Clinker cooler POLYTRACK® – function of the hydraulic

system
Training PODFA
New Kiln 7 Dry Line Project - JSC Podilsky Cement / Ukraine
November 2010

Polys ius
POLYTRACK® – Hydraulics

1. Arrangement drawing
and
2. Mode of functioning

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
1. Components 1.1 Tank station
1.2 Drive station
1.3 Hydraulic cylinder unit

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
Item 1 Oil tank
1.1 Tank station Item 3 Oil level check

Item 4 Temperature control

system
Item 5 Oil heating system
29 37
Item 6 Oil cooling system
38 30 Item 10 Tank pump
Item 14 Oil filter
28 36 Item 22 Feed oil pump
6
48 33 14
Item 23 Control oil pumps

Items 36, 28 Oil filters

Item 33 Diaphragm
10 accumulator
3 4 Item 48 Bladder
accumulator
22 23 Items 29, 37 Pressure
1 5 switches
Items 30, 38 Pressure
valves

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
1.2 Drive station

Item 51 Main pump with

68
adjusting cylinder

57 Item 63 Valve block

68
63
Item 57 Proportional 3-way
pressure reducing
valve
51
Item 68 Pressure sensor

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
1.3 Hydraulic cylinder unit

81
F
Item 80 Cylinder

D Item 81 Flush valve

80 80 Item C Position measuring device

C
Item D Transport track
Item F Flushing pipe

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
6 Polysius

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POLYTRACK® – Hydraulics
2. Mode of functioning

Principle of functioning of the hydraulic drive

The hydraulic drive operates on the closed circuit principle, i.e. the operated
transport track is held by two cylinders between two pressurised oil columns that are moved by the main pump
(axial piston pump).

The volume flow and also the delivery direction of the main pump are adjustable.

The direction and speed applied by the pistons are transmitted to the pressure control valve by the control
system in the form of a signal. This pressure control valve transforms the signal into a proportional pressure
value, which affects the adjusting device of the main pump and rotates this accordingly.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2. Mode of functioning
2.1 Filter and cooling circuit
with discharge and filling spouts,
with oil filter,
keeps the oil at operating temperature

2.2 Control circuit

auxiliary power for controlling the valves of the main pump

2.3 Main circuit

for moving the transport tracks

2.4 Feed oil circuit

replaces the unavoidable oil losses in the main circuit

2.5 Flushing cycle

ensures the exchange of a large quantity of hot oil in the main circuit
Clinker cooler POLYTRACK® – function of the hydraulic system
Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.1 Filter and cooling circuit Toil < 20°C
Backflow for feed and control oil Heater on,
Backflow on
Toil > 35°C
Heater switches off
Toil > 45°C
Cooling system on
Toil < 40°C
Cooling system switches off
Oil cooler
(coolant is water)
Discharge spout

Filling spout

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.2.1 Control circuit
Towards main pump.
Pressure switch.

Control oil filter with Pressure limiting valve

differential pressure monitor. (70 bar).

Diaphragm accumulator
with pressure limiting valve
(100 bar)
and 2/3-way control valve
for maintenance work.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.2.2 Control oil circuit
Proportional valve in
direction A.
Electrical signal proportional to
control oil pressure.

a b

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.2.3 Control oil circuit
Proportional valve in
direction B.
Electrical signal proportional to
control oil pressure.

a b

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.3.1 Main pump – No-load operation 1. No-load operation.
• Main pump runs, but
in no-load condition.
• Oil in the piping is
unpressurised and not
moving.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.3.2 Main pump – Movement in direction A 2. Movement in direction A.
• Main pump runs in position A.
• Oil flow in direction A.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.3.3 Main pump – Movement in direction B 3. Movement in direction B.
• Main pump runs in
position B.
• Oil flow in direction B.
B

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.4.1 Feed oil circuit Towards main pump.

Pressure switch

Control oil filter with

differential pressure monitor.

Bladder accumulator
with pressure limiting valve
(100 bar) and valves for
maintenance work

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.4.2 Feed oil circuit – Main punp, no-load operation 1. No-load operation
• Main pump runs, but in no-load
condition.
• Oil in the piping unpressurised and
not moving.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.4.2 Feed oil circuit

This valve block controls the

feed oil supply in the
main circuit.
B

The non-return valve on the

pressure side of the main
pump is closed.

The non-return valve on the

suction side of the main pump
is open, and oil is fed into the
main circuit.

Feed oil.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.5 Flushing cycle

To ensure an exchange of oil in the long pipelines between the drive station and the cylinder unit during the
manufacturing process, flushing cycles are started at regular intervals.

For flushing, the transport track is moved to the mechanical end position of the return stroke and the flush
valve is opened.

The flushing time is fixed at 10 seconds in the control system.

The flushing intervals can be set at will at the control panel. As standard, the intervals are set at 30 minutes.

A flushing cycle is activated before every start during continuous operation.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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POLYTRACK® – Hydraulics
2.5 Flushing cycle Flushing cycle
• Pumps move the

transport tracks into the

return position.
• Flush valve open.

• Main pump runs in

direction A.

• Exchange of oil in the piping.

Clinker cooler POLYTRACK® – function of the hydraulic system

Training PODFA
November 2010
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Clinker cooler POLYTRACK® – function of the hydraulic system
Training PODFA
November 2010
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