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This page includes a small number of basic notes and calculations to enable
selection and sizing of various hydraulic components including .
Pipes
Pumps
Motors
Air Blast Coolers
Accumulators
Linear Actuators
Heat Loss form Reservoir
Power loss from pipe friction
The calculations are simplified and should only be used for initial design
purposes. Theoretical ideal values for the pumps and motors are calculated if
1(100%) is included for the efficiency .
Actual efficiency values are obtained
from suppliers literature.
Approximate efficiencies are provided in my notes of
pumps and motors.
Note effieciency values used on this page are between 0 and 1 to represent
efficiencies between 0 and 100%.
I have tried to include supplementary unit equations to identify the factors used,
as I have based the units generally on practical working units and not absolute
units eg. litres/min as opposed to m3 /s, and bars as opposed to N/m2. I have
also assumed that gauge pressures are used.
I have created a excelcalcs spreadsheet for convenient access to all of the
equations found on this page for members of Exelcalcs.com . This is located
at ExcelCalcs.com calculation Simple Hydrostatic Transmission system
calculations
Units
F = Force(N)
T = Torque ( N.m )
p = Pressure ( bar = 10^5 Pa = 10^5
N/metre2 )
K = Bulk Modulus ( bar = 10^5 Pa = 10^5
N/metre2 )
= Dynamic viscosity (Pa.s )
= Kinematic viscosity (metre2.s )
W = Work /Energy (Joule = N.m)
Po = Power (W = J/s = Nm/s )
T = Temperature ( deg. C)
= Efficiency
Pipe sizing
The recommended flow velocities for hydraulic fluid are listed below.
The pump fluid delivery is the pump displacement per revolution x the rotational
speed
>
vp = displacement /rev (cc /rev )
n = revs/min
q = litres /min
v = Volumetric Efficiency
The speed is the fluid flow rate q divided the motor displacement/rev
m ) . pm / m
oil.V )/ t
Hydraulic Accumulator
It may be necessary for an hydraulic system to work with a pump operating at
constant speed while the motor or cylinder is not working at a steady speed.
An accumulator acts as an hydraulic flywheel to even out the energy flow and
enable a lower pump specification for a given duty.
An accumulator is often placed close to the pump with a non-return valve
preventing flow back to the pump, when the accumulator is used to smooth
pulsations.
It also helps protect the system from fluid hammer. An additional
benefit is the surplus energy that can be stored while the pump is subject to low
demand. The designer can often use a smaller-capacity pump relative to a
short term high flow demand.
The outflow of energy from a discharging
accumulator can be greater, for a short time, than the pump could develop. The
precharge is the pressure of the gas in the accumulator with minimum hydraulic
fluid in the fluid side. A gas accumulator is precharged with nitrogen gas, to the
desired pressure, when there is no hydraulic fluid in the accumulator.
A rule of thumb for bladder accumulators is to set the precharge pressure to
approximately 80% of the desired minimum hydraulic system pressure. A rule of
thumb for gas piston accumulators is to set the precharge pressure to
approximately 90% of the of the desired minimum hydraulic pressure. hydraulic
system pressure.
The useable volume Vu (litres) is the volume of fluid an accumulator will deliver
as the system pressure falls from the maxiumum pressure p max (bar) to the
minimum presssure pmin (bar).
Hydraulic cylinder
The hydraulic force exerted by an extending Hydraulic Cylinder is calculated
shown below. Please not the seal friction and fluid backpressure is not taken
into account . The resulting forces will therefore be a little high The
backpressure can easily be accounted for by calculating the resultant extending
or retracting force as F1 - F2
Mineral oil as used for hydraulics systems has a density of approx 850 kg/m 3
I list a few approx. viscosity values below
Viscosity cP
oil grade
at 40o C
at 100
27
4.7
39
5.9
57
8.7
82
9.4
125
12
It is normal to use a Moony chart to evaluate the friction factor f based on the
tube roughness and the Renold number.
To simplify this process I have determined some approximate friction factors
based on a range of Re numbers and assuming the tube is smooth bored
Reynolds
Number range
0-2500
Friction
factor (f)
64/Re
2500 - 10
0,03
104 -105
0,02
10 -10
0,016
It will be necessary to detemine the flow path from the pump to the actuator
estimate the pipe length and number of elbows and tees to complete the
calculation for the pressure side. Then repeat the process for the return route
which should have lower velocities and a larger diameter
The pressure loss and the power loss is calculated from the total pipe head loss
as follows
Example :
Consider a hydrostatic power transmission system. The tube from the pump to
the motor is 20mm i.dia, 20m long, and includes 3 elbows and 2 tees .
The
flow rate is 50 litres/min and the oil is grade ISO 68 at 40 deg.C
Viscosity = 57cP, Density = 850 kg/m3.
Fluid velocity = 2,65m/s Using equation at Pipes
Re Number = d.v. /=795 (laminer) and as a result f =
0,081
head loss h = ( f.1000.L/d + 3.f.30 + 2 .f* 60).v2 /19.62 =
35m
Pressure loss