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and Controls
Hydraulics
Project Manual
Industrial Hydraulics
Trainers manual
Pneumatics
Service
RE 00845/04.07
Foreword
Foreword
In July 2004 the Federal Minister for Economics and Labor passed the new regulations for
vocational training in industrial metalworking professions.
Basic training for the entire field of professions, the structure and objectives of vocational training are set out in paragraph 3. Skills and knowledge (qualifications) are to be imparted with
reference to practical needs. To be capable of carrying out qualified work, the trainees are to
be trained in particular in independent planning, execution and checking as well as acting in
the overall operative context.
Specialist
qualification
Core qualification
Project Manual
The present Project Manual Industrial Hydraulics is intended as accompanying and exercise
book to help trainers and technical instructors to impart knowledge through project work.
BIBB
In line with the exercises compiled by the Bundesinstitut for berufliche Bildung in Berlin BIBB
(Federal Institute for Vocational Training in Berlin BIBB) project tasks are described, which are
oriented towards the restructured industrial metalworking and electrical engineering professions.
Practice-oriented
project tasks
With all practice-oriented project tasks core and specialist qualifications are imparted in an
integrated form involving independent planning, execution and checks.
The training course was structured in a way that the project manager/trainer explains the project
order first and also supports the trainees during their project work.
In the course of the further project tasks, the information and assistance provided by the project manager is reduced. In this way the trainees learn to actively proceed in line with project
management requirements.
Foreword
Notes
Introduction
1987
2004
3,5
3,5
Subject
area-specific
specialized
training
Subject
area-specific
specialized
training
Profession-specific
specialized training
over 21 months, including
specialized task in the
companys field of
activities
Integrated training
1
Common
core qualification
21 months
Qualification requirements
The requirements for core qualification are met by solving tasks set in the form of project
steps, which involve informing, planning, decision-making, executing, checking and assessing. Mastering and internalizing the multitude of qualifications finally results in the professional
competence to act.
ns
at
io
Synthesis of
qualification contents
al
ns
qu
ifi
ca
tio
ist
ia
l
ec
al
qu
re
- Core qualifications
- Specialist qualifications +
Fields of activities
Sp
Training pattern
(technical structure)
2nd step
ifi
c
Analysis of qualification
requirements
Co
1st step
Field of
activities
Time frame
(time structure)
In the sense of fields of
work/activities within the
context of professionspecific business
processes
Introduction
is to understand the physical laws and technical interrelationships (area, pressure, force,
work and power),
is to become able to explain the function, structure, practical operating principle and possible applications of hydraulic equipment,
is to become able to read and understand symbols and circuit diagrams,
is to get to know basic controls of hydraulics and assemble units according to prepared
circuit diagrams,
is to be made familiar with types, properties, requirements and application of hydraulic
fluids.
Framework
curriculum
The project tasks and project work described in the Project Manual Industrial Hydraulics provide trainers and trainees with information and instruments that will help them comply with the
demands made on the transfer of specialist know-how in the field of hydraulics.
The sub-objectives listed below, which are taken from the framework curriculum for vocational
training of industrial mechanics, are matched with the regulations for vocational training in
industrial metalworking professions dated 09.07.2004 (BGBl. I. S. 1502). The sub-objectives
listed refer to training objectives given for hydraulic control technology.
Industrial mechanics
plan and organize work sequences, check and assess work results,
verify mechanical and physical variables,
assemble and disassemble machines, equipment, fixtures and systems,
commission systems and plants, including open and closed-loop control equipment, and
instruct customers,
carry out maintenance work and ensure the operability of technical systems,
prepare technical documentation,
apply standards and regulations for safeguarding the process and product quality and
contribute to continuing improvements in the work sequences in the company.
Fields of activities
Industrial mechanics are mainly assigned to professional activities in the field of production,
assembly, maintenance and automation of technical systems. The fields of activities mentioned
before are dealt with in individual training sections. Within the fields of activities, the training
sections of the individual training years are based on each other.
Training sections
In training section-oriented lessons the solutions required for project handling are not imparted
like in conventional lessons. The solution of the task set is worked out alternately in systematic,
technical and situation- or case-related training. In the course of the project work it should
be envisaged that the trainee can handle the projects on his/her own and under his/her own
responsibility and, whenever possible, in a team.
This brings the training contents closer to the trainee's real world of experience, which enables
and simplifies imparting the professional competence to act in the lessons.
To solve a more complex project task, it may be required to impart the basic principles for this
project in systematic technical training.
Introduction
The trainees are to install and commission control systems. They determine the control
components to be used and the functional sequence for controls on the basis of circuit
diagrams and other documentation for various component technologies. For this, they use
manufacturers's documents.
The trainees plan and realize the set-up of the control. They commission the control system
observing rules for safety at work. They develop strategies for troubleshooting and optimization of the control systems and apply them.
They document and present their results utilizing suitable user programs.
Contents:
Technology diagram
Hydraulic power part
Supply unit
Sensors
Flow of material, energy, information
Electrical circuit diagrams
Pressure fluids
Pressures, forces, velocity, flow
Operating modes
Plant safety
Training schedule
The starting point of didactic-methodical structuring of the training situation in the individual
training sections is to be the business and work process in the vocational field of activities. This
is reflected in the formulation of objectives in the individual training sections. The objectives of
the training sections are the decisive factors for the structuring of the lessons and represent
the minimum scope together with supplementary contents.
The technical contents of the individual training sections are formulated generally and are not
listed in a differentiated way. The individual contents of the training sections are coordinated
with the training curriculum for in-company training.
According to 7 of the regulations for vocational training in industrial metalworking professions
deviations from the training curriculum are permitted in terms of technical contents and time
schedule, in particular, where practical requirements necessitate this deviation.
The project tasks described in the Project Manual Hydraulics are structured so that the trainee
achieves the training objectives described in the project definition in 6 project steps:
Informing,
Planning,
Deciding,
Executing,
Checking,
Evaluating.
Introduction
Specialist
competence
The objectives described are geared to the development of competence to act. The trainee will
develop his or her competence to act from the capability and willingness to solve tasks and
problems and evaluate results in a target-oriented manner, skillfully, methodically and independently on the basis of technical knowledge and skills.
Professional
competence to act
The projects described in the project definition are oriented towards practical needs and are
characterized by a high level of conformity with customer orders from industry and trade. Customer orders represent complete activities and develop and promote the trainee's professional
competence.
As mentioned before, the trainee is to work off the project task or the project order in 6
steps.
1. Informing
Based on the project definition, the trainee is to get a clear idea of the finished solution, including
any required details. This is achieved through a systematic analysis of the project documentation and, if required, by asking questions.
Possible questions:
What is to be done?
Have I understood the task completely?
Which hydraulic component/system is to be dealt with?
2. Planning
Planning means the theoretical preparation and anticipation of the concrete execution. In detail,
planning requires competence to handle the project order and to organize the project handling
steps.
Possible questions:
How to proceed?
What knowledge is required?
Which aids are available?
Are there comparable applications in my company?
3. Decision-making
After the planning stage, the trainee determines the aids to be used, e.g. which data sheets are
required for coping with the project task. He/she decides on the sequence and the interrelationships of the individual project steps. Moreover, a decision should be made as to whether it
would be easier to solve the project task in a team.
Possible questions:
Which hydraulic components will be used?
How can you know that technical data sheets are up to date?
Have I utilized all available sources of information?
Are the prescribed safety instructions at hand?
4. Executing:
The order is to be executed according to the work instructions given in the chapter "order execution", taking all safety notes into account. After a thorough preparatory phase, the trainee is to
carry out the project order largely on his/her own. After the solution was worked out in writing,
it should be verified or questioned, whether the right attempt at a solution was selected.
Depending on the project order, the possibilities of execution may be limited. This is valid, for
example, in the case of costly work in the field of information technology.
Possible questions:
5. Checking:
The trainee must check intermediate results as early as during the execution stage, and finally
the result of the customer requirement. In some cases, the result can be compared with the
manufacturer's documents. In the case of measuring exercises, it must be checked, whether the
measured results are realistic. The documentation should also be finally corrected, improved
and completed. This also includes the preparation of a final report. After completion, the trainer
makes a final check.
Introduction
Possible questions:
6. Evaluating:
In the final evaluation phase, an external or self-evaluation is to be carried out on the basis of
a comparison of project order documents, the installed control and results of measurements
and checks.
Faults, if any, and their causes must be analyzed and possibilities discussed as to how faults
can be avoided in the future.
The trainee must learn to assess his/her strengths and weaknesses and develop objective quality
standards for his/her acting, which ultimately leads to personal competence. The evaluation can
be finalized in a technical discussion, possibly also in a discussion with the customer.
General notes:
For didactic reasons, we refer exclusively to trainees and trainers in the present manual. We
expressly point out that these terms include all persons involved in the basic and advanced
training: Instructors, teachers, project managers, etc., whether male or female.
Procedural
knowledge
Pictogram
The pictograms, which are used as recurrent symbols, are to transfer important information
as quickly as possible in the form of a simplified graphical representation and independently
of languages.
Introduction
01
02
03
Single-rod cylinder,
pressure intensification
04
Single-rod cylinder,
flow
Different traversing speeds when extending and retracting a single-rod cylinder. Application of different types of
hydraulic cylinders.
05
Hydraulic motor
Powering a hoist with the help of a hydraulic motor for lifting and lowering of a load.
06
07
Check valve
08
Check valve,
pilot operated
09
Throttle valve,
adjustable
10
11
12
13
14
15
Pressure switch
Introduction
16
Pressure switch,
hysteresis
17
Hydraulic accumulator
Moving the tool from the working range of the machine tool
using the oil volume stored in the hydraulic accumulator.
18
Regenerative circuit
19
Rapid speed/creep speed Rapid speed/creep speed control for lifting a pallet onto a
control
conveyor belt at load-independent, adjustable creep speed
and with fastest return stroke possible.
20
21
Commissioning,
Observing regulations, safety rules and generally recinspection, maintenance, ognized technical rules when handling production and
...
hydraulic systems in everyday work.
Introduction
Project
no.
Project designation
Project content
BIBB
01
A1
02
A2
03
Single-rod cylinder/pressure
B 1.1
04
Single-rod cylinder/flow
Traversing speeds
B 1.2
05
Hydraulic motor
B2
06
B3
07
Check valve
C1
08
C1
09
D1
10
D3
11
Tool drive
D2
12
Characteristic curve
E1
14
Tool advance
E3
15
Pressure switch
E4
16
Characteristic curve
E4
17
Hydraulic accumulator
F1
18
Regenerative circuit
G1
19
G2
20
G3
21
Commissioning
Commissioning, troubleshooting,
maintenance
H1
13
E 1.2
Introduction
Component matrix
The matrix below provides an overview of the components, which are required for the individual project exercises.
Project 01 02
Component designation
ZY 1.3
Double-acting cylinders
ZY 1.Load
Double-acting cylinders with load
DM 2.N
Hydraulic motor
DW 3E
4/2 directional valve C
DW 4E
4/3 directional valve G
DW 10E
4/3 directional valve J
DW 13E
4/3 directional valve E
DS 2.1
Check valve
DS 1.1
Check valve, pilot operated
DZ 2.1
1
Shut-off valve
DD 1.1
Pressure relief valve
DD 2
Pressure reducing valve
DF 1.2
1
Throttle valve
DZ 2.2
Throttle check valve
DF 3
Flow control valve
DD 6.E
Pressure switch
DZ 3.2
Hydraulic accumulator
DE 2
Limit switch
DZ 4.1
2
Distributor plate
DZ 1.4
1
Pressure gauge/minimess connection
DZ 25.1
1
Hydraulic hose/minimess connection
03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
Introduction
10
Overview of components
Symbol
Component designation
Type designation
Double-acting cylinder
with single-sided piston rod
ZY 1.3
Double-acting cylinder
with single-sided piston rod with load
ZY 1.Load
DM 2.N t
DW 3E
DW 4E
DW 10E
DW 13E
DS 2.1
Pilot operated check valve, with spring, pilot pressure enables flow in both directions
DS 1.1
DZ 2.1
DD 1.1
Introduction
11
DD 2
DD 6E
DF 1.2
DZ 2.2
DF 3
DZ 3.2
DZ 1.4
DZ 25.1
Hose
VSK 1
Introduction
12
DZ 4.1
Flow-meter
DZ 30
Tachometer
1)
red
black
blue
1)
Stopwatch
1)
DE 2.2
Introduction
13
Safety aspects
Safety and the economic use of resources are essential demands that are placed on modern
plant and machinery and serve to protect people. These two requirements have in common
that they have to be taken into account as early as possible, that is, at the product concept
stage. Only in this way can optimized and low-priced solutions be found. Safe machines with
low consumption demonstrate that the manufacturer masters his processes; they are a quality
feature.
In order that hazards to plant and machinery can be recognized, safety regulations, product
information brochures and operating instructions must be observed. Corresponding notes on
the handling of electrohydraulic components and systems of Bosch Rexroth can be found in:
General product information on hydraulic products
RE 07008/02.05
Operating instructions for hydraulic systems
AB 01-01.02
Hydraulic cylinders of tie rod/mill-type design (operating instructions)
RE 07100-B/10.04
Operating instructions DS4 1X
RE 00225-B/05.05
The safety notes and product information in the above documentation are exclusively valid for
Bosch Rexroth hydraulic products.
Only when operating instructions, safety notes and product information are observed can the
trouble-free operation of Rexroth products be ensured.
The present Project Manual Industrial Hydraulics includes warning notes, which precede instructions for activities that involve a risk of personal injury or damage to property. The described
precautions for averting risks must be taken.
Conventions
This symbol refers to imminent danger that, if not avoided, can lead to severest injuries or death.
Warning
This symbol refers to a potential risk, which can lead to light or serious injuries
or damage to property.
Caution
Note:
The electrohydraulic components and systems described in this Project Manual are technical
equipment, which is not intended for private use.
The use for the intended purpose also includes that the safety regulations, product information
and operating instructions described in the following are read and understood.
Introduction
Qualification of
personnel
14
Installation, commissioning and operation, disassembly, upkeep and maintenance require fundamental knowledge of mechanics and electrohydraulics as well as the knowledge of related
technical terms. In order to ensure operational safety, these activities may only be carried out by
a corresponding specialist or by an instructed person under the supervision of a specialist.
A specialist is, who, due to his/her professional training, his/her knowledge and experience and
the knowledge of relevant regulations, can asses the duties assigned to him/her, recognize potential risks and take suitable precautions. A specialist must observe relevant technical rules.
Consequently, this means that the trainer must point out potential risks to the trainees and
provide information on how to avert such risks.
Warning
Liability
In the case of damage resulting from improper use and unauthorized interventions, which are
not provided in the Project Manual Industrial Hydraulics, any liability claims for defects or other
liability claims vis--vis Bosch Rexroth AG become void.
If Projects 01 to 21 described in the Project Manual Industrial Hydraulics are carried out on
training stands and with electrohydraulic components that were not delivered by Rexroth, that
is, products of competitors' make, any defect or liability claims vis--vis Bosch Rexroth AG shall
be void as well.
When using competitors' products, observe the safety notes of the manufacturer and make sure that the components and systems comply with currently
valid EU Directives.
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
Warning
Note:
The required safety regulations, product information documents* and operating instructions
must be handed over or be accessible to the trainee in their latest issue.
In the Project Manual Industrial Hydraulics we do not refer in detail to the correct handling of
hydraulic fluids in the project exercises 01 to 21. The corresponding information can be found
in the safety data sheet.
The correct handling of hydraulic fluids and possible risks as well as measures for averting
risks are described in a separate topic "Hydraulic fluids" in the following.
* Rexroth product information sheets are valid exclusively for hydraulic products, which are
operated with hydraulic fluids based on mineral oil, unless the use of other hydraulic fluids
is expressly permitted in the operating instructions.
Hydraulics, derived from the Greek word hydro = water, refers, in a scientific sense, to the science of still and moving fluids (hydrostatics and hydrodynamics).
If we speak of hydraulics in mechanical, vehicle and aircraft engineering, we understand by this
the practical application of this discipline of physics in the fields of power transmission and
open and closed-loop control technology.
Comparison of
systems
Source of energy
(drive)
Hydraulics
Pneumatics
Electrics
Mechanics
El. motor
El. motor
Mains
El. motor
Combustion engine
Combustion engine
Battery
Combustion engine
Pressure vessel
Weight
Tension force by
spring
Electric cables
Mechanical parts:
Levers, shafts, etc.
Magnetic field
Energy carriers
Fluids
Air
Electrons
Force density
(power density)
High
Relatively low
Low
High
High pressures
Low pressures
cf. power/weight
ratio of el. motor to
hydraulic motor 1:10
Good to excellent
Poor
Large forces
Small installation
space requirement
Smooth control
(accelerating,
decelerating)
Motion types of
drives
System planning
The specific advantages of hydraulic technology over other technologies such as pneumatics,
electrics and mechanics, can only be utilized to the full extent, if the system planner knows the
typical features offered by hydraulic control technology.
Pressure and flow losses (fluidic friction) in line systems and control elements
Dependence of viscosity of the hydraulic fluid on temperature and pressure
Leakage problems; therefore risk of accidents and risk of fire
Compressibility of the hydraulic fluid
Energy conversion
Hydraulic systems convert mechanical energy into hydraulic energy, transport it in this form in
an open or closed-loop controlled way and then re-convert it into mechanical energy.
For the conversion of energy, hydraulic pumps are used on the primary side, and hydraulic
cylinders and hydraulic motors on the secondary side.
Hydraulic energy and hence the transmitted power can be influenced in pressure and flow by
hydraulic pumps, and in its magnitude and direction of action by open and closed-loop control
valves.
The hydraulic fluid that is directed via pipes, hoses and bores in control blocks or manifolds
assumes, among others, the energy transport.
For storing and maintaining the hydraulic fluid, additional equipment such as reservoirs, filters,
coolers, heaters, measuring and testing instruments are required.
Drive
Electric motor,
combustion engine,
manual drive
Hydraulic system
Drive
Energy conversion
Energy conversion
Hydraulic pump
Hydraulic open
and closed-loop
control valves
Electric energy,
thermal energy,
mechanical energy
Hydraulic energy
Working element
to be actuated
Mechanical energy
As illustrated in the schematic above, an oil-hydraulic system firstly converts mechanical energy
into hydraulic energy, transports it in an open or closed-loop controlled way, and then converts
it into mechanical work. The components used in hydraulics can be classified according to
their function.
The figure below schematically shows the components of a simple hydraulic system.
Hydraulic cylinder
Throttle
check valve
Directional valve
Check valve
Pressure relief
valve
Instead of sectional drawings, standardized symbols according to DIN ISO 1219 part 1 are
used in hydraulic circuit diagrams. More detailed information is provided in the next chapter
"Symbols".
The symbols included in standard DIN ISO 1219 should preferably be used, but their use does
in no way rule out the use of symbols commonly applied in other technical areas for identifying
pipes and hoses.
The followings lists are not complete, but must be regarded as working aid for the preparation
or completion of project-related circuit diagrams.
The graphical symbols used in the manual comply with DIN ISO 1219 - fluid power technology;
graphical symbols and circuit diagrams; part 1: Graphical symbols.
Basic symbols
The basic rules for the preparation of hydraulic circuit diagrams are determined in part 2 of
standard DIN ISO 1219. Circuit diagrams are a tool to simplify the planning and description of
a hydraulic system in order to prevent - through a standardized representation - uncertainties
and faults at the planning stage, during production, installation, and servicing.
Supply line, return flow line, frames for components and symbols
Internal and external pilot line, leakage line,
flushing line, venting line
The crossing of two lines without connection point indicates that there is no connection
The connection of two lines is represented
by means of a connection point.
Hose
Function unit for valves having a maximum
of four service ports
Frame for energy conversion unit
(pump, compressor, motor)
Adjustability of a pump/motor
Overview of
symbols
Directional valves
Check valve
Throttle valve/orifice
Sequencing valve
Hydraulic circuit
systems
Open circuit
In an open circuit, the hydraulic pumps usually aspires hydraulic fluid through the suction pipe,
which is installed below fluid level. The hydraulic fluid is directed by directional valves to the
actuator and fed back to the storage reservoir; this means, there is no connection between the
suction pipe of the hydraulic pump and the hydraulic fluid returning from the actuator.
Typical features of the open circuit:
The hydraulic pump aspires oil directly from the hydraulic tank,
the hydraulic fluid flows via control elements to the actuator,
the hydraulic fluid flows from the actuator back to the hydraulic tank,
simple structure,
better cooling,
contamination can settle in the hydraulic tank,
large amount of fluid,
large hydraulic tank required,
large space requirement,
unfavorable volumetric efficiency
Input speed
n = constant
Schematic
diagram
Lifting speed
v = constant
Flow
qV = constant
The open circuit is employed, for example, in machine tools, handling systems, press controls,
winch drives, and gears for mobile applications. The actuators can be hydraulic cylinders and
hydraulic motors.
Closed circuit
In a closed circuit, the hydraulic fluid returning from the actuator is directly re-fed to the hydraulic
pump. The high-pressure side of the system is protected by a pressure relief valve. The pressure
is unloaded to the low-pressure side, that is, the hydraulic fluid remains in the circuit.
The design-inherent permanent, internal leakage of the hydraulic pump and the hydraulic motor is compensated for by a separate auxiliary pump, which is flange-mounted to the hydraulic
pump in most of the cases.
Typical features of the closed circuit are:
The hydraulic fluid is fed by the pump to the actuator,
the hydraulic fluid flows from the actuator directly back to the pump,
compact design,
silent, smooth running,
good controllability,
good volumetric efficiency,
complicated structure,
greater stressing of the oil,
sensitive to contamination
Schematic
diagram
Flow
qV = variable
Output speed
n = variable
Cooler
The closed circuit is used almost exclusively in mobile applications, e.g. for powering a wheel
loader travel drive. The hydraulic pumps and hydraulic motors used are in most of the cases
axial piston units.
10
Semi-closed circuit
The semi-closed circuit is a combination of the open and the closed circuit and is used, if the
volume must be balanced by means of anti-cavitation valves, for example, when a single-rod
cylinder is employed in a mobile machine.
The schematic illustration "drive and control / driving - controlling - and moving" on the next
page shows the task set to a hydraulic cylinder or hydraulic motor as machine element.
The travel speed of the actuator is realized by the hydraulic pump flow.
The direction, start and stop are controlled by directional valves.
The required force can be varied by adjustable pressure control valves.
The specified travel speed of the actuator can be influenced by means of a flow control
valve.
Optimized system technology includes monitoring elements such as pressure switches and
pressure gauges. Hydraulic accumulators can be provided for realizing faster movements.
Heat exchangers optimize the oil quality and hence the availability of the system.
11
Driving machines
and systems
Flow
Pumps
+
storage tank
Hydraulic fluids
Direction + position
are to be controlled
Pressure
Velocity
12
Pressure (p) in the vessel results from force (F), which acts on the piston. This means that a
greater force (load) generates a higher pressure, whereas with decreasing force (load), the
pressure falls.
The second relationship lies in the size of the area (A), onto which the force acts.
The smaller the area, the higher the pressure; and, of course, vice versa, the greater the area,
the smaller the pressure.
Consequently, the pressure is dependent on the amount of the effective force (F) and the size
of the area (A) onto which this force acts.
Pascal's law:
p=
F
A
or:
A=
F
p
F = pA
Force = pressure area
F
1 kg
m s
= 1 N/m2
The force in Newton per surface area of one square meter, where:
1 bar = 100,000 Pascal (105 Pa)
1 bar = 10 N/cm2
In pressure calculations, the unit Dekapascal (daPa) is often used, where one Dekapascal
corresponds to 0.1 mbar.
100 Pa = 10 daPa = 1 haPa = 1 mbar
100,000 Pa = 0.1 MPa = 1 bar = 1,000 mbar
1.000.000 Pa = 1 MPa = 10 bar = 1 N/m2
Force transmission
13
In a closed system with two cylinders of different size, only one pressure (p) can prevail. If both
cylinders are to be held in balance and the areas (A1 - A2) have different sizes, the loads (F)
acting on the areas must consequently be different.
Cylinder 1 means:
p=
F1
Cylinder 2 means:
p=
F2
A1
A2
F1
F1
Rearranged by force:
A2
A1
A1
F2
A2
A2
= F2
A1
Consequently:
Example:
Area A1
Area A2
Weight force F1
Weight force F2
F1 = F2
Solution:
=
50 cm2
= 750 cm2
= 1.000 daN
=
?
F1
750 cm2
1.000 daN
or with =
A2
= F2
A1
50 cm2
A2
A1
= 15.000 daN
750
= 15
50
F1 = F2
1.000 daN 15 = 15.000 daN
This means that cylinder 1 with a force of 1,000 daN, which corresponds to a mass of 1,000 kg,
can hold cylinder 2 with a load of 15,000 kg or 15 t.
F1
F2
A1
A2
Pressure intensification
14
AK
AR
Solution:
pK = pR
2
100 bar
= 200 bar
1
pR = 200 bar
Conclusion:
Meter-out throttling involves the risk of pressure intensification!
ASt
AK
pK
pR
AR
Flow
15
The flow is the amount of fluid (nominal volume) that moves in a hydraulic systems within a
certain time.
In conjunction with pumps, we also speak of displacement.
The unit commonly used in industrial hydraulics is l/min.
If in the schematic diagram below the lever of the pump is shifted to the right, the piston displaces fluid into the system. If there is no counterforce (counterpressure), almost no pressure
will consequently build up in the pump. The fluid is fed to the system at zero pressure.
Only when the displacement is opposed by a resistance (directional valve, throttle, cylinder
piston or similar elements), can a counterforce be generated. The pump continues to displace
fluid and compresses the fluid. Pressure builds up, which depends on the resistance not generated by the pump.
The pump only displaces fluid into the system.
qV in l/min
t in
s in mm
A in cm2
qV in l/min
V
As
=
t
t
qV = A v 6 in l/min
qV =
A in cm2
s
v = = Velocity in m/s
t
s in mm
A in cm2
v in m/s
In technical data sheets, the size of the pump is given in cm3/revolution. The following formula
is applied for determining the power:
qV =
Vg n
1.000
in l/min
Vg = displacement in cm3/rev
n = speed of the pump shaft in min-1
(rule of thumb without consideration of the volumetric efficiency).
Flow law
16
The identical volumes flow through a pipe with different cross-sections within the same time.
This means that the flow velocity of the fluid must increase at the narrow point.
qV =
V
t
qV =
V=As
As
t
v=
s
t
Flow q hence equals the product from the cross-sectional area of pipe A multiplied by the
velocity of the fluid v qv = A v.
Flow
Flow q in L/min is the same at any point in a pipe. If the pipe has two cross-sections A1 and A2,
corresponding velocities must occur at the two cross-sections.
q1 = q2
q1 = A1 v1
q2 = A2 v2
A2 v2
17
Hydraulic fluids
General
In a hydraulic system, the fluid assumes the task of force transmission. This means that certain
demands must be placed on the fluid.
The fluid should:
be incompressible for the transmission of forces
dissipate heat that is generated
not change its viscosity at different temperatures
carry away abrasion from hydraulic components
be easy to filter
be neutral against metal guides, seals and paints
feature good lubrication properties
be resistant to aging
not be detrimental to health
be easy to dispose of after use
Environmentally friendly
Neutral against seals, plastics, paint
Corrosion protection
Good lubrication properties
Good dirt transportation capacity
Temperature stability
Resistant to aging
18
Requirements of
the market
None of the fluids offered on the market today can meet all of the requirements listed on the
previous page. Even in view of ongoing discussions about environmental compatibility of hydraulic fluids and in spite of all concerns, mineral oil is still the most common hydraulic fluid
used in hydraulic systems.
Selection criteria
Being an important design element and machine element, the hydraulic fluid must be taken
into account at the planning stage, and during engineering and commissioning of hydraulic
systems.
The hydraulic fluid to be used is selected according to the prevailing operating conditions such as:
Operating temperature range
Concept of the hydraulic system
Hydraulic pump type
Working pressure and environmental requirements
Operating time and availability
Economic and ecological factors
Viscosity
Viscosity is the most important criterion for the selection of the hydraulic fluid. Viscosity data
indicate whether a pressure medium is light or viscous at a certain temperature and hence
whether friction between the fluid layers is smaller or greater.
The viscosity is measured in the SI unit mm2/sec. It changes as temperature changes. In a
diagram with a double logarithmic scale for the viscosity axis, the representation in the change
in viscosity in dependence upon temperature T shows a straight line.
Manufacturer's
data
For determining the application limits of a hydraulic system and consequently for the selection
of the hydraulic fluid, it is important to take minimum and maximum viscosity values into account
that are given by the manufacturer in his documentation for the hydraulic components used.
The component manufacturer Rexroth, for example, indicates the data for the selection of the
hydraulic fluid in the technical data sheet of the component - RE data sheet - in the section
Technical data, hydraulic. Here, you can find details about the hydraulic fluid, hydraulic fluid
temperature and viscosity range.
19
Classification of
hydraulic oils
Hydraulic oils
Hydro-kinetic application
DIN 51 502
ISO 6743/4
ATF
HA
HN
Hydrostatic application
Flame-retardant hydraulic
oils
Fast bio-degradable
hydraulic oils
7. Lux. report,
ISO 6743/4, ISO/CD
12922, DIN 51 502,
Factory Mutual - USA
DIN 51
524
ISO/DIS
11158
Containing
water
HL
HLP
HLPD
HVLP
HVLPD
HH
HL
HM
HR
HV
HS
HG
HFAE
HFAS
HFB
HFC
Water-free
HFDR
HFDU
Waterinsoluble
Watersoluble
HETG
HEES
HEPR
HEPG
HSF H1
NSF H2
Basis white
oil
Basis white
oil
Basis PAO
Basis PAO
Basis
mineral oil
20
Classification of
hydraulic fluids
based on mineral
oil
Class L: Lubricants, industrial oils and related products; Class H: Hydraulic systems
Code letter
(symbol) DIN
Code letter
(symbol) ISO-L
Composition
Typical properties
Field of application
Operating temperature
HH
HL
HM
--
HR
HVLP
HV
--
HS
HG
--
--
HL
HLP
(HLPD)
HLPD
21
Classification of
flame-retardant
hydraulic fluids
and water-free,
fast bio-degradable hydraulic
fluids
Code letter according to
Composition
7th Luxemb. report,
Typical properties
DIN 51 502 and
DIN EN ISO 6743/4: April 2002
Field of application
Operating temperatures
(Notes)
Oil-in-water emulsions, mineral oil / Power hydraulics of about 300 bar, for
synth. esters
example in shield tunneling in the field
Concentrate share < 20 %
of mining
HFA-S
HFB
Water-in-oil emulsion
Share of mineral oil 60 %
HFC
HFD-R
Lubrication and control of steam turSynthetic fluids based on phosphate bines, industrial hydraulics
esters,
-20 to 150 C
water-free
in hydrostatic systems often
10 to 70 C
HFD-U
Composition
Typical properties
Field of application
Operating temperatures
(Notes)
Polyalkylene glycol
Water-soluble
Hydrostatic drives,
e.g. ship lock hydraulics
-30 to < 90 C
HETG
Hydrostatic drives,
mobile hydraulics
-20 to 70 C
HEES
Synthetic esters
Not water-soluble
Hydrostatic drives,
mobile and industrial hydraulics
-35 to 90 C
HEPR
Hydrostatic drives,
Polyalpha olefins (synth. hydrocarbons)
mobile and industrial hydraulics
Not water-soluble
-35 to < 80 C
10.000
Viscosity mm2/s
Viscosity/
temperature
diagram
22
1.000
* Max. permitted
100
20
12
10
9
8
0
68
10
G
VG V
46
2
O SO
2
G
I
3
2
15
V
IS
VG VG
VG
O
O
IS
IS
* Min. permitted
(lubrication problems)
IS
IS
5
4
3,0
-40
-30
-20
-10
10
20
30
40
50
60
70
80
90 100
120
140
Temperature C
Reference temperature for ISO viscosity classes
Viscosity
Comparison of
different
viscosity classes
SAE classes
ISO - VG
(DIN 51519)
SAE classes
30
100
68
68
20, 20 W
46
10 W
32
5W
22
49
36
25
16
(15)
10
Additives
23
No hydraulic fluid can meet all requirements. Thanks to additives, certain properties of the
hydraulic fluid can be optimized to suit the requirements of specific applications.
For example:
for improving:
corrosion protection
pressure resistance
resistance to aging
viscosity/temperature behavior
for reducing:
the pour-point
foaming
wear
24
Practical notes
Effects of air
in the oil
Air can be present in hydraulic oils in the following forms: as dissolved air (invisible), as surface
foam (visible), and as undissolved, dispersed air (visible). While dissolved air and minor surface
foam hardly show any adverse effects, dispersed air can cause severe problems. Since the oil
contains very small air bubbles, which are finely dispersed and can rise to the surface only very
slowly, the following troubles can occur:
Uneven or jerky movements of hydraulic spools, vibration in the system due to increased
compressibility, changed actuating times of servo-valves
Pump noise
Damage to pumps, lines and seals caused by cavitation
Accelerated aging of the oil
Micro-diesel effect, a form of thermal cracking due to high temperatures in compressed air
bubbles
Environmental
aspects
Hydraulic systems are closed systems. When hydraulic systems are used properly, hydraulic fluid
does therefore not get into the environment. Care must be taken that power units are leak-free
and maintenance/repairs are carried out in due time. Especially hydraulic hoses and hose connections must be intensively observed and inspected. Oil changes must be made properly and
thoroughly; waste oil must be disposed of in accordance with all relevant legal stipulations.
Safety aspects
Hydraulic fluids based on mineral oil are water-endangering and inflammable. Pressure fluids may only be used, if the corresponding safety data
sheet of the manufacturer is at hand and all precautions prescribed therein
are observed.
Danger
Filters
25
Causes of contamination
One of the preconditions for the trouble-free operation of a hydraulic system is filtration of the
hydraulic fluid and the ambient air connected to the tank.
The contamination to be removed by means of filters enters the hydraulic system from the surroundings via the filling connection or past the seals.
This type of contamination is termed external contamination or contamination that enters the
system from outside.
The contamination ingression rate to be expected depends exclusively on the contamination of
the surroundings and the design of systems and components.
Moving parts in the hydraulic system such as pumps, spools and valves also generate particles
(abrasion). This type of contamination is termed internal contamination.
Especially during commissioning of the system, there is a risk that the individual components
are damaged or destroyed by solid particles that were transported into the system already
during assembly.
The majority of malfunctions in hydraulic systems are caused by strongly contaminated hydraulic
fluids. Fresh pressure fluid, with which the hydraulic fluid is to be filled, is often contaminated
to an impermissibly high level.
Contamination during the production of components
(component contamination)
Due to the often highly complicated internal contours of housings and internal parts of components, the latter cannot in every case be sufficiently cleaned. When the hydraulic system
is flushed, the contaminants get into the hydraulic fluid.
Components are often preserved for intermediate storage. The preservatives bind dirt and
dust. This dirt also gets into the hydraulic fluid when the system is commissioned.
Typical contaminants are:
Chips, sand, dust, fibres, paint flakes, water or preservatives.
When individual parts are joined, e.g. installation of fittings, solid particles may be produced.
Typical contaminants are:
Seal material, scales, welding beads, rubber parts from hoses, residues of pickling and
flushing fluids, cutting and grinding dust.
Critical tolerances
for hydraulic
components
26
Gear pump
J1 from 0.5 to
J2 from 0.5 to
5 m
5 m
Vane pump
J1 from 0.5 to 5 m
J2 from 5 to 20 m
J3 from 30 to 40 m
Piston pump
J1 from 5 to 40 m
J2 from 0.5 to
1 m
J3 from 20 to 40 m
J4 from 1 to 25 m
Valve
J1 from 5 to 25 m
Servo-valve
J1 from 0.5 to 8 m
J2 from 100 to 450 m
J3 from 20 to 80 m
Causes and
sources of
contamination
1
2
3
4
5
External contamination
Installation + repair
Fresh oil
Abrasion in the pump
Abrasion of seals
27
Arrangement of
filters in the open
circuit
28
Control
1
8
10
3
2
5
4
Off-line filtration
Filter types
29
30
31
Symbol for filler and breather filter without (on the left-hand
side) and with by-pass valve (on the right-hand side)
In the past minor importance had been attached to these filters in hydraulic systems. However,
according to latest findings, they are one of the most important elements for the filtration of
hydraulic fluids in hydraulic systems. A significant part of contaminants gets into hydraulic
systems through unsuitable venting equipment. Design measures such as pressurization of oil
tanks are often uneconomical when compared with the highly efficient breather filters offered
on the market today.
Depending on the required cleanliness class, breather filters are equipped with replaceable
elements of different filtration ratings. The filters should be fitted with a connection for clogging
indicators (2).
Filler and breather filters basically consist of an air filter (1) for filtering the air flowing into the
tank and a filling strainer (3) for retaining coarse particles when the system is filled with fluid.
The air filters are available with different filtration ratings so that CETOP standard RP 70 can
be complied with, which prescribes the same filtration rating for system filters and air filters.
The requirements for this filter type are laid down in DIN 24557.
Filtration media
32
For the filtration methods described, various filter media or a combination of filter media are
used.
a) Surface filtration
With surface filters, the particles are separated directly at the surface of the filter media.
Particles that get into the filter medium due to their small diameter can pass through the filter
without any hindrance. However, the filter resistance increases as the surface is clogged.
The filter cake built up on the surface can result in a reduction in the filtration rating.
For surface filtration, diaphragm filters of filter materials made of wire mesh, metal edges or
Dutch weave are used.
b) Deep filtration
The fluid to be filtered penetrates the filter structure. The particles to be removed are also
retained in the deeper layers of the filter. As more and more particles are retained by the
filter, the flow resistance increases so that the filter element has to be replaced. For these
filters, filter media are used, which are made of
impregnated cellulose materials (organic filter material),
glass fiber material (inorganic filter material),
sintered metal meshpacks,
porous, sintered metal.
33
Finest particle
contamination
Finest particles (3 to 5 m)
cause an impairment of
function and reduction in the
performance due to:
the erosive effect of finest
particles (often erosion on
control lands)
fine sedimentation in narrow gaps (through edge
filtration effect - risk of
clogging)
Changes of the operating
medium (oil aging) as a result of chemical reactions
on the particle surface
Finest filtration
Fine particle
contamination
Fine particles (5 to 20 m)
cause cratering mainly in
narrow fits.
The consequences are:
Increase in clearance due
to abrasion (increased
internal leakage)
Temporary failure (brief
seizing effect on sliding
spool valves or leakage on
valve seats)
Coarse particle
contamination
Coarse particles > 20 m
often cause a sudden total
failure due to clogging and
blocking effects or direct
destruction.
Typical:
Blocking of nozzles
Jamming or seizing of
spools
Material breakouts due to
effect of large forces
Fine filtration
Coarse filtration
Separation of mainly coarse
particles (bX 100)
X = m particle size, which
can cause a sudden failure
on the component to be
protected.
Coarse filters protect the
system against coarse
particle contamination
They reduce the risk of a
sudden failure or total loss.
Classification
systems for the
degree of contamination of the
hydraulic fluid
34
The solid particle content in the hydraulic fluid is determined with the help of classification
systems (standardized cleanliness classes).
The most common standards today are NAS 1638 (National Aerospace Standard) and DIN
ISO 4406.
Classification according to NAS 1638
14 cleanliness classes are available for the classification of the hydraulic fluid. For each class,
a certain number of particles (in 100 ml) is specified for each of the 5 sizes.
Contamination class
Particle size in m
5 - 15
15 - 25
25 - 50
50 - 100
> 100
00
125
22
250
44
500
89
16
1000
178
32
2000
356
63
11
4000
712
126
22
8000
1425
253
45
16000
2850
506
90
16
32000
5700
1012
180
32
64000
11400
2025
360
64
128000
22800
4050
720
128
10
256000
45600
8100
1440
256
11
512000
91200
16200
2880
512
12
1024000
182400
32400
5760
1024
Classification
according to
ISO DIS 4406
Assignment of
scale numbers
35
Scale number
up to and including
2500000
> 28
1300000
2500000
28
640000
1300000
27
320000
640000
26
160000
320000
25
80000
160000
24
40000
80000
23
20000
40000
22
10000
20000
21
5000
10000
20
2500
5000
19
1300
2500
18
640
1300
17
320
640
16
160
320
15
80
160
14
40
80
13
20
40
12
10
20
11
10
10
2.5
1.3
2.5
0.64
1.3
0.32
0.64
0.16
0.32
0.08
0.16
0.04
0.08
0.02
0.04
0.01
0.02
0.00
0.01
Filter clogging
indicators
36
Inside the clogging indicators, each change in pressure is recorded as change in travel by means
of metering pistons or diaphragms. A piston with attached magnet is moved against the force
of a spring inside the clogging indicator. On visual clogging indicators, a unipolar magnet is
mounted in the indicator head. The closer the poles come to each other, the greater becomes
the repulsive force between the magnets, until finally the red indictor button pops out.
With the electrical variant, a switching contact picks up.
For a permanent indication of the element contamination electronic clogging indicators were
developed. Through the use of these indicators, maintenance intervals become foreseeable.
With these fully electronic clogging indicators, the differential pressure building up as a result
of contamination of the element is converted contact-free into an analog electrical output
signal with the help of a sensor. A pressure peak suppression and cold start suppression are
additionally integrated.
Safety notes
Warning
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
of all relevant EU Directives.
Observe
Warning
Safety notes
Adjustment features on components may exclusively be operated or changes to programmable control systems made by authorized personnel within the framework of the intended use
of the hydraulic system.
In the case of an emergency, fault or other irregularities:
hydraulic systems must be switched off and the main circuit breaker be secured against
restarting,
the danger zone must be fenced off in order that nobody can enter the danger zone unknowingly or in an uncontrolled manner,
immediately inform the responsible specialist personnel.
Uncontrolled access by external persons to the direct operating area of the hydraulic system
is prohibited (even in case that the hydraulic system is at rest).
Note:
These are the fundamental safety regulations that must be observed for every project task.
Project 01:
Hydraulic power unit
01
Project 01:
Hydraulic power unit
The required drive elements and the accessories such as control and monitoring devices as
well as maintenance equipment can be mounted on top or to the hydraulic fluid reservoir.
The size of the power unit, e.g. the capacity of the reservoir, depends on the given conditions
and customer requirements.
In this project task, the trainee is to set up a power unit on the basis of the conditions listed
below and draw a sketch of a schematic diagram:
Hydraulic pump in the form of a pilot operated, variable vane pump with a displacement of
qV = 20 l/min;
electric motor for a maximum system pressure of p = 80 bar,
reservoir according to the displacement (3 - 5 times qV),
carrier components,
hydraulic filter with visual, mechanical clogging indicator,
filler and breather filter,
level monitor and
drain valve for changing the hydraulic fluid.
A hydraulic accumulator is not provided.
Notes on the detailed technical information about hydraulic power units:
The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, chapter 17
The Hydraulic Trainer Volume 3/Bosch Rexroth AG
Planning and design of hydraulic systems
Technical data sheet RE 51098
Modular standard power units
Technical data sheet RE 10515
Variable vane pump, pilot operated
01
Project 01:
Hydraulic power unit
01
Project definition
In a hydraulic system for driving lifting equipment for heavy loads, a hydraulic power unit with
a variable displacement pump powered by an electric motor and associated accessories is to
be used.
The customer wishes to get information about the structure of a hydraulic power unit with pilot
operated vane pump. In the list of the hydraulic power unit components he requests the provision of short information about the selected components, including a schematic diagram of the
hydraulic system and a parts list.
Fig. 01.1 Practical example: Hydraulic power unit with hydraulic pump/el. motor and
accessories
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet for a standard power unit with pilot operated vane pump
(technical qualification)
Handling of hydraulic components in line with functional needs
Project 01:
Hydraulic power unit
01
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others, through the selection of power unit construction parts from a technical
data sheet (RE 91098 / modular standard power units).
Deciding:
Executing::
Checking:
Evaluating:
Project 01:
Hydraulic power unit
01
Item 10.0
Item 9.0
Measuring glass
Item 6.0
Item 2.0
Item 4.0
Item 7.0
Item 8.0
Item 3.0
Item 1.0
Item 5.0
Project 01:
Hydraulic power unit
01
Qty
Component designation
Type designation
1.0
2.0
3.0
Level control
FSK
4.0
Electric motor
4 KW/1450 rev/
min.
5.0
6.0
S6-1X/...
7.0
RF 060...
8.0
9.0
10.0
Measuring glass
Symbol
100 L/steel
PV7-1X/16-30...
Table 01.1 Parts list for hydraulic circuit diagram Fig. 01.2
Project 01:
Hydraulic power unit
01
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Notes
Project 01:
Hydraulic power unit
01
Piston area AP
Force F
v
Pressure differential p
Energy converter
e.g. cylinder
Annulus area AA
Directional valve
Start, direction, stop
Force
pA
10
F =
F = force in N
p = pressure in bar
A = area in mm2
Velocity
v=
s
t
v = velocity in
s
s = travel in m
t = time in s
Displacement/flow
Vg n vol
qV =
1000
qV = flow in
l
min
cm3
rev
n = Speed of the pump shaft in rev
min
Vg = geometric displacement in
= volumetric efficiency in %
Pressure control
valve
Force / pressure
limitation
Motor power
PM =
PM
p
qV
total,P
Energy converter
e.g. fixed displacement pump
p qV
600 total ,P
=
=
=
=
power in kW
pressure in bar
l
flow in
min
overall efficiency in %
Project 01:
Hydraulic power unit
Ambient temperatures
Heat dissipated by the reservoir
Cooling (air, water)
Heating
Acoustic insulation
Hoses
Compensators
Anti-vibration mounts
Low flow velocity
Pump selection
Encapsulation
Hydraulic accumulator
Silencers
etc.
01
Project 01:
Hydraulic power unit
10
Hydraulic pump:
The following must be known for rating the hydraulic pump:
qV = ? l/min., i.e. which volume is the pump to provide within which time.
Since manufacturers usually indicate only the sizes in technical data sheets (how much is
displaced during one revolution of the pump?), the speed of the drive/electric motor must be
known. In industrial applications, motors of approx. 1,500 rev/min. are employed. For converting
the displacement into power per unit of displacement the following formula can be applied:
qV =
Vg n
in l/min
1.000
Because no manufacturer will be able to offer a hydraulic pump with exactly the requested
power, the next larger size is usually selected.
Electric motor:
For rating the electric motor, the possible maximum system pressure must be known apart from
the displacement of the hydraulic pump in l/min.
Calculation formula for the selection of the hydraulic motor:
P=
p qV
600
in kW
p in bar
qV in l/min
Also here, the next larger frame size of the manufacturer's electric motor is selected. Typical
frame sizes are, e.g. 3 kW, 4 kW, 5.5 kW, 7.5 kW, etc.
The selection of the required carrier components such as coupling, pump mounting bracket
and damping elements will not be considered here and are not part of the order execution.
Hydraulic fluid reservoir:
Hydraulic fluid reservoirs are selected on the basis of practical experience such as:
Reservoir size = displacement of the hydraulic pump 5
Whenever possible, standard reservoirs of standardized sizes should be used. The topic of
cooling is not dealt with in this simple engineering task. The provision of a drain valve is always
recommended for changing the hydraulic fluid.
Accessories:
In this project task, required accessories for a hydraulic fluid reservoir are a return flow filter, a
filler/breather filter and a level control device. For the selection, please refer to technical data
sheets of the manufacturers.
When selecting the return flow filter, the actual flow required for operating a single-rod cylinder
must in any case be taken into account, i.e. how much oil returns from the hydraulic cylinder to
the filter (see Project 04).
The factors that have an influence on the selection of a return flow filter are listed on the previous page.
01
Project 01:
Hydraulic power unit
11
As additional aid for rating a hydraulic power unit we recommend the use of a hydraulic slide
rule.
For the simplified rating of a return flow filter, see technical data sheet RE 50081.
Detailed notes on the engineering and design of hydraulic systems can be found in The Hydraulic
Trainer Volume 3/Bosch Rexroth AG.
General note:
In contrast to the following project tasks, this order execution does not involve any practical
work on the training system.
A component arrangement drawing and a general layout of the training system are therefore
not provided.
01
Project 01:
Hydraulic power unit
Notes
12
01
Project 01:
Hydraulic power unit
13
Q.
Public, John
Project handler
Customer requirement:
Parts list
Project designation
Informing
from the project definition.
Planning steps
Planning
of the project objective and
the proceeding.
System rating/calculation
Identifiy components
Rate components
Sources of information
DIN ISO 1219
Project manager
Data sheets
Internet
Hydraulics supplier
Make calculations
Decision-making
Deciding on
and selecting components;
complementing the circuit
diagram and parts list.
(Overleaf)
01
Project 01:
Hydraulic power unit
14
01
Summarize the information obtained
Execution
Set-up of the electrohydraulic control and acquisition of required data.
Special points?
Pump data sheet RE 10515 is very complex
Quality check
Checking
Are all customer requirements met?
Evaluating
Optimize project steps
Project 01
Project 02:
Hydraulic variable displacement pump
02
Project 02:
Hydraulic variable displacement pump
Project definition
In a hydraulic power unit, the hydraulic energy is to be provided by a variable, pilot operated
vane pump. The power that can be generated by the hydraulic pump is to be measured in an
experiment set-up.
The customer wishes detailed information about the pros and cons of this vane pump, including
a flow characteristic curve, from which the relationship between increasing system pressure
and losses of the vane pump can be seen.
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet for a pilot operated vane pump (technical qualification)
Handling of hydraulic components in line with functional needs
02
Project 02:
Hydraulic variable displacement pump
Project steps
Notes
Informing:
Planning:
Deciding:
Executing::
Working out the set-up of a hydraulic control on the training system, documenting the characteristic curve required by the customer and providing
explanations with regard to the characteristic curves and power losses.
Checking:
Evaluating:
02
Project 02:
Hydraulic variable displacement pump
02
Item 1.1
Item 1.2
Item 0.1
Item 1.0
Measuring
glass
Project 02:
Hydraulic variable displacement pump
Qty
Component designation
Type designation
1.0
DD 1.1
1.1
DF 1.2
1.2
DZ 2.1
0.1
DZ 1.4
DZ 25.1
Symbol
VSK 1
Stopwatch
Table 02.1 Parts list for hydraulic circuit diagram Fig. 02.2
02
Project 02:
Hydraulic variable displacement pump
Component arrangement
Connection block
Measuring glass
02
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 02.3 Recommended component arrangement with component designation for parts list table 02.1 and hydraulic circuit diagram Fig. 02.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
Project 02:
Hydraulic variable displacement pump
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 02.2 by means
of hoses.
For connections, to which pressure gauges with minimess hose DZ 1.4 are to be connected,
use hydraulic hoses DZ25. Hand-tighten the pressure gauge measuring lines hand tight at
the relevant minimess connection of the hydraulic hose.
The proper and tight fit of hose connections of components can be easily checked by
slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
Completely close throttle valve item 1.1. To this end, turn the adjustment element clockwise
to the mechanical limit stop. Close shut-off valve item 1.2.
2. Switch the hydraulic pump on and check and the set up control for any leakage.
3. Adjust the system pressure on pressure relief valve item 1.0 to 50 bar plus one turn.
4. Check the set pressure on the variable displacement pump of the drive power unit (zero
stroke pressure 50 bar).
02
Project 02:
Hydraulic variable displacement pump
Flow measurement
5. Open shut-off valve item 1.2.
6. Open throttle valve item 1.1 until a pressure of 15 bar is present at measuring point M1.
7. Flow measurement by means of the measuring glass; to this end, close shut-off valve item
1.2, close the measuring glass, open shut-off valve item 1.2 for 10 s.
Record the filling quantity and enter the measured value in Table 02.2.
8. Take flow measurements as described in points 6. to 7. at pressure values of 30 bar,
40 bar, 45 bar and 50 bar and enter the recorded measured values in Table 02.2.
Caution
After completion of practical work, switch the hydraulic pump on the training
system off! Turn pressure relief valve item 1.0 back to minimum pressure.
Open throttle valve item 1.1 completely. No pressure gauge may indicate a
pressure!
9. Calculate the measured oil flow/time and enter it as flow in qV = l/min in Table 02.2.
Enter the individual values as points in Diagram 02.3 and connect the individual points with
a line to create a curve.
The resulting curve is the typical characteristic curve of the pilot operated, variable vane
pump.
Measured values
Pressure
bar
15
30
40
45
50
Time
10
10
10
10
10
Volume
1.32
1.25
1.20
1.10
Flow
qV
l/min
7.92
7.50
7.20
6.60
02
Project 02:
Hydraulic variable displacement pump
Flow qV in l/min
02
Project 02:
Hydraulic variable displacement pump
10
Notes
02
Project 03:
Single-rod cylinder / pressure intensification
p in bar; A in cm
m2
The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to change, i.e. reduce, the piston velocity. When throttling, for
example, the piston extension velocity, important physical laws must be taken into account.
In the following Project 03 knowledge can be imparted with regard to the use of single-rod
cylinders as machine elements.
In the project order, the trainee is to work out the physical basic principles of pressure intensification with single-rod cylinders. On the basis of this project task, he/she is to understand
the following:
The hydraulic cylinder performs a straight movement and transmits the supplied piston pressure in the form of force.
Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
Forces and velocities can be kept constant over the entire stroke.
Biased on the control set up on the training system the trainee is to learn that the use of a meterout throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can
be varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished
with the help of a 4/2 directional valve.
Notes on detailed technical information about hydraulic cylinders:
The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, Chapter 7
Technical data sheet RE 17039
Hydraulic cylinders of tie rod design
03
Project 03:
Single-rod cylinder / pressure intensification
Project definition
A workpiece is to be shifted by a horizontally installed single-rod cylinder to the working range
of a simple fixture when the hydraulic pump is switched on. To this end, the extension velocity
of the cylinder must be adjustable. Retracting is to be achieved by means of a 4/2 directional
valve.
The customer installed a throttle valve on the piston rod side and, while adjusting the extension
velocity, recognizes that the pressure upstream of the throttle becomes higher than the set
system pressure. Apart from the technical documentation he wishes to get an explanation of
the pressure intensification of the single-rod cylinder.
Project tasks
Independent understanding and execution of the task set through application of hydraulic
control technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a hydraulic cylinder (specialist qualification)
Handling of hydraulic components in line with functional needs
03
Project 03:
Single-rod cylinder / pressure intensification
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others, through the selection of hydraulic components from the data sheet
collection (RE 17039 Hydraulic cylinders, tie rod design).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer and explanations with regard to pressure intensification on the basis of a calculation
example.
Checking:
Evaluating:
03
Project 03:
Single-rod cylinder / pressure intensification
03
Item 1.0
Item 0.2
Item 0.3
Item 1.3
Item 1.1
Item 0.1
Item 1.2
Measuring
glass
Project 03:
Single-rod cylinder / pressure intensification
03
Project 03:
Single-rod cylinder / pressure intensification
Qty
1.0
Double-acting cylinder
with single-sided piston rod
ZY 1.3
1.1
DW 3 E
1.2
DD 1.1
1.3
DF 1.2
DZ 4.1
DZ 1.4
DZ 25.1
0.1 - 0.3
Component designation
Hose
Table 03.1 Parts list for hydraulic circuit diagram Fig. 03.2
Type designation
VSK 1
Symbol
03
Project 03:
Single-rod cylinder / pressure intensification
Component arrangement
Connection block
Measuring glass
03
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 03.4 Recommended component arrangement with component designations for parts list Table 03.1 and hydraulic circuit diagram Fig. 03.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 03:
Single-rod cylinder / pressure intensification
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 03.2 by means of
hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Check the pressure set on the variable displacement pump of the drive power unit (if
required, correct to 50 bar).
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn; operate
push-button S2 to prevent the piston of hydraulic cylinder Item 1.0 from extending.
5. Through operation of push-button S1 the control voltage of solenoid Y1 of the 4/2 directional
valves Item 1.1 drops, and the piston of the hydraulic cylinder extends due to the pump flow
supplied directly to the piston side.
03
Project 03:
Single-rod cylinder / pressure intensification
6. Switch the hydraulic pump off and wait until the system is depressurized. Close throttle
valve Item 1.3. To this end, turn in the adjustment element counter-clockwise to the limit
stop.
7. Switch the hydraulic pump on. The piston of the hydraulic cylinder cannot extend, because
the counterforce on the piston rod side is greater than the force on the piston side, since
the throttle valve is closed. Pressure gauge M3 indicates the value of pressure intensification. Note the measured values and enter them in Table 03.2.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.2 back to minimum
pressure. No pressure gauge may indicate a pressure!
Measured values
Hydraulic
cylinder
Measuring point M1
System pressure p in bar
M2 piston side
p in bar
48
48
82
Extending/
Y1 not operated
25 mm
18 mm
4,91 cm2
2,54 cm2
= 2,07 : 1
03
Project 03:
Single-rod cylinder / pressure intensification
10
03
Project 04:
Single-rod cylinder/flow
AK
AK
AR
AR
10
Values in l/min
20
e.g.
qV = 20 l/min
= 2 : 1
The following Project 04 is intended to impart knowledge of the use of single-rod cylinders as
machine element, in particular with reference to the piston velocities and flows.
In this project order, the trainees are to be made familiar the velocity behavior during the extension and retraction of the cylinder piston of single-rod cylinders. Through this project task, they
are to understand the following:
The piston velocity of a double-acting cylinder - single-rod cylinder - depends on the cylinder
size and the supplied flow.
The different piston areas result in different flow velocities, which have an influence on the
selection of connection elements, the line system and power unit accessories such as filtration and cooling systems.
In the case of double-rod cylinders, the forces transmitted and the piston velocities are
identical in both directions of action of the piston.
On the basis of the control set up on the training system the trainees are to recognize that the
cylinder piston retracts and extends at different velocities. When the hydraulic pump is switched
on, the piston of the single-rod cylinder extends. Controlled by a 4/2 directional valve, the piston of the hydraulic cylinder retracts. The extension and retraction velocity can be changed by
means of a throttle valve on the piston rod side.
Notes on detailed technical information about hydraulic cylinders:
The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, Chapter 7
Technical data sheet RE 17039
Hydraulic cylinders, tie rod design
04
Project 04:
Single-rod cylinder/flow
Project definition
Like in Project 03 a workpiece is to be moved to the working range of a simple fixture by a
horizontally installed single-rod cylinder when the hydraulic pump is switched on. To this end,
the extension velocity of the cylinder must be adjustable. The return is to be accomplished with
the help of a 4/2 directional valve.
The customer observes that with an open throttle valve the piston velocities during extending
and retracting of the cylinder are different. Apart from the technical documentation, he wishes
to obtain an explanation with regard to the different piston velocities of the single-rod cylinder.
He also requests details about the filling volume of the hydraulic cylinder used.
Fig. 04.1 Practical example: Schematic illustration of flow velocities in the single-rod cylinder
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a hydraulic cylinder (specialist qualification)
Handling of hydraulic components in line with functional needs
04
Project 04:
Single-rod cylinder/flow
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others,
through the selection of hydraulic components from the data sheet collection
(RE 17039 Hydraulic cylinders of tie rod design).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Prepration and documentation of the information and explanations with regard to the single-rod
cylinder as demanded by the customer.
Checking:
Evaluating:
04
Project 04:
Single-rod cylinder/flow
Item 1.0
04
Item 0.2
Item 0.3
Item 1.1
Item 0.1
Item 1.3
Item 1.2
Measuring
glass
Project 04:
Single-rod cylinder/flow
04
Project 04:
Single-rod cylinder/flow
Qty
Component designation
Type designation
1.0
ZY 1.3
1.1
DW 3 E
1.2
DD 1.1
1.3
DF 1.2
DZ 4.1
DZ 1.4
DZ 25.1
0.1 - 0.3
Hose
1
Stopwatch
Flowmeter
Table 04.1 Parts list for hydraulic circuit diagram Fig. 04.2
VSK 1
DZ 30
Symbol
04
Project 04:
Single-rod cylinder/flow
Component arrangement
04
Measuring glass
Note:
The component arrangement
shows the optional variant with
electronic flow measurement
Connection block
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 04.4 Recommended component arrangement with component designations for parts list Table 04.1 and hydraulic circuit diagram Fig. 04.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 04:
Single-rod cylinder/flow
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 04.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Check the pressure set on the variable displacement pump of the drive power unit (if
required, correct to 52 bar).
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn; operate
push-button S2 to prevent the piston of hydraulic cylinder Item 1.0 from extending.
5. Due to the operation of push-button S2 the control voltage of solenoid Y1 of the 4/2 directional valve Item 1.1 drops and the piston of the hydraulic cylinders extends due to the
pump flow fed directly to the piston side.
6. The extension velocity of hydraulic cylinder piston Item 1.0 is to be adjusted to 5 s by
means of throttle valve Item 1.3 while directional valve Item 1.1 is not operated.
04
Project 04:
Single-rod cylinder/flow
7. Measure the pressures at measuring points M1, M2, M3 during extending, retracting and
at the relevant end position of the cylinder and enter the values in Table 04.2.
Establish the time required for extending and retracting by means of a stopwatch and enter
the values also in Table 04.2.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! Turn all pressure valves of the electrohydraulic control
back to minimum pressure. Completely open throttle valves, if installed. No
pressure gauge may indicate a pressure!
Measured values
Hydraulic
cylinder
Piston position
Position
4/2 directional
valve
M1
M2
M3
p in bar p in bar p in bar
t
in s
v
in m/s
V
in l
Extending
49
0.051
Extended
50
49
0.098
Retracting
49
3.2
0.073
Retracted
50
49
0.058
200 mm = 20 cm
V = A s
Fill:
Piston volume:
Type: CD T3...25/16...200
A in cm2
s in mm
V in l
04
Project 04:
Single-rod cylinder/flow
10
04
Project 05:
Hydraulic motor
05
Project 05:
Hydraulic motor
Project definition
Heavy loads are to be lifted and lowered by means of a rope winch. The velocity of the rope
winch is to be adjustable. For space reasons, the use of a hydraulic cylinder is impossible, i.e.
the rope winch must be powered by a hydraulic motor. Also an electrical solution is not desirable due to changing loads.
In order that the customer can understand the hydraulic solution proposed, he requires technical
documentation such as a hydraulic circuit diagram with parts list and the required measured
data such as an evaluation of the differential pressure across the hydraulic motor at different
flows.
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a hydraulic motor (specialist qualification)
Handling of hydraulic components in line with functional needs
05
Project 05:
Hydraulic motor
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others,
through the selection of hydraulic components from the data sheet collection
(RE 91001 Axial piston motor).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer.
Checking:
Evaluating:
05
Project 05:
Hydraulic motor
Item 0.2
Item 0.3
Item 1.0
05
Item 1.1
Item 0.4
Item 1.4
Item 1.3
Item 0.1
Item 1.2
Measuring
glass
Project 05:
Hydraulic motor
05
Stop
Fig. 05.3 Wiring diagram for hydraulic circuit diagram Fig. 05.2
Rotation
Rotation
-Hydraulic motor-
Project 05:
Hydraulic motor
Qty
1.0
1.1
DW 13 E
1.2/1.4
DD 1.1
1.3
DF 1.2
DZ 4.1
DZ 1.4
DZ 25.1
0.1 - 0.4
Component designation
Hose
1
Stopwatch
Tachometer
Flowmeter
Table 05.1 Parts list for hydraulic circuit diagram Fig. 05.2
Type designation
Symbol
DM 8
05
VSK 1
DZ 30
Project 05:
Hydraulic motor
Component arrangement
Connection block
Measuring glass
05
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 05.4 Recommended component arrangement with component designations for parts list Table 05.1 and hydraulic circuit diagram Fig. 05.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 05:
Hydraulic motor
Component arrangement/optional
Note:
The component arrangement
shows the optional variant with
electronic flow measurement
Connection block
Measuring glass
05
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 05.6 Recommended component arrangement with component designations for parts list Table 05.1 and hydraulic circuit diagram Fig. 05.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 05:
Hydraulic motor
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 05.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Check the set pressure on the variable displacement pump of the drive power unit (if
required, correct to 50 bar).
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
05
Project 05:
Hydraulic motor
10
In the next working step the hydraulic motor rotates. Take care that clothes,
hair, etc. cannot get caught by the motor plate.
Caution
5. By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.1 is energized.
Hydraulic motor Item 1.0 rotates clockwise.
While the hydraulic motor is rotating, adjust preload pressure M4 to 20 bar by means of
pressure relief valve Item 1.4.
6. Close throttle valve Item 1.3, then open it by turn (the first value given in Table 05.2).
7. By actuating push-button S2 solenoid Y1a of 4/3 directional valves Item 1.1 is energized.
The hydraulic motor rotates counter-clockwise.
Use the measuring glass and a stopwatch or optionally an electronic flow measuring system
to acquire the flow qV in l/min and enter the values in Table 05.2. Also measure pressures
M1, M2, M3, M4 and enter them in Table 05.2.
8. Continue to set throttle valve Item 1.3 to the values given in Table 05.2 and enter the measurement result in Table 05.2.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.2 back to minimum
pressure, completely open throttle valve Item 1.3. No pressure gauge may
indicate a pressure!
Measured values
Adjustment of speed of rotation
Throttle valve Item 1.3
M1
M2
M3 M2 - M3 M4
qV
n
p in bar p in bar p in bar Dp in bar p in bar in l/min in min-1
Throttle closed
50
turn opened
49
20
17.5
2.5
15
264 *
turn opened
48
22
19
16
2.6
335 *
1 turn opened
48
25
21
17.5
3.7
435 *
1 turn opened
48
30
25
18
4.7
540 *
2 turns opened
48
31
25
19
5.1
595 *
48
34
27
19
5.7
655 *
Table 05.2 Measured values from the work order for counter-clockwise direction of rotation of the motor
* The values in column 8 were established by means of a speed sensor.
05
Project 05:
Hydraulic motor
11
Additional tasks:
Calculation of the output power at maximum speed using the formulas below.
P=
qV =
n=
p qV
600
in kW
V
60
t
qV vol
Vg
1000
P = output power in kW
p = pressure in bar
qV = swept volume in l/min
V = content of the measuring glass in l
t = measuring time in s
n = drive speed in min-1
hvol = volumetric efficiency of the motor
Vg = geometric swept volume (displacement) of the
motor in cm3/rev
hvol = 0.8
Vg = 4.93 cm3/rev - DM2
05
Project 05:
Hydraulic motor
12
Notes
05
Project 06:
4/3 directional valve
06
Project 06:
4/3 directional valve
Project definition
A single-rod cylinder is to shift and position tools horizontally in a fixture. When in the rest position the hydraulic cylinder must not move, and the fixed displacement pump is to be spared
and thus energy saved.
The customer wants to be informed about the pros and cons of the various spool shapes, in
particular blocked and circulation position. In order that the customer can understand your
proposed solution, he requires technical documentation such as the hydraulic circuit diagram
with parts list, and the required measured data for the spool shapes/symbols.
06
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a directional valve (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 06:
4/3 directional valve
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others, through the selection of hydraulic components from the data sheet
collection (RE 23178/4/3 directional valve).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters as required by the customer.
Checking:
Evaluating:
06
Project 06:
4/3 directional valve
Item 1.0
Item 0.2
Item 0.3
06
Item 1.1
Item 0.1
Item 1.3
Measuring
glass
Project 06:
4/3 directional valve
06
Circulation
Fig. 06.3 Wiring diagram for hydraulic circuit diagram Fig. 06.2
Extension Retraction
-Single-rod cylinder-
Project 06:
4/3 directional valve
Item 1.0
Item 0.2
Item 0.3
06
Item 1.2
Item 0.1
Item 1.3
Measuring
glass
Project 06:
4/3 directional valve
06
Stop
Fig. 06.5 Wiring diagram for hydraulic circuit diagram Fig. 06.4
Retraction Extension
-Single-rod cylinder-
Project 06:
4/3 directional valve
Qty
1.0
Double-acting cylinder
with single-sided piston rod
ZY 1.3
DW 4E
1.2
DW 13E
1.3
DD 1.1
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
1.1
0.1 - 0.3
Component designation
Flowmeter
Table 06.1 Parts list for hydraulic circuit diagrams Fig. 06.2 and 06.04
Type designation
Symbol
06
DZ 30.N
Project 06:
4/3 directional valve
Note:
The component arrangement
shows the optional variant with
electronic flow measurement
Connection block
Measuring glass
Component arrangement/task 1
06
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 06.6 Recommended component arrangement with component designations for parts list Table 06.1 and hydraulic circuit diagram Fig. 06.02
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 06:
4/3 directional valve
10
Note:
The component arrangement
shows the optional variant with
electronic flow measurement
Connection block
Measuring glass
Component arrangement/task 2
06
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 06.8 Recommended component arrangement with component designations for parts list Table 06.1 and hydraulic circuit diagram Fig. 06.4
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 06:
4/3 directional valve
11
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 06.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve Item 1.3 to 30 bar,
and: By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.1 is energized. The pump flow is fed against the piston rod side of hydraulic cylinder Item 1.0
and the system pressure can be set to 30 bar.
4. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized.
The piston of the hydraulic cylinder extends.
06
Project 06:
4/3 directional valve
12
Caution
Task 2
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.3 back to minimum
pressure. No pressure gauge may indicate a pressure!
6. Modify the hydraulic control according to hydraulic circuit diagram 06.4. Proceed as described in task one, steps 1 and 2.
7. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
8. Set the system pressure on pressure relief valve Item 1.3 to 30 bar.
9. By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.2 is energized. The piston of hydraulic cylinder Item 1.1 extends.
By actuating push-button S2 the piston of the hydraulic cylinder retracts.
In contrast to task 1, positions "a and "b of the 4/3 directional valve are exchanged due
to the spool shape/symbol.
Measurements for task 2:
10. Measure the specified values in the end positions of the hydraulic cylinder and in the rest
position (central position) of the 4/3 directional valve as listed in Table 06.3 and enter the
values in Table 06.3.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.3 back to minimum
pressure. No pressure gauge may indicate a pressure.
Directional valve
position
M1
p in bar
M2
p in bar
M3
p in bar
qV
in l/min
Piston extended
30
30
7.66
Piston retracted
30
30
7.66
06
Project 06:
4/3 directional valve
13
Directional valve
position
M1
p in bar
M2
p in bar
M3
p in bar
qV
in l/min
Piston extended
30
30
7.66
Piston retracted
30
30
7.66
30
7.66
06
The values were measured at an oil temperature of approx. 20 C.
The values measured by the trainees can deviate by 10 %.
Project 06:
4/3 directional valve
14
Notes
06
Project 07:
Check valve
07
Project 07:
Check valve
Project definition
In a fixture, a load suspended on a vertical cylinder is to be held by means of a check valve.
Lowering of the load should be possible with a shut-off valve. The piston rod side is to be protected by means of a pressure relief valve. (The lowering movement via the electrical control is
not an integral part of the order). The velocity is to be adjustable.
In order that the customer can understand your proposed solution, he requires technical documentation.
In addition, he wants to know whether particular problems could arise, if a check valve is installed
on the piston rod side.
07
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a check valve (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 07:
Check valve
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others, through the selection of hydraulic components from the data sheet
collection (RE 20375 Check valve).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters requred by the customer.
Checking:
Evaluating:
07
Project 07:
Check valve
Item 0.3
Item 1.6
Item 0.2
Item 1.5
Item 1.3
07
Item 1.4
Item 1.1
Item 0.1
Item 1.2
Fig. 07.2 Hydraulic circuit diagram: Control of a vertical cylinder with suspended load
Measuring
glass
Project 07:
Check valve
07
(Emergency stop)
Stop
Project 07:
Check valve
Qty
1.0
Double-acting cylinder
with single-sided piston rod with
load
1.1
DW 10E
1.2/1.5
DD 1.1
1.3
DS 2.1
1.4
DZ 2.1
1.6
DF 1.2
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.3
Component designation
Table 07.1 Parts list for hydraulic circuit diagram Fig. 07.2
Type designation
Symbol
ZY 1.Last
07
Project 07:
Check valve
Measuring glass
Component arrangement
Connection block
07
D
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 07.4 Recommended component arrangement with component designation for parts list Table 07.1 and hydraulic circuit diagram Fig. 07.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Project 07:
Check valve
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 07.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn (in
pressure line M1).
07
Project 07:
Check valve
4. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized,
i.e. the cylinder retracts. Opening of shut-off valve Item 1.4 causes the cylinder to extend.
5. Safety valve setting against pressure intensification on the piston rod side:
Starting position of the cylinder: B.D.C. (bottom dead center, cylinder extended).
Close shut-off valve Item 1.4. Set pressure relief valve Item 1.5 on the piston rod side to
maximum pressure (spring tensioned - 1 turn).
Move the cylinder to the U.D.C. by operating push-button S2. Move directional valve Item
1.1 by manual operation to position Y1b while opening pressure relief valve Item 1.5 on
the piston rod side until pressure gauge M3 indicates a pressure of 80 bar (safety setting
against pressure intensification on the piston rod side).
Check the set value by extending the cylinder again.
6. Check lowering of the load in the de-energized condition by opening shut-off valve Item 1.4.
The lowering velocity can be adjusted by means of throttle valve Item 1.6.
The pressure that builds up when the cylinder supports on the counterforce of pressure
relief valve Item 1.5 on the piston rod side is called load holding pressure. To determine
the load holding pressure, the cylinder must be at the U.D.C. While the shut-off valve is
closed, slowly open the pressure relief valve until the cylinder starts to lower. M3 indicates
the load holding pressure. On the basis of the load holding pressure and the dimensions of
the hydraulic cylinder the weight of the load can be calculated.
Note:
To prevent pressure intensification, a safety valve (pressure relief valve) is used in practical applications, e.g. in a welding fixture. The upward stroke is accomplished via a check
valve installed in parallel.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! Set the throttle valve and the pressure relief valves to
minimum pressure. For the disassembly, the load must be lowered. No pressure gauge may indicate a pressure!
07
Project 07:
Check valve
10
Notes
07
Project 08:
Check valve, pilot operated
08
Project 08:
Check valve, pilot operated
Project definition
A cylinder in a rig (gripper) is to be protected against lowering by a pilot operated check valve. The
hydraulic control from Project 07 is to be modified according to the customer requirements.
In order that the customer can understand your proposed solution, he requires the modified
technical documentation.
As the lowering speed should also be adjustable here, the customer wants to know, at which
position the throttle valve can be installed. Moreover, he wants to know at which pilot pressure
the pilot operated check valve opens.
08
Fig. 08.1 Practical example: Hydraulically pilot operated check valves in a rig (gripper)
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet for a pilot operated check valve (technical qualification)
Handling of hydraulic components in line with functional needs
Project 08:
Check valve, pilot operated
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others, through the selection of hydraulic components from the data sheet
collection (RE 21460 / pilot operated check valve).
Deciding:
Executing::
Checking:
Evaluating:
08
Project 08:
Check valve, pilot operated
Item 0.3
Item 1.6
Item 0.2
Item 1.4
Item 1.3
Item 1.5
08
Item 1.1
Item 0.1
Item 1.2
Fig. 08.2 Hydraulic circuit diagram: Check valve, hydraulically pilot operated
Measuring
glass
Project 08:
Check valve, pilot operated
Stop
08
Note:
Extension = Y1.b + Y2
Project 08:
Check valve, pilot operated
Qty
1.0
ZY 1.Last
1.1
DW 10E
1.2/1.5
DD 1.1
1.3
DW 3E
1.4
DS 1.1
1.6
DF 1.2
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.3
Component designation
Table 08.1 Parts list for hydraulic circuit diagram Fig. 08.2
Type designation
Symbol
08
Project 08:
Check valve, pilot operated
Measuring glass
Component arrangement
Connection block
08
D
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 08.4 Recommended component arrangement with component designations for parts list Table 08.1 and hydraulic circuit diagram Fig. 08.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Project 08:
Check valve, pilot operated
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
08
Execution of the order
Set-up of the control as described in the following:
1. Mount the components required according to Table 08.1 on the training system in a clearly
arranged manner according the prepared circuit diagram.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 08.2 by means
of hoses.
For connections, to which pressure gauges with minimess hose DZ 1.4 are to be connected,
use hydraulic hoses DZ25. Hand-tighten the pressure gauge measuring lines hand tight at
the relevant minimess connection of the hydraulic hose.
The proper and tight fit of hose connections of components can be easily checked by
slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and check the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Adjust the system pressure on pressure relief valve item 1.2 to 50 bar plus one turn.
4. The operation of pushbutton S2 causes the energization of solenoid Y1a of 4/3 directional
valve item 1.1, i.e. the cylinder retracts. Turn item 1.5 in until the cylinder starts to move.
Project 08:
Check valve, pilot operated
Caution
Only operate S3; turn in pressure relief valve completely, then turn pressure
relief valve out until 80 bar is applied at M3. The cylinder is to come to a
standstill.
5. The actuation of pushbutton S3 causes 4/3 directional valve item 1.1 to be operated, i.e.
pressure is supplied to the the piston side of the hydraulic cylinder. The piston cannot extend.
Measure the pressures in M1, M2 and M3 and enter the values in Table 08.2.
6. Only when pushbutton S4 is operated additionally is port X of pilot operated check valve
item 1.4 controlled via 4/2 directional valve item 1.3 and the check valve opens. Fluid can
now flow at zero pressure from the piston rod side via 4/3 directional valve item 1.1 to the
reservoir.
Measure the pressures at M1, M2 and M3 during operation and enter the values in Table
08.2.
Caution
While the throttle is open and the piston is lowering, the movement of the
piston may be very jerky. The piston can advance due to the load on the vertical cylinder. This causes underpressure in the piston chamber and hence
an absence of pilot pressure at port X of the pilot operated check valve, i.e.
the valve closes abruptly. When pressure is built up again on the piston side,
port X on the check valve is again supplied with pilot pressure. The check
valve opens abruptly.
7. Set the lowering speed of the cylinder to a lowering time of approx. 5 s on throttle valve
item 1.6.
Caution
Notes
Before converting the circuit for the further execution of the order, switch
the hydraulic pump off!
08
Project 08:
Check valve, pilot operated
10
Measured values
M1
p in bar
M2
p in bar
M3
p in bar
45
45
70
20
10
15
Measuring point
08
Caution
After having completed the practical work on the training system, switch the
hydraulic pump off! Set the throttle valve and the pressure relief valves to minimum pressure. No pressure gauge may indicate a pressure!
Project 09:
Throttle valve, adjustable
09
Project 09:
Throttle valve, adjustable
Project definition
In the plant of the customer, a conveyor belt, on which unchanged loads are transported, is
powered by a hydraulic motor. The drive speed of the hydraulic motor is to be adjustable in
both directions of travel.
In order that the customer can understand the proposed solution, he requires technical documentation.
As an option, he wants to know whether the drive speed changes when loads of different
weights are transported.
09
Fig. 09.1 Practical example: Conveyor belt for transporting printed-circuit boards
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a throttle valve (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 09:
Throttle valve, adjustable
Project steps
Informing:
Planning:
Planning and organizing the execution of the customer order; among others, through the selection of hydraulic components from the data sheet
collection (RE 27219 Throttle check valve).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters requred by the customer.
Checking:
Evaluating:
09
Notes
Project 09:
Throttle valve, adjustable
Item 0.2
Item 0.3
Item 1.3
Item 1.0
Item 1.5
Item 1.1
Optional
09
Item 1.4
Load pressure
Item 0.1
Item 1.2
Measuring
glass
Project 09:
Throttle valve, adjustable
Stop
09
Fig. 09.3 Wiring diagram for hydraulic circuit diagram Fig. 09.2
Rotation
Rotation
-Hydraulic motor-
Project 09:
Throttle valve, adjustable
Qty
1.0
DM 2.N
1.1
DW 13E
1.2/1.4
DD 1.1
1.3
DF 1.2
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.3
Component designation
Stopwatch
Flowmeter
Table 09.1 Parts list for hydraulic circuit diagram Fig. 09.2
Type designation
DFF 1
Symbol
09
Project 09:
Throttle valve, adjustable
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 09.4 Recommended component arrangement with component designation for parts list 09.1 and hydraulic circuit diagram Fig. 09.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
09
Project 09:
Throttle valve, adjustable
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
09
Connect the hydraulic control according to hydraulic circuit diagram Fig. 09.2 by means of
hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
4. By actuating push-button S1 solenoid Y1b of 4/3 directional valve Item 1.1 is energized,
the hydraulic motor Item 1.0 rotates.
Throttling process 1:
5. Close throttle valve Item 1.3. Then open the throttle valve by turn of the adjustment knob.
Marking with a point for the precise adjustment (1st position).
Project 09:
Throttle valve, adjustable
While directional valve Y1b is operated, the load pressure can be adjusted to 20 bar on
pressure relief valve Item 1.4, which is installed in the return line of the 4/3 directional valve,
and the pressure value read off from pressure gauge M3.
6. The flow measurement can be taken with the help of a measuring glass in liters/time or
optionally using flowmeter Item 1.5. Measure the pressure differential p across throttle
valve Item 1.3 using pressure gauges M2 and M3 and enter the values in Table 09.2.
7. While the throttle position remains unchanged (1st position) increase the load pressure
to 25 bar, 30 bar, 35 bar, 40 bar and 42 bar.
Throttling process 2:
8. Throttle valve Item 1.3, turn opened (2nd position).
Follow the instructions in points 6 to 8 and enter the values in Table 09.2.
Throttling process 3:
9. Throttle valve Item 1.3, 1 turns opened (3rd position).
Follow the instructions in points 6 and 7 and enter the measurement result in Table 09.2.
Caution
After having completed practical work on the training system, switch the
hydraulic pump off! Open the throttle valve and set the pressure relief valves
to minimum pressure. No pressure gauge may indicate a pressure!
Measured values
Throttle
Item 1.3
1st
position
Throttle
Item 1.3
2nd
position
Throttle
Item 1.3
3rd
position
M3
p in bar
M2
p in bar
M2 - M3
p in bar
q
in l/min
M3
p in bar
M2
p in bar
M2 - M3
p in bar
q
in l/min
M3
p in bar
M2
p in bar
M2 - M3
p in bar
q
in l/min
20
25
30
35
40
50
46
46
47
47
47
48
26
21
17
12
1.98
1.74
1.47
1.20
0.87
20
25
30
35
40
50
44
45
45
46
47
48
24
20
15
11
3.64
3.22
2.77
2.26
1.71
20
25
30
35
40
50
39
41
43
44
45
48
19
16
13
6.40
5.82
5.09
4.20
3.18
09
Project 09:
Throttle valve, adjustable
10
1st position
2nd position
3rd position
30
25
20
15
10
5
09
0
0
Flow qV in l/min
Diagram 09.1 Diagram with measured values
Project 10:
Throttle check valve
10
Project 10:
Throttle check valve
Project definition
In a machining station (bending of a roll seam) the hydraulic advance velocity is to be adjustable.
The return stroke is to be performed at maximum velocity.
As in Project 09, the customer requires technical documentation in order to be able to understand the proposed solution. In addition, measurements of meter-in and meter-out throttling
are required.
10
Fig. 10.1 Practical example: Tool advance for roll seam bending
Project tasks
Independent understanding and solving of the task set by applying hydraulic control technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a throttle check valve (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 10:
Throttle check valve
Project steps
Informing:
Planning:
Planning and organizing the customer order with the help of, among others,
the technical data sheets RE 27219 and RE 27506.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer.
Checking:
Evaluating:
10
Notes
Project 10:
Throttle check valve
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Fig. 10.2 Hydraulic circuit diagram: Meter-in throttle - extending a single-rod cylinder
Measuring
glass
Project 10:
Throttle check valve
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Fig. 10.3 Hydraulic circuit diagram: Meter-out throttle - extending a single-rod cylinder
Measuring
glass
Project 10:
Throttle check valve
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Fig. 10.4 Hydraulic circuit diagram: Meter-in throttle - retracting a single-rod cylinder
Measuring
glass
Project 10:
Throttle check valve
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Fig. 10.5 Hydraulic circuit diagram: Meter-out throttle - retracting a single-rod cylinder
Measuring
glass
Project 10:
Throttle check valve
Stop
10
Fig. 10.6 Wiring diagram for hydraulic schematic diagrams Fig. 10.2 to 10.5
Retraction Extension
-Single-rod cylinder-
Project 10:
Throttle check valve
Qty
Component designation
Type designation
1.0
Double-acting cylinder
with single-sided piston rod
1.1
DW 13E
1.2
DD 1.1
1.3
DF 2.2
Symbol
ZY 1.3
10
0.1 - 0.3
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
Table 10.1 Parts list for hydraulic circuit diagrams 10.2 to 10.5
Project 10:
Throttle check valve
10
Connection block
Measuring glass
Component arrangement 1
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 10.7 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
10
Project 10:
Throttle check valve
11
Connection block
Measuring glass
Component arrangement 2
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 10.8 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram Fig. 10.3
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
10
Project 10:
Throttle check valve
12
Connection block
Measuring glass
Component arrangement 3
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 10.9 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram Fig. 10.4
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
10
Project 10:
Throttle check valve
13
Measuring glass
Component arrangement 4
Connection block
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 10.10 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.5
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
10
Project 10:
Throttle check valve
14
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 10.2 by means of
hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
Task 1
10
Project 10:
Throttle check valve
15
Before making any conversion for further order processing, switch the hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 2
Task 3
Task 4
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
10
Project 10:
Throttle check valve
16
Measured values
M2
p in bar
M3
p in bar
50
77
27
50
Measuring points
Warning
10
Project 11:
Flow control valve
11
Project 11:
Flow control valve
Project definition
In a machining station, a hydraulic rotary drive is to swivel a drum from the horizontal to the
vertical position after a welding process. The movement is to be performed by a hydraulic motor. Despite varying loads, the motor speed must remain constant.
Applying the knowledge that was gained in Project 09, a load-independent throttle valve is to
be used in the velocity control.
In order that the customer can understand the solution, he requires, apart from the technical
documentation for the use of different workpiece weights, a flow/pressure differential curve for
varying loads and falling system pressures.
11
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet for a flow control valve (technical qualification)
Handling of hydraulic components in line with functional needs
Project 11:
Flow control valve
Project steps
Notes
Informing:
Planning:
Planning and organizing the execution of the customer order; among others,
by dealing intensively with data sheet RE 28163.
Deciding:
Using the sketches of the circuit diagrams from Project 10: Throttle check
valve, selection of the relevant sketch with selection of the hydraulic components.
Executing:
Set-up of the hydraulic control on the training system and preparation and
documentation of the system parameters requested by the customer.
Checking:
Evaluating:
11
Project 11:
Flow control valve
Item 0.2
Item 0.3
Item 1.3
Item 1.0
Item 1.1
Item 0.4
Item 1.4
Load pressure
11
Item 0.1
Item 1.2
Fig. 11.2 Hydraulic circuit diagram: Load-independent speed control of a tool spindle
Measuring
glass
Project 11:
Flow control valve
Stop
11
Fig. 11.3 Wiring diagram for hydraulic circuit diagram Fig. 11.2
Rotation
Rotation
-Hydraulic motor-
Project 11:
Flow control valve
Qty
Component designation
Type designation
1.0
DM 2.N
1.1
DW 13E
1.2/1.4
DD 1.1
DF 3
1.3
0.1 - 0.4
11
DZ 1.4
DZ 25.1
Hose
1
Stopwatch
Symbol
VSK 1
Project 11:
Flow control valve
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 11.4 Recommended component arrangement with component designations to parts list Table 11.1 and hydraulic circuit diagram Fig. 11.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
11
Project 11:
Flow control valve
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
If work on electrohydraulic components is carried out improperly, risks of
injury and a safety risk can arise during operation of the system, including
danger to life.
Warning
Caution
Before starting work on the training stand, make sure that electrical ON/OFF
switches on the hydraulic power unit are pressed in, that is, that the system
is switched off. Check on the system pressure gauge that the system is
depressurized.
Hydraulic systems can store pressure energy at rest. This can cause injury
when the system is opened.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 11.2 by means of
hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25.1. Hand-tighten the pressure gauge measuring lines hand tight
at the relevant minimess connection of the hydraulic hose.
The proper and tight fit of hose connections of components can be easily checked by
slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Task 1
11
Project 11:
Flow control valve
6. Stepwise increase (in 5 bar increments) the load pressure on the hydraulic motor by means
of pressure relief valve item 1.5 in the return flow line to 40 bar and enter the pressure
values M2, M3, the Dp and flow qV in Table 11.1.
7. Turn flow control valve item 1.3 to scale position 4.
8. Repeat order steps 5 to 6 and enter the measured values in Table 11.2.
Measured values
Measuring point M2
p in bar
M3
p in bar
Pressure differential
Dp in bar
Flow
qV in l/min
Scale
position 2
Scale
position 4
Load
pressure
Scale
position 2
Scale
osition 4
Scale
position 2
Scale
position 4
42
40
10
32
30
0.47
1.92
42
40
15
27
25
0.47
1.92
42
40
20
22
20
0.46
1.90
42
40
25
17
15
0.46
1.90
42
40
30
12
10
0.45
1.86
42
40
35
0.31
1.30
42
42
40
11
Table 11.2 Values measured during the execution of the order, increasing load pressure
Scale position 4
2,5
Flow qV in l/min
2
1,5
1
0,5
0
0
10
15
20
25
30
35
40
Project 11:
Flow control valve
Task 2
10
13. Stepwise reduce (in 5 bar increments) the system pressure by means of pressure relief
valve item 1.2 down to the minimum pressure of 10 bar.
Caution
After completion of the practical work on the training system, switch the hydraulic pump off! Set the throttle valve and pressure relief valves to minimum
pressure. No pressure gauge may indicate a pressure!
Measured values
Measuring point M1 Measuring point M3 Pressure differential
p in bar
p in bar
Dp in bar
Flow
qV in l/min
40
35
0.5
35
30
0.5
30
35
0.5
25
20
0.5
20
15
0.5
15
10
0.5
10
0.4
11
Project 11:
Flow control valve
11
0,6
Flow qV in l/min
0,5
0,4
0,3
0,2
0,1
0
0
10
15
20
25
30
35
40
11
Project 11:
Flow control valve
12
Notes
11
Project 12:
Pressure relief valve, direct operated
12
Project 12:
Pressure relief valve, direct operated
Project definition
On a lifting platform, the system pressure is to be reduced due to the use of lower weights.
The new setting is to save energy.
The customer requires work instructions in order that he can adjust the pressure without requiring expert help. Moreover, he is interested in the pressure/flow relationship characteristic
curves of pressure relief valves.
12
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a pressure relief valve (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 12:
Pressure relief valve, direct operated
Project steps
Informing:
Planning:
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer.
Checking:
Evaluating:
Notes
12
Project 12:
Pressure relief valve, direct operated
Item 1.1
Item 1.5
Item 0.1
Item 1.0
Fig. 12.2 Hydraulic circuit diagram: Determination of technical data of a pressure relief valve, direct operated
Measuring
glass
12
Project 12:
Pressure relief valve, direct operated
Qty
Component designation
Type designation
1.0
DD 1.1
1.1
DF 1.2
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1
Stopwatch
Flowmeter
Table 12.1 Parts list for hydraulic circuit diagram Fig. 12.2
DZ 30
Symbol
12
Project 12:
Pressure relief valve, direct operated
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 12.3 Recommended component arrangement with component designation for parts list Table 12.1 and hydraulic circuit diagram Fig. 12.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
12
Project 12:
Pressure relief valve, direct operated
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 12.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
12
Project 12:
Pressure relief valve, direct operated
4. Open throttle valve Item 1.1 in individual steps (5 bar increments). The pressure is shown
on pressure gauge M1. Enter the M1 measurement results and flow qV in Table 11.2.
5. Carry over the measurement results from Table 12.2 to Diagram 12.1.
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
Caution
Measured values
Throttle valve
System pressure M1
p in bar
Flow
qV in l/min
through pressure relief
valve
Closed
30
7.6
25
4.3
20
1.8
15
10
Open
12
Project 12:
Pressure relief valve, direct operated
35
30
25
20
15
10
5
0
0
12
Project 12:
Pressure relief valve, direct operated
10
Notes
12
Project 13:
Pressure relief valve control
13
Project 13:
Pressure relief valve control
Project definition
On a punching rig, three, electrically controllable pressures are to be callable for different tools
and different working sequences.
The customer wishes solution proposals for the simple realization of a pressure control and
requires technical documentation with the necessary system parameters.
13
Fig. 13.1 Practical example: Punching equipment
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet for a pressure relief valve (technical qualification)
Handling of hydraulic components in line with functional needs
Project 13:
Pressure relief valve control
Project steps
Informing:
Planning:
Planning and organizing the execution of the customer order, among others,
by dealing intensively with data sheet RE 25402.
Deciding:
Executing::
Checking:
Evaluating:
Notes
13
Project 13:
Pressure relief valve control
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
glass
Item 0.1
13
System
Project 13:
Pressure relief valve control
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
glass
Item 0.1
13
System
Project 13:
Pressure relief valve control
Item 0.2
Item 0.3
Item 1.1
Item 1.2
Item 1.0
Measuring
glass
Item 0.1
System
13
Project 13:
Pressure relief valve control
Circulation
13
Fig. 13.5 Wiring diagram for hydraulic circuit diagrams Fig. 13.2 and 13.4
Solenoid b
Project 13:
Pressure relief valve control
Qty
Component designation
Type designation
1.0
DW 4E
1.1/1.2
DD 1.1
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.3
Table 13.1 Parts list for hydraulic circuit diagrams Fig. 13.2 to 13.4
Symbol
13
Project 13:
Pressure relief valve control
Connection block
Measuring glass
Component arrangement 1
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 13.6 Recommended component arrangement with component desgnations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
13
Project 13:
Pressure relief valve control
10
Connection block
Measuring glass
Component arrangement 2
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 13.7 Recommended component arrangement with component designations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.3
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
13
Project 13:
Pressure relief valve control
11
Connection block
Measuring glass
Component arrangement 3
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 13.8 Recommended component arrangement with component designations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.4
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
13
Project 13:
Pressure relief valve control
12
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
If work on electrohydraulic components is carried out improperly, risks of
injury and a safety risk can arise during operation of the system, including
danger to life.
Warning
Caution
Before starting work on the training stand, make sure that electrical ON/OFF
switches on the hydraulic power unit are pressed in, that is, that the system
is switched off. Check on the system pressure gauge that the system is
depressurized.
Hydraulic systems can store pressure energy at rest. This can cause injury
when the system is opened.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 13.2 by means
of hoses.
For the connections, to which the pressure gauges with minimess line DZ 1.4 are to be
connected, use hydraulic hoses DZ 25. Hand-tighten the pressure gauge line hand tight to
the relevant minimess connection of the hydraulic hose.
The proper and tight fit of hose connections of components can be easily checked by
slightly turning the hoses.
Warning
Caution
Task 1
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
Check the pressure set on the control pump of the drive power unit and, if required, correct it to 50 bar.
13
Project 13:
Pressure relief valve control
13
4. Operate directional valve item 1.0 by actuating pushbutton S2. Set the system pressure
on pressure relief valve item 1.2 at port A to 20 bar (pressure gauge M3).
Enter the measured values (pressure gauge M1, M2, M3) in Table 13.2.
Before converting the circuit for the further execution of the order, switch the
hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 2
Parallel circuit
5. Connect the hydraulic control according to circuit diagram Fig. 13.3 by means of hoses.
Do not change the pressures set on pressure relief valves item 1.1 and item 1.2!
6. Operate directional valve item 1.0 by actuating pushbutton S2.
Enter the measured values (pressure gauges M1 and M2) in Table 13.3.
Before converting the circuit for the further execution of the order, switch the
hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 3
Series circuit
7. Connect the hydraulic control according to circuit diagram Fig. 13.4 by means of hoses.
Do not change the pressures set on pressure relief valves item 1.1 and item 1.2!
8. Operate directional valve item 1.0 by actuating pushbutton S2.
Enter the measured values (pressure gauges M1, M2, M3) in Table 13.4.
Caution
Notes
After completion of the practical work on the training system, switch the
hydraulic pump off! No pressure may indicate a pressure! Open the throttle
check valve.
13
Project 13:
Pressure relief valve control
14
Measured values
Spool position
DW 4E
23
20
18
15
Spool position
DW 4E
Measuring point M1
p in bar
Measuring point M2
p in bar
18
15
Spool position
DW 4E
38
35
20
13
Project 14:
Pressure reducing valve
14
Project 14:
Pressure reducing valve
Project definition
In Project 11 a workpiece is to be swiveled by a hydraulic motor in a machining station. In a
further step of the project the same workpiece is to be clamped at reduced pressure. In order
that the hydraulic motor only starts to rotate after clamping is completed, it is to be hydraulically pre-loaded.
The customer wishes a solution with which the control can easily be realized and requires the
associated technical documentation with the necessary system parameters. In addition, he
needs information about the setting options and wants to know, why a by-pass check valve is
required.
14
Fig. 14.1 Practical example: Swiveling/clamping unit
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a pressure reducing valve (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 14:
Pressure reducing valve
Project steps
Informing:
Planning:
Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 26564.
Deciding:
Executing:
Checking:
Evaluating:
Notes
14
Project 14:
Pressure reducing valve
Item 2.0
Rotate
Clamp
Item 0.3
Item 1.3
Item 0.2
Item 2.1
Item 1.4
Item 1.1
Item 0.1
Item 1.2
Measuring
glass
14
Power unit limit
Project 14:
Pressure reducing valve
Stop
14
Retraction Extension
-Single-rod cylinderClockwise rotation
-Hydraulic motor-
Fig. 14.3 Wiring diagram for hydraulic circuit diagram Fig. 14.2
Project 14:
Pressure reducing valve
Qty
1.0
Double-acting cylinder
with single-sided piston rod
ZY 1.3
2.0
DM 2.N
1.1
DW 13E
1.2/2.1
DD 1.1
1.3
DS 2.1
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
1.4
0.1 - 0.3
Component designation
Table 14.1 Parts list for hydraulic circuit diagram Fig. 14.2
Type designation
Symbol
DD 2
14
Project 14:
Pressure reducing valve
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 14.4 Recommended component arrangement with component designation for parts list Table 14.1 and hydraulic circuit diagram Fig. 14.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
14
Project 14:
Pressure reducing valve
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 14.2 by means
of hoses.
Observe installation direction of check valve Item 1.4!
Warning
For the connections, to which pressure gauges with minimess line DZ 1.4 are to be connected, use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at
the relevant minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
14
Project 14:
Pressure reducing valve
Task 1
Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
3. Actuate push-button S4 to operate directional valve Item 1.1. Hydraulic motor Item 2.0
rotates clockwise; set pressure relief valve Item 2.1 on the hydraulic motor (port B) to a
load pressure of 40 bar (pressure gauge M2).
4. Set the clamping pressure to 20 bar on pressure reducing valve Item 1.3.
Enter the values measured during extending and retracting of the advance cylinder piston
(pressure gauge M1, M2, M3) in Table 14.2.
Task 2
Do not change the load pressure on hydraulic motor Item 2.0 and the pressure on clamping cylinder Item 1.0.
6. Actuate push-button S4 to operate directional valve Item 1.0. The hydraulic motor rotates
against the load pressure of 40 bar, and the clamping cylinder clamps at a pressure of
20 bar.
7. Enter the values measured during extending and retracting of the clamping cylinder piston
(pressure gauge M1, M2, M3) in Table 14.2.
Note:
When the clamping piston retracts after operation of push-button S2 the cylinder moves against
a clamping pressure of 20 bar provided via port A of the pressure reducing valve.
In this case, the pressure reducing valve assumes a pressure relief function.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
14
Project 14:
Pressure reducing valve
10
Measured values
Measuring point
M1
p in bar
M2
p in bar
M3
p in bar
M1
p in bar
M2
p in bar
M3
p in bar
Clamping cylinder
extending
20
15
20
15
Clamping cylinder
extended
45
40
20
45
40
20
Clamping cylinder
retracting
45
15
20
48
26
Clamping cylinder
retracted
50
50
14
Project 15:
Pressure switch
15
Project 15:
Pressure switch
Project definition
Two hydraulic workpieces are to be pressed together in a fixture by means of a hydraulic cylinder. After the pressing pressure was reached, the hydraulic cylinder is to retract automatically.
The pressing velocity is to be adjustable.
The customer wishes to obtain a proposed solution for an automatic, hydraulic pressing process. In the event of a fault of pressure monitoring, it should be possible to release the pressing
fixture electrically. The customer also wants to know the settable minimum pressing pressure.
For his technical documentation, the customer requires a circuit diagram with parts list and
functional description.
Fig. 15.1 Practical example: International pressure indications on pressure switches for system monitoring
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a piston-type pressure switch (specialist qualification)
Handling of hydraulic components in line with functional needs
15
Project 15:
Pressure switch
Project steps
Informing:
Planning:
Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 50060.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out the setting options of the pressure switch at different, given system pressures.
Checking:
Evaluating:
Notes
15
Project 15:
Pressure switch
Item 1.3
Item 1.4
Item 0.3
Item 1.1
Item 0.1
Item 1.2
Measuring
glass
15
Project 15:
Pressure switch
15
Control 4/2 directional valve
Extension
-Single-rod cylinderNote:
Retracting of the single-rod cylinder
can additionally be controlled
by means of push-button S1.
Fig. 15.3 Wiring diagram for hdraulic circuit diagram Fig. 15.2
Project 15:
Pressure switch
Qty
1.0
Double-acting cylinder
with single-sided piston rod
ZY 1.3
1.1
DW 3E
1.2
DD 1.1
1.3
DD 6E.1
1.4
DZ 2.2
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.3
Component designation
Table 15.1 Parts list for hydraulic circuit diagram Fig. 15.2
Type designation
Symbol
15
Project 15:
Pressure switch
Component arrangement
Connection block
Measuring glass
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 15.4 Recommended component arrangement with component designation for parts list Table 15.1 and hydraulic circuit diagram Fig. 15.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
15
Project 15:
Pressure switch
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 15.2 by means
of hoses.
Observe direction of installation of the throttle check valve!
Danger
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Set the system pressure to 30 bar on pressure relief valve Item 1.2.
Set piston-type pressure switch Item 1.3 to maximum by turning the setscrew completely
in using an Alllan key 10 A/F.
15
Project 15:
Pressure switch
3. Check that the pressing cylinder extends and retracts correctly while the throttle check valve
is open. Actuate push-button S2 to operate directional valve Item 1.1. Adjust the extension
velocity of the pressing piston to a forward speed of 0.05 m/s by means of throttle check
valve Item 1.4. To this end, calculate the velocity as a function of the measured extension
time and the stroke length.
4. Adjust the pressing pressure on piston-type pressure switch Item 1.3 (release spring)
so that the pressing cylinder piston retracts automatically. To this end, extend the pressing
piston to the end position.
5. Set the pressures given in Table 15.2 and verify whether the cylinder retracts automatically.
Measured values
Pressure relief valve
p in bar
Retracts automatically
Yes/no
20
No
28
No
30
Yes
32
Yes
40
Yes
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
15
Project 15:
Pressure switch
10
Notes
15
Project 16:
Pressure switch hysteresis
1
0
1
0
Hysteresis
16
Project 16:
Pressure switch hysteresis
Project definition
Scatter
min.
max.
16
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a piston-type pressure switch (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 16:
Pressure switch hysteresis
Project steps
Informing:
Planning:
Planning and organizing the customer order using, among others, technical
data sheet RE 50060.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out the
hysteresis of a piston-type pressure switch at various, given system pressures.
Checking:
Evaluating:
Notes
16
Project 16:
Pressure switch hysteresis
Item 1.1
Item 1.2
Item 0.1
Item 1.0
Measuring
glass
16
Project 16:
Pressure switch hysteresis
16
Note:
The pressure switch is
supplied with voltage via
push-button S1.
Fig. 16.3 Wiring diagram for hydraulic circuit diagram Fig. 16.2
Project 16:
Pressure switch hysteresis
Qty
Component designation
Type designation
1.0
DD 1.1
1.2
DF 1.2
1.1
0.1
DZ 1.4
DZ 25
Hose
VSK 1
Symbol
DD 6E.1
Table 16.1 Parts list for hydraulic circuit diagram Fig. 16.2
16
Project 16:
Pressure switch hysteresis
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 16.4 Recommended component arrangement with component designation for parts list Table 16.1 and hydraulic circuit diagram Fig. 16.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
16
Project 16:
Pressure switch hysteresis
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 16.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set piston-type pressure switch Item 1.1 to 30 bar; to this end, set pressure relief valve
Item 1.0 to 30 bar. To this end, close throttle Item 1.2 and operate push-button S1.
4. Set the system pressure to 25 bar on pressure relief valve Item 1.0.
16
Project 16:
Pressure switch hysteresis
Slowly increase the system pressure to 30 bar while observing indicator lamp H1 on the
electrical control.
Increase the system pressure by further 5 bar to 35 bar. During this, lamp H1 must not go
out.
5. Slowly reduce the system pressure until lamp H1 goes out. The pressure indicated by the
pressure gauge should be 27.5 bar.
Note:
The value given under point 5 can deviate by 1 - 2 bar.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
16
Project 16:
Pressure switch hysteresis
10
Notes
16
Project 17:
Hydraulic accumulator
Warning
Caution
17
Project 17:
Hydraulic accumulator
Project definition
In a fixture, a tool is to be moved by means of a hydraulic cylinder into and out of the machining
area. In the event of a hydraulic pump failure, the tool most be extended by means of stored
energy.
Since the customer has never utilized an accumulator before, he would like to know whether he
selected the correct accumulator size, i.e. whether the usable accumulator volume is sufficient.
He uses various system pressures and therefore requires documents that describe the usable
volume. In addition, he is interested in test documents such as a table that shows the various
system pressures and the usable oil volume.
17
Fig. 17.1 Practical example: Bladder and diaphragm-type accumulators with accumulator safety block
Project 17:
Hydraulic accumulator
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of a hydraulic accumulator (specialist qualification)
Handling of hydraulic components in line with functional needs
Project steps
Informing:
Planning:
Planning and organizing the customer order by, among others, working out
the topic of hydraulic accumulators (The Hydraulic Trainer - Basic Principles)
and the technical data sheet RE 50130/Accumulator safety block.
Deciding:
Executing:
Checking:
Evaluating:
17
Project 17:
Hydraulic accumulator
Item 0.2
Item 1.0
Item 1.4
Lead-
sealed
Item 1.1
Item 0.1
Item 1.3
Item 1.2
Measuring
glass
17
Project 17:
Hydraulic accumulator
Circulation
Fig. 17.3 Wiring diagram for hydraulic circuit diagram Fig. 17.2
Retraction Extension
-Single-rod cylinder-
17
Project 17:
Hydraulic accumulator
Qty
1.0
Double-acting cylinder
with single-sided piston rod
1.1
DW 13E
1.2
DD 1.1
1.3
DS 2.1
1.4
DZ 3.2
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.2
Component designation
Table 17.1 Parts list for hydraulic circuit diagram Fig. 17.2
Type designation
Symbol
ZY 1.3
17
Project 17:
Hydraulic accumulator
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 17.4 Recommended component arrangement with component designation for parts list Table 17.1 and hydraulic circuit diagram Fig. 17.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
17
Project 17:
Hydraulic accumulator
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 17.2 by means
of hoses.
Warning
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Observe direction of installation of check valve Item 1.3. Hand lever (P) on
the accumulator safety valve open, rotary knob (T) of the discharge valve
closed.
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
17
Project 17:
Hydraulic accumulator
Task 1
Task 2
Switch the hydraulic pump off. Carefully open the discharge valve (rotary knob T) on the
accumulator safety valve until the pressure shown on M2 slowly falls. The pressure slowly
decompresses down to the gas charging pressure and then rapidly falls to 0 bar. The pressure value at which the pressure starts to fall quickly is the nitrogen charging pressure.
Set the system pressure on pressure relief valve Item 1.2 to 10 bar. Extend and retract
cylinder Item 1.0 by operating push-buttons S4 and S2 and provide markings on the base
plate at the end positions (the stroke should be 200 mm). Retract cylinder Item 1.0 to the
basic position.
Extend and retract cylinder Item 1.0 by operating push-buttons S4 and S2 until the piston
does no longer move. The required oil volume is now taken from the hydraulic accumulator.
Note the number of strokes (extending and retracting), including the residual stroke during
extending and retracting, and enter the values in Table 17.2.
6. Switch the hydraulic pump on and set the system pressure on pressure relief valve Item 1.2 to
15 bar.
Repeat the experiment set-up as described under point 5 and enter the measurement results in Table 17.2. Repeat the experiment with the accumulator charging pressures given
in Table 17.2.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Unload the
hydraulic accumulator via the accumulator safety valve (rotary knob T).
Evaluating
Calculation of the useful volume of the accumulator
On the basis of the total number of strokes of the hydraulic cylinder the useful volume of the
hydraulic accumulator can be calculated according to the following formula.
V =
d K2
4
( a s + x ) + (d
2
K
- d St2
e s z
4
dm3
17
Project 17:
Hydraulic accumulator
10
After having calculated the useful volume, prepare a characteristic curve (Diagram 17.1)
Residual stroke in mm
Retracting x
Extending z
Useful
volume
V in dm3
10
15
195
0.25
20
95
0.36
25
50
0.42
30
10
0.47
35
100
0.52
40
160
0.55
45
0.57
17
Project 17:
Hydraulic accumulator
11
0,6
Useful volume V in l
0,5
0,4
0,3
0,2
0,1
0
0
10
20
30
Charging pressure M2 p in bar
40
50
17
Project 17:
Hydraulic accumulator
12
Notes
17
Project 18:
Regenerative circuit
18
Project 18:
Regenerative circuit
Project definition
On a machine tool the velocity of a feed cylinder is to be increased and thus the cycle time of
the system shortened without changing the pump flow. The advance velocity (extending time
of the hydraulic cylinder) is to be adjustable independently of the load.
In order that the customer can understand the circuit structure of the control, he requires the
associated documentation such as the hydraulic circuit diagram with parts list. He also requires
a table of the travel times of the hydraulic cylinder with different flow control settings.
Moreover, the customer wants to know which effect the increase in the cycle time has on the
advance force.
Fig. 18.1 Practical example: Control block with hydraulic components such as directional, pressure and flow control
valve
18
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet for velocity controls (specialist qualification)
Handling of hydraulic components in line with functional needs
Project 18:
Regenerative circuit
Project steps
Informing:
Planning:
Planning and organizing the customer order by, among others, working out
the technical data sheets relating to velocity controls.
Deciding:
Executing:
Checking:
Evaluating:
Notes
18
Project 18:
Regenerative circuit
Item 0.2
Item 0.3
Item 1.1
Item 1.2
Item 0.1
Item 1.3
Measuring
glass
18
Project 18:
Regenerative circuit
18
Fig. 18.3 Wiring diagram for hydraulic circuit diagram Fig. 18.2
Project 18:
Regenerative circuit
Qty
1.0
Double-acting cylinder
with single-sided piston rod
1.1
1.2
2-way flow control valve, adjustable, for one direction of flow, largely independent of viscosity and
pressure differential, adjustable,
with by-pass check valve
1.3
DD 1.1
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
0.1 - 0.3
Component designation
Type designation
Symbol
ZY 1
DW 3E
DF 3
Table 18.1 Parts list for hydraulic circuit diagram Fig. 18.2
18
Project 18:
Regenerative circuit
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 18.4 Recommended component arrangement with component designation for parts list Table 18.1 and hydraulic circuit diagram Fig. 18.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
18
Project 18:
Regenerative circuit
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 18.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25.1. Hand-tighten the pressure gauge measuring lines at the relevant minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Set the system pressure on pressure relief valve Item 1.3 to 50 bar plus one turn.
Extend hydraulic cylinder Item 1.0 by operating push-button S1. Measure the extension time;
enter the extension time and pressures M3 and M2 at the end position of hydraulic cylinder
Item 1.0 in Table 18.2.
18
Project 18:
Regenerative circuit
Operate push-button S1, which causes the piston of hydraulic cylinder Item 1.0 to retract again;
enter the retraction time of the piston and pressures M3 and M2 at the end position of
hydraulic cylinder Item 1.0 in Table 18.2.
4. Set flow control valve Item 1.2 successively to scale positions 1.2, 1.4, 1.6, 1.8 and 2.0
and enter the individual measuring results in Table 18.2 as described under point 3.
5. Enter the calculated traversing velocities of the feed cylinder as characteristic curve in
Diagram 18.1.
Caution
After having completed practical work on the training system, switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
M2
p in bar
M3
p in bar
Travel
time
t in s
Velocity
v in mm/s
1.0
Extended
Retracted
50
0
50
50
19
28
10.5
7.1
1.2
Extended
Retracted
50
0
50
50
16.5
20.7
12.1
9.7
1.4
Extended
Retracted
50
0
50
50
11.6
14.7
17.2
13.6
1.6
Extended
Retracted
50
0
50
50
8.6
10.5
23.3
19.0
1.8
Extended
Retracted
50
0
50
50
6.8
8.4
29.4
23.8
2.0
Extended
Retracted
50
0
50
50
5.3
6.5
37.7
30.8
6. Calculation of the area ratio of single rod cylinder ZY1 used in the regenerative circuit.
= 2.5 cm
= 1.6 cm
18
Project 18:
Regenerative circuit
10
Cylinder in
Cylinder out
4
3,5
Velocity v in cm/s
3
2,5
2
1,5
1
0,5
0
0
0,5
1
1,5
Position of flow control valve DF3
2,5
As mentioned in the introduction, a disadvantage of the regenerative circuit is that piston force
FK counteracts annulus piston force FR, i.e. the remaining useful force is the force of piston rod
area FST.
For information, please find below notes on pressures and flows for a single-rod cylinder controlled in a regenerative circuit, including the required calculation formula.
Single-rod cylinder
A special type of circuit for a single-rod cylinder is the regenerative circuit.
In this circuit, the cylinder is extended when the directional valve takes the spool position
and the oil displaced from the piston rod chamber is fed together with the pump displacement
to the piston chamber.
Note:
When neglecting the pressure drop in the lines and the directional valve, the pressure is
identical on both sides of the cylinder.
The cylinder force during extending consequently becomes
Fext = p AK p AR
18
Fext = p ASt
= p (AK AR )
and the piston velocity with pump displacement qP
Vext =
qP
AK AR
qP
AK
AR
ASt
ASt
because the pump flow must only fill the space that corresponds to the piston rod area.
Project 18:
Regenerative circuit
11
For retracting of the cylinder with spool position of the directional valve, the force is calculated as follows:
Fretr = pB AR pA AK
the retraction velocity
q
Vretr = P
AR
Thus, it becomes obvious that with an area ratio of
AK
=2
AR
qP
AK AR
qP
2 AR AR
qP
AR
= Vretr
AK
AR
consequently
Vext
Vretr
Vext
Vretr
qP AR
(AK AR ) qP
AR
AK AR
AK = AR
AR
AR AR
AR
AR ( 1)
1
1
1
1
18
Project 18:
Regenerative circuit
12
AK
AR
ASt
F1 (out)
F2 (back)
pmin
pA
qB
qA
qtotal = qB + qP
qA
qP
18
Project 19:
Rapid speed / creep speed control
19
Project 19:
Rapid speed / creep speed control
Project definition
At the end of a production line, workpieces are to be lifted from a conveyor belt and put down
on a pallet. The lifting movement is to be performed using a hydraulic cylinder. To achieve
shorter cycle times, fast motion sequences are required. Due to changing workpiece weights,
the residual stroke is to be performed independently of loads at strongly reduced velocity.
The return stroke is to be performed as fast as possible.
For his documentation, the customer wishes to obtain a travel/time diagram in addition to a
hydraulic circuit diagram and a parts list.
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of velocity controls (specialist qualification)
Handling of hydraulic components in line with functional needs
19
Project 19:
Rapid speed / creep speed control
Project steps
Informing:
Planning:
Planning and organizing the customer order, by, among others, examining
the technical data sheet for velocity controls.
Deciding:
Executing:
Checking:
Evaluating:
Notes
19
Project 19:
Rapid speed / creep speed control
Item 0.2
Item 1.0
Item 0.3
Item 1.4
Item 1.2
Item 1.1
Item 0.1
Item 1.3
Measuring
glass
19
Project 19:
Rapid speed / creep speed control
red
red
black
blue
black
blue
Fig. 19.3 Wiring diagram for hydraulic circuit diagram Fig. 19.2
19
Project 19:
Rapid speed / creep speed control
Qty
1.0
Double-acting cylinder
with single-sided piston rod
ZY 1.3
1.1 - 1.2
DW 3E
1.3
DD 1.1
DF 3
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
1.4
0.1 - 0.3
Component designation
Type designation
Symbol
red
B1/B2
black
DE 2
blue
Table 19.1 Parts list for hydraulic circuit diagram Fig. 19.2
19
Project 19:
Rapid speed / creep speed control
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 19.4 Recommended component arrangement with component designation for parts list Table 19.1 and hydraulic circuit diagram Fig. 19.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
19
Project 19:
Rapid speed / creep speed control
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 19.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
Position limit switches B1 and B2 so that the change-over takes place in the middle of the
total stroke.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Set the system pressure on pressure relief valve Item 1.3 to 50 bar plus one turn.
19
Project 19:
Rapid speed / creep speed control
Extend hydraulic cylinder Item 1.0 by actuating push-button S2. 4/2 directional valve Item
1.2 is operated by limit switch B1 and the flow is fed to the tank via flow control valve Item
1.4. When limit switch B2 is reached, 4/2 directional valves Items 1.1 and 1.2 are switched
again to the rest position and the cylinder retracts. Enter the retraction time of the piston
and the pressures M3 and M2 in Table 19.2. Enter the extension time over the entire stroke
and pressures M2 and M3 (during operation at reduced velocity) in Table 19.2.
Release push-button S2. This causes the piston of hydraulic cylinder Item 1.0 to retract
again. Enter the retraction time of the piston and pressures M3 and M2 in Table 19.2.
4. Set flow control valve Item 1.4 to scale position 1.5 and enter the measuring results in
Table 19.2 as described under point 3.
Caution
After having completed the practical work on the training system, switch the
pump off! No pressure gauge may indicate a pressure! Open the throttle
check valve.
Measured values
Flow control valve
scale position
Hydraulic cylinder
Rapid speed
Advance
Return stroke
1.0
1.5
M3
bar
M2
bar
Time
<1
<1
M3
bar
50
50
M2
bar
80
80
Time
23
12
M3
bar
19
19
M2
bar
38
38
Time
<1
<1
19
Project 19:
Rapid speed / creep speed control
10
For information, please find below the graphical representation of the piston velocity of the
single-rod cylinder.
Table 19.3 shows a function sequence chart commonly used in practice.
Travel
Rapid speed
Advance
t
Time
Return stroke
Item 1.1
Item 1.2
Advance lifting
Lowering
Legend:
0 not operated
1 operated
19
Project 20:
Valve circulation control
20
Project 20:
Valve circulation control
Project definition
For the assembly of heavy hydraulic control blocks, a scissors lift it used for lifting and lowering
pallets. In order that the hydraulic cylinder can be stopped at any position, a 4/3 directional
valve with blocked central position is used. To spare the hydraulic pump, a solution is to be
provided, with which the pump flow is directed at zero pressure to the tank when the hydraulic
cylinder is not operated.
The customer wishes to obtain several solution proposals and for his documentation, apart from
the hydraulic circuit diagram and the parts list, a comparison of the proposed solutions.
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the technical data sheet of fixed displacement pump (specialist qualification)
Handling of hydraulic components in line with functional needs
20
Project 20:
Valve circulation control
Project steps
Informing:
Planning:
Planning and organizing the customer order, among others, through dealing
with the technical data sheet for the 4/3 directional valve, RE 23178, and
in particular with the section of symbols.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Acquisition of measured values and preparation of a comparison table.
Checking:
Evaluating:
Notes
20
Project 20:
Valve circulation control
Item 0.2
Item 0.3
Item 1.1
Item 0.1
Item 1.4
Measuring
glass
20
Fig. 20.2 Hydraulic circuit diagram: Pressureless circulation using a 4/3 directional valve
Project 20:
Valve circulation control
Circulation
Extension Retraction
-Single-rod cylinder-
20
Fig. 20.3 Wiring diagram for hdraulic circuit diagram Fig. 20.2
Project 20:
Valve circulation control
Item 0.2
Item 0.3
Item 1.1
Item 1.3
Item 0.1
Item 1.4
Measuring
glass
20
Fig. 20.4 Hydraulic circuit diagram: Pressureless circulation using an additional 4/2 directional valve
Project 20:
Valve circulation control
Circulation
Extension Circulation
-Single-rod cylinder-
20
Fig. 20.5 Wiring diagram for hydraulic circuit diagram Fig. 20.4
Project 20:
Valve circulation control
Qty
1.0
Double-acting cylinder
with single-sided piston rod
ZY 1.3
DW 4E
1.2
DW 13E
1.3
DW 3E
1.4
DD 1.1
DZ 4.1
DZ 1.4
DZ 25
Hose
VSK 1
1.1
0.1 - 0.3
Component designation
Type designation
Symbol
Table 20.1 Parts list for hydraulic circuit diagram Fig. 20.2 and 20.4
20
Project 20:
Valve circulation control
Connection block
Measuring glass
Component arrangement 1
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 20.6 Recommended component arrangement with component designation for parts list Table 20.1 and hydraulic circuit diagram Fig. 20.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
20
Project 20:
Valve circulation control
10
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 20.7 Recommended component arrangement with component designation for parts list Table 20.1 and hydraulic circuit diagram Fig. 20.4
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
20
Project 20:
Valve circulation control
11
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 20.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
To make clear that in the central position the total amount of fluid flows through 4/3 directional valve Item 1.1, port T of directional valve Item 1.1 can be connected to the measuring
glass (option).
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve Item 1.4 to 50 bar plus one turn.
The system pressure can only be adjusted while the cylinder is at its end position.
20
Project 20:
Valve circulation control
Task 1
12
Note pressure M1 in the relevant end position of hydraulic cylinder Item 1.0 while directional
valve Item 1.1 is in its central position.
Before making any conversion for further order processing, switch the hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 2
Circulation
5. Mount the components required according to parts list Table 20.1 in a clearly arranged form
on the training system according to the prepared circuit diagram.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 20.4 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
To provide more clarity that the entire flow is fed directly to the tank via 4/2 directional valve
Item 1.3 when directional valves Item 1.2 and Item 1.3 are not operated, port T of directional
valve Item 1.3 can be connected directly to the measuring glass (option).
6. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Set the system pressure on pressure relief valve Item 1.4 to 50 bar plus one turn.
The system pressure can only be adjusted while the cylinder is at its end position.
7. Hydraulic cylinder Item 1.0 can be controlled via directional valve Item 1.2 using push-buttons S2 and S4. To this end, directional valve Item 1.3 must be operated before by means
of push-button S3.
Measure and note pressure M1 in the relevant end position of hydraulic cylinder Item 1.0
(S2, S4 operated) while directional valve Item 1.3 is not operated.
Caution
After having completed the practical work on the training system, switch the
pump off! No pressure gauge may indicate a pressure! Open the throttle
check valve.
20
Project 20:
Valve circulation control
13
Measured values
Task 1
M1 p in bar
Circulation
Task 2
p in bar
p in bar
50
50
50
50
20
Project 20:
Valve circulation control
14
Notes
20
Project 21:
Commissioning, troubleshooting, maintenance
21
Project 21:
Commissioning, troubleshooting, maintenance
An indispensable tool for targeted fault analyses is the understanding of the function and
operating principle of all hydraulic components in the system.
Target-oriented communication simplifies the analysis of faults.
Preventive maintenance and inspection reduce failures of systems and prolong the service
life of components.
On the basis of the complex control set up on the training stand, the trainee is to work out commissioning of an electrohydraulic control and the order of adjusting the individual components.
Controlled by a 4/3 directional valve, a hydraulic cylinder is to lift a load. The lifting time is to be
adjusted by means of a throttle and take approx. 5 s. A hydraulic motor (set to 1.5 l/min), which
is to rotate independently of the load by using a flow control valve, is hydraulically pre-loaded
by a 4/2 directional valve connected in parallel. Controlled by an electrical push-button, first
the cylinder is to lift the load, and then the hydraulic motor is to rotate uniformly.
Notes on detailed technical information about the project order:
The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components
Technical data sheets for all hydraulic components listed such as directional, pressure,
and flow control valves
Technical data sheet RE 07100-B
Hydraulic cylinders/operating instructions (exemplarily for notes on: commissioning, inspection, maintenance, repair)
General product information on hydraulic products
Technical data sheet RE 07008
21
Project 21:
Commissioning, troubleshooting, maintenance
Project definition
On a machine tool, a workpiece is to be machined by a tool, which is powered by a hydraulic
motor. Before being machined, the workpiece is to be lifted by a lifting cylinder to the machining position.
The customer wishes to obtain the required machine documents such as hydraulic and electrical circuit diagrams with parts lists, system parameters and commissioning instructions such
as the order of adjustment of hydraulic components for documentation purposes. To be able to
advise the electrician, which solenoids are to be switched for the individual process sequences,
he requires a simple diagram showing the function sequence.
In addition, he wishes to obtain notes on preventive maintenance and inspection.
A flow chart is to provide information about assumed faults (hydraulic motor does not rotate).
Project tasks
Independent understanding of the task and its putting into practice using hydraulic control
technology
Planning and organizing the customer requirement (core qualification)
Analyzing the required technical documents (specialist qualification)
Handling of hydraulic components in line with functional needs
21
Project 21:
Commissioning, troubleshooting, maintenance
Project steps
Informing:
Planning:
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Acquisition of measured values and preparation of the technical documentation requested by
the customer.
Checking:
Evaluating:
Notes
21
Project 21:
Commissioning, troubleshooting, maintenance
Notes
21
Project 21:
Commissioning, troubleshooting, maintenance
Item 0.2
Item 0.3
Item 2.2
Item 2.3
Set to
1.5 l/min
Item 1.3
Item 1.1
Set to
text = 5 sec
Item 2.1
Item 0.1
Item 1.2
Measuring
glass
21
Project 21:
Commissioning, troubleshooting, maintenance
Stop
-Single-rod cylinder-
Rotation
-Hydraulic motor-
21
Project 21:
Commissioning, troubleshooting, maintenance
Qty
Component designation
1.0
1.1
DW 13E
1.2/2.3
DD 1.1
1.3
DF 1.2
2.0
DM 8N
2.1
DW 3E
2-way flow control valve, adjustable, for one direction of flow, largely independent of viscosity and
pressure differential, adjustable,
with by-pass check valve
DF 3
DZ 4.1
DZ 1.4
DZ 25.1
2.2
0.1 - 0.4
hose
Table 21.1 Parts list for hydraulic circuit diagram Fig. 21.2
Type designation
VSK 1
Symbol
21
Project 21:
Commissioning, troubleshooting, maintenance
Connection block
Measuring glass
Component arrangement
Note:
In the case of connection
elements marked with D, the
components can be connected
directly with each other.
Fig. 21.4 Recommended component arrangement with component designation for parts list Table 21.1 and hydraulic circuit diagram Fig. 21.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
21
Project 21:
Commissioning, troubleshooting, maintenance
10
Safety notes
To ensure the operability of plant and machinery, and consequently to allow
the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
Warning
Caution
Connect the hydraulic control according to hydraulic circuit diagram Fig. 21.2 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Caution
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
pressure (spring unloaded) and all throttle valves are open.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
21
Project 21:
Commissioning, troubleshooting, maintenance
11
Measure pressure M1, M2 and M3 during operation of the lifting cylinder and enter the
values in system parameter sheet Table 21.2.
While the hydraulic motor is rotating, adjust flow control valve Item 2.2 so that a flow of
approx. 1.5 l/min can be measured by means of the measuring glass. After having adjusted
the speed of the hydraulic motor while the latter was rotating, set pressure relief valve Item
2.3 to a hydraulic pre-load pressure of 20 bar.
Acquire pressures M1 and M4 while the hydraulic motor is rotating and enter the values in
system parameter sheet Table 21.2.
For system-inherent reasons, the motor only rotates clockwise!
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
Measured values
Actuator
Lifting cylinder
Lifting cylinder
Hydraulic motor
Function
Lifting
Lowering
Rotating
Measuring point
Value in bar
M1
48
M2
M3
M1
48
M2
47
M3
30
M1
48
M4
20
21
Project 21:
Commissioning, troubleshooting, maintenance
12
Valve solenoid
Lifting cylinder
Hydraulic
motor
Y1.a
Y1.b
Y2
Lifting
Lowering
Holding
Rotating
Stop
Legend:
21
Project 21:
Commissioning, troubleshooting, maintenance
13
Constant, load-independent rotating of the hydraulic motor by means of flow control valve
Item 2.2 which is set to qV = 1.5 l/min and pre-loading valve Item 2.3 set to 20 bar.
After completion of the machining process, the machine operator stops the hydraulic motor
by actuating push-button S5 and then moves the workpiece to the basic position for the
hydraulic cylinder by operating push-button S4.
Chips produced during machining are transported from the operating range of the machine
tool by a chip conveyor.
Sequence chart
for troubleshooting
Workpiece correctly
put down?
yes
no
System pressure
available?
Check loading
Are faults/fault messages present such as: filter, oil level, temperature?
no
no
Check motor
no
Check by activating
emergency stop
yes
no
Check and, if
required, correct
position
no
no
Check settings
yes
Valve Y2
activated
Pump pressure
available?
yes
yes
yes
yes
Note:
Possibly mechanical fault of the
hydraulic motor?
yes
Check DB valve
Item 2.3/20 bar
21
Project 21:
Commissioning, troubleshooting, maintenance
14
Questions
Question 1:
Name the systematic working steps during commissioning and for adjusting the electrohydraulic
control.
Check the electrical control for function
Check the set-up of the hydraulic control
Set the pressure relief valves to minimum pressure/spring unloaded
Adjust flow control valves to adequate flow
Switch the hydraulic pump on/Leakages?/Direction of motor rotation OK?/No excessive pressures
in the system?
Set the system pressure to 50 bar plus one turn/DB valve Item 1.2
Check the LIFTING/LOWERING function of the lifting cylinder/push-buttons S4 - S2
Adjust the lifting time to 5 s/throttle Item 1.3
Measure the operating pressures and enter them in the system parameter table
Check the rotating function of the hydraulic motor.
Adjust the rotary speed/close flow control valve/measure the flow by means of the measuring glass/1.5 l/min.
Set the pre-loading valve/DB valve Item 2.2 to 20 bar.
Enter the machining pressure of the hydraulic motor in the system parameter table
Question 2:
Which 6 machine documents are indispensable for electrohydraulic systems?
Hydraulic circuit diagram/with parts list
Wiring diagram
Function chart
Operating instructions
Machine key data/system parameters
Measurement report of initial commissioning
Question 3:
Why should a hydraulic system be flushed prior to initial commissioning?
The flushing process removes dirt particles from the individual components such as pipes. It
must be ensured that the permissible maximum cleanliness class to ISO 4406 KL. 21/18/15
is not exceeded for the entire system.
Question 4:
How should the hydraulic fluid be disposed of?
The fluids must be disposed off in accordance with environmental regulations, i.e. the
contaminated fluid must be made available to approved recycling companies in suitable
containers for disposal. The notes on waste disposal given in the safety data sheet of the
hydraulic fluid must be observed.
Question 5:
Into which areas is maintenance subdivided?
DIN 31051 classifies maintenance in the following areas:
Maintenance - Inspection - Repair
Question 6:
Which work (measures) must be carried out during an inspection?
Check of set operating values
Visual inspection of the complete system for external leakage, wear, damage, ...
Check of hydraulic fluid for fluid level and appearance
21
Project 21:
Commissioning, troubleshooting, maintenance
15
Question 7:
Which work (measures) are to be carried out during maintenance?
Changing the filter inserts
Checking or changing the hydraulic fluid
Cleaning the inside of the tank, if required
Replacing hydraulic hoses at given intervals
Question 8:
Which of the following faults are causes for malfunction that can be traced back to improper
installation and which faults occur on running systems?
Incorrect directional valve installed
Electric motor incorrectly connected
Contaminated hydraulic fluid
Hydraulic hose improperly connected
Wear of hydraulic seals
Filter clogged
Cable break at the connection of the solenoid
Pressure switch does not switch
Hydraulic component does not operate due to a broken spring
Throttle bore clogged on the pilot part
Question 9:
Name a systematic order for the localization and elimination of faults.
Recognizing faults on the system and their effect
Analyzing the cause of fault
Planning of how to eliminate the fault
Proper elimination of the fault
Re-commissioning the system
Documenting the fault and its elimination
21
Project 21:
Commissioning, troubleshooting, maintenance
16
21
Project 21:
Commissioning, troubleshooting, maintenance
17
Notes
21
DE
EN
FR
IT
FI
ES
NL
SV
PT
DA
EL
RE 07008/02.05
1/32
2/32
Bosch Rexroth AG
Hydraulics
Contents
1
Page
1.1
1.2
1.3
2.1
2.2
2.3
2.4
Copyright
3.1
What to do in an emergency
3.2
3.3
Proper use
3.4
3.5
11
4.1
11
4.2
Ambient conditions
11
13
5.1
13
5.2
13
5.3
Viscosity
13
5.4
Leakage fluid
14
5.5
Topping up/refilling
14
15
6.1
Definitions of terms
15
6.2
Schematic
15
6.3
Safety concept
15
16
16
8.1
16
8.2
17
RE 07008
RE 07008
Hydraulics
Bosch Rexroth AG
Contents
9
3/32
Page
18
9.1
18
9.2
18
9.3
19
10
Operation
22
11
Trouble-shooting
22
11.1
22
11.2
22
11.3
Trouble-shooting tables
23
12
13
14
Maintenance
24
12.1
Definitions of terms
24
12.2
24
12.3
25
12.4
28
12.5
29
12.6
29
12.7
Repair
29
30
13.1
General
30
13.2
30
Hydraulic systems
31
14.1
31
4/32
1
1.1
Bosch Rexroth AG
Hydraulics
DANGER
This symbol indicates a threat of danger which will result
directly in death or very serious injury if not avoided.
WARNING
This symbol indicates a threat of danger which may result
in death or very serious injury if not avoided.
CAUTION
This symbol indicates possible danger which may lead to
minor or serious injury and/or to material damage.
IMPORTANT
1.3
Hydraulic components
Hydraulic systems.
1.2
RE 07008
If you do not have all three parts, please request the missing
part from Bosch Rexroth. Only if all the information contained
in all parts of the three-part Operating Instructions is observed
can safe operation of Rexroth hydraulic products be ensured.
Specific cross-references are used to draw your attention to
information that you can find in the Operating Instructions.
The Operating Instructions contain detailed information about
the product, including
Safety instructions
This product information applies exclusively to hydraulic products that are operated with mineral-oil-based pressure fluids, if
the Operating Instructions do not expressly permit the use of
other pressure fluids.
IMPORTANT
Layouts, drawings
RE 07008
Hydraulics
Bosch Rexroth AG
5/32
Installation of Rexroth hydraulic products in a machine or system may increase this value, and if so, the manufacturer of the
machine/system must document this.
2.1
Rexroth hydraulic products fulfil all safety requirements applicable to fluid power systems and their components.
IMPORTANT
For the scope of delivery and the responsibilities of
Bosch Rexroth with respect to the product, please refer to the
Product-specific Operating Instructions.
2.2
CAUTION
If Rexroth hydraulic products are positioned in the vicinity
of sources of ignition or strong radiators of heat, protection must be put in place that would prevent any escaping
pressure fluid from igniting and the hose lines from aging
prematurely.
Mineral-oil-based pressure fluid is hazardous to water and
flammable. It may only be used if the relevant safety datasheet from the manufacturer is available and all the measures stipulated therein have been implemented.
If there is a risk of fluid leaking from the hydraulic product and contaminating water or the ground, the hydraulic
product in question must be placed in a suitable collecting trough. In connection with this, the applicable statutory
regulations must be observed.
You must also observe the EU directives for the use of work
equipment (Directive 89/391/EC) and the associated individual directives, especially Directive 1999/92/EC for the protection
from the danger arising from potentially explosive atmospheres
and their implementations in national legislation. The legislation contains minimum requirements with respect to the making
available by the employer of work equipment and for the use
of work equipment by employees at work, including the regulations for operating equipment requiring supervision and the
obligation to produce explosion protection documentation. This
involves, for example, dividing areas endangered by potentially
explosive atmospheres into zones and specifying suitable work
equipment and procedures for these areas.
IMPORTANT
Bosch Rexroth points out that, at the time of their first introduction on to the market, hydraulic products comply with the
requirements of all relevant EU directives and/or their implementation into national legislation in Germany. If the scope of
delivery is intended to be installed in a machine or system, then
the Machinery Directive applies as appropriate including the
then currently applicable amendments in that the scope of
delivery does not necessarily comply with the requirements
of the Machinery Directive because the scope of delivery is
intended for installation in a machine or because the scope of
delivery is intended for combination with other machines into a
machine or a hydraulic system.
The bringing into use of the scope of delivery shall therefore not be permitted until the machine or system in which the
scope of delivery is to be installed or of which it represents a
component complies with the requirements of all relevant EU
directives.
Details of further responsibilities can be found in
3 Important basic safety instructions and in the Operating
Instructions.
6/32
2.3
Bosch Rexroth AG
Hydraulics
Bosch Rexroth shall not be liable for damages that result from
non-compliance with or disregard of these and other parts of
the Operating Instructions.
Unauthorised tampering shall render the warranty null and void.
Bosch Rexroth shall only be liable if the scope of delivery was
shown to be defective. Bosch Rexroth shall not be liable if a
deficiency occurs that involves parts having been replaced by
the customer with equivalent but not identical parts as specified by the manufacturer.
Please refer to our general terms of supply or your contract for
details of the guarantee and manufacturers warranty.
2.4
Copyright
This product information may only be reproduced electronically or mechanically, in whole or in part with the express written permission of Bosch Rexroth. It may likewise not be distributed, amended, transmitted, translated into another language
or employed or copied for other purposes or by other parties
without such consent.
RE 07008
RE 07008
3
3.1
Hydraulics
7/32
IMPORTANT
What to do in an emergency
The hydraulic product shall be operated exclusively with pressure fluids complying with DIN 51524. Where other pressure
fluids are permitted, for example brake fluids for brake valves,
this is specially mentioned in the Operating Instructions.
2.
3.
Secure the danger area so that no one can enter the danger area unknowingly or uncontrolled.
4.
5.
WARNING
Fighting fires with materials other than those permitted
can lead to explosions and/or more rapid spread of the
fire!
Danger to life from smoke inhalation!
3.2
Bosch Rexroth AG
IMPORTANT
The meanings of the safety labelling on the Rexroth product are explained in the Operating Instructions.
Dependencies and time factors shall not be modified without prior consultation.
Unless otherwise agreed, the Rexroth hydraulic product satisfies at least safety category B in accordance with EN 954-1.
The specified maintenance tasks in the Operating Instructions shall be carried out at the intervals stated in the
Operating Instructions.
3.3
Proper use
8/32
3.4
Bosch Rexroth AG
Hydraulics
RE 07008
Uncontrolled access by persons unfamiliar with the system to the immediate operating zone of Rexroth hydraulic
products is prohibited (even if the product in question has
been shut down).
Servicing personnel (who carry out filter and oil changes, for
example) shall fulfil the following requirements:
RE 07008
3.4.5 Training
Hydraulics
What to do in an emergency.
IMPORTANT
Bosch Rexroth can provide you with training support in specialist areas.
9/32
Bosch Rexroth AG
CAUTION
Handling pressure fluid without protection is hazardous to
health.
Please observe the manufacturers safety instructions and the
safety datasheets for the pressure fluid that you are using.
DANGER
Serious damage to health or death may result if pressure fluid
enters the blood stream or is swallowed. If this occurs, contact
a doctor immediately!
3.5
The use of dirty (unfiltered) pressure fluid when the pressure fluid is changed.
In spite of the high intrinsic safety of Rexroth hydraulic products, the risk of personal injury or damage to the environment
cannot be excluded, even when the equipment is properly
used.
DANGER
CAUTION
When changing the pressure fluid, always use factory-fresh
pressure fluid and filter it before filling to remove any contaminants in the pressure fluid that it often contains from the packaging container (drum). Flush out lines and hoses before installation.
The cleanliness class of a pressure fluid is specified in accordance with ISO 4406. Detailed information can be obtained
from the relevant datasheet or the Operating Instructions.
10/32
Bosch Rexroth AG
Hydraulics
In older datasheets, the cleanliness class is sometimes specified in accordance with NAS 1638. The following table can
be used to convert this to an equivalent ISO 4406 cleanliness
class:
Comparison table for cleanliness classes
Earlier class to
Current class to
NAS 1638
ISO 4406 (c)
Class 7
Class 18/16/13
Class 9
Class 20/18/15
RE 07008
3.5.5 Disposal
Take metal, cable and plastic ducts to a recycling materials collection centre.
Lock the main switch, remove the key and keep it in a safe
place until the work is completed.
DANGER
Even after disconnection of the electrical supply
(main switch OFF) the following supply systems/danger
areas can still give rise to life-threatening voltages:
Main switch
CAUTION
Please observe the disposal regulations specified in
the appropriate Safety Datasheets.
RE 07008
IMPORTANT
The product-specific technical data, operating limits and ambient conditions for the operation of your Rexroth hydraulic product can be found in the Operating Instructions.
This includes the following information:
Performance data
Connections.
4.1
IMPORTANT
Bosch Rexroth recommends a maximum operating temperature of 55 C, because the rate of ageing of the pressure fluid
increases and the service life of the seals and hoses is reduced
at higher temperatures.
Viscosity ranges:
see RE 07075 and RE 90220
IMPORTANT
Rexroth hydraulic components are tested with test oil MZ45
manufactured by ESSO (class ISO VG 46 at 40 C),
(Viscosity = approx. 46 mm2/s).
Hydraulics
4.2
Bosch Rexroth AG
11/32
Ambient conditions
DANGER
Rexroth hydraulic products shall be used in potentially
explosive atmospheres only if they are designed for this
purpose and this is expressly stated in the Operating
Instructions.
IMPORTANT
Directive 1999/92/EC of the European Parliament and Council dated 16 December 1999 concerning the minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres governs
protection from danger from potentially explosive atmospheres.
Observe the requirements contained in the regulations for
operating equipment requiring supervision and the obligation to
produce explosion protection documentation.
This involves, for example, dividing areas endangered by potentially explosive atmospheres into zones and specifying suitable
work equipment and procedures for these areas.
Observe the requirements of Directive 94/9/EC of the European Parliament and Council dated 23 March 1994 on the
approximation of laws of the member states concerning equipment and protective systems intended for use in potentially
explosive atmospheres (ATEX Product Directive) and/or the
corresponding national legislation by means of which the Directive was implemented in law in the EU member states. The
directive contains requirements for the use of equipment and
protective systems in potentially explosive atmospheres.
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Hydraulics
for drive units with electric motors without heat exchangers, surface-cooled by free air circulation:
0 C+30 C
IMPORTANT
For systems with oil-air heat exchangers:
Observe the information given in the circuit diagram in the
Operating Instructions.
DANGER
Rexroth hydraulic products shall not be used in aeronautical equipment, except where they have been specially
approved and appropriately labelled to this effect.
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5.1
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IMPORTANT
Observe the following rules of thumb:
At pressure fluid temperatures >70 C, the rate of ageing doubles for each 10 C.
Viscosity
DANGER
Mineral-oil-based pressure fluid is hazardous to water and
flammable.
It may only be used if the relevant safety datasheet from
the manufacturer is present and all the measures stipulated therein have been implemented.
5.2
Due to the many tasks of pressure fluid, its selection, inspection and maintenance are of vital importance for:
proper functioning
operating safety
service life
corrosion protection
to remove contaminants
high temperatures
air humidity
water
metallic catalysers
operating pressure
contaminants.
Viscosity
800 mm2/s
500 mm2/s
100 mm2/s
20 mm2/s
12 mm2/s
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Bosch Rexroth AG
Hydraulics
Leakage fluid
CAUTION
Make sure that the leakage fluid is fed back into the tank
in a proper manner.
Dispose of leakage fluid that is not fed back into the tank
properly, in compliance with the applicable environmental
protection regulations.
5.5
Topping up/refilling
CAUTION
When topping up/refilling your hydraulic system, make
sure that you use pressure fluid of the same sort and type
and from the same manufacturer.
If the fluid is heavily contaminated or prematurely aged,
then the system, including the tank must be cleaned and
flushed before refilling. New pressure fluid must always be
filtered in accordance with the required cleanliness class,
as it does not normally meet the required cleanliness class
in the as-supplied state.
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Bosch Rexroth AG
Hydraulics
Definitions of terms
Hydraulic system
4
3
Component
A single unit (e.g. a valve, filter, cylinder, motor) that consists
of one or more parts and which is a functional constituent of a
hydraulic system.
Drive
A component that converts the energy of the hydraulic fluid
into mechanical energy (e.g. motor, cylinder).
6.2
Schematic
In a system operated with hydraulic oil, first of all mechanical energy is converted into hydraulic energy, transported and
controlled in this form, to finally be converted once more into
mechanical work.
The hydraulic elements are arranged in accordance with these
functions. The following diagram shows a schematic representation of the elements of a complete hydraulic system.
To demonstrate their operating principle, standardised symbols
(ISO 1219) are used instead of sectional diagrams of the various devices. Line connections are represented by simple lines,
as can be seen in the example.
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2
1
1
Tank
Filter
Pump
Directional valve
Check valve
Throttle valve
Hydraulic cylinder
Hydraulic motor
6.3
Oil preparation
Energy conversion
Energy control
Energy conversion
Safety concept
Hydraulic products contain sensors and actuators, the interaction of which is particularly important with regard to the fulfilment of technical safety functions.
Individual hydraulic products form part of an overall safety concept.
Applications required to perform safety functions are designed
using special hydraulic components that satisfy the requirements of the relevant directives, such as the Pressure Equipment Directive and other standards.
The manufacturer of the overall machine or system defines and
bears responsibility for the safety category to EN 954-1 to be
fulfilled.
IMPORTANT
A more detailed description of the safety concept and the specific safety components installed can be found in the Operating
Instructions and the Operating Instructions of the supplier of
the overall system in which the hydraulic product is installed.
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Hydraulics
IMPORTANT
For details see the Operating Instructions.
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IMPORTANT
The factory-applied corrosion protection is adequate provided
that
Contact Bosch Rexroth if you are not clear about the consequences of long standstills on the state of the hydraulic product.
CAUTION
Always ensure hydraulic products are empty of pressure
fluid for transportation.
Rexroth hydraulic products are delivered empty of pressure
fluid. However, products may contain oil residues left over from
the final inspection at our factory.
8.1
CAUTION
If a hydraulic system is to be brought into use again following a long standstill, it must first be flushed clean.
8.1.1
IMPORTANT
If all the openings on the hydraulic products are not sealed so
as to be air-tight, this will reduce the storage life of the hydraulic product by nine months.
After the specified storage time has expired, in any event not
longer than 24 months, the corrosion protection must be
checked and further conservation measures applied if necessary.
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8.2
CAUTION
Seals:
Observe the requirements of ISO 2230 and/or DIN 7716
and the specific manufacturers data on seals.
Hoses and hose lines:
In the Federal Republic of Germany, please observe the
requirements of DIN 20066, ZH 1/74 Safety rules for
hydraulic hose lines and the specific manufacturers data
on hoses and hose lines.
In addition, the following conditions shall be observed:
Seals, hoses and hose lines are stored in cool, dry and
dust-free conditions.
Do not store elastomers below 10 C. The ideal storage conditions for seals are temperatures from +10 C
to +20 C and a relative humidity of between 65 % and
75 %.
Seals, hoses and hose lines must not come into contact
in particular with materials or vapours that could damage
them (e.g. acids, alkalis, solvents).
Store seals, hoses and hose lines lying down and free
from tension. If the hoses and hose lines are coiled, take
care not to bend them to less than the smallest bending
radius specified by the manufacturer.
Hoses: 4 years
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Hydraulics
IMPORTANT
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Filling the pressure fluid tank must always take place through a
suitable filter unit. Experience has shown that even new pressure fluid can often have more than the maximum permissible
level of contamination.
9.2
1.
2.
3.
The functional or failure behaviour of identical hydraulic products may vary due to conditions specific to the machine or system in which the hydraulic product is installed (mass, speed,
electrical triggering at setpoint values, etc.), see also Section
11 Trouble-shooting.
9.1
4.
5.
6.
7.
DANGER
Hydraulic products are generally intended for installation
in machines/systems or devices.
The function of the hydraulic product must therefore
always be seen in relation to the function of this machine
i.e. seemingly identical hydraulic products may demonstrate different functional behaviours as a result of the
function of the machine in which they are installed.
For this reason, a hydraulic drive must not be brought into
use until it has been determined that the machine in which
it is installed conforms to EU standards.
Do not bring hydraulic drives into use until you have familiarised yourself completely, firstly with the function of the
hydraulic product and hydraulic equipment and secondly
with the hydraulically powered machine functions, and
have clarified and dealt with any possible dangers.
Ensure that the cylinder piston rod can move out without danger.
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8.
As part of bringing into (first) use, check whether the electric motors and valve solenoids can be switched manually
using the electrical controls of the system/machine. If they
cannot be switched manually or can but with difficulty
you must provide a remote control (e.g. test boxes for
Rexroth proportional valves) for the internal function test of
the hydraulic system.
IMPORTANT
Starting up the hydraulics solely by means of emergency manual operation is not recommended, as several valves at once
cannot be switched as required in the correct sequence.
9.
Hydraulics
9.3
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DANGER
Before bringing into (first) use, have all pressure accumulators and safety systems checked by an expert or specialist in accordance with national regulations.
1.
2.
3.
4.
5.
Hydraulic consumers (cylinders, motors) with specially assigned valves, e.g. braking valve.
CAUTION
Remove all residues of water and cleaning agents
before performing further work.
6.
10. Divide the functional circuit diagram into separate mini-circuits that can each be started up in succession.
7.
IMPORTANT
Pump circuit
DANGER
Make sure that pipes and hoses are connected at all
ports or that the ports are sealed with screw plugs.
8.
Carry out a special check to make sure that the union nuts
and flanges are correctly tightened at the pipe connections and flanges.
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Hydraulics
IMPORTANT
CAUTION
Connect the hydraulic consumers. Dimension the connection lines in accordance with the performance data in the
Circuit Diagram and the Operating Instructions.
10. Install the electrical system for the drive and control system:
Use oil filler units (filter units) suitable for pressure fluids.
Do not remove the filter strainers from filler necks or the filter element from filters before filling the pressure fluid tank.
13. Fill the pressure fluid tank up to the upper mark on the
inspection window. Observe the maximum fluid level, taking into consideration the volume in the connection lines
and hydraulic consumers.
14. Set the pressure and flow control valves, pump regulator, signalling elements such as pressure switches, limit
switches and temperature regulators to the settings and
values defined in the sequential program (see 9.2 Before
bringing into first use).
DANGER
Do not change the settings of valves with a safety
function, valves with a position switch or valves with
preset electronics.
CAUTION
Never fill new hydraulic products with used pressure
fluid.
IMPORTANT
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15. If applicable:
Fill the pressure accumulator to the specified gas precharge pressure and then check the pressure, see Operating Instructions.
Use a filter unit to fill the pressure fluid tank. Ensure that the filter element is clean.
17. If applicable:
Open the cocks in the suction line.
IMPORTANT
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IMPORTANT
Details on bleeding can be found in the Operating Instructions.
Bleeding has been accomplished fully and correctly if the pressure fluid in the tank does not foam, if the hydraulic consumers
do not make any jerky movements and if no abnormal noises
can be heard.
20. Set the valves and sensors and start up the machine:
Set the switching operations of valves with a switching time adjustment/ramp in accordance with the
dynamic conditions, see Operating Instructions.
Finely adjust and optimise the setting of proportional
valves without on-board electronics (OBE).
IMPORTANT
Details on fine-tuning can be found in the Operating Instructions.
21. Check the operating temperature after the machine has
been running continuously for several hours. Too high an
operating temperature indicates that there are faults that
need to be analysed and rectified.
22. Rectify any leakages, e.g. by relieving couplings from pressure and then retightening.
IMPORTANT
Apart from moisture, which should not be sufficient to form one
drop, no measurable, unintentional leakage shall be found.
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23. After bringing the machine into first use, have a sample of
the pressure fluid analysed to ensure that it achieves the
required cleanliness class. Change the pressure fluid if the
required cleanliness class is not achieved.
If the pressure fluid is not tested in the laboratory after
bringing the machine into first use:
Change the pressure fluid.
24. Replace the pressure fluid filter.
25. Document and file all set values.
DANGER
26. To ensure the safety of persons and the system, after
bringing the machine into first use, perform the following
tests using the defined maximum values:
Function test
Pressure test.
Prepare a record of the bringing into (first) use or acceptance and have it signed by the plant operator. This record
is an important document and requires to be filed.
IMPORTANT
Information on how to perform the function test and pressure test can be found in the Operating Instructions.
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Hydraulics
Operation
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IMPORTANT
Please refer to the Operating Instructions for all information on
how to operate the Rexroth hydraulic product.
11
Trouble-shooting
Even if you are under time pressure, proceed systematically and methodically.
Indiscriminate, hasty dismantling and readjustments may,
in the worst case, result in the original cause of failure
being impossible to determine.
DANGER
In the event of abnormal occurrences or malfunctions, stop
all work on the Rexroth hydraulic product immediately and
inform the responsible personnel.
IMPORTANT
A table for product-specific trouble-shooting can be found in
the Operating Instructions.
If the responsible personnel are unable to rectify the problem
immediately:
Switch off the main switch. If applicable, turn off any combustion engines used as drive motors.
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Make a note of causes of failures with a low probability. Only investigate the failure causes you have noted
down if all failure causes with a high probability have
been proven to be inapplicable.
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IMPORTANT
The causes of failure in hydraulic systems can be extremely
complex. Therefore, general rules for trouble-shooting can only
be laid down to a limited degree.
Please refer to the relevant Operating Instructions for product
specific information about trouble-shooting the Rexroth hydraulic product.
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Bosch Rexroth AG
Hydraulics
Maintenance
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DANGER
Please refer to the Operating Instructions for all the necessary information on depressurisation and on those parts of
the Rexroth hydraulic product that are not depressurised
automatically.
Switch off the pressure supply and secure the hydraulic product against being inadvertently switched on
again.
DANGER
In the interests of safety, please observe all the following
safety instructions carefully and at all times.
Check safety devices regularly to see that they are working properly.
Since check valves are located in the pressure lines above the
pumps, the hydraulic system may still be under pressure even
after it has been disconnected from the actual pressure supply.
Certain segments, such as servo cylinders, also continue to
remain under pressure because the proportional valves remain
in the closed position (all valves are illustrated in their basic
position in the hydraulics diagram).
Observe the following:
Exercise extreme vigilance when operating the hydraulic product in maintenance mode, which may in certain circumstances
necessitate the temporary removal of certain safety devices.
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Make sure that all safety devices are properly installed and
have undergone a function test before bringing the system
(back) into use.
Perform welding, burning or grinding work on the hydraulic unit or its attachments only with the approval of local
safety authorities/fire brigade and with suitable protective
covering to prevent ingress of contaminants.
IMPORTANT
The following general specifications are based on use of the
hydraulic product in central Europe and under the usual operating conditions of commercial and industrial plants.
We strongly recommend the use of an inspection and servicing
book, in which all work specific to that site, and all inspection
and servicing intervals should be defined and documented.
An inspection and servicing book is also helpful in that
CAUTION
Ensure cleanliness during all work.
Please observe the requirements for pressure fluids mentioned in Section 9 Assembly and bringing into first use.
Hydraulics
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IMPORTANT
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IMPORTANT
Please refer to the Operating Instructions for the installation
location of filling level indicators, filling points, drainage points,
filters, testing points, strainers, solenoids, etc. that require regular inspection and servicing.
Keep the indicated typical test equipment ready for this type of
work.
Type of test
Typical test
equipment
Typical
testing activities
Pressure
measurement
Pressure gauge
or sensor with
suitable measuring
range and connection pipe and connection coupling
Checking of
Visual
inspection
specified pressure
opening pressure
pressure difference
before and after the
object under test
Temperature
inspection
Acoustic
inspection
all components
securely seated
damage
wear
leakage (formation of
oil droplets)
presence of all
warning and
informative signs
Checks for
Temperature
measuring
instrument
Checks for
Touch
inspection
unusual local
vibrations
Checks for
unusual local
temperature zones
Checks for
changes in running
noise of the unit
changes in flow
noise
changes in operating
noise in the unit and
valve control.
1
4
1
2
Wear margin Z0
Time t
5
6
The reduction in the wear margin reflects wear. The curve represents one possible form of the wear profile during the period
of use. It is determined during inspection and varies depending, firstly, on the system itself (e.g. material selection, surface treatment, quality) and secondly on external influences
or boundary conditions such as servicing levels, corrosive circulating air and dust. Thirdly, it depends on how the system
is operated; whether with partial load or partially with excess
load, whether it is subject to surge loads or steady load, etc.
Where hydraulic systems are concerned, the curve is also influenced by the cleanliness class and degree of fouling of the
pressure fluid, the number of cycles and the ambient conditions.
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An increase in the wear margin to over 100 % above its baseline may be achieved through corrective maintenance, if such
measures entail an improvement and this increase is established as the new desired condition for future corrective maintenance.
Certain system parts may be subject to a wear margin which
diminishes in such a way that the time available for use is insufficient for the requirements of the plant or operation. In this
case, investigations must be carried out to ascertain whether
the introduction of suitable technical measures might counter
this reduction in the wear margin to a satisfactory extent. The
time and expenditure required for such measures must naturally be kept in reasonable proportion to the expected degree
of success.
IMPORTANT
IMPORTANT
The details of the specified lubricants, lubrication points and
associated lubrication cycles can be found in the Operating
Instructions.
Pressure and flow control valves, pump regulators and signalling elements such as pressure sensors, pressure switches,
limit switches and temperature regulators are given their optimum setting when the system is brought into first use.
IMPORTANT
Check regularly whether all values are correctly set with the aid
of the hydraulics diagram and the documented values.
IMPORTANT
The appropriate component characteristics relevant to servicing can be found in the Operating Instructions.
DANGER
The set values of valves with position switches shall only
be calibrated or readjusted at the factory.
The set values of safety valves shall not be altered by the
user. Any readjustment shall be performed by authorised
testing bodies only.
Too low a pressure difference between the operating pressure and the opening pressure can lead to frequent opening
of safety valves. This leads to increased power losses and an
unacceptable increase in temperature of the pressure fluid. In
this event, select a lower operating pressure.
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Hydraulics
CAUTION
Unfiltered pressure fluid filters lead to increased wear of
all the systems hydraulic products and can cause functional failures with dangerous effects. Therefore, always
replace contaminated oil filters immediately.
Clogged ventilation filters result in inadequate cooling and
can therefore cause excessive heating up and malfunctions of the hydraulic system. Therefore, always replace
contaminated ventilation filters immediately.
Allow the contents of the replaced oil filter to drip and fully drain.
IMPORTANT
Check the contamination indicator when the pressure fluid is
warm (during or immediately after operation).
If the ambient temperature is low or the pressure fluid is cold,
its high viscosity may cause clogging to be indicated, although
the pressure fluid is in fact clean.
Procedure:
1.
2.
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CAUTION
In certain circumstances the contamination indicator does
not show a required filter replacement.
If the check function never indicates filter replacement and the
contamination indicator is functioning correctly, this may have
the following causes:
Faulty filter
IMPORTANT
In terms of the service life of hydraulic hose lines in these
Operating Instructions, replacement and storage lives are measured from the date of manufacture of the hose line.
Even when properly stored and subjected to permissible loads,
seals, hoses and hose lines undergo a natural ageing process.
The replacement and storage lives of seals, hoses and hose
lines are therefore limited (see 8.2 Seals, hoses and hose
lines).
DANGER
Hose lines must be replaced in accordance with the provisions of the servicing plan, even if there are no detectable
technical defects in the hose line.
Hoses that have already been used as part of a hose line
shall not be reused in a hose line.
The first use may have changed the properties of the hose
material to such an extent that reuse of the hose represents a very high risk.
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12.7 Repair
IMPORTANT
IMPORTANT
When changing or topping up the pressure fluid, fill the pressure fluid tank on the hydraulic product as follows:
1.
Fill the pressure fluid tank using a special filling unit with
an integral filter (min. 10 m).
2.
3.
Fill and bleed the line system of the hydraulic product from
the unit to the cylinder. To do this actuate the cylinder in
both directions, see Operating Instructions.
4.
5.
7.
Check the level of the fluid after the hydraulic product has
warmed up to the operating temperature and adjust if necessary.
IMPORTANT
Check the contamination indicator when the pressure fluid is
warm (during or immediately after operation).
If the ambient temperature is low or the pressure fluid is cold,
its high viscosity may cause clogging to be apparently indicated.
DANGER
Pressure accumulators are subject to the national legislation on safety requirements for pressure vessels applicable in the place of installation.
Observe the Pressure Equipment Directive 97/23/EC.
IMPORTANT
The gas precharge pressure is measured with a testing and filling device.
Details of the procedure can be found in the Operating Instructions.
Inspection and servicing
DANGER
Ensure cleanliness during all work.
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Bosch Rexroth AG
Hydraulics
DANGER
Repair work shall only be done by an authorised hydraulics
expert who has the required specialist hydraulics knowledge.
Specialist hydraulics knowledge means, among other things,
that the person can read and fully understand hydraulics drawings. In particular, he must fully comprehend the range of functions of the integrated safety components.
Components may only be dismantled for the purpose of repair
to the extent described in the Operating Instructions.
Never repair a defective safety valve. It must be completely
replaced.
Faulty parts may only be replaced by new, interchangeable,
tested components in original-equipment quality. Any deviations from this can be found in the Operating Instructions.
Before each subsequent bringing into use after repair work, the
hydraulic product shall be accepted by a hydraulics expert.
The operator of the hydraulic product is required to check by
means of a servicing record that the inspection and servicing
plan as been complied with.
Pressure vessels have to be pressure tested every 10 years
and the information recorded in accordance with the Pressure
Equipment Directive 97/23/EC or its implementation in national
legislation.
13
13.1 General
The regulations applicable at the place of installation concerning hydraulic pressure accumulators (hydrostatic accumulators) must be observed before bringing into use and during
operation.
The plant operator bears sole responsibility for compliance with
the existing regulations.
Hydrostatic accumulators are subject to the national implementation of the EU Pressure Equipment Directive 97/23/EC.
Documents supplied with accumulators must be preserved
with care; they will be required during recurring inspections by
specialists.
The bringing into use of hydrostatic accumulators shall be carried out by trained expert personnel only.
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WARNING
Do not perform any welding, soldering or mechanical work
on accumulator vessels.
Welding and soldering carry a risk of explosion!
Mechanical tampering may cause the vessel to burst and
the operating permit will be withdrawn.
Do not charge hydrostatic accumulators with oxygen or air.
Risk of explosion!
Depressurise the system before working on hydraulic
installations.
Improper installation can lead to serious damage to persons and property.
Shut-off device
IMPORTANT
See the Operating Instructions.
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14
Hydraulic systems
WARNING
Before installing a hydraulic system in a machine or modifying an existing hydraulic system in a machine, satisfy
yourself that
Hydraulics
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DE
RD 07008
EN
RE 07008
FR
Information de commande pour la notice franaise Informations gnrales sur les produits :
RF 07008
IT
RI 07008
ES
RS 07008
FI
RSF 07008
NL
RNL 07008
SV
RSK 07008
PT
RP 07008
DA
RDK 07008
EL
RGR 07008
Hydraulics
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http://www.boschrexroth.com/bri-products
Datenblatt-Suche/Datasheet search
Suche nach Datenblatt/Search by datasheet
07008
Bosch Rexroth AG
Hydraulics
Zum Eisengiesser 1
97816 Lohr am Main, Germany
Tel. + 49 (0) 93 52 / 18-0
Fax + 49 (0) 93 52 / 18-23 58
documentation@boschrexroth.de
www.boschrexroth.de
All rights reserved, Bosch Rexroth AG, including applications for intellectual property rights. We reserve all power of disposal, rights of reproduction
and issue.
The data specified above only serve to describe the product.
No statements concerning a certain condition or suitability for a certain
application can be derived from our information. The given information does
not release the user from the obligation of own judgement and verification. It
must be remembered that our products are subject to a natural process of
wear and aging.
Bosch Rexroth AG
Training Systems and Teachware
Maria-Theresien-Strae 23
97816 Lohr a. Main, Germany
Phone +49 9352 18-1041
Fax +49 9352 18-1040
trainingsystems.brs@boschrexroth.de
www.boschrexroth.com
This document, as well as the data, specifications and other information set forth in it, are
the exclusive property of Bosch Rexroth AG.
It may not be reproduced or given to third parties wihout its consent.
Made in Germany
Document number: RE 00845/04.07
Material number:
R961003790