Hydraulics is one of the most widely used
Power Transmission Systems. It finds immense applications in the
manufacturing industry, material handling Industry, Mobile/Earth
moving equipment, Marine and Off-shore applications and
Aerospace Industry.
|
Why,
the Hydraulic Power Transmission Mode ? |
 |
Excellent power to
weight ratio, low inertia |
|
|
Compact construction
that simplifies the power train. No more Gear Boxes |
|
|
Stiff motion control
capability, high torque transmission at low speeds. |
|
|
Smart Power saving
controls |
|
|
High reliability |
|
|
Easy to maintain. |
|
Applications: System building with
Electro-Hydraulic controls:
|
| SG Iron Foundry
: |
Cooling Line and
other material handling equipment. |
| Spiral Welded Pipe Mill
: |
Machine Drives and
Hydro-Tester Press Systems. |
| Pipe Coating Plants: |
Conveyor Drives and material
handling equipment |
| Industrial Mixers
: |
Constant HP Drives, such as
RMG machines. |
| Steel Blast
Furnace: |
Clay-Gun and Tap Hole Drill
equipment. |
|
Textile Applications:
|
Flatbed Printing machines,
Direct Warping machines, Dyeing machines popularly known as Jiggers.
|
|
Machine Tool
drives: |
Gang Drilling machines,
Indexing tables, Gear mfg. machines, Orbital Riveting
machines. |
Extrusion Blow
Molding and Injection Molding machine Drives.
Hydraulic systems for Die-casting machines.
Power Units for
Presses - Sheet-metal working, Compacting, Extrusion.
Power Units
for Shears and Press Brakes.
Applications in Motor manufacturing
Industry: Stator assembly presses and other SPMs. |
|
System
Design: |
|
|
Precise
derivation of connected power, Power conservation with
various techniques. System to facilitate No Load starting
and safe Idle running. |
|
|
Proper
derivation of Oil-Tank capacity. Consider the Oil level
fluctuations and Heat dissipation. |
|
|
Using the
correct elements to achieve desired functional parameter.
Such as Breaking, Clamping, regulated pressure, sequencing
operations, fine speed controls, safety functions. |
|
|
Incorporating
Cartridge elements for high flow circuits. Electro-modulated
Control Valves and Pumps where NC automation is desired.
Closed circuit Hydrostatic drives for stiff rotating motion
control. |
|
Components of
a System: |
|
Main Hydraulic
Elements like Pumps, Control valves, Hydraulic Motors and
Pressure line Filters preferred reputed manufacturers like
Bosch, Vickers, Rexroth, Yuken, Denison, Parker, Danfoss.
Most components adhere to international standards such as
DIN, ISO, CETOP, interchangeable. |
|
|
Electric Motors
normally TEFC type, of a reputed manufacturer |
|
|
Good quality
accessories. |
|
Motor-Pump
Units: |
|
|
Fixed
displacement pumps normally assembled vertical with the Pump
immersed in the tank, improve pump performance and reduce
noise level. Large Motor-Pump units assembled horizontal by
the side of the Tank on a common Base Structure, with Ball
valves and sensors provided on the Suction line. |
|
|
Variable
Delivery Pump units, assembled on top of the Tank or by the
side of tank, Air-Bleed valve provided for pump safety. |
|
|
Motor-Pump Units
to have Anti-vibration pads to reduce Vibration and Noise
level. The Motor Pump coupled with good quality Flexible
Coupling. Exposed rotating parts well covered. |
|
Circuit
Manifolding |
|
|
Manifolded
circuit construction has distinct advantages. Enables
compact construction of the System. |
|
|
Reduces piping
and joints there by diminishing leakage points. Utilises
Gasket Mounting type of elements that is easy to
maintain/replace. Improves System Stiffness and performance.
|
|
Oil Grades and
Level of Cleanliness |
|
|
Life of the
system mainly the pump/hydraulic motors, depends on the
quality of oil. The pump manufacturer recommendations are
final. |
|
|
Viscosity
depends on the ambient temperatures. The minimum cleanliness
level in most cases is to NAS1638 class 9 or 18/15 to ISO. |
|
|
In practice,
Pump suction is provided with 125-micron filters commonly
known as Strainers. Return oil filtration is over a
10-micron filter commonly known as Return-line filter.
Pressure line filters provided when proportional or servo
elements are in the circuit. |
|
|
In special cases
systems are provided with continuous off-line Filtration,
Magnetic Grids and Moisture absorbing filters. |
|
Hydraulic Tank |
|
|
Tanks are
generally made from sheet-steel, fabricated with minimum
welded joints. Baffle plates inside the tank is to reduce
turbulence near to the Pump Suction. Large tanks have
Manhole covers to facilitate cleaning. Tank inside
thoroughly de-scaled and treated to minimise contamination.
Tanks carefully sealed to maintain Oil cleanliness. |
|
|
Tanks to have
generous ground clearance and proper lifting arrangement. |
|
|
Standard
accessories on the tank: Drain Port, Inspection cover,
Oil-Level indicator, Air-breather. |
|
|
Optional
Accessories: Oil level Switch, Temperature Indicator,
Thermostat, oil coolers |
|
Hydraulic Piping |
|
|
Good quality
piping contributes to the system performance, Preferred Cold
drawn seamless tubes to DIN2391. Ermeto Bite type Ferrule
Fittings as end connectors. Tubes thoroughly cleaned prior
to final assembly. Piping should be well supported. |
|
|
Tubes correctly
sized considering oil Velocity and Pressure. |
|
|
Usage of Hoses
mainly on Pump Delivery and areas where flexibility is
required. |
|
Oil Cooling |
|
|
Generally, Tanks
are sized such that the Oil temperature is maintained within
limits. |
|
|
Some cases where
oil temperature needs a tight control, or circuits that
produce heat such as constant breaking circuits. Additional
cooling arrangement is provided. This is achieved by
incorporating Oil to water Heat exchangers, commonly known
as Oil coolers. |
|
|
Impeller type
Air-Oil Cooler fitted on the motor shaft to cool the Case
Drain of variable delivery pumps. |
|
Typical Power unit for a Steel Plant
Stand-by Motor
pumps and Hand pump for Emergency.
Mobile
Unit for High Pressure Oil flushing With Rexroth elements and
Intensifier.
100HP
Power unit for a 200 Lts.
150 HP Power unit
for Pipe conveyors, Poclain Radial Piston Integrated Pumps, with Positive
suction arrangement
Power unit for
Billet Cutting Machine
Vickers Elements, Oil Cooling
System
Typical Power
Unit for an SPM, Manifolded multiple Circuit, Variable pump and Pressure
line filter
Power Unit for a
turning SPM, accumulator for clamping circuit
9? Power Unit for
a 100T Vertical Die-Casting Machine
Power unit for a
Gang Drilling Machine Variable pump with air-oil cooler, manifolded
circuit
|
HYDRAULIC SYSTEMS 