Hydraulics Basics, Pumps & Accessories

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1.1

Hydrostatic pressure

Hydrostatic pressure is the pressure created above a certain level within a liquid as a result of the weight of the liquid mass. Hydrostatic pressure is not dependent on the shape of the vessel concerned but only on the height and density of the column of liquid. Hydrostatic pressure can generally be ignored for the purpose of studying hydraulics (exception: see topic 2). 1.2 Pressure propagation If a force F acts on an area A of an enclosed liquid, a pressure p is produced which acts throughout the liquid (Pascal's Law). Hydrostatic pressure has been ignored here. The term pressure propagation is also used to mean the pulse velocity in liquids (approx. 1000 m/s). 1.3 Power transmission If a force F_1 is applied to an area A_1 of a liquid, a pressure p results. If, as in this case, the pressure acts on a larger surface A_2, then a larger counter-force F_2 must be maintained. If A_2 is three times as large as A1, then F_2 will also be three times as large as F_1. Hydraulic power transmission is comparable to the mechanical law of levers.

1.4

Displacement transmission (1) If the input piston of the hydraulic press travels a distance s_1, a volume of fluid will be displaced. This same volume displaces the output piston by the distance s_2. If the area of this piston is larger than that of the input piston, the distance s_2 will be shorter than s_1. Hydraulic displacement transmission is comparable to the mechanical law of levers. 1.4.1 Displacement transmission (2)

1.5

Pressure transfer (1)

The fluid pressure p_1 exerts a force F_1 on the surface A_1 which is transferred via the piston rod to the small piston. The force F_1 thus acts on the surface A_2 and produces the fluid pressure p2 . Since the piston area A_2 is smaller than the piston area A_1, the pressure p_2 must be larger than the pressure p_1. The pressure-transfer (pressure-intensification) effect is put to practical use in pneumatic/hydraulic pressure intensifiers and also in purely hydraulic systems when extremely high pressures are required which a pump cannot deliver. 1.6 Pressure transfer (2) A pressure-transfer effect also occurs in conventional double acting cylinders with single piston rod. This effect also causes problems in hydraulics. If, for example, an exhaust flow control is fitted to a differential cylinder for the advance stroke, a pressure- intensification effect results in the piston-rod chamber. 1.7 Types of flow A distinction is made between laminar flow and turbulent flow. In the case of laminar flow, the hydraulic fluid moves through the pipe in

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Hydraulics Basics, Pumps & Accessories

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ordered cylindrical layers. If the flow velocity of the hydraulic fluid rises above a critical speed, the fluid particles at the center of the pipe break away to the side, and turbulence results. Turbulent flow should be avoided in hydraulic circuits by ensuring they are adequate sized. 1.8 Diesel effect A pressure drop to the level of vacuum may occur at points of restriction, causing precipitation of the air dissolved in the oil. When the pressure rises again, oil bursts into the gas bubbles and spontaneous ignition of the oil/air mixture may occur. 1.9 Cavitation Motion energy is required for an increase in the flow velocity of the oil at a restriction. This motion energy is derived from the pressure energy. If the vacuum which results is smaller than -0.3 bar, air dissolved in the oil is precipitated out. When the pressure rises again due to a reduction in speed, the oil bursts into the gas bubbles. Cavitation is a significant factor in hydraulic systems as a cause of wear in devices and connections. 1.10 Cavitation Local pressure peaks occur during cavitation. This causes the erosion of small particles from the wall of the pipe immediately after the reduced cross-section, leading to material fatigue and often also to fractures. This effect is accompanied by considerable noise. 1.11 Input and output power Various losses occur at the individual devices within a hydraulic control chain. These consist essentially of mechanical, electrical and volumetric losses. After an installation has been in service for some time, there will be a change in particular in the volumetric efficiency of the pump, as the result, for example, of cavitation 2.01 Hydraulic power unit The hydraulic power unit (power supply unit) provides the energy required for the hydraulic installation. Its most important components are the reservoir (tank) , drive (electric motor), hydraulic pump, pressure relief valve (safety valve), filter and cooler. The hydraulic power unit may also act as a carrier for other devices (gauges, directional control valves). 2.2 Hydraulic power unit: Reservoir The hydraulic reservoir contains the hydraulic fluid required the operate the installation. Within the reservoir, air, water and solid matter are separated out of the hydraulic fluid. The size of the reservoir will depend on the practical application involved; for stationary systems, the volume of fluid delivered by the pump in 3 to 5 minutes can be taken as a guide. In mobile hydraulic systems, on the other hand, the reservoir contains only the maximum quantity of hydraulic fluid required. 2.2 Externally toothed gear pump The increase in volume which results when a tooth moves out of mesh produces a vacuum in the suction area. The hydraulic fluid is conveyed into the pressure area. The hydraulic fluid is then forced out of the tooth gaps by the meshing of the teeth and displaced into the above supply line.

2.3 Internally toothed gear pump

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the teeth, causing hydraulic fluid to be sucked in. On the other side, the teeth engage once more and oil is displaced from the tooth chambers. The design can deliver pressures of up to approx. 175 bar. Hydraulic motors represent the reverse of the function principle. 2.4 Circuit diagram: Return flow filter An oil filter situated in the return line to the tank has the advantage that the filter is thus easy to maintain. A disadvantage, however, is that contamination is removed from the hydraulic fluid only after it has passed through the hydraulic components. This configuration is often used. 2.5 Circuit diagram : Pump inlet filter With this configuration, the pump is protected from contamination. The filter is, on the other hand, less easily accessible. If these filters have a too fine mesh, suction problems and cavitation effects may occur. Additional coarse filters upstream of the pump are recommended. 2.6 Circuit diagram: Pressure line filter Pressure filters can be installed selectively upstream of valves which are sensitive to contamination; this also enables smaller mesh sizes to be used. A pressure-resistant housing is required, which makes this configuration more expensive. 2.7 Circuit indicator diagram: Contamination

It is important that the effectiveness of a filter can be checked by a contamination indicator. The contamination of a filter is measured by the pressure drop; as the contamination increases, the pressure upstream of the filter increases. The pressure acts on a spring- loaded piston. As the pressure increases, the piston is pushed against a spring. There are a number of different display methods. Either the piston movement is directly visible or it is converted into an electrical or visual indication by electrical contacts. 2.8 Water cooler With this design of cooler, hydraulic fluid is fed through tubes over which coolant (water) flows. The heat which is discharged can be re-used. The operating temperature in hydraulic installations should not exceed 50 - 60 C, since this would cause an unacceptable reduction in viscosity, leading to premature aging of the fluid. In comparison with air cooling, operating costs a higher due to the required coolant and the susceptibility to corrosion. Temperature difference of up to approx. 35 C can be handled. 2.9 Air cooler Hydraulic fluid from the return line flows through a coiled pipe which is cooled by a fan. The advantages here are simplicity of installation and low operating costs. The noise of the fan may be a nuisance 2.10 Heating element : Heaters are often required to ensure that the optimum operating temperature is reached quickly. Heating elements or flow preheaters are used for heating and preheating hydraulic fluid. If the viscosity is to high, the resulting increase in friction and cavitation leads to greater wear.

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