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arlier this year, we discussed the general concepts of energy conservation in fluid power systems. Now well take a look at specific types of systems and how they can be optimized to conserve energy.
Demand Flow Systems Demand flow systems are defined as those that use fluid sources which are responsive to the spontaneous flow rate demand of output devices and use closecenter directional control valves. Examples of fluid sources are: accumulators, charged by fixed displacement pumps which are bypassed through an unloading valve during standby periods; or pressurecompensated variable displacement pumps, which deadhead during standby or overload conditions. The concepts for energy conservation previously discussed for constant flow systems apply equally to demand flow systems. The difficulty arises in providing a simple representation like that in Fig. 1 because p vs. Q characteristics change constantly. Component sizing for a demand flow system should be made at maximum flow rates. The circuit designer may treat it as a constant flow system, with Qc = Qmax for sizing purposes, knowing that energy losses will be smaller for lower flow rates. If peak flow demand is short of duration, it may be more economical to size for lower flows. Rethink The Circuit Some system designers tend to follow a cookbook approach based on examples of existing circuits. The danger is that these so-called typical circuits may not properly match the requirements of the application cycle profile. Damaging inefficiencies can result. A hot-running system is the common consequence of circuit-toload mismatches. If analysis of the application indicates
Fig. 1. Simple constant flow systems: (a) shows the system drawn with ISO fluid power symbols; (b) shows pressure drops and levels across each flow element in the system shown in (a); (c) is a graphic technique for evaluating pressure drops throughout the system based on emperical expressions of fluid mechanics. widely varying loads, the designer should be alert to watch for excessive inefficiencies. The design sequence can be summarized as follows: 1. perform the load analysis; 2. produce the cycle profile of the application; 3. select design pressure; 4. from force/torque profiles, size the cylinder or motor; 5. from the velocity profile, calculate flow rates using calculated cylinder and/or motor sizes; 6. calculate power profile base on P = K (Qp)/eso, where eso is system overall efficiency. The first two steps of the sequence are load orientated, that is, not discretionary and dependent on the machine cycle. The third, fourth and fifth are hydraulic circuit oriented. It is at these steps that the designer can control circuit parameters which affect efficiency they are discretionary. The final step is the power cycle and is not discretionary. It depends on flow rate and pressure. Clearly, selection of system design pressure pd is of prime importance because it virtually predetermines all other circuit design parameters. Note that design pressure differs from component rate pressure. Design pressure is the acceptable pressure at the actuator corresponding to the maximum load reac-