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PRESENTATION BY

Mr. KALU CHARAN SIA


Sr. MAINTENANCE ENGINEER
THE SUPREME INDUSTRIES LIMITED
KHARAGPUR -PPD
Tips to be Covered
 INTRODUCTION OF HYDRAULICS
 HYDRAULIC PUMPS
 HYDRAULIC VALVS
 HYDRAULIC SYMBOL AND CIRCUITS
 TROUBLE SHOOTING OF HYDRAULIC SYSTEM
 HYDRAULIC LUBRICANTS
 HYDRAULIC ACCUMULATORS
 PNEUMATIC SYSTEM
INTRODUCTION OF HYDRAULICS:
Hydraulics deals with the generation and transfer of forces
from one point to another point through pressurized oil.
Hydraulic cylinders convert hydraulic energy into mechanical
energy.

The word hydraulics is based on the Greek word for water,


and originally covered the study of the physical behavior of
water at rest and in motion. Use has broadened its meaning to
include the behavior of all liquids, although it is primarily
concerned with the motion of liquids. Hydraulics include the
manner in which liquids act in tanks and pipes, deals with
their properties, and explores ways to take advantage of these
properties.
Hydraulics can be divided into two areas, hydrostatics and
hydrokinetics. Hydrostatics, the consideration of liquids at rest,
involves problems of buoyancy and flotation, pressure on dams
and submerged devices, and hydraulic presses
Hydrodynamics
The relative incompressibility of liquids is one of its basic
principles. Hydrodynamics, the study of liquids in motion, is
concerned with such matters as friction and turbulence
generated in pipes by flowing liquids, the flow of water over
weirs and through nozzles, and the use of hydraulic pressure in
machinery
Hydraulics is based on the principle “Pascal’s law”, states that,
Pressure applied on a confined fluid is transmitted
undiminished in all directions, and acts with equal force on
equal areas, at right angles to them.
ADVANTAGES
1. Transmission of large forces using small components.
2. Precise positioning
3. Start-up under heavy load
4. Smooth operation and reversal
5. Good control and regulation
DISADVANTAGES
1. Pollution of the environment by waste oil
2. Sensitivity to dirt
3. Danger resulting form excessive pressures
4. Temperature dependence
APPLICATIONS
1. All types of production and assembly machines
2. Lifting and conveying devices
3. Presses
4. Injection moulding machines
5. Rolling lines
6. Lifts
The various applications of Hydraulics:
HYDRAULIC PUMPS:
Hydraulic pumps converts mechanical energy from a prime
mover (Engine or Electric motor) into hydraulic (pressure)
energy. The pressure energy is used then to operate an actuator
.Pump push on a hydraulic fluid and create flow.
Usage of hydraulic pumps in excavators, cranes, loaders,
tractors, vacuum trucks, dump trucks, and other such vehicles
that are extensively used in construction and industrial sector.
CLASSIFICATION OF PUMPS:
All pumps create flow, They operate on the displacement
principle, Pumps that discharge liquid in a continuous flow are
non positive-displacement type . Pumps that discharge volume
of liquid separated by period of no discharge are positive –
displacement type.
GEAR PUMP:
Gear pumps are fixed displacement pumps since the displaced
volume, which is determined by the tooth gap, is not
adjustable.
Gear pumps are External, internal or Lobe types.
The gear pump shown in figure is in section. The suction area
is connected to the reservoir. The gear pump operates
according to the following principle:

One gear is connected to the drive; the other is turned by the


meshing teeth. The increase in volume which is produced
when a tooth moves out of a mesh causes
a vacuum to be generated in the suction area. The hydraulic
fluid fills the tooth gaps and is conveyed externally around the
housing into discharge side. The hydraulic fluid is then forced
out of the tooth gaps by the meshing of tooth and displaced
into the lines.
Fluid is trapped in the gaps between the teeth between suction
and discharge. This liquid is fed to the discharge area via a
groove since pressure peaks may arise owing to compression of
the trapped oil, resulting in noise and damage.
The leakage oil from the pump is determined by the size of the
gap, the overlapping of the gears, the viscosity and the speed.
VANE PUMP:
The operation of the vane pump is based on , the rotor which
contain radial slots rotate by a shaft and rotate in cam ring
(housing), each slot contain a vane design as to comes out from
the slot as the rotor turns. During one half of the rotation the oil
inters between the vane and the housing then this area starts to
decrease in the second half which permit the pressure to be
produced , then the oil comes out pressurizes to the output port.
TYPE OF VANE PUMP:
1- Fixed Displacement vane pump
2- Variable Displacement vane pump
FIXED DISPLACEMENT VANE PUMP:
In this type of pump the eccentricity between pump cam-ring and
rotor is fixed and pump discharge always remain same at a
particular pressure.
There are two types of fixed displacement Vane Pump:-
1- Unbalanced Vane Pump
2- Balanced Vane Pump
1- Unbalanced Vane Pump:
A slotted rotor is eccentrically supported in a cycloidal cam. The
rotor is located close to the wall of the cam
so a crescent-shaped cavity is formed. The rotor is sealed into the
cam by two side plates. Vanes or blades fit within the slots of the
impeller.
A disadvantage is that an unbalanced pressure at the outlet is
effective against a small area of the rotor’s edge, imposing side
loads on the shaft. Thus there is a limit on a pump’s size unless
very large hearings and heavy supports are used.
2.BALANCE VANE PUMP:
A balanced vane pump is one that has two intake and two outlet
ports diametrically opposite each other.
Pressure ports are opposite each other and a complete
hydraulic balance is achieved.
One disadvantage of the balanced vane pump is that it can
not be designed as a variable displacement unit.
It have elliptical housing which formed two separate
pumping chambers on opposite side of the rotor. This kind
give higher operating pressure.
2.VERIABLE DISPLACEMENT VANE PUMP:
In variable displacement the discharge of pump can be
changed by varying the eccentricity between rotor and
pump cam-ring, As eccentricity increases pump
discharge increases.
PISTON PUMP:
A piston pump works on the principle that a reciprocating
piston can draw in fluid when it retracts in a cylinder bore and
discharge it when it extends.
They are mainly used in systems which need pressure of 140
bar and above.
It used in high efficiency at high pressure which is important
when a constant flow is required independent of pressure
variations.
CLASSIFICATION OF PISTON PUMPS:
Pistons pumps are either radial or axial.
Piston pumps

Axial Piston Radial Piston


Pump Pump

Bent Axis Swash Plate


Pump Pump
AXIAL PISTON PUMP:
Axial piston pump consists of a number of pistons which are
caused to reciprocate by the relative rotation of an inclined
plate or by angling the piston block.
BENT AXIS DESIGN:

 Bent axis piston pumps have a rotating cylinder containing


parallel pistons arranged radially around the cylinder centre
line.
 The pressure in the fluid causes the pistons to reciprocate over
a stroke based on the relative angle of the shaft and cylinder.
 The motion of the pistons results in the rotation of the shaft.
 The cylinder is driven by an shaft which is arranged at an angle
to the cylinder axis.
 The shaft includes a flange with a mechanical connection to
each piston.
 The greater the angle of the cylinders to the shaft axes the
longer the pistons stroke and the less the rotation speed per unit
fluid flow rate.
SWASH PLATE PUMP:
 Swash plate pumps have a rotating cylinder containing pistons.
 A spring pushes the pistons against a stationary swash plate,
which sits at an angle to the cylinder.
 The pistons suck in fluid during half a revolution and push
fluid out during the other half.
 It contains two semi-circular ports.
 These ports allow the pistons
to draw in fluid as they move
toward the swash plate
(on the backside and not shown
here) and discharge it as
they move away.
Swash plate Piston Pump

Q
 For a given speed swash plate pumps can be of fixed
displacement like this one, or variable by having a variable
swash plate angle.
REDIAL PISTON PUMP:-
This kind of pump consists of piston mounted radically in a
housing and spring loaded which permit the piston to goes out
to be filled with oil.
Another type the pistons remains in contact with the reaction
ring due to the centrifugal force, as the piston rotate the piston
comes out to make a suction and by returning around the ring it
goes back to the cylinder to make the pressure. Certain models
are operate at 1000 bar and flow rate 1000 liter/min.
The outer ring for bracing of the pumping pistons is in eccentric
position to the hollow shaft in the center. This eccentricity
determines the stroke of the pumping piston.
The piston starts in the inner dead center (IDC) with suction
process. After a rotation angle of 180° it is finished and the
workspace of the piston is filled with the to moved medium. The
piston is now in the outer dead center (ODC). From this point on
the piston displaces the previously sucked medium in the
pressure channel of the pump.
DIFFERENT TYPES OF PUMP:
Type of Pressure Speed Rating Overall HP per Flow in
Pump Rating (rpm) Efficiency Ib Ratio Ipm
(bar) (%)

External gear 130-200 1200-2500 80-90 2 5-550


pump
Internal gear 35-135 1200-2500 70-85 2 5-750
pump
Vane pump 70-135 1200-1800 80-95 2 5-300
Axial piston 135-800 1200-1800 90-98 4 5-750
pump
Radial piston 200-800 1200-3000 85-95 3 5-750
pump
HYDRAULIC SYMBOL AND CIRCUITS
Based on the standard the circuit structure & symbols
are shown below
STRUCTURE OF A HYDRAULIC SYSTEM
PUMPS & MOTORS SYMBOL:
Hydraulic pumps with fixed displacement

with one flow direction

with two flow directions

Hydraulic motors with fixed displacement

with single direction of rotation

with two directions of rotation


DIRECTIONAL CONTROL VALVES SYMBOL:
Directional control valves are shown by means of several
connected squares.
 The number of squares indicates the number of switching
positions possible for a valve.
 Arrows within the squares indicate the flow direction.
 Lines indicate how the ports are interconnected in the
various switching positions.
Port designations:
P – Pressure port
T – Return port
A, B – Power ports
L – Leakage oil
VARIOUS DIRECTIONAL CONTROL VALVES
Number of ports
Number of switching positions
2 / 2 – way valve

3 / 2 – way valve

4 / 2 – way valve

4 / 3 – way valve
PRESSURE VALVES :
Pressure valves are represented using squares. The flow
direction is indicated by an arrow. The valve ports can be
labeled P (pressure port) and T (tank connection) or A and B.
The position of the valve within the square indicates whether
the valve is normally open or normally closed.
Pressure valves are divided into Pressure relief valves and
Pressure regulators.
FLOW CONTROL VALVES :
NON – RETURN VALVES :
The symbol for non – return valves is a ball which is pressed
against a sealing seat. This seat is drawn as an open triangle
in which the ball rests. The point of the triangle indicates
the blocked direction and not the flow direction.
CYLINDERS:
Single acting cylinder, return by external force

Single acting cylinder, with spring return

Single acting telescopic cylinder

Double – acting

Double – acting cylinder with single piston rod

Double – acting cylinder with through piston rod


Energy transfer and fluid conditioning
Hydraulic pressure source
Electric motor
Non-electric drive unit
Pressure, power, return line
Control (pilot) line
Flexible line
Line connection
Lines crossing
Exhaust, continuous
Quick-acting coupling
Reservoir
Filter
Cooler
Heater
Measuring devices :
Pressure gauge
Thermometer
Flow meter
Filling level indicator
Hydraulic power pack
It is the power supply and control section in a hydraulic
system. It incorporates the following components:
a. Electric motor
b. Hydraulic Pump
c. Pressure relief valve with gauge
d. Reservoir
Reservoir
The reservoir in a hydraulic system fulfills several tasks:
 It acts as intake and storage reservoir for the hydraulic fluid
required for operation the system.
 It separate air, water and solid materials.
 It dissipates heat.
 It supports drive motor, pump and other hydraulic components,
etc.
Size of the reservoir depends on:
 Pump delivery
 The maximum possible difference in the volume of liquid which
is produced when supplying and relieving consuming devices
(ex., cylinders, hydraulic fluid reservoirs)
 The place of application and the circulation time.

The following components are used to condition the hydraulic fluid:


a. Filter b. Cooler c. Heater
d. Thermometer e. Pressure gauge f. Hyd. Fluid
g. Filling level indicator
HYDRAULIC VALVS
If the pump is the heart of a hydraulic system then the valve is
the brain. Valves are used to perform a large variety of
governing and controlling functions
CLASSIFICATION
Hydraulic valves are classified by
 Pressure control valves
 Flow control valves
 Direction control valves
 Non-return valves or Check valves
PRESSURE CONTROL VALVES:
Pressure-control valves are found in virtually every
hydraulic system, and they assist in a variety of functions,
from keeping system pressures safely below a desired upper
limit to maintaining a set pressure in part of a circuit.
Different type of pressure control valve based the
application hydraulic system are
a. Pressure relief valve
b. Pressure reducing valve
c. Unloading valve
d. Sequence Valve
e. Counter balance valve etc.
a. Pressure relief valve:
It is a normally closed valve connected between the pressure
line (pump outlet) and the reservoir. The purpose of the valve is
to limit pressure in the system to a preset maximum by
diverting some or all of the pump’s output to tank when the
pressure setting is reached.

b. Pressure Reducing Valve


It is normally open valve with pilot line to sense from outlet
line.
Pressure reducing valve provide a steady pressure into a
part of the system that operates at a pressure lower that
normal system pressure. A reducing valve can normally be
set for any desired downstream pressure within its design
limits. Once the valve is set, the reduced pressure will be
maintained regardless of changes in the supply pressure
and system load variations.
c.Unloading Valve:
The symbol for an unloading valve is similar to the symbol
for a relief valve except that the pilot line is not connected
to sense pressure at the valve inlet.
The pump builds pressure in the accumulator until the
setting of the unloading valve is reached. At this point, the
unloading valve opens, and flow bypasses to the reservoir.
The pressurized fluid is trapped in the accumulator by the
check valve and the closed-center directional control valve.
d. Sequence valve:
Sequence valves control the sequence of operation between
two branches in a circuit; that is, they enable one unit to
automatically set another unit into motion.

e.Counter balance valve:


Counterbalance valves are used with cylinders to safely hold
suspended loads and deal with over-running loads. This
valve can also be used with hydraulic motors and is then
commonly called a brake valve. Both counterbalance valves
and pilot-operated check valves can be used to lock fluid in
a cylinder to prevent drifting.
With no pressure in the line leading to the cylinder’s cap-end
port, the counterbalance valve prevents the load from
dropping. The check valve lets fluid flow into rod-end port to
raise the load
2.FLOW CONTROL VALVE:
The basic function of a flow control valve is to reduce the
rate of flow in its leg of a hydraulic circuit. One of the most
important applications of flow control valves in hydraulic
systems is in controlling the flow rate to hydraulic
cylinders. A flow control valve also used for adjusting or
manipulating the flow rate of a oil in a pipeline. The valve
contains a flow passage or a port whose flow area can be
varied. The role of a flow control valve in a hydraulic circuit
is very important and its very location is critical to
optimum system performance.
3.DIRECTIONAL VALVES:
Directional control valves are components, which open or
close flow paths in hydraulic components. They are use to
control the direction of motion of power components.
Directional control valves are classified according to the
number of ports:
 2 / 2 – way valve
 4 / 2 – way valve
 4 / 3 – way valve
4 / 2 – way valve
The 4 / 2 – way valve has two working ports (A, B), a
pressure port and a tank connection (T).
Normal position: flow from P to B and from A to T
Actuated position: flow from P to A and from B to T.

4 / 3 – way valve:
4 / 3 – way valves has four ports and 3 switching positions.
The various 4 / 3 – way valves are
a. Mid position – pump by-pass (Tandem)
b. Mid position – closed c. H – mid position
d. Mid position – working lines de-pressurized
e. Mid position – by-pass
HYDRAULIC CIRCUITS
Speed Control circuits
(meter-in circuits) (Meter-out circuits)

M M
(Bleed –off circuits) (Pressure control circuits)

M
ACCUMULATORS:
Accumulators are use to store the incompressible fluid
under pressure and it discharges the stored energy into the
system when required.
The various types of accumulators are:
1. Weight – loaded accumulator
2. Spring loaded accumulator
3. Gas charge accumulator
a. Diaphragm or bladder type
(Figure-1)
b. Piston type (Figure-2)
STANDARD MAINTENANCE PRACTICES
1. Periodic checking of oil level in the reservoir.
2. Periodic cleaning of suction strainer.
3. Return line filter element to be changed after 100 hours and at 500
hours there after.
4. Periodic analysis of oil sample to check the contamination level.
5. Flushing of the system after major breakdown & restart.
6. Ensure proper type & quantity of spare items & proper storage .
7. Mounting of magnetic in reservoir to prevent entry of ferrous
particles.
8. Do not return to the system any fluid that has leaked out.
9. Do not mix two different grades/makes of oil.
10. Use clean containers, hoses & funnels for filling the oil in to the
reservoir. Use of portable filtration unit is recommended.
11. Use only cloth for cleaning or wiping of hydraulic component
TROUBLE SHOOTING
Required Pressure not Developing
Probable Cause Remedy
• Present pressure of relief valve too • Reset the relief valve pressure with
low the help of a pressure gauge.
•Relief valve is opened •Open the relief valve ,check for
smoothness in movement of spool.
•Check the seating area is proper
•Clean the orifice hole
•Excessive internal Leakage •Check actuator/valve for excess
internal leakage
•System oil flows back to reservoir •Check the valve for mal function
•Incorrect spool function of DC Valve
change to correct spool function.
•Incorrect adjustment or •Make setting again or eliminate the
malfunctioning of flow regulator. malfunction.
Excessive noise:
Probable cause Remedy
•Pump noisy-Air in the system •Tighten all connecting parts of pipe &
pump inlet port(Apply grease/fill with
oil)
•Air entry through pump shaft seal •Replace pump shaft seal if worn out
•Air bubble in reservoir •Return line pipe should terminate
below oil surface in reservoir at any time
•Location of return pipe with respect to
suction pipe to be proper and also flow
path
•Small size of the suction strainer •Change to larger size suction strainer
•Pump speed is too high • Reduce the pump speed below the
rated, max speed recommended in
manual
•Coupling misalignment •Alignment the coupling proper
Oil leakage
Probable Cause Remedy
•The Line pressure is out of the rated •Check the seal if it meets with the use
pressure range of the seals. for the line pressure ,If not replace it.

•Seal is not compatible with the oil •Either swelling or shrinkage can occur
due to chemical reaction. Change the
seals to particular type of oil used

•Deformation due to self life of seals •Flatness or hardness may change or


degradation can occur since the seals
have a specific self life

•The finish of the surface which •Check the surface for roughness, burrs
interfaces with the seal is improper and contaminant particle on the area,
Refinish the surface ,get rid of burrs,
clean the surface area.
THANK YOU

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