m = a. S 2 2 =. = oy = =. a 2 Ss = ao EoFluid Power Engineering This page intentionally left blankee Copyright ©2009 by The MeGnw-Til C ised Stes Copyright At of form or by ay ans, or sored sa dbase or rie ‘hepubisher Ine. Alsighis reserved Except as pei de the ‘ay be repre or cette in any os without he pce ween permiion af ISBN. oT OT LK is eBook also appens in he punt vetsion of his 42 ISBN 978-0.07-162246-2, ‘ofan ppoptintepoesiogn should We Suga ‘TERMS OF USE 1LY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCEUDING RUT N PARTICULAR PURPOSE. ‘To my wife Fatemah RafatThis page intentionally left blank ‘About the Author M. Galal Rabie, Ph.D, is a professor of mechanical engineering, Currently, he works in the Manafacturing Engineering and Production Technology Deparimen’ of the Moder Academy for Engineering and Techno! ‘ogy. Cairo, Egypt. Previously, he was 2 professor at ge, Cairo, Egypt. He is the 35 papers published in interna wurnals and presented at refereed conferences, and the supervisor of 24 MSe and Ph.D. theses.MATLAB and Simulink are rogistered trademarks of The MathWorks, Inc. See wrwemathworks com /trademarks for a list of additional trademarks. The MathWorks Publisher Logo identifies books tain MATLABY and/or Simulink® content. Used with permission, The MathWorks does not warrant the accuracy of the text or exercises in this book Thisbook’s use or discussion of MATLAB® and/or Simulink® software or related products does not constitute endorsement or spor sorship by The MathWorks ofa particular use ofthe MATLAB® and/or Simulink? software or related products For MATLAB and Simulink® product information, or information on other related products, please contact The MathWorks, Ine. 3 Apple Hill Drive Exmail info@mathworks.com Web: werw-mathworks com Contents Preface 1 Introduction to Hydraulic Power Systems 11 Introduction 12. The Classification of Power Systems 12.1 Mechanical Power Systems 122. Electrical Power Systems 123 Pneumatic Power Systems 124 Hydrodynamic Power Systems ie Power Systems ydraulic Power Systems The Advantages and Disadvantages of Hydraulic Systems 15 Comparing Power Systems 16 Exercises 17 Nomenclature 2. Hydraulic Oils and Theoretical Background 21 Introduction 22 Basic Properties of Hydraulic Oils 22.1 Visco 222 Oil Density 223 Oil Compressibility 224 Thermal Expansion 22.5 Vapor Pressure 22.6 Lubrication and Anti-Wear Compatibility 8 Chemical Stability 9 Oxidation Stability 10. Foaming 7 3 Cleanl Thermal Properties Acidity u B 1s 15 16 16 25 30 37 38 30 39 30 39 38 40 45 45Contents Hydraulic Oils 23. Classification of Hydraul 23.1 Typically Used 232 Mineral Oils 233 Fire-Resistant Fluids 24 Additives 25 Requirements Imposed on the Hydraulic Liquid 26 Exercises 27 Nomenclature Appendix 2A Transfer Functions Appendix 2B Laminar Flow in Pipes, Hydraulic Transmission Lines 3.1 Introduction 32. Hydraulic Tubing 33. Hoses 34 Pressure and Power Losses in Hydraulic Conduits 34.1 Minor Losses 3.42 Friction Losses 35. Modeling of Hydraulic Transmission Lines 36 Exercises 37 Nomenclature Appendix 3A The Laplace Transform The Direct Laplace Transform The Inverse Laplace Transform Properties ofthe Laplace Transform Laplace Transform Tables Appendix 3B Modeling and Simulation of Hydraulic Transmission Lines ‘The Single-Lump Model The Two-Lump Model The Three-Lump Model ‘The Four-Lump Mode! Higher-Order Models, Case Study 44. Cavitation in Displacement Pumps Contents 45 Pulsation of Pumps 46 Classification of Pumps 46.1 Bent Axis Axi 462 ow of Displacement jon Pumps Swash Plate Pumps with 463. Swash Plate Pumps with Inclined Pistons 4.64 Axial Piston Pumps with Rotating Swash Plate-Wobble Plate 465. Radial Piston Pumps with Eccentric Cam Ring 466 Radial Piston Pumps w Eccentric Shafts 467. Radial Piston Pumps of Crank Type 468 External Gear Pumps 469. Internal Gear Pumps 4.6.10 Gerotor Pumps 46.11 Screw Pumps 46.12 Vane Pumps 47. Variable Displacement Pumps 47.1 General 472. Pressure-Compensated Vane Pumps 47.3. Bent Axis Axial Piston Pumps with Power Contral 48 Rotodynamic Pumps 49 Pump Summary 4.10 Pump Specification 411 Exercises 4.12 Nomenclature Hydraulic Control Valves 51 Introduction 52. Pressure-Control Valves 52.1 Direct-Operated Relief Valves 52.2. Pilot-Operated Relief Valves 52.3. Pressure-Reducing Valves 524 Sequence Valves 52.5 Accumulator Charging Valve 53. Directional Control Valves 53.1 Intn 53.2 Popp 533 Spool-Type DCVs 98 100 100 103 105, os 106 os 139 Be 141 Mt M4 7 152 155 157 157 7 158Contents 534 Control of the Directional Control Valves 5.5 Flow Characteristics 5.3.6 Pressure and Power Losses in the Spool Valves 5.3.7 Flow Forces Acting on the Spoo! 53.8 DirectOperated Directional Control Valves 53.9 Pilot-Operated Direct Control Valves 54 Check Valves 54.1 Spring-Loaded Direct-Operated Check Valves 542 Direct-Operated Check Valves Without Springs 5.43. Pilot-Operated Check Valves Without External Drain Ports 544 Pilot-Operated Check Valves with External Drain Ports 545 Double Pilot Operated Check Valves 546 Mechanically Piloted Check Valves 55. Flow Control Valves 55.1 Throttle Valves 55.2 Sharp-Fdged Throttle Valves 553. Series Pressure-Compensated Flow Control Valves 554 Parallel Pressure Compensated Flow Control Valves—Three-Way FCVe 555. Flow Dividers 56 Exercises 57 Nomenclature Appendix 5A Control Valve Pressures and Throttle Areas Conical Poppet Valves Cylindrical Poppets with Conical Seats Spherical Poppet Valves, Circular Thr ‘Triangular Throttling Area Appendix 5B Modeling and Simulation of Direct-Operated Relief Valve a lel 167 169 170 in 13 15 V5 176 176 178 178 179 179 180 180 181 188 185 188, 190 191 12 183 196 197 198 Construction and Operation of the Valve Mathematical Modeling Computer Simulation Static Characteristics Transient Response Nomenclature 6 Accessories 61 62 Int Hydraulic Accumulators 62.1 Classification and Operation 62.2 The Volumetric Capacity of Accumulators 62.3 The Construction and Operation of Accumulators 624. Applications of Hydraulic Accumulators Energy Storage. [Emergency Sources of Energy Compensation for Large Flow Demands Pump Unloading Reducing the Actuator’s Response Time Maintaining Constant Pressure ‘Thermal Compensation Smoothing of Pressure Pulsations Load Suspension on Load “Transporting Vehicles Absorption of Hydraulic Shocks Hydraulic Springs ters Hydraulic Pressure Switches 6.4.1 Piston-Type Pressure Switches 642 Bourdon Tube Pressure Switches 643 Pressure Gauge Isolators Exercises Nomenclature Appendix 6A. Smoothing Pressure Pulsations by Accumulators juction Contents 199 199 201 201 202 204 207 207 208 208 231 232 235 237 238 238 239 240 241 243 243xy Contents Appendix 6B Absorption of Hydrauli Shocks by Accumulators ‘Nomenclature and Abbreviations 7. Hydraulic Actuators 71 72 73 74 75 76 Introdu Hydraulic Cylinders 72.1 The Construction of Hydraul Cylinders 72.2 Cylinder Cushioning 723. Stop Tube 724. Cylinder Buckling 72.5 Hydraulic Cylinder Stroke fications of Hydraulic ders 727 .der Mounting 728 \der Calibers Hydraulic Rotary Actuators 73.1 Rotary Actuator with Rack and Pinion Drive 732. Parallel Piston Rotary Actuator 733. Vane-Type Rotary Actuators Hydraulic Motors, 74.1 Introduction 742. Bent-Axis Axial Piston Motors 743. Swash Plate Axial Piston Motors 744 Vane Motors 745 Gear Motors Exercises Nomenclature Appendix 7A Case Studies: Hydraulic Circuits 8 Hydraulic Servo Actuators. 81 82 83 84 Construction and Operation Applications of Hy Servo Actuators 8.2.1 The Steering Systems of Mobile Equipment 82.2. Applications in Machine Tools 823. Applications in Displacement Pump Controls The Mathematical Model of HSA ‘The Transfer Function of HSA 8.4.1 Deduction of the HSA Transfer Function, Based on the Step Response 246 249 251 251 251 252 253 256 256 258 10 Contents 8.42 Deducing the HSA Transfer Function Analytically Controlled Actuators 85.1 Flow Characteristics 352 Power Characteristics 86 Exercises 87 Nomenclature Appendix 8A Modeling and Simulation of a Hydraulic Servo Actuator ‘A Mathematical Mos of the HSA Simulati 7 of the HSA Nomenclature Electrohydraulic Servovalve Technology 91 Introduction 92 Applications of Electrohydraulic Serves 93 Electromagnetic Motors 9.4 Servovalves Incorporating Flapper ‘Valve Amplifiers 9.4.1 Single Stage Servovalves 9.42 Two-Stage Flectrohydraulic Servovalves| 95 Servovalves Incorporating Jet Pipe Amplifiers 9.6 Servovalves Incorporating Jet Deflector Amplifiers 9.7 Jet Pipe Amplifiers Versus Nozzle Flapper Amplifiers 98 Exercises ‘Modeling and Simulation of Electrohydraulic Servosystems - a 301 Introduction 102 Electromagnetic Torque Motors 102.1 Introducing Magnetic 10.22 Magnetic Circuit of an Electromagnetic Torque Motor 23. Analysis of Torque Motors Flapper Valve Modeling of an Electrohydraulic Servo Actuator Exercises Nomenclature Appendix 10A Modeling and Simulation of an EHSA 289 292 292 295 296 297 298 299 300 303 305 305 306 306 sit 3il 313 304 307 w