UNIVERSITY OF ADEN

FACULTY OF ENGINEERING
DEPARTMENT OF MECHANICALENGINEERING

Prepared by:

RIYADH HADI SALIM ABAD

Under supervision of:

Dr. Ma'an Garada

March ( 2007)

7022

Acknowledgements

We would like to express my sincere thanks and gratitude to the supervisor of the
work, Dr. Ma'an Garadh for all what she had done to help make this work rigorous
and successful.
Special thanks to our parents for their efforts and support.

CONTENTS
SUBJECT

PAGE

Introduction
1-1 Hydraulic system.....1
1-2 Forklifts .2

Lifting & pushing cylinder hydraulic system

2-1 Displacement-step diagram... ......3

2-2 Control chart......4
2-3 Function diagram.......5
..
2-4 Function chart........6
2-5 The mechanism & operation circuit

..........7

Components description
3-1 Tank...9
3-2 Pump unit (simplified)..........9
3-3 (2/2) Way steam-actuated valve... ............. 10
3-4 (4/3) Way hand-level valve with shutoff position.......10
3-5 Double acting cylinder..........11
3-6 Pressure relief valve......11
3-7 Check valve..12
3-8 Check valve with pilot control12
3-9 Line (hydraulic)....13

II

Hydraulic system software

4-1 About FluidSIM.....14
4-2 Steps operation of Forklift.........15
4-2-1 Step No. (1)....15
4-2-2 Step No. (2). .. ......16
4-2-3 Step No. (3). ......17
4-2-4 Step No. (4)....18
4-2-5 Step No. (5)...19
4-2-6 Step No. (6)...20
Conclusion 22
References......23

III

ForkLeft

Introduction

1-1 Hydraulic system

Hydraulics is the science of transmitting force and/or motion through the medium
of a confined liquid. In a hydraulic device, power is transmitted by pushing on a
confined liquid. The transfer of energy takes place because a quantity of liquid is
subject to pressure. To operate liquid-powered systems, the operator should have
knowledge of the basic nature of liquids.
Generally speaking. A number of fluids can be used in devices and systems. The
term hydraulic refers to a liquid. For example, the term hydraulic turbine can be used to
designate a turbine in solving water flow. In a hydraulic system, oil, water, or other
liquid can be used. In actual practice, fluid are most commonly used are oil.

Fig. (1)

ForkLeft

Introduction

1-2 Forklifts
The standard forklift, also known as a counterbalanced sit-down lift truck, is the
vehicle most people think of when they think Lift truck or Forklift. It is available with
any of the fuel types and tire types as well as numerous weight capacities, lift heights
and attachment options.
The smaller 3000 lb to 4000 lb trucks are the workhorses of most warehouses. If
you are running a small operation and will only have one truck, this is probably the
vehicle for you.
The standard forklift is a wide aisle truck, which requires at least 11' aisles to turn
in. The aisle width is determined by the size of the truck, the turn radius, and the size of
the load. Available options and attachments include side shifts, fork shifts, hydraulic
clamps, and slip sheet attachments, to name a few. The side shift is becoming standard
equipment on many trucks (I would not purchase one without it).
Standard forklifts are usually used for lift heights under 20 feet.

Fig. (2)

Forklift

Lifting&pushing cylinder hydraulic system

2-1 Displacement-step diagram

The displacement-step diagram used for motion sequence. It is represents the
operating sequence of the actuators; the displacement is recorded in relation to the
sequence step.
If a control system incorporates a number of actuator, they are shown in the same
way and are drawn one below the other. Their interrelation can be seen by comparing
the steps. See Fig. (3)

Fig. (3)

Forklift

Lifting&pushing cylinder hydraulic system

2-2 Control chart

In the control chart, the switching status of the control element is represented in
relation to the steps or the time. The switching time is not taken into account. Fig. (4)

Status

Open
1V
Closed

Open
2V
Closed
Open
3V
Closed
Steps
Fig. (4)

Forklift

Lifting&pushing cylinder hydraulic system

2-3 Function diagram

The function diagram is combination of the motion diagram and control chart. The
line representing the individual states are referred to as function lines. Fig. (5)

Forklift

Lifting&pushing cylinder hydraulic system

2-4 Function chart

The function chart gives clear picture of action, and reaction in sequences. Fig. (6)

From step 9
1v+

1A+

1v0

1A+

2v+

2A+

2v0

2A+

3v+

3A+

3v0

3A+

3v-

3A-

2v-

2A-

1v-

1A-

To step 1
Fig. (6)

Forklift

Lifting&pushing cylinder hydraulic system

2-5 The mechanism & operation circuit

A forklift truck, a lift truck or a forklift is a powered industrial truck used to lift
and transport materials, normally by means of steel forks inserted under the load.
Forklifts are most commonly used to move loads stored on pallets.
Forklift trucks are tilt and clamping the materials. Fig. (7)

Fig.(7)
Then the forklift truck raises the fork. Fig. (8)

Fig.(8)

After that, the fork advances to empty the materials from the fork. Fig. (9)

Fig. (9)

Forklift

Lifting&pushing cylinder hydraulic system

The fork returns to start new process in the same way and the complete process
shown in fig. (10).

Fig. (10)

Forklift

Components description

3-1 Tank
The tank is integrated into the pump unit and has a pressure of 0 bars. It can be
inserted into the circuit diagram as an independent component. Fig. (11)

Fig. (11)

3-2 Pump unit (simplified)

Simplified representation of the detailed pump unit. The component does not have
tank connections in the circuit diagram. Fig. (12)

Fig. (12)

Forklift

Components description

3-3 (2/2) Way steam-actuated valve

The configurable 2/n way valve is a way valve with two connections, where both
its body elements and its operation modes are user-definable.
Additionally, the hydraulic connections can be closed with blind plugs. Fig. (13)

Fig. (13)

3-4 (4/3)Way hand-level valve with shutoff position

Directional valve with three positions, four connections, and an arrangement
that closes that valve when in the center position. Fig. (14)

Fig. (14)

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Forklift

Components description

3-5 Double acting cylinder

Double acting cylinder with piston rod on one side. The piston of the cylinder
contains a permanent solenoid which can be used to operate a proximity switch
adjustable parameters. Fig. (15)

Fig. (15)

3-6 Pressure relief valve

Directly operated pressure relief valve.
In normal position the valve is closed. If the opening pressure is reached at P, T
opens. When the pressure drops below the preset level, the valve closes again. The flow
direction is indicated by the arrow.
The pressure drop that is caused by a pressure relief valve that opens depends on its
nominal pressure respecting some definite flow. Thus, for a precise behavior
specification of a pressure relief valve both its nominal pressure and a flow must be
specified. Together these values denote a definite characteris tic curve of the valve. Fig.
(16).

Fig. (16)

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Forklift

Components description

3-7 Check valve

Check valve, which allows fluid to flow in only one direction.
If the input pressure is at least 1 bar (and 5 bar resp.) higher than the output
pressure, the check valve opens. Otherwise, it is shut adjustable parameters. Fig. (17)

Fig. (17)

3-8 Check valve with pilot control

If the input pressure is higher than the output pressure, the check valve opens.
Otherwise, it is shut. In addition, the check valve can be opened via a control line,
allowing flow in both directions. Fig. (18)

Fig. (18)

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Forklift

Components description

3-9 Line (hydraulic)

A hydraulic line links two hydraulic connections. Note that a hydraulic connection
may be a simple hydraulic connection or a T-junction.
A hydraulic line causes no pressure drop, i. e., it has no fluidic resistance.
From a drawing point of view, FluidSIM distinguishes between control lines and
main lines. The former is represented by a dashed line, the latter is represented by a
solid line and establishes the default case. Fig. (19)

Fig. (19)

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orkLeft

hydraulic system software

4-1 About Fluid SIM

Fluid SIM-H is the result of a joint research venture between the Measuring
and Control Technology Department of Duisburg University and the Knowledgebased Systems Department of the University of Paderborn.
Fluid SIM-H is a teaching tool for simulating hydraulics basics and runs using
Microsoft Windows . It can be used in combination with the Festo Didactic GmbH
& Co. KG training hardware, but also independently. Fluid SIM was developed as a
joint venture between the University of Paderborn, Festo Didactic GmbH & Co. KG,
and Art Systems Software GmbH, Paderborn.
A major feature of Fluid SIM is its close connection with CAD functionality and
simulation. Fluid SIM allows DIN-compliant drawing of electro-hydraulic circuit
diagrams and can perform realistic simulations of the drawing based on physical
models of the components. Simply stated, this eliminates the gap between the
drawing of a circuit diagram and the simulation of the related hydraulic system.
The CAD functionality of Fluid SIM has been specially tailored for fluidics. For
example, while drawing, the program will check whether certain connections
between components are permissible.
Another feature of Fluid SIM results from its well thought-out didactic concept:
FluidSIM supports learning, educating, and visualizing hydraulic knowledge.
Hydraulic components are explained with textual descriptions, figures, and
animations that illustrate underlying working principles; exercises and educational
films mediate knowledge about both important circuits and the usage of hydraulic
components.
The development of Fluid SIM included special emphasis
on both an intuitive and easy-to-learn user interface. The user will quickly learn
to draw and simulate electro-hydraulic circuit diagrams.
I used this program to created the operating sequence diagrams for the fork left

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hydraulic system software

4-2 Steps operation of Forklift

4-2-1 Step No. (1):
Starting the program. Manually open valve No. 1, the cylinder (A1) is up due to
pressure of the oil flow through the valve, then closed this valve. This is shown in
fig. (20).

A1
V1

Fig. (20).

15

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hydraulic system software

4-2-2 Step No. (2):

Manually open valve No.2, then cylinder (A2) is up due to pressure of the oil
flow through the valve, after that closed this valve. Fig. (21)

A2

V2

Fig. (21)

16

orkLeft

hydraulic system software

4-2-3 Step No. (3):

Manually open valve No.3, then cylinder (A3) is extend due to pressure of the
oil flow through the valve, after that closed this valve. Fig. (22).

A3

V3

Fig. (22).

17

orkLeft

hydraulic system software

4-2-4 Step No. (4):

Open the valve No. (3) in the opposite direction, then the cicuct of the oil flow
in the opposite direction compresed the cylinder (A3) to the initial position. Fig.
(23).

A3
V3

Fig. (23).

18

orkLeft

hydraulic system software

4-2-5 Step No. (5):

Open the valve No. (2) in the opposite direction, then the cicuct of the oil flow
in the opposite direction compresed the cylinder (A2) to the initial position. Fig.
(24).

A3

V3

Fig. (24).

19

orkLeft

hydraulic system software

4-2-6 Step No. (6):

Open the valve No. (1) in the opposite direction, then the cicuct of the oil flow
in the opposite direction compresed the cylinder (A1) to the initial position. Fig.
(25).

A3
V3

. Fig. (25).

20

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hydraulic system software

There are one valve from type of (2/2) Way steam-actuated valve used to
emergency which cut the circuit . Fig. (26).

Emergency valve

Fig. (26).

21

ForkLeft

Conclusion

Conclusion
Hydraulic systems have become an integral part of modern drive and control
techniques. Hydraulics is extremely suitable for controlling linear and rotating
movement, both as regards to large forces and precision of movement path and
speed.
Lifting and transporting are preformed by heavy freight machinery.
Hydraulic systems are the basis for components carrying out the linear shifting
during the lifting, tilting and orientation of a payload.
The hydraulic system includes dual-action tilt cylinders and a hoist cylinders.
Tilting action is smooth and sure for better load stability and easier load
placement. A lowering valve in the hoist cylinder controls the speed of descent
even if the hydraulic circuit is broken. Hydraulic power steering is available as an
optional feature.

22

ForkLeft

Referances

References:
1. "Hydraulics Theory & Applications", second edition, Robert
Bosch Gmbh, 1998, Germany.
2. L. Stewart, Harry, "Pneumatics & Hydraulics", AUDEL, 1998,
India.
3. Esposito, Anthony, "Fluid Power with Applications", Fourth
Edition, ESPOSITO, 1997, U.S.A.
4. Forklift truck Wikipedia, the free encyclopedia.htm.
5. Lift Truck Basics.htm.

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