Hydraulics Training

E.I.S
 Why Choose Hydraulics
Alternatives Hydraulics
• Pneumatics :- Low force- • Vast range of force
simple response- capability
• Mechanical:- • Responsive
• Electro-Mechanical:- • Versatile
• Resonance Systems:-
 Hydraulic System Components
• Pumps
• Filters
• Ring Mains
• Coolers
• Actuators
• Valves
• Controllers
• Safety
 Hydraulic Pumps
• FIXED PUMPS deliver oil at constant flow and
pressure, VARIABLE PUMPS deliver oil at
variable flow and pressure depending upon
system demand.
• GEAR PUMPS

• PISTON PUMPS
 Oil and Filters
• New oil is dirty (25μ), typical
pump filter 5μ, manifold filter
3μ, servo valve filter 1μ.
• Contaminants (solids + water)
• Modern oils – additives include
Lanolin & Ammonia
• Good filtration monitoring is
better than regular oil changes
Ring Mains

• Ring mains are used to distribute oil from the

pump to a test facility.
• Typically 150mm bore steel pipe for main run
and 30mm dia. steel pipe to manifold blocks
• Actual pipe size depends on flow requirements,
but typical flow velocity is 5m/s
 Cooling Systems
Oil Temperature <55 C to prevent
additive breakdown
• Heat Exchangers
– Bowman tube type use water to
extract heat from oil.
– Air fan systems cool the oil
circulating in the radiator.
• Main considerations:-
– Running costs
– Environment (noise, legionela)
– Efficiency
 Hydraulic Actuators
• Linear Type
– Static or dynamic
– Double or single acting
– Equal area or compound
– Fixed or swivel mountings
• Rotary Type
– Static or dynamic torque
– Displacement depends on
number of vanes (typically
100 degrees for a twin vane)
 Servo Valves
• Provide closed loop control
of an actuator
• Valve size depends on flow
and response requirements

2 stage servo valve

 Accumulators
• Accumulators are energy stores

• They enable the supply circuit to

respond more quickly to any
temporary demand and to smooth
pulsations.

• This means that the pump doesn't

need to be so large to cope with
extremes of demand

• Accumulators should be positioned

as close as possible to the hydraulic
actuator
 Transducers
• Load

• Position (linear
or angular)

• Strain

• Acceleration
 Servo Controllers
• Can be Analogue or Digital, normally 10V fsd
• P.I.D (Proportional, Integral, Differential)
control.
• Feedback can be Load, Strain, Position or
Acceleration depending on the test spec.
• Signal output types:-
– Static
– Simple constant amplitude
– Complex real time
 Safety Systems
• Oil Supply
– Pressure
– Temperature
– Filtration
Outer
• Control Inner

– Limits Inner
Outer
• Mechanical
– Guarding
– Hoses and connections
 System Specifications
• Test Requirements
• Actuator Sizing / Performance Calcs.
• Oil Flow Requirements
• Cooling Requirements
• Control & Monitoring
• Electrical Supplies
 Environmental Considerations
• Floor Loading
• Bed Plates
• Seismic Blocks
• Ventilation
• Noise & Vibration
• Accommodation / Access
• Health & Safety
 Practical Example
• Test Requirements
• Bi Axial Fatigue Testing on
Rubber Isolation Mounts

• Typical Test Requirement

• Vertical load 25kN, 40 mm at

5 Hz

• Longitudinal load 35kN, 4mm

at 10Hz
Leaf Spring Suspension

Pot Hole
Brake Event
POT HOLE BRAKING MEASUREMENTS
Test Schematic

Av Flow Vert. = 88 Litres / min

TOTAL FLOW = 106 Litres / min

Vert
Av Flow Long. = 18 Litres / min

Long
BASIC HYDRAULIC CIRCUIT
pressure
pump return

drain
lcu

Distribution manifold
Controller
 Controller Selection

Static Test

Mono-frequency cyclic
fatigue test
Block Loading cyclic
fatigue test

PSD Shaped random fatigue

f test

Service load simulation

fatigue test
Summary of Considerations

1. What components are going to be tested (now & future)

2. What is the complete test specification (simple or complex)
3. How are the results to be presented
4. Details of site installation (space, power supplies)
5. Hydraulic installation (Cooling, hose lengths, cables)
6. Complete equipment list for supply
7. Calibration requirements
8. Training requirements for engineers and technicians
9. Installation & commissioning agreements
10. Acceptance test details