1 / 22

Advanced Hydraulic Testing Solutions for Engineers: Components, Applications, and Safety Systems

Explore the world of hydraulics and discover a vast range of force capabilities paired with responsive versatility. Learn about hydraulic system components, oil and filters, ring mains, cooling systems, actuators, valves, controllers, safety features, and more. Understand the importance of maintaining system cleanliness, efficient filtration, and proper oil management. Dive into the realms of hydraulic actuators, servo valves, accumulators, transducers, and controllers to enhance system performance. Discover the significance of safety systems in hydraulic setups to ensure optimal operations and prevent hazards. Gain insight into system specifications, environmental considerations, and practical examples such as biaxial fatigue testing. Uncover the intricacies of basic hydraulic circuits, testing requirements, and controller selections for various applications. Be equipped with comprehensive knowledge on hydraulic testing solutions, installation, calibration, training, and commissioning procedures for successful engineering projects.

nnichols
Download Presentation

Advanced Hydraulic Testing Solutions for Engineers: Components, Applications, and Safety Systems

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Hydraulics Training E.I.S

  2. Why Choose Hydraulics Alternatives Hydraulics Vast range of force capability Responsive Versatile • Pneumatics :- Low force-simple response- • Mechanical:- • Electro-Mechanical:- • Resonance Systems:-

  3. Hydraulic System Components • Pumps • Filters • Ring Mains • Coolers • Actuators • Valves • Controllers • Safety

  4. 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

  5. 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

  6. 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

  7. 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

  8. 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)

  9. Servo Valves • Provide closed loop control of an actuator • Valve size depends on flow and response requirements 2 stage servo valve

  10. 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

  11. Transducers • Load • Position (linear or angular) • Strain • Acceleration

  12. 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

  13. Safety Systems • Oil Supply • Pressure • Temperature • Filtration • Control • Limits • Mechanical • Guarding • Hoses and connections Outer Inner Inner Outer

  14. System Specifications • Test Requirements • Actuator Sizing / Performance Calcs. • Oil Flow Requirements • Cooling Requirements • Control & Monitoring • Electrical Supplies

  15. Environmental Considerations • Floor Loading • Bed Plates • Seismic Blocks • Ventilation • Noise & Vibration • Accommodation / Access • Health & Safety

  16. Practical Example • 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 • Test Requirements

  17. Leaf Spring Suspension Pot Hole Brake Event

  18. POT HOLE BRAKING MEASUREMENTS

  19. Test Schematic Av Flow Vert. = 88 Litres / min TOTAL FLOW = 106 Litres / min Vert Av Flow Long. = 18 Litres / min Long

  20. BASIC HYDRAULIC CIRCUIT pressure pump return drain lcu Distribution manifold Controller

  21. Static Test Mono-frequency cyclic fatigue test Block Loading cyclic fatigue test Shaped random fatigue test PSD f Service load simulation fatigue test Controller Selection

  22. Summary of Considerations • What components are going to be tested (now & future) • What is the complete test specification (simple or complex) • How are the results to be presented • Details of site installation (space, power supplies) • Hydraulic installation (Cooling, hose lengths, cables) • Complete equipment list for supply • Calibration requirements • Training requirements for engineers and technicians • Installation & commissioning agreements • Acceptance test details

More Related