VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnanasangama, Belagavi – 590018

AN INTERNSHIP REPORT

ON

“DESIGN AND ASSEMBLY OF HYDRAULIC POWER PACK SYSTEM FOR

AUTOMATION APPLICATION”

Submitted in partial fulfillment of the requirement for the award of

BACHELOR’S DEGREE

IN

TELECOMMUNICATION ENGINEERING

BY

SOURAV KARTHIKEYAN
(1BY16TE046)
Under the guidance of
Internal guide: External guide:

Dr. Raju Hajare Mr. Vedagiri Karthik

Associate Professor, Director of Operations, Assembly Wing,
Department of TE,
BMSIT&M Continental Hydro Systems

Avalahalli, Yelahanka, Doddaballapura No.39/1, West Park Road, 13th Cross,

Main Road, Bengaluru-560064 Malleshwaram, Bangalore-560003
 BMS INSTITUTE OF TECHNOLOGY & MANAGEMENT
Avalahalli, Yelahanka, Doddaballapura Main Road,

Bengaluru-560064

CERTIFICATE

This is to certify that the Internship training entitled “DESIGN AND ASSEMBLY
OF HYDRAULIC POWER PACK SYSTEM FOR AUTOMATION APPLICATION ”

has been successfully carried out by Sourav Karthikeyan of 8th semester,

bearing USN 1BY16TE046 in partial fulfillment for the award of Bachelor’s
Degree in Telecommunication Engineering, prescribed under Visvesvaraya
Technological University, Belagavi during the academic year 2019-2020.

Signature of Guide Signature of HOD Signature of Principal

[ Dr. Raju Hajare] [Dr. Seema Singh] [Dr. Mohan Babu G N]

EXTRERNAL VIVA

Name of the examiners Signature with date

1.

2.
I
 ACKNOWLEDGEMENT
I am thankful and express our heart-full gratitude to B. M. S. INSTITUTE
OF TECHNOLOGY & MANAGEMENT for providing an opportunity of
fulfilling our goals and helping to the pave the bright career path for us. The
satisfaction and euphoria that accompanies the successful completion of any task
would be incomplete without the mention of the people who made it possible and
whose constant encouragement and guidance has been a source of inspiration
throughout the course.
I would like to express my gratitude to Dr. Mohan Babu G N, Principal,
BMSIT&M, for providing us with a congenial environment to work in.
I would also wish to express my gratitude to Dr. Seema Singh, HOD,
Department of Telecommunication, BMSIT&M for her constant support and
encouragement.
I would like to thank my External guide, Mr. Vedagiri Karthik, Director
of operations, Continental Hydro Systems, India for his valuable guidance in
completion of the internship.
I would like to thank my internal guide, Dr. Raju Hajare, Department of
Telecommunication Engineering, BMSIT&M, for his valuable guidance in
completion of the internship.
I would also like to thank our Internship coordinator Mrs. Thejaswini S,
Asst. Prof, Department of Telecommunication, BMSIT&M for providing
necessary facilities for the completion of the internship.
Finally, I thank and acknowledge the immense help extended by my
parents, staff of telecommunication department and friends, without whom this
report would not have reached completion. Sourav Karthikeyan
(1BY16TE046)
II
 CONTENTS
1. ABOUT THE COMPANY 1-2
2 ABOUT THE DEPARTMENT 3-4
3. TASK PERFORMED 5-16
4. LEARNING OUTCOMES 17
5. CONCLUSION 18
BIBLIOGRAPHY 19

III
LIST OF FIGURES
2.1 Flow of functionalities of the assembly department

3.1 The first Hydraulic Press invented in 1795 AD by Joseph

Bramah, named as Bramah Hydraulic Press

3.2 Basic Hydraulic Circuit Design

3.3 Reservoir with a baffle sheet arrangement

3.4 Schematic diagram of a reservoir

3.5 Assembly of hydraulic and electric components of a power pack

st
3.6 A 21 Century In-house Hydraulic Power Pack in assembled
condition

3.7 Imported Compact DC power pack for mobile applications

3.8 Hydraulic test bench

3.9 Fields of application of hydraulic power packs

LIST OF TABLES
Table 1. Bill of materials
Table 2. Volume Calculations for a rectangular reservoir

IV
DESIGN AND ASSEMBLY OF HYDRAULIC POWER PACK SYSTEM FOR AUTOMATION APPLICATION

CHAPTER 1
ABOUT THE COMPANY
Continental Hydro Systems

VISION – “To be recognized as the bench mark in the Hydraulics industry, through Product
Perfection, Engineering Excellence and the Best customer services.”

Mission of the company:

 To jointly build with Reputed International Hydraulic Group of companies high capacity,
efficient and cost effective Products for timely and speedy delivery.

 To design and develop safe Hydraulic valves , Pumps, Cylinders, seamless piping and
Power Pack systems.

 To offer customers versatility in design and developing Hydraulic systems to meet their
exact requirements.

“CONTINENTAL HYDRO SYSTEMS”- have more than 30 years of experience in

Manufacturing & Supply of Hydraulic systems in Bangalore. The company is also associated with
Polyhydron Group of Industries to cater Hydraulic components to various applications in Machine
Tool, Defence, Mobile, Steel Industries, Wood industries, Public sectors and undertakings. They
are on to the process of continuous technological revolution in the field of Advanced Hydraulics,
having their own strategy to provide the best of services. At Continental Hydro Systems, complete
Engineering Solutions in the field of Hydraulics complying to the requirements stated in the
international standards are provided, in terms of quality products and services.

Export of equipment have been made to countries like Srilanka, South Africa and the Middle
East countries.

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The company is also authorized in distributing products of various brands,viz.,REXROTH,

DENISON, PARKER, EATON,VICKERS, YUKEN, SUN CARTRIDGES, POLYHYDRON,
HYDAC, HALLITE SEALS & HYLOC HYDROTECHNIC-ERMETTO END FITTINGS.

CUSTOMERS SERVED:

1) ASHOK LEYLAND LTD-HOSUR

2) CARGOTEC INDIA PVT. LTD.
3) LARSEN AND TURBO LTD.
4) BEML LTD.
5) BHEL LTD.
6) HINDUSTAN AERONATICS LTD.
7) NATIONAL AERONAUTICS LTD.
8) ISRO
9) CPRI
10) GLOBAL HYDRAULICS-CHENNAI.
The company has certain values with which it abides itself :

1. Be a leader and not a follower

2. Share knowledge and success with others

3. Forge local alliances wherever you go.

4. Apply only the latest design and Hydraulic codes.

5. Continually improve your products

6. Customer service makes all the difference, customers are lifetime partners, always seek a win-
win solution.

7. The longest journey begins with the smallest step, so begin with the end to mind, and focus on
the long term, not just the short term.

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CHAPTER 2
ABOUT THE DEPARTMENT
Assembly Department

Misson of the Department :“ To assemble, test and install leakage-free power pack systems for
various applications.”

Hydraulic power units are main driving components of driving system. Consisting mainly a motor,
a reservoir and a hydraulic pump these units can generate a tremendous amount of power to drive
any kind of hydraulic ram. Hydraulic power units are based on Pascal's law of physics drawing
their power from ratios of area and pressure. Heating of hydraulic oil in operation is caused by
inefficiencies. Inefficiencies result in losses of input power, which are converted to heat. If the
total input power lost to heat is greater than the heat dissipated, the hydraulic system will
eventually overheat.

Continental Hydro Systems is one of the leading hydraulic power pack manufacturers and
suppliers in India. Hydraulic power packs are hydraulic equipments with pumps, valves, motors
and other accessories that are widely used in pressers and filters. These hydraulic power packs
systems are available for both small and large duty applications. The valves of these hydraulic
power packs are specially designed and tested on various industrial standards and hence reduce oil
leakage during working. They provide these power packs in both standard and custom built designs
and also ensure that the power pack systems have rust free nature.

Functions of the Department : 1) Fabrication of reservoir

2) Assembly of Hydraulic and Electronic components with piping

3) Testing of Power pack

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Fig.2.1 Flow of functionalities of the assembly department

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CHAPTER 3
TASK PERFORMED
PROCEDURE OF TASK UNDERTAKEN:

 Design

 Sourcing of hydraulic elements and accessories

 Fabrication of reservoir

 Assembly

 Testing

Fig.3.1 The first Hydraulic Press invented in 1795 AD by Joseph Bramah, named as Bramah
Hydraulic Press

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A hydraulic system employs enclosed fluid to transfer energy from one source to another, and
subsequently create rotary motion, linear motion, or force. Hydraulic power units apply the
pressure that drives motors, cylinders, and other complementary parts of a hydraulic system.
Unlike standard pumps, these power units use multi-stage pressurization networks to move fluid,
and they often incorporate temperature control devices. The mechanical characteristics and
specifications of a hydraulic power unit dictate the type of projects for which it can be effective.

3.1. DESIGN:

• The design of a hydraulic power pack should be done with the performance of the power
pack kept in mind:

Actuator/Cylinder

Solenoid control valve

Manifold
Pressure gauge

Return line Filter

Relief valve Electric Motor
Pump
Reservoir

Fig.3.2 Basic Hydraulic Circuit Design

• At Continental, advanced engineers design hydraulic circuit diagrams using various

software tools ranging from SOLIDWORKS to AUTOCADD.

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3.2. SOURCING OF HYDRAULIC ELEMENTS AND ACCESSORIES

 Bill of Materials for a 100 bar Power Pack System:

Sl.No. Components Brand

1. ELECTRIC MOTOR (240-280 v, 1450 rpm) ABB

2. HYDRAULIC GEAR PUMP (120 lpm, 100 bar) DOWTY

3. RESERVOIR (450 liters capacity) CONTINENTAL HYDRO SYSTEMS

4. BELLHOUSING WITH COUPLING CONTINENTAL HYDRO SYSTEMS

5. RELIEF VALVE (SAFETY VALVE) POLYHYDRON

6. MANIFOLD BLOCK CONTINENTAL HYDRO SYSTEMS

7. CHECK VALVE POLYHYDRON

8. RETURN LINE FILTER HYDROLINE

9. LEVEL GAUGE HYDROLINE

10. FILLER CUM BREATHER HYDROLINE

11. SEAMLESS TUBES GANDHI TUBES

12. HYDRAULIC TUBE COUPLINGS HYLOC

13. PRESSURE GAUGE DELTA

14. RETURN LINE FILTER HYDROLINE

Table 1. Bill of materials

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 Various hydraulic brand products are used generally for high pressure customized
applications, viz.,

1) Hawe- radial piston pumps (700 bar-1000 bar)

2) Bosch-Rexroth- high pressure valves (700bar)
3) Eaton- variable axial piston pump (450 bar)
4) Yuken- vane pump ( 250 bar)
5) Hydac- pressure line and return line filters with ± 3% filtration accuracy
6) Positron- oil coolers

3.3. FABRICATION OF RESERVOIR

• The design of the reservoir should be of sufficient capacity to contain all of the fluid in the
hydraulic system with at least a 10% excess margin. For static hydraulic transmission
systems the reservoir capacity of about 4 x the pump flow/minute should be available. On
mobile units it is often necessary to have a smaller reservoir.
• The return line to the reservoir should be at the furthest end from the pump inlet feed to
allow solid particle the drop out and entrained air to be released to the open surface. The
return pipe can include a pepper pot arrangement well below the fluid surface level to
encourage dispersion of flow.
• The reservoir should be designed with a safe working level such that the pump inlet and
the system return pipe are continuously immersed at all times during the operating cycle.
The oil flow through the reservoir should be at a low rate and preferable through perforated
baffle plates to encourage air and precipitation of contaminants.
• The reservoir normally provides a cooling function, often eliminating the need for oil
cooler.
• The construction of the reservoir is generally based on a simple rectangular box with a
floor sloping down to a drain plug. The tank should have internal corners suitably designed
to ensure convenient cleaning and the surfaces should be descaled and painted with a paint
which is corrosion resistant and suitable for the oil contained. The tank should include a
sealed lid which includes a Filler/breather cap with air filter included and a sight level
gauge on the side.
• Fluid power systems must have a sufficient and continuous supply of cool, uncontaminated
fluid to operate efficiently. A hydraulic system has a reserve of fluid in addition to that
contained in the other components of the system. This reserve fluid compensates for
changing fluid levels from system operation, loss of volume due to cooling and fluid
compression from the pressure. This extra fluid is contained in a tank usually called a
hydraulic reservoir. Most reservoirs have a capped opening for filling, an air vent, an oil

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level indicator or dip stick, a return line connection, a pump inlet or suction line connection,
a drain line connection, and a drain plug.

Fig.3.3 Reservoir with a baffle sheet arrangement

• A properly designed reservoir has internal baffles to prevent excessive sloshing of the fluid
and to put a partition between the fluid return line and the pump suction line. The partition
forces the returning fluid to travel farther around the tank before being drawn back through
the pump inlet line.
• This does 3 things; it helps cool the fluid more effectively, aids in settling contaminants to
the bottom and separates air from the fluid. Larger reservoirs are desirable as all 3 of the
above benefits are further enhanced. As a rule of thumb the ideal reservoir will hold about
4 times the pump output per minute.
• The benefits of a large reservoir are sometimes sacrificed due to space limitations in mobile
systems. As a minimum they must be large enough to accommodate thermal expansion of
the fluid and changes in fluid level due to system operation.
• Reservoirs are of two general types - non-pressurized and pressurized.
• Pro power manufactures non-pressurized hydraulic reservoirs and pressurized reservoirs
operating up to 5 psi.
• Most systems are normally designed for equipment operating at normal atmospheric
pressure. This includes hydraulic systems for truck or stationary installations.

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• A typical reservoir for use in industrial installations is made of hot rolled steel plates, has
welded seams and is not commonly used for mobile operation. The bottom of the reservoir
is often convex, and a drain plug is incorporated at the lowest point.
• Most non-pressurized reservoirs are constructed in a cylindrical shape. The outer housing
is manufactured from a strong corrosion-resistant metal. To keep the fluid clean filter
elements are normally installed within the reservoir or externally to clean the returning
fluid.
• Reservoirs that are filled by pouring fluid directly into them have a strainer in the filler
well to strain out impurities when fluid is added. The quantity of fluid in the reservoir is
indicated by a direct reading sight gauge, a clear tube, or a float/dial gauge.
 Reservoirs are designed and fabricated as per customized design requirements.

 Construction of reservoirs:
1. Mild steel plates are cut by manual gas torches as per design measurements.

2. These cut mild steel plates are further welded along it’s length and breadth.

3. After welding, the reservoir’s grinding is done for chipping off extra weld materials.

4. Anti-rust coating is provided to the internal surface of the reservoir.

5. The top cover is duly machined with measured cut-outs for mounting hydraulic
components conveniently.

Fig.3.4 Schematic diagram of a reservoir

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L W H

30 IN 30 IN 30 IN

Volume = 450 liters (approx.)

1 inch = 0.0163871 liters

Table 2. Volume Calculations for a rectangular reservoir

3.4. ASSEMBLY:

• Some of the important factors that influence a hydraulic power unit’s performance are
pressure limits, power capacity, and reservoir volume. In addition, its physical
characteristics, including size, power supply, and pumping strength are also significant
considerations.
• To better understand the operating principles and design features in a hydraulic power unit,
it may be helpful to look at the basic components of a standard model used in industrial
hydraulic systems.
• As the temperature of hydraulic oil increases, input power falls – and if the total loss of
power is greater than the heat dissipated, the hydraulic system will eventually overheat.
And if oil overheats, it loses its lubricating properties and increases friction and wear on
hydraulic components, meaning hardened seals and increased wear to the system.
• Another problem caused by high oil temperatures is reduced oil viscosity – which often
leads to oil leakages. Because hydraulic components are constructed with very close
tolerances, high heat and lubrication loss can also cause severe damage or seizure.

• Final assembly of power pack:

1. Installation of electric motor duly assembled to pump with intermediate bellhousing and
coupler.

2. Piping with couplings from the pump to in-line check valve and safety relief valve with
pressure gauge monitoring

3. Further piping extended to manifold block with solenoid directional control valve to
actuate the cylinder in forward direction and later retract back to the tank.

4. After retraction, the hydraulic fluid returns to the tank through the return line filter.

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5. Filler cum breather and level gauge are fitments of the reservoir.

6. Few specific details regarding the hydraulic medium used are as follows:

• Hydraulic Medium used: Mineral oil (ENKLO-68)

• Temperature range: -20 deg. C to +80 deg. C

• Viscosity range: 10 cSt to 100 cSt

• Fluid cleanliness required: ISO 4406 20/18/15 or better

Fig.3.5 Assembly of hydraulic and electric components of a power pack

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Fig.3.6 A 21 Century In-house Hydraulic Power Pack in assembled condition

Fig.3.7 Imported Compact DC power pack for mobile applications

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3.5. TESTING:

Stage 1: Testing of reservoir

1. On completion of fabrication of reservoir, water is filled and stored into the tank.

2. The tank is then observed for 4-5 hours to check if any leakages are found.

3. Water is used instead of the hydraulic fluid due to it’s low viscosity.

Stage 2: Testing of power pack

1. The assembled power pack is tested based on few parameters such as:
Pressure

Pressure testing is a process which is done to check for any errors in the installation or
defects in the piping components.

Basically the ertected system is proof tested using the working fluid to something know
as Test Pressure (usually 1.5 times the working pressure).

Flow

To ensure correct flow rate is crucial to customer application run at the speeds expected.

Flushing

This is carried out to remove debris and contamination from all valves pipework and
reservoir internals for ensuring sufficient and smooth flow in the system.

Load holding

Systems manufactured for lifting or clamping applications where load holding for long
durations is critical to the machine performance.

Cleanliness

This test focuses on the cleanliness of the hydraulic system as any contaminants from
particles and foreign bodies entering the system can greatly affect its operating ability.

Filtration

Return line filters should be inspected and cleant regularly to ensure excess particulates
do not clog the filters and in turn affect the system performance.

Power
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Measuring the power input to a system is fundamental to confirming that the system has
firstly been designed correctly and secondly that the combination of the pressure and flow
are being achieved within parameters set by our hydraulic design engineers.

Test Temperatures

A vital system test which focuses on the system temperature in varying operating
conditions and is carried out to make sure that temperatures are within standard set
tolerances and do not exceed them when increased load is added.
The test ensures that system components do not suffer damage and wear from the increased
heat levels given off by the system, which could render a system inoperable and could
potentially result in large repair bills.

Filtration and Particulate Cleaning

Hydraulic filters work to ensure that particulate matter doesn’t find its way into the
hydraulic system. It is essential that they are inspected and cleaned regularly to ensure
excess particulate isn’t clogging the filter and affecting system performance.
Environmental conditions such as dusty workshops and foundries can affect the levels of
contaminants entering the filter, and in these situations the filters will have to be checked
more frequently and cleaned or replaced accordingly.

Fig.3.8 Hydraulic test bench

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3.6. APPLICATIONS:

Applications ( 100 bar power pack):

1. Industrial machine tool applications such as CNC/VMC.

2. Scissors lifts for material handling.

3. Hand presses for plastic injection molding components.

Applications (Higher pressure power packs) :

1. Aluminium extrusion presses.

2. Plywood industry.

3. Steel industry.

4. Rubber molding presses.

5. Deep drawing presses.

6. For marine and aeronautical applications.

Fig.3.9 Fields of application of hydraulic power packs

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CHAPTER 4
LEARNING OUTCOME
1. Gained a vast experience in the hydraulic industry and understood it’s real-
time relevance.

2. Communication and interaction with highly experienced in-house engineering

team.

3. Had a close observation of the team leader to handle critical issues and to
overcome with immediate solutions.

4. Learnt the future of advanced hydraulics scattered in numerous fields.

5. Trained well on various advanced hydraulic elements by highly skilled

engineers.

6. Became well-versed with the design, assembly and testing of hydraulic power
packs.

7. An overall personality development during the course of my professional

internship.

8. I would be able to integrate much faster into the hydraulic industry in the
future with an experience of working in a reputed organization- Continental
Hydro Systems.

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CHAPTER 5
CONCLUSION
In the duration of my internship at Continental Hydro Systems, I gained a very good exposure of
the hydraulic industry, which improved my personality to a greater height. It enhanced my
communication skills and presentation skills with team co-ordination. Apart from this I understood
the scope of the hydraulic industry and it’s various fields of applications. Thus, I had a great
opportunity to learn in depth the functionalities of the assembly department of a reputed hydraulic
network. Further, I was exposed to various international brands of hydraulic elements used in
different fields of applications. I had the privilege of working with the highly experienced
engineers and could closely observe the decisions taken by the team leader. I would finally thank
my College for giving me an opportunity to attend the internship at an esteemed company-
“Continental Hydro Systems”.

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BIBLIOGRAPHY

[1] https://www.polyhydron.com/

[2] http://www.polyhydronsystems.com/

[3] https://www.dynamatics.com/

[4] https://hydroline.com/

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