HYDRAULIC SYSTEMS

Hydraulic mechanism of
Acme cutting machine
What is hydraulics???

 It is a topic of science and engineering

dealing with mechanical properties of liquids.
 Fluid mechanics forms the theoretical
foundation for hydraulics.
 Fluid mechanics is the study of how fluids
move and the forces on them
 Fluids include liquids and also gases.
Pascal’s principle and hydraulics.

 Hydraulic systems use a incompressible

fluid, such as oil or water, to transmit forces
from one location to another within the fluid.
 The basic principle behind this system is the
Pascal’s law.
 It states that “when there is an increase in
pressure at any point in a confined fluid,
there is an equal increase at every other
point in the container.”
Hydraulic drive system.

 Cutting machines uses the science of

hydraulics in the form of a drive system to
transmit the power.
 Hydraulic or hydrostatic drive system or
hydraulic power transmission.
 This system makes use of hydraulic fluids
under pressure to drive the machinery.
Parts of the system.

 The hydraulic drive system generally consists of:

*Generator part of the transmission generally a hydraulic
pump driven by a electric motor.
*Valves, filters, piping etc. to guide and control the system
*Motor part of the transmission a hydraulic motor or hydraulic
cylinder to drive the machinery.
Hydrostatic means that the energy comes from the flow and pressure
and not from the kinetic energy of the flow.
Pascal’s principle.

 Pascal's law is the basis of hydraulic drive

systems.
 As the pressure in the system is the same,
the force that the fluid gives to the
surroundings is equal to pressure x area.
 In such a way, a small piston feels a small
force and a large piston feels a large force.
Cont….

 Most hydraulic drive

systems make use of
hydraulic cylinders
where a small torque
can be transmitted in to
a large force.
Hydraulic cylinders

 Hydraulic cylinders (also called linear hydraulic

motors) are mechanical actuators that are used to
give a linear force through a linear stroke
 They give pushing and pulling forces of millions of
metric tons with a simple hydraulic system.
 The cylinder consists out of a volume in a piece of
iron with a plunger pushed in it and sealed with a
cover. By pumping hydraulic fluid in the volume, the
plunger is pushed out with a force of plunger
area * pressure.
Cont….

 More sophisticated cylinders have a body with end

cover, a piston-rod with piston and a cylinder-head
 The cylinder shell normally has hydraulic
connections at both sides. A connection at bottom
side and one at cylinder head side.
 If oil is pushed under the piston, the piston-rod is
pushed out and oil that was between the piston and
the cylinder head is pushed back to the oil-tank
again.
Hydraulic motor

 The hydraulic motor is the rotary counterpart of the

hydraulic cylinder.
 Conceptually, a hydraulic motor should be
interchangeable with hydraulic pump, because it
performs the opposite function
 However, most hydraulic pumps cannot be used as
hydraulic motors because they cannot be .
 Also, a hydraulic motor is usually designed for the
working pressure at both sides of the motor.
Hydraulic valves

 These valves are usually very heavy duty to

stand up to high pressures.
 Some special valves can control the direction
of the flow of fluid and act as a control unit for
a system.
Acme cutting machine
Clamp

 The clamp is hydraulically operated.

 The clamp can be brought down by means of
a foot peddle manual cycle of operation or
during the automatic cycle of cutting
operation by pressing two cut buttons
simulataneously.
Working

 In both the cases, solenoid valves are energized

which result in the movement of the piston outside.
 The piston is connected to a ‘Y’ section.
 As arm A is pushed out by the piston, arm B
descends down.
 The clamp is connected to arm B and hence it
descends along with the arm B
 The spring is now under the tension
Cont....

 When the clamp is to be released, the solenoid

valves are de-energized and the piston is no longer
pushed out.
 The spring under tension now assumes its initial
position thus pushing the arm A inwards and hence
the piston inwards.
 This causes arm B and hence the clamp to ascend
upwards.
 The stroke of the piston determines the pressure
applied by the clamp.
Cont….

 This can be regulated by adjusting the relief valve by

means of an adjusting knob provided.
 Clockwise rotation of the knob increases the
pressure and the counter clockwise decreases the
pressure.
 The clamp pressure range from 150-3000kg.
 The entire mechanism requires a power of 4 HP
Hydraulic circuit

 Clamp descending is possible in two ways as before.

 Manual cycle: when the foot pedal is operated, the
electrical lead from FSW energizes solenoid valve
SV1so that the fluid pushes the piston rod out, thus
bringing ht e clamp down.
 Automatic cycle: when the two cut buttons are
presses simultaneously, electrical leads energize
solenoid valve SV2 thus causing the clamp to
descend.
Filling up the hydraulic tank.

 The main cover is removed first.

 The recommended hydraulic oil(E38) is filled
into the power pack unit, provided in the right
side leg of the machine, through the opening
provided in front of the leg, till the oil is visible
through an oil level indicator.
Maintenance

 Contamination in the form of a solid, liquid or

gas will be detrimental to the hydraulic
system
 The source of contamination may be
 Assembly or machine fabrication
 The system’s operational fators
 Careless maintenance and service practices.
Some problems confronted

 Lack of full pressure in the system.

 No pressure develops in the system.
 Actuating cylinder fails to develop full speed.
 Erratic motion of an actuating cylinder.
 Actuating cylinders fail to move.
 Excessive noise during operation.
 Electric motor driving the pump keeps kicking out.
 Stator wear, rotor wear.
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