDRAULIC SYSTEM? When the machine is switched OFF, you are viewing the exterior shell of a lifeless system. When the machine is switched ON, you are viewing the exterior shell of a live system in a standby condition. When the machine services are OPERATIONAL you are viewing the exterior shell of a live and often potentially dangerous system. This view of the exterior shell tells us very little, we need to dig deeper into the heart and circulatory system to better understand the function and operation of the individual components. THIS IS ULTIMATELY DEALT WITH BY STUDYING THE CIRCUIT DIAGRAM and breaking it down in to individual operations from start up to the full sequence of operations with a cycle of events. LETS NOW STUDY HYDRAULIC SYMBOLS, the shape, construction, terminology and control features. This will enable YOU to improve your ability to read and interpret circuit diagrams and to break them down in to their various operations. ANNNNNANAANAARNANKRANRARARARARARARARARARRAR —— sparrows FLUID POWER Lets use this open circuit to introduce HYDRAULIC SYMBOLS To enable Engineers to communicate and understand the circuitry associated with hydraulic systems there is an INTERNATIONAL STANDARD for symbols (ISO 1219 /1). Circuit diagrams enable the reader to identify the valve type and function and in some cases, their locations relating to other components. The symbols do not identify component size or their actual position on the machine but the symbols do provide vital information relating to configurations and flow path connections. The circuit diagram is a vital tool through out the life of a system and should be kept up to date at all times should any modifications or changes be to the system. Circuit diagrams often include technical data relating to component settings and performance. The circuit diagram becomes a very important document when carrying out fault-finding procedures. a 12 18 National Fluid Power Centre (UK) ee sparrows FLUID POWER Typical Open Circuit- NAME THE COMPONENTS Recognised as follows: 4, olor 2. wasralle Myde. pump ville pos. wert uf 3. towle 4, ress. Celie 7 Be tye taki Iv (ateucid ar Dew) adtelec fore could TPA Cylinder wily cushion 8. W/o pirehrucl ww (tos operl. phi toaded) 9. gor. tuahOr 10. Flor Ane «outa YY eo 14 1. wot 12 yucky, one Cy pom) al Fluid Povier Centre (UK) and Sparrows Fuld Power - All rights a a sparrows FLUID POWER Multiple Circle ROTARY FLOW DIVIDER The pump-motor symbol is combined at this stage and represents a rotary flow divider. The mechanical link between the rotary sections ensures that the distribution of fluid is a product of the displacement of each section Refer to Launch and Recovery Circuits) Single squares Pressure control valves cover a PRESSURE CONTROLS | range of applications including the following functions: Pressure relieving, reducing, unloading, counterbalance and sequence control and represent normally closed or normally open configurations. Periodically measuring and recording pressure, flow and temperature is a vital part of the regular health and performance mentoring of all priority systems which should be part of your proactive maintenance programme. P Q ir Diamonds are With machine performance dependent upon the CONDITIONING UNITS | 9Uality of the hydraulic fluid, the condition of the fluid is also vital. The cleanliness level of the fluid and its operating temperature must be effectively controlled within recommended limits if the performance of the system is to be maintained. - F c H Flow control Where ever actuator speed is to be controlled the use of flow control ! Y\3 + valves playa vital role. Choosing the areas * correct valve for a particular application is vital to the system performance. 16 National Fluid Power Centre (UK) and Sparrows F — a sparrows FLUID POWER Multiple squares Direction control valves fall into two categories: DIRECTION CONTROL | * ON- OFF, some times termed bang- bang control, in which the valve operates to and from dedicated a spool position. + Where it is considered necessary to improve system performance the use of proportional control valves becomes apparent and the additional lines included on symbol represent the infinite positioning of the spool under the influence of the proportionally administered control signal. This symbol can now be be interpreted as providing both direction and flow control. Where proportional DCVs are employed, many include the addition of load sensing. The symbol for such a valve initially appears complex until the various ports are clearly identified. The symbol shown represents a closed centre DCV in which both the service ports and the load sensing connections are drained to tank when the valve is in the neutral condition ISO equivalent This symbol has the same layout of external ports as the valve above but the centre condition is different. “A" and “B" ports are blocked in neutral L Xx Oo and the LS lines are once again drained to tank. 1SO equivalent 17 ; ANRARARARARARARARARRARARARANRARARARARAANRARAR —— ea sparrows FLUID POWER ~ the inline check valve symbol shown allows flow on one direction only. Where a reverse flow of cil is required the check valve must be lifted from its seating by applying a pilot signal to the pilot piston via the “x” port. Inline Double Pilot Operated Check Valve Pilot Check Valve (pilot to open) and (pilot to close) Other Symbols in use Shuttle valve e Self sealing coupling (Normally representing a test point connection) One way flow control. (check valve allows free flow in one direction) Hose burst protection valve (closes down if hose burst occurs in line 2, otherwise valve is non-intrusive) ria 18 All rights reserved — a ae sparrows Pressure Reducing Valve i FLUID POWER This is a normally open valve. Pressure in port “A” is only allowed to build up to the setting of the valve, at this stage the valve is piloted into a closed condition. The “Y" port connection drains the valve spring chamber of any internal leakage. The valve can also take up a third position (A-T) acting as a relief valve within the “A’ port The pressure reducing valve forms the basis of the joystick oil pilot control valve used to initiate the movement of the main spool of a proportional DCV (this is shown in symbol format) Over centre counterbalance valve Actuator nal Fluid Power Centre (Uk __. Remote Pilot This valve provides a non-intrusive action whilst the remote pilot maintains a positive signal able to hold the valve open. The valve will react providing a back pressure braking action if the remote pilot falls below the required leve. 19 ARARRARARARARARRARARAAARARARRARRARARARAR —— ABBR sparrows FLUID POWER Let us now investigate the BASIC HYDRAULIC Principles that underpin the operation of all hydraulic systems. ‘As we have already stated, hydraulics is a very effective means of transmitting power. Understanding that process and how it is affected by outside elements and the components parts is an extremely important part of your knowledge "NEED TO KNOW” How adjustments to the contro! aspects of pressure and flow is an important issue from both performance and safety. This next section will give you a thorough understanding and will take a very practical and simplistic approach starting with a simple process model and progressively building this up to that of an operating system. At this early stage lets become familiar with the 7 Basic Rules and move on from there. 1. FLOW MAKES IT GO 2. PRESSURE PROVIDES THE PUSHING FORCE 3. OILIN A SYSTEM ALWAYS TAKES THE PATH OF LEAST RESISTANCE 4. PRESSURE IS A MEASURE OF THE RESISTANCE TO FLOW 5. FOR OIL TO FLOW IN ANY SYSTEM THERE MUST ALWAYS BE A PRESSURE DIFFERENCE 6. THE GREATER THE PRESSURE DIFFERENCE THE GREATER THE FLOW POTENTIAL, 7. WHEN OIL FLOWS FROM A HIGH PRESSURE TO A LOW PRESSURE WITHOUT DOING WORK HEAT IS GENERATED You need to remember these for the rest of your working life and bring them to mind at every level from maintenance, to modifications to testing to that of checking the health of a system to thatof fault diagnosis. These are the 7 COMMANDMENTS. 4 a nt 2008 National Fluid Power Centr ARANRARARAARARARARARRARARAARARARARHRARANHRRARAR —— AEE sparrows FLUID POWER Basic Hydraulic Principles Its starts with the PRIME MOVER providing the input POWER Fixed SPEED —_ The ENGINE is considered a variable speed unit whilst the Variable SPEED ™ajority of electric motors in common use are fixed speed devices The out put power from the prime mover is a combination of TORQUE and SPEED. We connect to the prime mover a pump which in turn converts the mechanical power to hydraulic power, a combination of PRESSURE and FLOW Flow Meter The hydraulic power of the pump can be quickly assessed by multiplying the size of the pump (displacement) by the pump shaft speed and dividing the answer by 1000. This will give an output in litres per minute (Ipm) However, this is a theoretical value. The actual flow rate will be less than this due to the internal leakage and the oil leaving the pump at the case drain Internal leakage is necessary to ensure the moving parts are lubricated but excessive leakage affects the overall system performance. More about that later vr 22 —_ —— meee sparrows FLUID POWER This represents the INPUT TO THE SYSTEM Torque & Speed "IN" Pressure & Flow “IN” Pressure pate Torque & Speed “OUT” eFiowk Our Force & Velocity “OUT” a Gearlorbit Radial piston | Axial Piston Piston ra Mill standard cvlinder 23 tre (UK) and Sparrows Fluid Power All rights a ae sparrows FLUID POWER Torque & Speed “IN” POWER OUT Pressure & Flow “IN” Pressure _ A & Flow “OUT” “Torque & Speed “OUT + Force & Velocity “OUT” If we examine the basic model of the hydraulic system as a power transmission process we suddenly realise that ‘power is nothing without control “ At this early stage of the basic understanding of hydraulics systems we need to be conscious of PRESSURE and FLOW and the ways in which they are to be controlled. This concern will be linked to SAFETY as well as that of PERFORMANCE, too much pressure can result in a dangerous situation for both the system and the people working with it, whilst insufficient pressure will reduce the performance potential of the system. POWER IN POWER OUT Torque & Speed “IN Pressure & Flow “IN” POWER IN Pressure riert & Flow “OUT” “Torque & Speed “OUT” + Force & Velocity “OUT” If we add PRESSURE CONTROL to our model we now have a built in safety - device if the valve is a pressure relief valve. Another fundamental principle states PRESSURE PROVIDES THE PUSHING FORCE 24 sparrows FLUID POWER Effective AREA Effective Oil PRESSURE Radius FORCE The torque transmitted in this case is a product of FORCE x RADIUS and the force is generated by the magnitude of the oil pressure acting upon the surface area of the gear, in the case of a vane motor or fixed displacement piston motor the same principle would apply From this simple explanation it can be seen that the torque potential of the motor is related to pressure and effective surface area on which the oil acts. Therefore adjusting the pressure would change the torque. We vary rarely describe a motor in terms of AREA. The size of a motor linked specifically to the effective area is termed DISPLACEMENT. If we were to install a motor with a larger displacement this in turn would increase the gear or vane width, therefore exposing a larger surface area on which the oil would act. Displacement in relationship to motors represents the amount of oil supplied to ‘the motor to turn the output shaft one revolution. Displacement is normally expressed in cm*/ revolution. “Motor Sizes in a manufacturers catalogue are expressed in these units. Therefore a size 200 motor would represent 200 cm* rev. LETS NOW LOOK AT THE FACTS. + MOTOR TORQUE IS PROPORTIONAL TO DISPLACEMENT + MOTOR TORQUE IS PROPORTIONAL TO PRESSURE 25 ANNNNANANANANANNAANRNANRARANRARARARARARRARR. — a sparrows FLUID POWER Relief valve set at 120 bar Torque & Speed Motor Size ( 200 cm*/revolution) Torque is the rotary force transmitted at the motor output shaft and the level of output torque will governed ultimately by the setting of the pressure control, in this case a direct operating relief valve set at 120 bar The two factors that are considered when calculating the torque capability of a motor are: * Motor size (displacement in cm*/rev) in this example motor size = 200 cm*/rev. + Limiting pressure ( in this example it is 120 bar) SO LETS TRY A SIMPLE CALCULATION Motor Torque (Nm) = Motor size x Pressure drop across motor 207 200 x 120 201T 382 Nm Lets examine the results a little closer. Torque is a product of motor size and pressure, therefore the maximum torque tramsmitted before the motor finally stalls will be dominated by the setting of the relief valve or equivalent. If the motor is a variable displacement unit then changes in displacement will also affect the torque r 26 4 Sparrows Fluid Power - All rights reserved National Fluid Power Centre sparrows Level 1 Hydraulics FLUID POWER Basic Hydraulic Pri Lets now consider MOTOR SPEE! Flow Meter Symbol Relief valve set at 120 bar Torque & Speed — Load on Motor Motor Size ( 200 cm*/revolution) Flow rate to motor = 20 litres per minute Under ideal conditions based upon the motor size and flow rate supplied to it we can quickly calculate the motor speed as follows: MOTOR SPEED = Flow rate to motor x 1000 20 Ipm x 1000 Motor displacement (size) 200cm? /rev ANSWER = 100 RPM However, motors leak internally as they are subjected to higher load pressures and this is also affected by changes in oil viscosity and internal wear. The term associated with leakage and motor performance is VOLUMETRIC EFFICIENCY. see next page Motor Speed fe Typical Motor Performance ) in respect to speed Ideal (geometrical Slippage rates increase as the load on the motor also increases resulting in a lower output shaft speed. Load induced pressure 27 ANNNANNARANRANARARANHRAKRRANARARARARARRKRARARR sparrows ———— ye FLUID POWER If the motor at a particular induced load pressure was found to be operating at 90 tpm the cause may relate to the following: The leakage from the motor relating to a volumetric efficiency of ......... 2% 2. The induced load pressure has reached the cracking pressure of the relief valve and speed is being lost due to both these potential leakage paths In either case the motor and / or the relief valve will experience a rise in temperature. WHEN OIL LEAKS IN THIS WAY USEFUL ENERGY IS CONVERTED IN TO HEAT ENERGY AND THE APPROXIMATE RATE OF TEMPERATURE INCREASE IS 0.7° Celsius rise for every 10 bar pressure drop. Fundamental Principles State: When oil passes from a high pressure to a low pressure without doing work HEAT IS GENERATED i 28 ae sparrows FLUID POWER The torque calculated is the theoretical value. Due to internal resistance of the motor which is a combination of mechanical friction and fluid viscous drag, energy is absorbed in overcoming this during both the initial start up (breakout torque and during continuous running. Therefore the ACTUAL RUNNING TORQUE available is always less than the value calculated. This is normally relating to what is termed motor torque or mechanical efficiency. Values very much vary upon the type of motor in use.

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