Академический Документы
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Культура Документы
Second Edition
Second Edition
Copyright 2011 by Ivan Gramatikov
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or transmitted in any form, or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of the author.
For permissions e-mail: gramatik.publishing@abv.bg
ISBN: 978-1-257-01500-9
Printed in the United States of America
Front cover photos: Courtesy of Balkancar Record (http://www.balkancar-record.com)
CONTENTS
Chapter 1:
Introduction
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2:
11
Properties
Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Specific weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Compressibility of fluids . . . . . . . . . . . . . . . . . . . . . .
16
18
Parameters
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
Fluid velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
25
Hydraulic shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
ii
Hydraulic Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
Obliteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Stiction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
30
31
Chapter 3:
Flow Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . .
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reduction Valves . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Compensated Flow Controls . . . . . . . . . . .
Directional Control Valves . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Accumulators . . . . . . . . . . . . . . . . . . . . .
Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Lines, Fittings and Couplings . . . . . . . . . .
Manifold blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
34
36
37
39
40
42
48
59
60
64
66
70
77
83
88
90
95
98
Chapter 4:
101
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
iii
106
108
110
Design guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
117
118
119
Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
122
123
Chapter 5:
125
Elevating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
128
Design principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
Design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .
130
146
153
158
160
165
171
174
176
Chapter 6:
181
iv
183
185
189
Hydraulic system for pallet trucks with long fork attachments 194
Hydraulic power-assisted steering . . . . . . . . . . . . . . . . .
197
199
Chapter 7:
202
203
207
208
Chapter 8:
Selected topics
I.
211
211
Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . .
System Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
212
212
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213
213
Servicing filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
216
Servicing reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
216
217
218
Servicing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
219
Servicing connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
220
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
221
II.
222
III.
Common problems . . . . . . . . . . . . . . . . . . . . .
223
IV.
225
V.
229
Appendixes
231
Appendix A
ITA classification
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
vi
Chapter 1
Introduction
Preface
The purpose of this book is to illustrate design principles and methods for
designing and calculating hydraulic systems for industrial lift trucks.
Determining the main parameters of these systems is based on principles
of hydraulics and mechanics. This book is to be used as a source of
information for mechanical engineers involved in designing, manufacturing
and servicing hydraulic systems for mobile lift trucks. This book can also be
used by engineering students in Industrial Truck Programs. To combine
these two purposes, there is an introductory chapter, Properties and
Parameters of Hydraulic Fluid, and a chapter on Hydraulic Components
describing the construction and the functions of components used in mobile
hydraulic systems. This book will also be beneficial for engineers working in
areas of design, fabrication and service of any other mobile off-highway
equipment.
In all universities, mechanical engineering students study the theoretical
foundations of fluid mechanics, fluid dynamics, and thermodynamics.
However few universities offer courses in hydraulics and pneumatics (also
called: fluid power), which are the applications of these disciplines. That is
why most design engineers learn the basics of the fluid power on the job.
Fluid power learning time can be reduced significantly if some basic
hydraulic principles are understood up front. This book will describe the
hydraulic principles and operation of the main hydraulic arrangements
which will give you the foundation for designing any system on your own.
It is more difficult to design hydraulic systems for smaller lift trucks. That is
because these systems must have the same performance as the bigger
trucks but they have to be put into a smaller space envelope. The smaller
design envelope is a major challenge to the design engineers. To meet this
and all other challenges through the design process, engineers have to
follow the principles of continuous improvement and design process quality.
Quality of the design process depends on the proper execution of each step
Chapter 1: Introduction
The best design is the simplest one that works Albert Einstein
Design is creative problem solving.
System design is finding the balance in system performance that
best satisfies the engineering requirements. This balance has to be
achieved first at the conceptual level and then maintained throughout
the whole design process.
When designing a system, the engineer must focus on four main aspects:
Regulations
In some countries, such as Canada, the engineering profession is selfregulated through provincial organizations. The governing body is
comprised of engineers chosen, through a voting process, by members of
the engineering organization.
In other countries, such as the USA, the state governments regulate the
licensing, the practices of the profession and approve the governing body of
the engineering organizations.
Chapter 1: Introduction
Calculations
Clarity and accuracy of the technical calculations are an important part of a
system design. All data, assumptions, mathematical and physical laws have
to be specified clearly. Calculations are an intellectual asset for a company.
Therefore any other engineer with the same background should be able to
understand and use them. This reduces the development time of future
projects and helps to bring new products to market in a shorter time. A
good practice is to put all calculations on a server in HTML or PDF format.
European countries (except the United Kingdom) use a comma as a
decimal marker. The UK, the USA and English speaking provinces of
Canada use a period as a decimal marker. In this book, since it is written in
English, I am going to use a period.
Systems of Units
International System (SI) of units
This system was adopted in 1960 at the Eleventh General Conference on
Weights and Measures as an international standard. SI is accepted by all
countries in Europe and most countries in the world. In the future, it is
expected to replace all other systems and to be used by all countries.
In this book we will primarily use SI units.
British Systems of Units
British Gravitational (BG) System
In the past, the BG system was used in the English speaking countries. In
the BG system the unit of length is foot (ft), the unit of force is pound (lb),
the unit of mass is obscure (slug) and the unit of temperature is degree
Fahrenheit (F).
slug =
lbm
gC
Area [m2]
Diameter [m]
dP
dM
EV
Force [N]
GQ
Ratio
Mass (kg)
Chapter 1: Introduction
RL
Re
SG
Temperature [C]
Torque [Nm]
Velocity [m2/s]
Greek alphabet
Angle [rad], []
Angle [rad], []
Deviation
Efficiency
Angle [rad], []
SG
Angle [rad], []
Hydraulic symbols
________
--------
Pilot line
Flexible line
Plugged line
Venting
Reservoir, open
Reservoir, pressurized
Filter
Accumulator
Chapter 1: Introduction
Pressure gage
Thermometer
Flow meter
Foot operated
Hand operated
Spring operated
Electrical control
10
Chapter 1: Introduction
Check valve
Pressure switch
Torque generator
11
Chapter 2
Properties
Density
Density of the fluid is defined as its mass per unit volume containing the
mass.
m kg
V m 3
Where:
2.1
12
m=
WO
[ slug ] , WO is the weight in pounds at sea level
32.174
kg
H 2O = 1000 3
m
A common reference for non-liquids is the density of iron:
kg
1 kg
v m 3
Where:
2.2
Unlike gases, the density of the fluids depends little on pressure and
temperature. Densities of different fluids are given in Appendix B.
Specific Weight
Specific weight is a characteristic for bodies under the influence of the
gravitational field. The gravitational field is not a force (because it is
massless) but it produces a force when it interacts with mater. As a result,
mater receives a gravitational acceleration which does not depend on the
physical state of the mass.
Specific weight of fluid is equal to the product of fluid density () and
gravitational acceleration g = 9.806 m/s (g = 32.174 ft/s). It is defined as
fluid weight per unit volume containing it.
13
= g 3
m
2.3
Specific Gravity
Specific Gravity is the ratio of the density of the fluid to the density of the
water at the same temperature.
SG =
2.4
H 2O
Viscosity
Viscosity of the fluid is a measure of resistance against friction between
fluid layers. It is related to the velocity gradient (
stress ( ) by the equation:
du
dy )
14
du
dy
[Pa.s]
2.5
m2
=
s
2.6
1St = 1cm 2 / s = 10 4 m 2 / s
1cSt = 1mm 2 / s = 10 6 m 2 / s
from 32 to 99
15
Because of the small temperature difference, ISO grades are a little more
viscous than the corresponding ASTM grades in SUS units. Viscosity
grade classification is given in Appendix C.
Another characteristic given by fluid manufacturers is the Viscosity Index
(V.I.). This index is a number that indicates changes of viscosity over
change of temperature. High V.I. means that there is little change in
viscosity with temperature change and vice versa. Fluid viscosity is a
main factor that determines the amount of friction between the fluid
layers, the boundary layers thickness along the inside walls and the
friction between metal surfaces of the hydraulic components. Viscosity
changes with the change of temperature, pressure and contamination.
When the pressure on the fluid increases, the shear stress increases
leading to viscosity increase. Also, when the fluid temperature increases
its viscosity decreases. The effect of temperature on kinematic viscosity
of some fluids is shown in Figure 2.1.
16
Compressibility of fluids
Compressibility of a fluid is a measure of how easy a fluid volume can be
changed under pressure. Compressibility is characterized with the Bulk
Modulus of Elasticity (Bulk Modulus or Modulus of Elasticity) EV. Modulus
of Elasticity shows the resistance of the fluid to compression and is
defined as:
Ev =
dp N
dV / V m 2
2.7
Where:
dp is differential change in pressure needed to create a differential
change in volume dV;
V is the initial volume of the fluid;
V/V is specific volume.
Because the specific volume is dimensionless, Modulus of Elasticity has
the same units as pressure. The negative sign shows that an increase in
pressure will cause a decrease in volume. In SI units Ev is given as N/m
(Pa). In BG (English) units it is given as lb/in (psi). Some values of Ev are
given in Appendix B.
In the case of using hydraulic oil, the value of V/V is very small (large
Ev). For this reason, for the engineering applications we accept that fluids
are incompressible and disregard the compressibility factor. Large values
for the bulk modulus indicate that the fluid needs a great amount of
pressure to make a small change in the volume. In other words, the
bigger the number is the bigger resistance to compression the fluid has.
Modulus of Elasticity can alternatively be expressed as
Ev =
dp
/ d
Where:
d is differential change in density of the fluid;
is initial density of the fluid.
2.8
17
Fig. 2.2
18
VL
Re =
2.9
Where:
V is velocity characteristic
L is lineal characteristic
is the dynamic (absolute) fluid viscosity
is fluid density
When the flow is in a pipe with a circular cross-section, the lineal
characteristic L is equal to the pipe diameter D. Then the equation can be
written as:
Re =
VD
Re =
VD
2.10
2.11
19
4000, the flow is transitional (between laminar and turbulent) and it has
elements of both flow types. For flows within circular pipes the critical
Reynolds number is generally accepted to be 2320.
Parameters
Pressure
Pressure is the normal force per unit area at a given point within the fluid.
For most engineering problems we assume that the fluid moves as a rigid
body (dealing with fluid at rest) therefore there is no shearing stress in it.
So, the only forces acting on the fluid are pressure and weight. This
allows us to obtain relatively simple solutions to most engineering
problems.
Pressure distribution (for incompressible fluids) is called hydrostatic
distribution.
p1 = h + p2
2.12
Where:
h = z1 z2 is the vertical distance from a point with pressure p1 to a point
with pressure p2. This distance is called pressure head and it is
interpreted as the height of a column of fluid of specific weight required
to give a pressure difference (p1 - p2). If we have a surface exposed to
the atmospheric pressure it is convenient to use a point on this surface as
reference point 2. Thus, we let: p2=p0.
In SI, unit pressure is expressed as Pa (Pascal), where: 1Pa=1N/m. In
some cases we use the unit bar (1bar = 0.1 MPa).
In BG, units are lb/ft or lb/in (psi). The relationship between the metric
and the English systems is: 1 bar = 14.5 psi
20
Ev
Where:
Ev is the modulus of elasticity (Pa)
2.13
21
Unit _ volume V m 3
Q=
=
Unit _ time
t s
2.14
In SI units flow rate can be expressed either in cubic meters per minute
[m3/min] or litters per minute [l/min]. In BG units the flow rate is expressed
in gallons per minute [gpm].
In systems working with incompressible fluids we use volumetric flow rate
in the calculations. In our further calculations, we are going to use
exclusively this type flow rate.
Mass flow rate, q
Mass flow rate is the unit mass per unit time
q=
Unit _ mass m kg
=
Unit _ time
t s
2.15
22
q = Q, [kg / s ]
GQ =
Unit _ force F N
=
Unit _ time
t s
2.16
GQ = gQ, [ N / s ]
2.17
=
Where,
Fig. 2.3
Q Qmin
Q
100 = max
100 _[%]
Qm
Qm
Qm
23
Fluid Velocity
Fluid velocity, in pipes is:
v=
Q m
A s
2.18
W = Fx [Nm]
2.19
F = pA [N ]
2.20
If we replace the force in the equation 2.19, work can be expressed as:
W = pAx [Nm]
2.21
24
W = pV [Nm]
2.22
P=
W Nm
t s
2.23
P=
pV
= pQ [W ]
t
2.24
Where:
Q=
V m3
[ ] is the flow rate;
t
s
p [Pa]
is the pressure.
The most convenient form of this formula for calculating the input power
on the pump shaft is:
P=
pQ
[kW ]
60 P
2.25
l
Q
min
p [MPa ]
25
26
p L =
l 2
(v )
d 2
2.26
Where:
=n
64
, for round cross sections n=1
Re
2.27
pT =
(v )2
2.28
27
Where:
v = Q/A is the flow velocity at the outlet of the component;
[Zeta] is the coefficient of local flow resistance.
Zeta depends on the geometrical shape, cross section and surface
roughness of the local restrictor. Approximate values of Zeta are given in
Table 2.1, Appendix D.
Hydraulic Shock
A Hydraulic Shock is also called: water hammer. It is caused by quick
closure of the hydraulic component causing pressure increases in the
pressure side of the closing element. When the free flow is closed the
kinetic energy of the moving fluid is transformed to potential energy,
which in turn creates a pressure wave (shock wave). In order to absorb
shock waves due to valve closure we use flexible hydraulic hoses as
hydraulic lines. In the full power brake systems where hydraulic lines are
metal tubing and a brake valve is used to redirect fluid to the wheel
cylinders, the shock waves can be absorbed by an accumulator.
Hydraulic Lock
One of the most common causes for failures in plunger type valves is
excessive frictional force between the plunger and the housing. Frictional
force (Fr) is due to uneven pressure distribution in valve clearances (fig.
2.4a). Different pressures on both sides of the plunger create a force
perpendicular to the plunger axis. This force pushes the plunger off its
center position against the housing increasing friction between internal
surfaces. Friction force higher than the control force causes seizing of the
plunger. This failure is called hydraulic lock. Valve designers add
balancing grooves to equalize the pressure distribution around the
plunger circumference (fig. 2.4b).
28
p1
Fr
pa
pb
p2
[p]
[p]
pa
pa
pb
p2
pb
p1
x
Fig. 2.4
pm
p=p2-p1
y
a)
distance
y
b)
Obliteration
It has been determined experimentally that flow rates through very small
openings can gradually diminish and become zero. This phenomenon is
called obliteration. It is caused by the adhesion forces between metal
surface and the fluid which results in the buildup of layers of molecules on
the surface. Adhesion force is an interaction at an atomic level and
depends on the chemical composition of the fluid. Experiments show that
obliteration exists in openings smaller than 0.01 mm and causes both
surfaces to stick together plugging the opening. When the opening is
plugged, the plunger is seized. This condition appears in plunger type
hydraulic components with small internal clearances. To eliminate the
stickiness and seizure of the valve, the plunger is subjected to vibrations
with frequency higher than 30 Hz. The high frequency input to the valve is
called dither signal.
29
Stiction
The term stiction is created by combining the words stick and friction.
Stiction occurs when the static friction force is higher than the moving
force. It measures the spool resistance to initial motion.
Cavitation
Cavitation in fluids is a process of formation and collapse of air or vapour
bubbles. This leads to micro jets of oil pounding and eroding adjacent
surfaces. Cavitation occurs when the absolute pressure of the fluid
becomes close to zero. Cavitation also occurs when the pressure drop is
enough that at a given temperature the air in the fluid starts to evaporate.
In this case we say that the pressure becomes equal to the vapor tension
of the fluid.
When cavitation is formed at the suction of the pump, several things
happen all at once.
Vaporization
Air ingestion
Internal recirculation
Flow turbulence
Vane Passing Syndrome
30
2. Suction-line leaks. Leaks between the tank and the pump can
introduce air into the system. Often this is associated with the shaft seal
at the pump that allows air to leak in.
3. Suction-line restriction. Sometimes suction lines are too long, too
narrow or they are plugged (e.g., a plugged suction strainer).
4. Water vapor. When hot oils become contaminated with water,
superheated seam will form vapor bubbles in the oil.
5. Insufficient head. Depending on oil viscosity and suction line
conditions, the pump must be located at a sufficiently low elevation to
enable oil to flow steadily from the tank to the inlet port of the pump.
6. Air release problems. As oils age and become contaminated, its air
release properties become impaired. This means that once air bubbles
are formed they stay locked into the oil and do not detrain out of the oil in
the reservoir. Moisture contamination and oxidation are the main
originators of this problem. ASTM D3427 is a test for air release
properties.
7. High viscosity. When fluid temperature in the reservoir is too low, the
viscosity may be too high to enable proper oil flow in the suction line and
into the pump. Any other cause of high fluid viscosity can lead to the
same problem.
p+
1
2 + z = pT = const.
2
2.29
1
2 is
2
z = gz
31
p1 +
1
1
1 2 + z1 = p 2 + 2 2 + z 2
2
2
2.30
Fig. 2.5
The Bernoulli equation was formulated it in 1738 by the Dutch born
mathematician and physicist Daniel Bernoulli (1700-1782).
Fig. 2.6
32
From,
p1 +
1
1
1 2 + z1 = p 2 + 2 2 + z 2
2
2
( z1 z 2 ) =
1
2 2
2
= g , we receive
2 = 2 gh
2.31
Q = A 2 gh
Q = A
2.32
33
Chapter 3
Hydraulic Components
Hydraulic components can be grouped according to their function:
I.
Valves
Hydraulic valves are grouped into three general categories: pressure
controls, flow controls and directional controls. Some valves can have
multiple functions and can fall into more than one category. The most
important valve characteristics are flow and pressure drop in the valve.
Flow can be calculated based on the port diameter and the flow velocity.
Pressure drop is more difficult to calculate accurately. That is why it is
usually determined experimentally by the manufacturer.
Based on the construction, the valves can be plunger or cartridge.
Cartridge valves are a screw-in type, which offer the designers the
potential of incorporating the valves into manifold blocks or the body of
other hydraulic components, such as cylinders.
II.
Actuators
This group consists of pumps, motors and cylinders. Actuators convert
fluid energy into mechanical energy or vice versa.
III.
Accessories
In this group are: Pressure and vacuum switches, accumulators, filters and
connectors.
IV.
Hydraulic reservoirs
There are two main types of reservoirs- open and closed. The hydraulic
systems for industrial trucks use open type reservoirs.
V.
Hydraulic fluid
The fluid is the single most important component of the hydraulic system.
Its main function is to transmit energy.
34
1.
35
p = RL Q
3.1
Where:
RL
is orifice resistance
In a system with an orifice, usually there is a varying pressure, p2, after the
restrictor is determined by the variation in resistance of the actuator.
The main flow restrictor characteristic is based on equations 2.26 and 2.28
and it is called: the flow-pressure drop characteristic. An experimental
graph of such a characteristic is shown in Fig. 3.1
36
16
14
12
10
8
6
4
2
0
0
10
20
30
40
50
Flow (l/min)
2.
Symbols:
Pressure relief valves (also called: relief valves) are pressure control type
valves. It is normally closed until it starts to operate. After the pressure is
increased, the valve opens and the plunger (poppet or ball) finds a balance
position. The balance is created between the pressure on one side and
spring force on the other. The valve plunger can have infinite positions
between closed and fully opened conditions. The relief valves main
function is to protect the system against excessive pressure. It is usually
37
installed between the pressure line, after the pump, and the return line
before the tank. Relief valves can be adjustable or non-adjustable. Valves
are adjusted by changing the spring pre-compression.
There are three types of balancing/closing elements: ball, poppet and spool
(plunger). The balancing element used determines the type of the valve.
Valves can be divided into two groups 1) Ball and Poppet and 2) Spool
Valves.
Ball and Poppet Valves
Ball and poppet valves are usually used for the construction of cartridge
valves. Cartridge valves are less expensive and have higher flow rates than
the same physical size spool valves. Ball and poppet valves are less
susceptible to fluid contamination because when closed, the valve moving
part is held tightly against a seat in the housing. On the other hand, they
are more sensitive to flow and pressure irregularity. Their positioning is less
balanced than spool valves, which leads to less accurate metering.
Spool Valves
Spool valves are easier to control and can move at smaller steps because it
is easier to proportionally control the stroke of the spool. On the other hand,
they are more expensive and more susceptible to contamination. Spool
valves have higher leakage rates than poppet valves.
3.
Check Valves
Symbol:
Check valves are unidirectional control valves. They have two positions:
ON or OFF. This valve has free-flow (open) and no-flow (close) direction.
When the flow pushes the ball (or the poppet) away, the valve opens and
permits free flow. Flow in the opposite direction pushes the ball against the
seat. The built-up pressure keeps the passage sealed and the flow is
blocked. These types of valves are designed to have a very small leakage
rate when they are closed. Usually, valve seats are hardened steel which
makes them more resistible to scoring from hard contaminants in the fluid.
38
The only difference between the check valve and the ball relief valve is the
spring. Check valves have light springs which are used only to return the
ball (poppet) to its seat when the flow stops. Because of the light spring, the
pressure drop in the valve during operation is very small (about 0.05 to 0.1
MPa). There are three general check valve designs: plunger, poppet and
ball design.
The check valve has a relatively small effect on system noise, vibration and
losses. When the check valve is built into another hydraulic component, the
pressure loss from it is included in the total pressure loss of the main
component. When we use an in-line check valve, it is acceptable to
disregard the pressure loss in it. Therefore, it is very important not to
undersize the valve. Undersizing it will increase the pressure drop, leading
to inaccuracy in the calculated pressure demand.
Check valves can have an internal or external pilot control. Fig. 3.2 shows
two valves with pilot ports.
outlet
outlet
pilot
pilot
inlet
inlet
b) pilot-to-close
p PILOT =
p OUTLET + p SPRING
,
r
Where:
pSPRING
r is the pilot ratio. It is the ratio of pilot piston area to poppet area.
39
Pilot-to-close also allows flow only in one direction in the absence of pilot
pressure. When pilot pressure is applied from the pilot port, it overrides the
free flow function and holds the valve closed. This feature is useful to
control regenerative flow in a cylinder circuit or in a hydraulic logic circuit.
Minimum pilot pressure required to close the valve is:
p PILOT =
p INLET p SPRING
,
r
4.
Reduction Valves
Symbol:
A reduction valve is a pressure control type of valve. Its function is to
reduce pressure and maintain a pre-set lower pressure value in the outlet.
The valve maintains a constant pressure in the outlet regardless of
pressure and flow rate changes in the inlet. This valve is normally open.
40
Principle of operation
Flow passes through an opening between a balanced plunger (spool) and
housing. Pressure in the outlet is applied under the valve plunger through
internal connection. A spring force, acting on the other side, balances the
plunger. When the pressure in the outlet increases, the plunger is pushed
up and the opening is reduced which, in turn, reduces the flow through the
valve. Spring chamfer is connected to the reservoir therefore external drain
to the reservoir is required for this valve.
5.
41
Pressure in point 1 must be higher than the pressure in point 3. When the
flow is reversed, from outlet to the inlet, the valve simply acts as a flow
restrictor.
1
2
3
Fig. 3.4 Two-way flow controls: a) balanced valve before the orifice, b)
balanced valve after the orifice.
The flow equation through the orifice is:
Q = A
3.2
Where:
is the flow coefficient
A is the area of the orifice opening
p is the pressure drop in the orifice
The only variable in flow equation is the pressure drop (p). The purpose of
the pressure balanced valve is to maintain a constant p which ensures a
constant flow rate (Q) through the orifice. The flow is as a function of the
42
In the hydraulic systems, the nearly constant flow rate is used to achieve
speeds of the hydraulic actuators which are independent from the pressure
variations. In mobile forklifts it is mainly used to maintain a constant
lowering speed of the load. A hydraulic system using this valve is described
in Chapter 5 (Hydraulic Systems for High Lift Trucks).
50
Flow (l/min)
40
30
20
10
0
0
10
15
20
6.
Directional valves control the direction of the flow path. These valves can
be classified on the basis of the number of possible ways the fluid can go.
Most common types are 2-way, 3-way, 4-way or 5-way valves.
Based on the neutral position of the valve plunger, there are three basic
valve configurations shown in Fig 3.6 (a, b, c)
Open center, a), is when the plunger is at a neutral position and the
inlet flow is open to all ports.
43
Close center, b), is when the plunger is at a neutral position and the
flow is blocked.
Tandem center, c), is when the plunger is at a neutral position and
the flow is unloaded to the tank.
Two other combinations of the first three, float center d) and open-to-three
port e), are also shown in Fig 3.6
Fig. 3.6
Directional-control valves have two primary characteristics: 1) number of
ports for the fluid and 2) number of positions for the controlling element.
Valve ports are the passageway for fluid in or out of the valve. The numbers
of positions refer to the number of distinct flow paths a valve can provide.
There are three types of spool valve laps (fig. 3.7): zero, positive and
negative. Valve lap is the distance the spool travels before valve opening.
Valves with large overlaps have less leakage but they have less accurate
flow metering.
a) zero lap
c) negative lap
44
Discrete positioning
Finite positioning is when the plunger is shifted from one discrete position to
another. For this reason these type valves are called discrete valves.
Plunger shift occurs in an instant, causing the fluid to rapidly accelerate or
decelerate. This causes fluid pulsations or in certain conditions it can cause
fluid hammer.
Switching time for these valves depends on the size of the coil. Actuation
time increases when the coil size and the valve size are increased. For
example the switching times of directional valves size 6 (20 l/min nominal
flow) with DC (direct current) magnet is about 40 milliseconds while the
switching time of size 10 directional valve (80 l/min nominal flow) is about
80 milliseconds.
Infinite positioning
In these valves, the plunger is shifted proportionally to the input signal. The
signal can be mechanical, electrical or hydraulic. The plunger can have
infinitive intermediate positions, which makes these types of valves ideal for
controlling speed and acceleration or deceleration of the actuators. Infinite
positioning is illustrated by adding two extra parallel lines indicating that the
plunger can slide inside the valve.
45
field, which in turn creates a magnetic force on the armature and makes it
move. The coil is placed in a metal housing which helps to retain the
magnetic field. In most valves, a flat spring is used to resist plunger
movement. The spring retains the plunger until the magnetic force on the
armature exceeds the spring force. The main reason for the performance
variation from one valve to another is the mechanical and geometrical
tolerances that occur in the manufacturing process. Solenoid magnetic field
can be adjusted so that it compensates for mechanical tolerances.
Therefore, this valve can create a consistent relationship between the flow
rate and the electrical current to the valve.
Proportional valves can be an open-loop or a closed-loop construction.
Open-loop valves do not have feedback between the solenoid input and
the valve spool or valve output. They have a lower response time than the
closed loop valves.
Closed-loop valves have an outer loop for spool location feedback. An
outer loop can be made by connecting a LVDT sensor to the spool. A
LVDT sensor measures small changes (in the range of microns) of spool
movement and converts them to electrical signals.
Proportional valves can be spool or poppet type. Most of proportional
valves are spool type designs because they have better control and
metering capabilities. Poppet type proportional valves are less susceptible
to fluid contamination. For this reason they are mainly used in systems
subject to high contamination. To minimize the leakage from a section with
high pressure to a section with low pressure, the plunger type valves are
manufactured to have as a small gap as possible between the body and the
plunger. The servo valves have 0.001 mm to 0.004 mm internal clearances
while the discrete directional valves usually have 0.005 mm to 0.012 mm
internal clearances.
Servo valves
Servo valves have a shorter response time than standard proportional
valves. They are always closed-loop valves. There is a mechanical
feedback link between the input command and the valve output. Servo
valves usually consist of a two-stage spool. The spool position is controlled
by two electromagnetic coils- one from each side. Manufacturing tolerances
of these valves are in the range of micrometers. The tight tolerance
requirements make them expensive to manufacture. Also, the reduced
46
clearances between the valve surfaces make this type of valve susceptible
to fluid contamination which can jam the valve. Because of the high cost
and the high fluid cleanliness requirements, servo valves are rarely used in
mobile hydraulic systems. Servo valves are used in applications where
short response time is critical. For this reason they are manufactured with
zero laps or near-zero overlaps.
Servo valves can have a response time as low as 0.0025 seconds (400
hertz). Where:
1Hz =
1
1sec
Q R = QOUT
p B
p A
Where,
QR = valve's rated flow for our application
QOUT = output flow needed for application
pB = rated pressure drop of proportional valve
p A = actual pressure drop needed for application
3.3
47
It is recommended that designers use this method to check the flow rate of
their valve. In most cases, the flow rate they obtain through this method will
differ from the flow rate in the catalogue.
Load sensing priority valves are used to split the flow in open loop systems
where one branch must have a guaranteed flow supply. This valve senses
the flow requirements and provides metered priority flow to this port. The
valve has one inlet and two outlets. One of the outlets is for the controlled
fluid (CF) and the other one is for the excess fluid (EF).
Dynamic load sensing valves have faster responses than static valves.
They have a passage between CF and LS lines. This passage supplies a
continuous pressurized flow to the LS line even when the line is not used
which keeps the valve in a ready-to-respond position.
Directional valves can have direct or indirect control. Direct control is
applied directly to the valve control element. Indirect control (pilot operated
design) is when the input signal controls a small pilot valve which in turn
controls the main valve (fig. 3.8).
Electrically controlled big valves require big and expensive solenoids. To
reduce manufacture cost of these valves, they are controlled indirectly.
Small solenoids are used to control the pilot valve which sends pressurized
48
fluid to control the main valve. Some proportional valves with indirect
control have a course filter (screen) that protects the pilot stage. If a filter is
used, the filter should be replaceable or washable.
a)
Symbol
b)
Detailed symbol
Fig. 3.8 Directional manual valve with indirect manual control
7.
Hydraulic Pumps
Symbols:
Constant flow pump
49
Pumping element designs include gears, lobes, rotary pistons, vanes, and
screws.
Positive displacement (PD) pumps can be either fixed or variable
displacement. Fixed displacement pumps have a constant relationship
between the flow rate and the drive shaft angular velocity. In variable
displacement pumps, the displacement can be changed so that the flow
rate can be independent from the drive shaft velocity. Gear pumps have
fixed displacement while vane and the piston pumps can be either fixed or
variable. Lift truck hydraulic systems use only PD type pumps such as:
vane pump, piston (axial and radial) pump and gear pump.
Systems with pressure up to 25 MPa usually have a gear or vane type
pumps. While high pressure systems 25 to 40 MPa (3600 6000 psi)
require using piston pumps.
Gear pumps
Gear pumps can have external or internal gear meshing. External pumps
have one or more sets of two spur gears while the internal have one or
more sets of spur and ring gear. In fork lift application external gear pump is
more popular because of the bigger selection and the lower cost.
External gear pump construction
A gear pump (Fig. 3.9) has a body in which there are two hardened steel
gears intermeshing together. One of the gears is a drive gear and the other
one is a driven gear. The drive gear is mounted on a shaft, which extends
outside and is connected to a motor. Meshing gears create two chambersthe first is the inlet (suction port) the second is the outlet (pressure port).
Rotating gears take fluid from the suction port, drive it around the gears and
push it into the pressure outlet. The highest quality gear pumps have zero
backlash gear meshing. Pumps with zero backlash meshing have high
efficiency and low noise. Pump main parameters specified by the
manufacturers are: flow rating (maximum and minimum shaft speeds),
maximum pressure rating, and the type of mounting.
50
51
2
3
1
Fig. 3.10a
1
Fig. 3.10b
Internal reliefs can be used in systems in which the pump works on request.
For steering systems in which the flow goes over relief 50% of the time,
internal reliefs are not recommended. They heat up the oil and the pump
and can cause leaks through pump inlet seals. When a system have an
internal relief valve, it is important to keep the fluid temperature in its
operating range. Overheating of the fluid can affect the relief valves
performance.
Pump delivery (flow rate in litters per minute)
QP =
dPn
L
V
1000
min
3.4
52
Where:
dP [cm3/rev] is the pump displacement. The displacement is a
measure of the pump size and is given by the manufacturer;
n [rev/min] is the shaft input rotational speed
V is pump volumetric efficiency.
In the BG units, flow rate is given in gallons per minute (gpm):
QP =
dPn
V [gpm]
231
in 3
dP
rev.
3.5
revolution.
Gear pump flow rate can be given at 1000 rpm by the manufacturer. In
fixed-displacement pumps, the flow rate can be changed only by changing
the drive shaft rotational speed. These pumps are used in open type
systems in which the flow after each work cycle is returned to the reservoir.
Variable displacement pumps are mainly used in closed systems (systems
where the pump continues to operate at a stand-by in a neutral position)
Torque on the pump shaft
T=
m [ Nm]
Where:
P is the hydraulic power in Watts (Nm/s)
m is pump mechanical efficiency
w is the shaft angular velocity in (rad/s)
In mechanical formulas, the shaft speed is expressed in radians per second
w (rad/s)
The angular velocity w (rad/s) can be converted to rotational speed, n
(rev/s):
w = 2n
T=
P
m
2n
T=
pQ
pd n
m = P m
2n
2n
T =
pd P
m ( Nm)
2
53
3.6
Slip
Slip is a leakage of fluid from the pressure outlet back to the inlet. Slip
increases with increasing pressure and wear. Increasing slip is referred to
as a loss of efficiency. Slip can be reduced by constructing the pump for
pressure and wear compensation.
Pump Efficiency
Overall efficiency is:
O =
Output _ Power
= V M
Input _ Power
3.7
It is determined as the ratio between the hydraulic power at the pump outlet
and mechanical power at the driving shaft at nominal pressure, rotational
speed, and fluid viscosity (rated power). The overall efficiency has two
components: volumetric and mechanical.
V =
Actual _ Flowrate
Rated _ Flowrate
The actual flow rate is the flow at the pump output when the pump is
working under load. It will vary at different pressures. Rated flow rate is the
theoretical flow at the pump outlet without volumetric losses. Volumetric
efficiency range is: v = 0.90 - 0.97. If volumetric efficiency is not known, for
initial calculations we can take the average values for gear pumps: v =
0.90 (low speeds 1000 rev/min) and v = 0.97 (high speeds 3000
rev/min)
54
M =
It is a result of lost power due to friction in the bearings and between the
meshing gears.
M = 0.90 0.93
The gear pumps overall efficiency is in the range of 82% to 88% depending
on the pressure and rotational speed. An example of pump overall
efficiency at different pressures is shown in Fig 3.11.
100
90
80
70
60
50
40
30
20
10
0
0
50
100
150
200
250
300
Pressure [bar]
Fig. 3.11
A disadvantage of gear pumps is that they create pressure and flow ripples
(pulses) in the discharge port. Pumps are one of the biggest sources of
noise and vibrations in the hydraulic system. Every time the fluid between
two teeth is pushed out of the pump, a peak in the pressure appears. A
typical pressure distribution at a discharge port is shown in Fig. 3.12.
Pulsations () can be expressed as the ratio of pulsations amplitude (p) to
an average value (p):
P =
Where:
p1
100 [%] ,
p is peak-to-peak amplitude.
55
p [MPa]
p3
p2
p1
t [s]
Fig. 3.12
Where:
Pump pressure pulsations travel along the hydraulic lines at the speed of
sound (about 1400 m/s in hydraulic fluid) until it is affected by a change in
diameter or direction. Therefore, pulsation amplitude depends on the
hydraulic lines (length and diameter) and fittings (type and size) in the
system. Although the direction valve, after the pump, smoothes the flow
and the pressure peaks, pulsations created by the gear pumps travel
through the system to the hydraulic actuators.
Internal gear pumps have smaller pressure pulses than external pumps
because the spur and ring gear set have more teeth meshing than two
external spur gears. Gear pumps are mainly used in systems with normalhigh pressures (from 15 to 25 MPa). For higher efficiency, they should be
driven at speed close to their rated maximum because internal leakage is
smaller at higher speeds. At low speeds, gear pumps have reduced
lubrication between side plates and gears. Pump manufacturers always
specify the minimum rotating speed.
Intermittent pressure is used for selecting lift pumps that work intermittently.
Continuous pressure is used for selecting steering pumps that have to run
continuously.
56
Vane Pumps
There are two types vane pumps: balanced and unbalanced. In the
balanced design the rotor and the sliding ring surface are coaxial. In the
unbalanced design they are not.
Construction
Similar to the gear pumps, a driving shaft coming from primary power
source drives the vane pump. Inside the pump, the driving shaft is
connected to a slotted rotor that is placed eccentrically from the center of
the circular opening of a casting housing. Vanes placed in the rotor slots
slide in and out. Centrifugal force causes them to slide out and the contour
of the cavity pushes them back in. Tips of the vanes slide on the inside
pump surface and seal the passage between the suction and the pressure
ports. The vanes push fluid from the inlet to the outlet through the gap
between the housing and the rotor. Vane pumps have higher efficiency than
gear pumps because of less fluid leakage from the pressure outlet back to
the inlet. They have less slip (smaller volumetric losses). Also, the
efficiency remains constant over time. As the vane tips wear the slip
remains the same because the centrifugal force always keeps the vanes in
contact with the housing surface. Pump housing is made from the same
materials as gear pumps. Mechanical efficiency is a result of the friction in
the bearings and the friction between the cam contour and vane tips.
57
Construction
There are two main types of rotary piston pumps: radial and axial.
In the radial type, pistons are placed in a cylinder block. Pistons move
radially in and out. The cylinder block (rotor) is located inside a fixed
housing (stator) and is rotated by a drive shaft. The rotor centerline is offset
from the stator centerline. The amount of offset determines piston stroke
and pump displacement.
In axial pumps (fig. 3.14), pistons move axially. They are placed into a
cylinder block which is rotated by the drive shaft. The piston ends are
depressed against a tilted disk (swash plate). The angle of the disk causes
cylinders to move axially. If the disk is perpendicular to the axis of rotation
(zero angle), pistons will not be compressed and there will be no flow
through the pump. The disk can have different angles. When the disc is
tilted to one side of the neutral, flow goes in one direction. When it is tilted
to the other side, flow direction is reversed. When the disc angle is fixed
the pump has fixed displacement. In pumps with variable displacement, the
disk angle is controlled by a yoke. The yoke can have mechanical, electric
or hydraulic control. At the released position of the yoke, the disk is
58
returned to neutral (zero) position and the pump stops delivering flow.
When the yoke is hydraulically controlled, a pressure compensator
maintains constant output pressure at different flow rates. Such pump is
called: pressure compensated pump.
8.
59
Hydraulic Motors
Symbol:
Motors have the same pressure rating as pumps. Some of them are
available with optional built-on holding (multi-disk) brake, dynamic (drum)
brakes, flushing valves or speed sensors.
Motor selection is based on two characteristics: motor shaft speed and
shaft torque. The shaft torque is a product of motor volumetric displacement
and pressure drop in the motor. Required shaft speed is determined by the
flow rate and the motor displacement. Shaft rotational speed usually is
determined by the performance of the other components in the truck and is
given when calculating the hydraulic system. Motor displacement (dM)
versus required output shaft torque (TM) is published by the manufacturer in
charts or tables.
For a required shaft torque, the motor displacement (dM) can be calculated
with the formula:
dM
62.83TM
=
( p ) M
cm 3
,
rev
3.8
Where:
TM
M = 0.90 0.95
60
QM =
d M nM
1000V
L
,
min
3.9
Where:
dM
nM
9.
Hydraulic Cylinders
Cylinders convert fluid energy into mechanical energy in the form of linear
motion and force.
Single-acting cylinders
In elevating systems, either single-acting telescopic or single-acting ram
type cylinders are used. Single-acting cylinders accept pressure fluid only
on one side of the piston. Volume on the other side can either be vented to
the atmosphere or connected to the tank. The return line to the tank is for
collecting eventual leaks through the seal. These types of cylinders are
called single-acting because the work done by the fluid is acting only in one
direction- for lifting. Weight of the load and the mast does the work in the
opposite direction. Ram type and telescopic type cylinders, shown in Fig.
3.15, are designed for applications where long strokes are required.
Telescopic cylinders (fig. 3.15b) have two or more stages. The outside body
is called: main cylinder and the smallest stage is called: plunger. When fully
extended, their stroke exceeds the length of the cylinder at fully retracted
condition. Collapsed length of a typical telescopic cylinder is about 20% to
40% of its extended length. Telescopic cylinders usually extend from the
largest to the smallest stage. This means that the largest stage inside the
main cylinder will start to extend first. There are telescopic cylinders that
are designed to have all stages extend at the same time. This construction
61
provides constant speed and constant push force throughout the extracting
and retracting.
INPUT
INPUT
Hydraulic cylinders have four main components: cylinder, piston, piston rod
and seals. Cylinders are made from steel or ductile iron tube. Pistons are
made from: alloy steel or high-tensile strength ductile iron. Piston rod is
usually made from chrome plated and polished steel alloy. Inside surfaces
of cylinders are coated and polished. Coating can be electrodeposited
chrome or nitriding.
Electro-deposition is the process of producing coating by putting a
negative charge on the part and dipping it into a chemical solution that
contains the coating metal. The thickness of the electrodeposited layer is
determined by the duration of the process.
Nitriding is a surface hardening process that introduces nitrogen into the
surface. There are three nitriting technologies: ion, gas and salt.
At the end of the telescopic cylinders there are at least one seal and a
wiper. The seal is usually a U-cup lip seal. This seal relies on hydraulic
pressure to press the seal lips against the rod and seal groove. It is better
to use a seal with a pre-energized lip (by spring or O ring) in order to avoid
leaks when the cylinder is unloaded and pressure is absent. The wiper
prevents external contaminants entering the cylinder.
62
F = pACYL
3.10
Where:
p = p1 p2
p1
A [m 2 ]
cylinder.
When the cylinder diameter is increased, the natural frequency (the
stiffness) of the system increases allowing the motion controller (the
direction valve) to manage faster acceleration and deceleration, which in
turn yields higher system performance. Roughly, the actuator (cylinder)
natural frequency should be 3 - 4 times higher than the frequency of the
motion controller.
A2
p1
F
p2
Fig. 3.16
Double-acting cylinders can have single piston rod (Fig. 3.16) or double
piston rod. They are used for auxiliary operations such as tilting, side shift
and reach/retract operations. These cylinders accept pressurized fluid on
both sides of the piston. When the cylinder has a single-piston rod,
63
extension force is greater than retraction force (if equal pressures are used)
because the area of the piston side (A1) is greater than the area of the face
of the rod end side (A2).
The force equation acting on the piston rod (shown in Fig. 3.16) is:
F = ( p1 A1 p2 A2 ) CYL [ N ]
3.11
Where:
A1 =
A2 =
D 2
4
[m ]
2
(D 2 d 2 )
4
[m ]
2
At the same flow rate, the cylinder retracts faster than it extends. Faster
retraction is a result of the smaller volume at the rod end side.
E =
Q m
,
A1 s
Extension speed
R =
Q
A2
m
,
s
Retraction speed
The relationships between the piston diameter (D) and the piston rod
diameter (d) of double-acting cylinders are standardized and are given in
table 3.1, where: = A1/ A2
64
D (mm)
d (mm)
= 1.25
= 1.6
14
18
22
28
32
36
40
45
50
56
63
70
80
90
20
25
32
40
45
50
56
63
70
80
90
100
110
126
32
40
50
63
70
80
90
100
110
125
140
160
180
200
Table 3.1
Symbol:
There are two main types of sensors: 1) pressure switch and 2) electronic
pressure sensor (pressure transducer).
Pressure switch is an ON-OFF type switch which is controlled by pressure.
Usually, it has a single-pole double-throw actuator. As the pressure
increases, it pushes a piston against a retainer which compresses a spring
and closes/opens the switch contact tips. The force on the piston
65
F = pA m
66
Symbol:
Hydraulic accumulators are used as a source of power at the systems
request. They store non-compressible fluids under pressure. The pressure
is created by an external force.
There are three types of accumulators with regard to the external force:
Weight loaded
Spring loaded
Gas loaded
67
Sizing Accumulators
The following case is when the accumulator is used as a power source.
The equation describing the gas in three different positions is (fig. 3.12):
n
3.12
Where:
68
Fig. 3.17
Determining the size of the accumulator
Size is determined by the relationship between the initial gas volume, V1,
and the needed fluid volume, VX:
Equation 3.12 can be written as:
V1 ( p1 )1 / n = V2 ( p 2 )1 / n = V3 ( p3 )1 / n
If we take the second two members we can express V2:
V2 ( p 2 )1 / n = V3 ( p3 )1 / n
Also,
V3 = V2 + V
Then
3.13
69
V2 ( p2 )1/ n V2 ( p3 )1 / n = V ( p3 )1 / n
V2 = V
( p 3 )1 / n
( p 2 )1 / n ( p3 )1 / n
V1 ( p1 )1 / n = V2 ( p 2 )1 / n
( p 2 )1 / n
V1 = V2
( p1 )1 / n
Replace V2:
( p 3 )1 / n
( p 2 )1 / n
V1 = V
( p2 )1 / n ( p3 )1 / n ( p1 )1 / n
Divide both sides by ( p 2 )1 / n to determine the size of the accumulator.
V1 = V
p3
p1
1/ n
p
1 3
p2
1/ n
[m 3 ]
3.14
p1 0.9 p3
It is recommended that the discharge pressure in the accumulator is:
P2 < 3 P3
70
The devices for cleaning fluid can be classified as: filters, strainers and
magnets.
Filters are devices whose primary function is the retention of insoluble
contaminants from the fluid.
Strainers are course filters. Their filtration ranges from 50 to 300 microns
(most strainers are 125 microns).
Magnets function is to attract and remove iron from the fluid. They must be
placed where they will attract most particles- between the return and the
suction lines. Magnets can be installed inside the reservoir plug (magnetic
plugs).
Hydraulic filters are classified by pressure rating as:
Low-pressure filters
High-pressure filters
Medium-pressure filters
There are five types of filters classified on the basis of their location and
function in the system.
Suction filters
These are low pressure filters located in the suction line before the pump.
They are usually placed inside the reservoir. Suction or return filters can be
combined with a breather when they are installed at the inlet or outlet of the
reservoir. In order to determine what type of filter to use, we have to
consider the requirements of each component and the hydraulic system as
a system.
71
Pressure filter
These types of filters that are placed in the pressure line either immediately
after the pump or before a component with high fluid clearness
requirements. They are either high or medium pressure.
Return filters
Return filters are installed in the return line. They can be placed outside or
inside the reservoir. It is recommended return filters have a bypass valve
which protects the filter element during cold start and pressure spikes.
Return filter which do not have a bypass valve mast be rated for pressures
higher that the system pressure. They can be subject to high pressure
when they are clogged.
Reverse flow filters
Reverse flow filters are used when the flow direction is reversed in the
lines. This filter has to retain contaminants in one direction and prevent
returning the contaminants into the system when the flow is reversed. This
is achieved by having two parallel lines and check valves in each line. In lift
truck applications, reverse flow filters are used in hydrostatic transmissions
and energy recovery systems with reversible pump/motor.
Air filters
Air filters are placed on the reservoir and they are usually combined with a
breather cap or a dip stick for fluid level indication. Breather cap air filters
range from 2 to 40 microns filtration.
Suction or return filters can be combined with a breather when they are
installed at the inlet or outlet of the reservoir. In order to determine what
type of filter to use, we have to consider the requirements of each
component and the hydraulic system as a system.
The most debated design to consider is the use of suction low-pressure
filters. In general, they are recommended for systems working in areas with
high air contamination. Suction filters main advantages and disadvantages
are as follows.
Advantages:
Dissipate any degree of turbulence left over from the returned oil.
Protect the whole system at the front and catch all contaminants
entering the oil through the air breather.
In order to minimize the pressure losses in the suction line, the
suction filter must have a bigger filtering area which increases the
72
73
particles larger than six microns entering the filter, one passes through. The
data given in the ISO standard or by the manufacturers are based only on
specific test conditions prescribed by the standard. Actual field conditions
may vary considerably.
Another measure is filter retention efficiency (R). It can be calculated as:
R = (1-1/BETA) x 100 [%]
The relations between Beta and R can be given in table 3.2.
Beta Number
Retention Efficiency
R [%]
50.0
10
20
90.0
95.0
50
75
98.0
98.7
100
200
99.0
99.5
Table 3.2
Fine media filters can remove some additives from the fluid. Many types of
lubricants have de-foaming additives. These are suspended semisolid
particles in the 5-10 micron range and are filterable. Efficient 1-micron filters
can potentially remove sulphur and phosphorus additives that are not
dissolved as well as suspended solid anti-scuff additives.
The best way to determine if the filter works properly is to do an upstream
and downstream particle count. It is a good practice to combine the filter
with a differential pressure switch. The switch signals the need for a filter
change before the filter is fully clogged and the contamination passes
through the check valve. Changing it on time prevents system component
damage and premature replacement of partially used filter elements. Most
filter manufacturers can determine how changes in the fluid viscosity at
operating temperatures affect the flow rate
74
75
76
77
Latest filter technologies have made possible filters with filtration as low as
one micron with minimum pressure loss across the filter. In this design, the
fluid is cleaned of ferrous particles by a magnet. This filter does not have a
filtration barrier and it has a smaller pressure drop. In hydraulic systems for
outdoor mobile equipment this filter is not used because most of the
contamination comes from the environment where the contaminants are
non-ferrous particles.
Symbols:
a) Open
b) Pressurized
The reservoir has two main functions: to store the hydraulic fluid and to
keep the fluid within defined working temperature limits. There are two
types of reservoirs: open (vented) and pressurized (non-vented). In this
section, we are going to discuss only the vented type since it is primary
used in the mobile industrial equipment.
A reservoir must be designed to meet the system requirements. These
requirements are:
Proper size
The reservoir has to have the smallest volume that holds the necessary
fluid for the system. The most economical size has to be calculated based
on the systems requirements. The formulas used for determining the
reservoir volume are based on calculation of the cooling surface and are
given further in this section.
Good sealing and filtration against contamination of the fluid
Air has to enter and exit the cylinder through a breather containing air filter.
The capture efficiency of the air filter has to be the same as or higher than
the capture efficiency of the main oil filter. Breathers without filters do not
prevent contamination from the air. In dusty environments, the air entering
78
High degree of heat exchange between the fluid and surrounding air
through the reservoir walls
Reservoir walls have to ensure good heat exchange between the fluid
inside and the surrounding air. Free air circulation around the reservoir
must be guaranteed. Reservoirs without enough surface area to dissipate
heat from natural circulation and reservoirs of systems with short work
cycles should have a partition (baffle) which separates the reservoir into
two parts. A baffle is a separation plate dividing the reservoir into two
sections: return and suction. Baffles cause returned flow to circulate around
the outer wall before it can get to the suction line. The benefit of this
circulation is better heat exchange and turbulence dissipation of the return
flow. Usually the lower corners of the baffle are cut off. The area of the cut
offs must be larger than the cross-section area of the inlet line.
Dissipation of air bubbles in the fluid along the path from the return
to the suction pipe.
Turbulent flow induces air bubbles in the fluid. These bubbles can enter the
suction pipe and cause cavitation damage in the system. To minimize this
risk, suction and return lines should be as far apart from each other as
possible. If there is a baffle in the reservoir, the suction and return ports
should be on opposite sides of the baffle. The suction line (or suction filter)
has to be a minimum of 20 mm above the bottom of the reservoir in order to
avoid taking contaminants along with the fluid. Also, return and suction lines
have to be submerged a minimum of 30 mm below the lowest fluid level.
Another way to dissipate the turbulence from the return line is to use a
diffuser (spreader) at the return line so that the return flow passes through a
spreader. Instead of diffuser, we can use two return filters connected in
parallel or a strainer. The strainer will cause backpressure, which is
desirable for some functions of the lift truck hydraulic systems. It is
recommended to make reservoirs deep and narrow instead of shallow and
wide in order to minimize the vortex effects in them.
Ability for fluid level observation.
Maximum and minimum levels have to be shown on the fluid level indicator
or marked on a deep stick.
Guaranteed atmospheric pressure.
The maximum fluid volume has to be approximately 10% smaller than the
reservoir volume. This will ensure a constant atmospheric pressure in the
reservoir during level changes.
79
Easy serviceability.
Main requirements include: accessible location of the hoses connected to
the reservoir, ability for quick discharge and refill and easy fluid level check.
Flushing connection ports.
Flushing is a procedure for cleaning the reservoir from contamination using
turbulent flow. Flushing fluid must be compatible with the fluid used in the
hydraulic system. The reservoir can be equipped with special flushing ports.
There are three cases when having flushing ports is recommended:
1) The reservoir has to be flushed regularly.
2) Fluid oxidizes rapidly as a result of overheating.
3) There is a quick fluid contamination from outside.
80
S=
QL
3600 PL
=
[m 2 ]
k (TMAX ) k (TMAX TO )
3.15
Where:
PL =
pQ
(1 S ) is the lost power in the system
60 P
k=
1
1
walls
81
kJ
k = 25 2 when the reservoir has poor air circulation around the
m hK
reservoir.
kJ
k = 45 2 when the reservoir has good air circulation around the
m hK
walls.
kJ
k = 90 2 when the reservoir walls are subject to air cooling by a
m hK
fan.
Using the described requirements and method for calculating the optimum
reservoir surface, the fluid in the reservoir can be reduced significantly by
achieving the desired temperature and turbulence dissipations.
Different materials have a different coefficient of heat transfer, k. For
example, a stainless steel reservoir has half of the heat transfer capability
of a carbon steel reservoir.
Reservoir testing
In order to guarantee that all design requirements for the reservoir are met,
it is recommended that we measure some of the main parameters of the
system. It is a good practice to build one prototype reservoir with plexiglas
windows and a temperature gauge in it. This will allow monitoring of fluid
turbulence as well as the change of temperature during the required duty
cycle of operation. Achieving acceptable maximum oil temperature is the
best measure of good reservoir design. It means that the reservoir can
properly dissipate the heat generated by the system.
Negative effect of moisture in the reservoirs
Hydraulic oil can absorb water. In general, if the reservoir is designed wellthere is no turbulence- and the flow cycle is low, the water will settle out on
the bottom. But, in lift truck applications, the hydraulic systems usually
have short fluid cycles for lifting, reaching and side shifting. Therefore, in
the reservoir design, we have to focus on the prevention of water entering
the reservoir.
82
The headspace of many tanks maintains a continuous moist fog. This can
lead to a buildup of water in the oil, especially in cold storage applications
where the truck has to go in and out of a freezer. The moisture condenses
on the reservoir ceiling and walls and then drips into the fluid. Moisture
signs can be found either by looking for oxidations (rust) on reservoir ceiling
or by touching the inside ceiling with our fingers looking for moisture or rust.
Materials
The most steel reservoirs are made from mild steel sheet metal.
Reservoirs with volume less than 100 litters are usually made from 1.5-2
mm thick sheets. Reservoirs are painted only from the outside. The
inside area above the oil can be a source of contamination. When
carbon steel reservoirs are used for fluid storage, their internal walls
must be coated against corrosion.
Aluminized steel and stainless steel reservoir are designed to eliminate
the contamination concern. Aluminized steel is mild steel coated with
aluminum-silicon alloy.
Stainless steel reservoirs are the most expensive to manufacture. For
this reason they are mainly used for storing hydraulic fluids.
Aluminum alloy reservoirs are usually die-casting.
Plastic reservoirs are usually made from polypropylene, polyethylene or
nylon. Resins used for reservoirs are usually rated for temperature
ranges from - 40 C to +120 C. Design of plastic reservoir must
consider coefficient of heat transfer (k) and the thermal deformation of
the material.
Polyethylene
resins
Crosslinked,
low density
Crosslinked,
high density
Linear,
low density
Linear,
high density
Temperature
Change of
material
properties
115 C (239 F)
Hydraulic fluid
170 C (338 F)
Pressurized hot
fluids
100 C (212 F)
Starts to melt
Hot water
130 C (266 F)
Starts to melt
Hydraulic fluid
and chemicals
Storage
application
83
The most widely used material for plastic reservoirs is polyethylene (lowdensity crosslinked or high-density linear). The name crosslinked shows
that the polyethylene structure consists of bonded and linked together
carbon chains at molecular level. Crosslinking of the molecules changes
the polymer properties from thermo-plastic to thermo-elastic. Thermoelasticity makes the material more resistant to ruptures and cracks. At
higher temperatures, thermo-elastic polyethylene will soften and become
more flexible. This softness allows impact energy to be absorbed easier by
the molecule chains. Crosslinking also improves the thermal properties of
the polymer.
84
85
Pressure lines
Maximum Pressure
Recommended velocity
v = 4 m/s
p = 50 to 100 bar
v = 4 to 5 m/s
v = 5 to 6 m/s
v = 6 to 7 m/s
It has been estimated that 80% of hose failures are caused by external
physical damage to the hose. In order to increase durability of the hose, the
hose manufactures use special hybrid compounds for the cover material
instead of standard rubber covers. This more durable compound increases
the service life, lowers the maintenance, and eliminates the need for costly
hose protectors such as guards and sleeves. The pressure ratings for
hoses are provided by the manufacturers.
Design principles
86
87
88
89
duty cycles, valves, port types, size, locations and materials. For systems
with pressure up to 25 MPa, manifolds are made from steel or aluminium.
For pressures above 25 MPa, it is more economical to have steel
manifolds. After machining, the manifold blocks must be washed, deburred
and surface finished against oxidation. Burrs and small particles are
removed thermally. Thermal deburring is a process where the manifolds are
put in a chamber filled with gas which is ignited. The temperature goes up
to 3500 C for about 20 milliseconds.
Manifolds have machined valve cavities specified by the valve
manufacturers. Valves are screw-in cartridge type. Valves must be
tightened to torque values provided by valve manufacturers. Solenoids, of
the electrically controlled valves, must be spaced from each other so that
their electromagnetic field does not interfere. The magnetic field can affect
the performance of neighboring valves.
Fittings are tightened according the manifold block material. Recommended
torque values for fittings are given in table 3.4.
Aluminum
manifold
Steel manifold
M8 x 1
M10 x 1
M12 x 1.5
8
10
15
8
12
25
10
18
30
M14 x 1.5
M16 x 1.5
M18 x 1.5
25
30
35
35
40
45
40
45
50
M20 x 1.5
M22 x 1.5
M27 x 2
45
55
75
55
65
100
70
120
145
100
120
150
120
150
180
180
200
250
M30 x 2
M33 x 2
M38 x 2
Table 3.4
90
91
92
93
Particle count
The particle count is a catch-all type test. Almost anything that goes
wrong in the machine will result, sooner or later, in an increased number of
particles. If misalignment in the components, overloading, water
contamination, viscosity breakdown, or bearing failure occurs, the particle
count will rise. The challenge of this test is the correct interpretation of the
test results. By definition, particle count is: the number of particles in the
fluid greater than a particular micron size per unit volume of the fluid. It is
often stated as particles larger than 10 microns per one milliliter (1mL).
Usually an optical microscope is used to count the particles. Filter and
hydraulic fluid manufacturers have recognized the importance of smaller
contaminants. As a result, they include particle count tests and evaluations
for particles smaller than 4m.
Analyzing fluid samples for the finest contaminants (4m) is included in the
latest ISO Cleanliness Code.
In order to evaluate the fluid, we have to know the threshold for various
performance characteristics. Test parameters for which threshold levels
may be established include:
Synthetic fluids are a good choice for equipment that is used outside and is
subject to temperature changes. Synthetic fluids can handle a wider range
of temperature changes than petroleum-based fluid.
Thermal effect
The trend in the hydraulic systems design is to increase system power
while using the same physical space. Power is increased by increasing fluid
pressure and it results in increased operating temperature. Some systems
now run with 100C fluid temperature instead of the recommended
maximum of 80C. High temperature changes the viscosity of the fluid,
therefore when selecting the fluid type designers should select the ones
with greater resistance to change in viscosity as a result of temperature
change.
94
One of the most common causes of thermal failure in hydraulic fluids and
some lubricating oils is aeration (presence of air bubbles). These bubbles
can become rapidly compressed in hydraulic pumps and bearings. This
results in extremely high localized temperatures (adiabatic compression)
and leading to sudden formation of carbon fines. Hot surface carbonization
is another form of thermal failure. When oil degrades as a result of high
temperature, it creates problems associated with sludge, varnish, deposits,
viscosity change and additive decomposition.
Negative effect of air
Air in the fluid can cause a great deal of damage to the hydraulic systems.
Air properties that affect the system properties and performance are:
Compressibility- it decreases the stiffness of the system, increases fluid
temperature and causes thermal degradation. Compressed air bubbles can
reach temperatures above 1000C and break down and darken the oil.
Gaseous cavitation- causes wear of the hydraulic components and
increases the noise in the system.
Contains oxygen promotes oxidation of the fluid. Oxidation also increases
at high fluid pressures, temperature or both.
Influence of additives
Industrial hydraulic fluids normally contain anywhere between 99% to
99.5% base oil and about 0.5% to 1.0% by additives. These additives are
important for the hydraulic system operation, particularly when the trend is
to use longer-life fluids. There are many different additive combinations that
can be used in fluids, and using the right additive combination is critical.
One of the main ingredients, which represents approximately 60% to 70%
of the additive package is a compound known as Zinc Dithiophosphate
(ZDP). Fluids containing this additive reduce the wear rate of the hydraulic
components. ZDP reacts with the metal and provides cushioning between
sliding surfaces. It also improves the oxidation stability of the fluid. A fluid
supplier can help identify what mix will provide the best performance for
your equipment. Despite all benefits of the additives, if the fluid is not kept
clean or it is overheated, the additives can be physically removed or
chemically decompose in service. Removing and decomposing the
additives is due to: oxidation, hydrolysis, thermal degradation or they can
be removed by the filter.
95
96
requirements for the fluid. This relationship is given in table 3.5. The
cleanliness code is given only by the second and the third number
(__/YY/ZZ format). Quantity of particles over 4 microns is not provided.
Recommended fluid cleanliness requirements for some common
components at different pressures are given in tables 3.6 (pumps), 3.7
(valves) and 3.8 (actuators). Component internal clearances between
moving parts and system pressures are the main factors determining fluid
cleanliness. The data is based only on the specific test conditions
prescribed by the standard. For different field conditions, the actual fluid
cleanliness requirements may vary.
Recommended filtration
(in microns)
System Maximum
Pressure
Recommended
cleanliness
19/16
15 to 25
p = 50 to 150 bar
18/15
12 to 15
16/13
10 to 12
15/12
5 to 10
for (x) 75
Table 3.5
System
components
More than
(2000 psi)
14 to 20 MPa
(2000 to 3000
psi)
Gear- constant
flow
20/18/15
19/17/15
18/16/13
Vane- constant
flow
20/18/15
19/17/14
18/16/13
Piston
19/17/15
18/16/14
17/15/13
19/16/14
18/15/13
17/15/13
18/16/14
17/15/13
16/14/12
Pumps
Table 3.6
14 MPa
20 MPa
(3000 psi)
97
Less than
More than
20 MPa
20 MPa
Directional (solenoid)
20/18/15
19/17/14
Check valves
20/18/15
20/18/15
Cartridge valves
20/18/15
19/17/14
20/18/15
19/17/14
19/17/14
19/17/14
19/17/14
19/17/14
20/17/15
18/16/14
19/16/14
17/15/13
Load-sensing directional
18/16/14
17/15/13
18/16/13
17/15/12
Proportional directional
18/16/13
17/15/12
18/16/13
17/15/12
Proportional cartridge
18/16/13
17/15/12
18/16/13
17/15/12
Servo valves
16/14/11
15/13/10
Valves
Table 3.7
Less than
More than
2000 psi
14 20 MPa
2000- 3000
psi
Gear motors
21/19/17
20/18/15
19/17/14
Hydraulic cylinders
20/18/15
20/18/15
20/18/15
Vane motors
20/18/15
19/17/14
18/16/13
Radial piston
motors
20/18/14
19/17/13
18/16/13
19/17/14
18/16/13
17/15/12
18/16/14
17/15/13
16/14/12
Actuators
Table 3.8
14 MPa
20 MPa
3000 psi
98
Series motor
Armature and field (stator) windings are part of the same circuit. There are
three configurations shown in fig. 3.19
a) Series
Armature and stator winding are connected in series.
b) Shunt
Armature and stator winding are connected in parallel.
c) Compound
A compound motor has three windings: one armature and two fields. One of
the field windings is connected in series and the other in parallel. These two
windings create two magnetic fields. The current flowing through the rotor
and the field is the same.
I = IK
Fig. 3.19
I = IK + IB
I = IK + IB
99
IK
IB
Fig. 3.20
AC induction motor
Only three phase motors are used in lift trucks applications. AC motors
require the use of an inverter which converts the DC to AC current. The
power can flow through the inverter in both directions from the DC battery
to the AC motor and vice versa. The inverter output voltage is always less
than the input voltage.
Knowing the characteristics of each motor, helps designers make better
choices when they are selecting the pump type for the hydraulic system.
Main advantages and disadvantages are listed in table 3.9
100
Type motor
Series
Advantages
Simple
construction motor
Require brush
maintenance
Difficult to
control high
speed
Separately
excited
Permanent
magnet
Disadvantages
Require brush
maintenance
Simple
construction.
Low cost
AC
induction
No brushes. Low
maintenance
Highest efficiency
Good rotational
speed control. It
has speed
feedback.
Table 3.9
Need DC to AC
inverter
More complex
controller
Hydraulic system
application
Systems with
constant pump speed
101
Chapter 4
102
103
dont layoff their full-time workers. Instead, they have part-time hourly
employees. Part-time employees are given more or less hours depending
on the production volume.
Introduction
Quality of the design directly affects public welfare, health and property.
The safety requirement must always be the number one requirement for
any new product. To ensure an accurately designed product, in many
countries, the firms that perform engineering design work are required to
obtain a Permit to Practice. To obtain such a permit, the firm must satisfy
two conditions:
1. Identify the individuals responsible for the engineering design and
services. The responsible individuals are required to have a professional
engineering license.
2. Carry liability insurance. In addition to the company insurance, some
countries or states require all engineering personal to have secondary
liability insurance.
The United States was the first country to regulate engineering practice.
There are three main factors that determine the quality of any product.
First: quality of the final product is determined by the quality of the design
process.
Second: quality of the final product is determined by the quality of the
manufacturing process.
Third: quality of the design and manufacturing processes are achieved by
defining and measuring each step of the process.
In this chapter, a step-by-step methodology for a hydraulic system design
process will be shown. In the past, quality strategies were focused on the
manufacturing process. Now, the focus is on process management. For
new system designs- the process management approach is a way to
control each step in the design process. In addition, an integration of the
organizational functions and the information flow through all steps of the
design will be shown. The process approach, which includes engineering
104
and management tools, will ensure a quality of the design that is built into
the final product. During the process, the factual approach to measure the
progress will be used. Factual approach is when each factor or parameter
at each step is measured against a predefined value. ISO 9000:2000 states
that the factual approach to decision making is "effective decisions that are
based on the analysis of data and information."
At the end of the chapter, a brief description of patents and their
applications will be included. Novel ideas, whose outcome is obtaining
patents, are the ultimate result of well managed and quality design process.
Factors
Main factors that influence the quality of the design are:
Stick to the companys goals and strategic objectives
Strategic objective are a set of long-term directions that would allow the
organization to achieve its long-term goals.
Effective professional communication
Effective professional communication is a two-way interaction which
includes listening, receiving and turning over information both verbally and
nonverbally. The communication is considered effective when the inputs
from this interaction are used to create desired results and solve problems.
Effective communication is a main factor for the continuous improvement of
the organization.
Leadership
Leadership is an ability to positively influence and motivate people to
achieve the teams goals in an effective way.
Engineering knowledge
Engineering knowledge is a base for any novel approach to new designs
and improvements. In order to design a hydraulic system for lift trucks, an
engineer has to know not only the hydraulic principles but also the
equipment principles of operation such as:
105
Innovations
The generating and testing of new and novel ideas must be one of the main
goals of any engineering organization. Innovating spirit must be
encouraged and rewarded in order to become an organizational culture.
o One technique to generate new ideas is using old ideas and
adding something new to them. This strategy is called:
knowledge brokering.
o Another technique is to take an existing idea in one application
and use it in another application. This technique has been used
the most through-out the history of the technological
development.
Old ideas are the main source of new ideas therefore we need to educate
ourselves and learn the existing practices in order to generate new ones. In
this aspect, it is important that the organization has the means of collecting
such data and making it available to all employees.
Motivation
There are a number of factors that motivate people. It has been proven that
the financial factor is not the main motivator because it has only short term
effects. Recognizing the individual as a valuable asset to the organization is
one of the biggest motivating factors for best performance and continuous
improvement.
Focus on quality
Quality of the design process is measured by the quality of the final
product. The final product must meet customer expectations in term of
performance, service, cost of operation and other factors identified by the
customer.
Time-to-market and greater value for the customer are the main driving
forces for todays companies success in the market.
106
Tools
1. Project scope
2. Evaluate available people
and financial resources
Strategy 3. Form a design team
4. Design team goals and
objective
5. Define customer
requirements
Requirements
6. Define engineering
definition
requirement
7. Concepts generation
Concept
8. Concept selection
development
QFD,
Functional
decomposition
QFD, DFX
Go/No-Go Screening
Decision matrix
9. System design
10. Benchmark 1
System
design
11. Evaluation
12. Design review 1
13. Design documentation
tune up
107
Calculations
QFD, DFX
FMEA
Taguchi
Poke Yoke
Problem solving
Calculations
Customer survey
Continuous
improvement
Table 4.1
A hydraulic system is a product in which the cost of the components
represents about 80% of the total manufacturing cost. Since the
components are usually off-the-shelf purchased parts, their cost is easy to
obtain. Therefore, our goal should be to predict the total cost of the system
with no more than a +/- 5% error.
108
109
Step one - find a single overall function that this system needs to
accomplish. For the hydraulic system, described in Chapter 5 (Fig. 5.1), this
function will be:
Design an electric forklift truck hydraulic system which will allow the
operator to manipulate the rated payload in all three degrees of freedom up
to the maximum height of the mast.
Step two - decompose the function into top level functions for the
system. The top level functions will identify what the system is supposed to
do.
Step three - decompose further any of the top level functions into
sub-function in order to refine the function as well as possible.
The process will go on until all functions become measurable and simple to
satisfy.
Go/No-Go Screening is an evaluation of whether a proposed concept
meets the corresponding engineering specification. If the answer is YES or
MAYBE, the concept is GO. If the answer is No, then the concept is a NOGO.
Decision matrix is used after a Go/No-Go screening. This tool provides a
means of scoring each concept against pre-defined criteria for comparison.
The matrix has weight columns in which each criteria is given a relative
importance. A decision matrix for a hydraulic system is given in Table 4.2
(Appendix E).
Steps for this method are:
1. Choose criteria for comparison- criteria can be either Customer
Requirements or Engineering Requirements
2. Select concepts to be compared
3. Generate scores
4. Compare scores
Taguchis Method is a technique to optimize the design process in order to
minimize its cost.
FMEA (Failure Mode and Effect Analysis) is a technique for improving the
quality of a design and manufacturing process by first identifying and then
eliminating or minimizing the potential quality problems.
110
Safe operation
Low acquisition cost
Low total cost (purchase, maintenance, operation)
Durability
Ergonomics- ease to use controls and operators comfort
Quiet operation
Little or no down time during the warranty period (1-3 years)
Ease of maintenance
Ability to add attachments to the truck
111
112
circuit design
calculation of the parameters
component selection
component layout
methods of component control (sequence of commands)
software development and tuning
System design will be our main focus in the following chapters of this book.
Software development and tuning will not be described. This last step has
to be done after assuring that all components are working properly.
Step 10 - Benchmark 1
Benchmark 1 is a comparison of the calculated values against the
engineering requirements, review manufacturing and assembly processes.
113
Step 11 - Evaluation
114
Our goal at this point is to verify the components and system parameters
over a period of time.
The best system performance is verified at 20 C room temperature and 40
C fluid temperature. The worst performance is tested at the extreme
conditions defined in the project specification. All test results must be
recorded and used in the next step.
Another factor is the supplied power. When the hydraulic system is
designed for an electric truck, a fully charged battery must be used. If the
battery voltage goes down, the motor speed also goes down. As a result
the truck performance is decreased and it goes outside the advertised
operating range. For example: if the battery charge goes down to 50%, the
lift motor speed can go down 10% or more during lifting.
Step 16 - Benchmark 2
Benchmark 2 has three sub-steps:
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116
Design guidelines
1. Address each function of the system separately before combining
them in a system
2. Minimize the number of component
3. Use standard components
4. At each step of the process- consider the efficiency of the system
5. Lower potential assembly errors (mistake-proof design)
Easy to assemble
117
118
All issues and action items have been completed and signed off
All required work products have been produced
All deficiencies have been logged and signed off
All quality assurance issues have been addressed
A project termination or cancellation statement exists.
119
120
Patents
A patent is an intellectual property, recognized to be a novel idea, granted
by a Patent Office to the inventor (sole or joint). The legal purpose of the
patent is to exclude others from making, using or selling the invention.
121
There are three important parts which any patent must have: 1) a novel
idea, 2) usefulness to society (diligence) and 3) not obvious. There are two
types of industrial patents:
Design Patent
Design type is a novel idea only in the appearance of an object. Its
protection is 14 years from issuing the patent.
Utility Patent
Utility type is a novel idea that is useful to society. These types are
inventions of machines/mechanisms or processes (method of operation or
manufacture); articles of manufacture (casting, molding). Its protection is 20
years from filing.
The first step toward obtaining a patent is preparing and filing a patent
application. The application contains three main parts: a specification
(description of the invention and claims), drawings and an oath by the
inventor(s). The claims define the invention. When more than one person
works on a design, it is difficult to determine the inventors of the subject
matter described in the claims. The rule is that anyone who made a
significant contribution should be included as an inventor.
When filing for a patent, the timing is very important. In the USA and
Canada, the filing must be done within one year from the public disclosure
of the invention. For this reason, it is very important to have confidentiality
agreements with your business partners who have had any involvement
during the design process. The US and the Canadian patent offices apply
first-to-invent rule when they grant a patent, while the European offices use
first-to-file rule.
The government of the United States can stop any patent application from
publishing if it is considered it to be a danger to the national security. In
cases like this, they label the information as classified and instruct the
inventor/s not to disclose or publish the invention. The government is not
obligated to financially compensate the inventor/s.
Patent protection extends only over the country that issues the patent. If we
want to have protection in more countries, we have to file an application in
each of these countries in their official language and according to their
patents laws.
122
123
2.
124
3.
The engineering design firm, on the other hand, has to prove that in their
design process they:
1.
2.
3.
4.
When the system design is completed, the design engineer should be able
to predict the behavior of the system for a defined period of time and
assume responsibility for the safe operation of the system.
125
Chapter 5
126
In fig. 5.1 is shown a sit-down counterbalanced lift truck. This type is the
most common lift truck type. The weight the rear of the truck
counterbalances the weight of the load. The truck has two parts: mobile
(tractor) and elevating (mast). Tractor consists of chassis (containing the
battery, the counterweight and the controls), steering and drive units. Mast
frame is constructed from structural steel profiles. Hydraulic cylinders
mounted on the mast are used to lift the loads. Mast can have two or more
sections where the first section is always fixed while the others are
movable.
Elevating system
A triple-mast elevating system is shown in fig. 5.2. This elevating system
has three structural profiles (masts). One of them (1) is fixed while the other
two (2 and 3) are movable vertically. There are two ram type lift cylinders.
The free-lift cylinder (4) is mounted on the outside movable mast (3). It lifts
127
the fork carriage without lifting the mast profiles (fig. 5.2b). The main lift
cylinder (9) is mounted on the fixed carriage (1). It function is to elevate the
movable mast sections 2 and 3 (fig. 5.2c).
Vc = Vcarriage
Vd = Vcyl
Ve = 0
c
Vcarriage
Fig. 5.2
a) lowered position
Components:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Main mast
Middle mast
Free lift mast
Free lift cylinder
Pulley 1 (free lift)
Chain 1 (free lift)
Pulley 2 (main lift)
Chain 2 (main lift)
Main lift cylinder
b) free lift,
maximum
height
c) main lift
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129
A full load sensing system can also be closed or open. Closed systems use
a pressure-flow compensated pump and at least one load sensing valve.
The pressure-flow compensated pump is a variable volume piston pump,
which senses the system flow and pressure requirements and delivers
variable flow at variable pressures per these requirements. The pump
stands by at a low pressure in order to save energy. In addition, this system
has a load sensing directional valve which has a pressure feedback. The
valve receives the pressure requirements from the actuator and sends a
pressure signal to the pump. The advantage of this system is the higher
power efficiency. A disadvantage of the system is its high cost. Because of
the high cost, full load sensing systems currently are not used for industrial
truck applications.
Instead of full load sensing, the hydraulic system can be designed as an
open type system which uses a non-compensated fixed-displacement
pump and at least one load sensing valve. This combination appears to
have the lowest cost-per-power ration. For this reason, these types are
becoming more popular and all new designs have elements of pressure
sensing feed back in order to improve efficiency. An example of systems
with a load sensing valve will be discussed in this chapter (fig. 5.13) and
next chapter (fig 6.4).
In the 1990s, lift truck manufactures started using electronically controlled
AC and DC motors as power sources for the hydraulic systems. Availability
of variable-speed motors to drive the hydraulic pumps provided more
design options to the engineers. Mating variable-speed motors with fixeddisplacement hydraulic pumps allows designers to control pump flow rates
by controlling the pump motor rotational speed which improves energy
efficiency of the system.
In this chapter, step 9 (System Design) of the design process, described in
chapter 4, will be explained in detail. System Design includes the following
activities: 1) circuit design; 2) calculation of the parameters; 3) component
selection and 4) component layout.
Design Principles
There are a number of design principles that need to be kept in mind during
the systems design.
130
1.
2.
Design Requirements
Before we start designing the system, we have to specify the system
requirements. System requirements (design requirements) are the technical
interpretation of the customers requirements. Two techniques- QFD and
Functional Decomposition- are used for converting the customers
requirements into manageable design requirements as described in
Chapter 4. These design requirements become the performance and
hydraulic system requirements. In addition, we have to include the
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132
133
Circuit design
The hydraulic system should control different functions (lift/lower, side shift,
tilt or others) independently or simultaneously when necessary. Each
function is controlled by a directional valve. Valves could be independent
components or combined in a valve stack which consisted of different
sections. There are two main types of directional valve stacks: valves
sections connected in parallel (Fig. 5.3) and valves sections connected in
series (Fig. 5.4a and Fig. 5.4b). Valves have a bypass flow path which is
closed when fluid is redirected to the actuators.
The arrangement in figure 5.3 is the most popular directional valve stack
used in the mobile hydraulic systems. For this reason, only this system will
be used for further analysis and its operation will be described in details.
While the system operation is described, we will also discus the different
types of components and determine the ones that best fit our application.
The size of the components will be determined after we calculate the
systems pressure and flow requirements.
134
Fig. 5.4a
135
Fig. 5.4b
136
137
its pressure setting should be about one (1) bar lower than the valve setting
and its role is only to alert the operator.
The suction line is the ideal location for a filter because the filter prevents
contamination from entering the system. In some designs, suction filters are
avoided because they create pressure drop and increase the risk of forming
a vacuum in the pump inlet. A vacuum at the inlet can reduce up to 50% of
the life of the gear and vane pumps. To avoid vacuum creation we can
place the pump below the oil level in the reservoir.
Pump (4) delivers the necessary flow for all consumers in the system. For
systems with high pressure and high efficiency requirements, the first
choice is an axial-piston pump. For a cost sensitive system, the first choice
is a gear pump. In this system we are going to use a fixed-displacement
gear pump. When we have an IC (internal combustion) lift truck, the
hydraulic pump is mounted on the drive shaft of the IC engine and a
dedicated electric motor for the pump is not required. In the electric trucks,
the pump is connected to a dedicated electric motor (3). In this system, the
pump always starts before the directional valve opens. The reason is that
pump has to reach a minimum rotational speed and build up pressure first.
Pressure relief valve (5) is built into the directional valve (6). Its function is
to limit the maximum pressure in the system. We use an adjustable valve
when different applications require different pressures. The spring tension
is adjusted in order to provide the desired pressure level in the system. This
can be done by the valve manufacturer or by the hydraulic system
assemblers. The pressure level depends on the maximum load lifted by the
cylinders.
A relief valve has two positions that are controlled 1) when the valve starts
to open and 2) when the valve is fully opened. At the first position, the valve
begins to bypass part of the flow from the pressure line to the reservoir. The
pressure at which this happens is called cracking pressure. The cracking
pressure must always be more than the working pressure of the system. At
fully open position, the valve allows all flow to go back to the reservoir.
Usually the full relief pressure is 20% above the cracking pressure.
When the same valve or the same hydraulic system is installed on different
load- capacity trucks, assemblers on the production floor have to adjust the
relief valve. There are two adjustment procedures used to ensure that the
valve is fully closed during system operation. The first is when the relief
valve is adjusted to the cracking pressure with a load on the forks 10% to
20% higher than the maximum rated load. The second is when the valve is
138
adjusted with the maximum rated load on the forks. In the second case,
pressure readings are used to set up the valve. First, the assemblers
measure the maximum working pressure of fully loaded mast. Then,
unloaded mast is extended until it hit the stops and the flow is bypassed
through the relief valve. The valve spring is adjusted until pressure before
the relief is 10% above the maximum pressure recorded earlier. Correctly
adjusted relief valve does not affect the lifting times. Increased lifting times
indicates that part of the fluid is bypassed to the reservoir. Lifting time within
the design specification indicates that the valve setting is correct.
Check valve (6a), prevents backflow from the system to the pump. It is
placed before each section of the directional valve. The check valve can
also be built into the pump or it can be an in-line type valve.
Directional valve (6) used in this hydraulic system is a manually controlled
proportional type. Proportional type valves allow smooth flow change and
therefore smooth piston motion. The manual control is usually a lever which
is moved by the operator. The valve has a stack of four sections built as
one module. Each section has three positions- one neutral (middle position
2) and two operational (positions 1 and 3). In the neutral position there is no
flow from the valve to the cylinders or from the cylinders to the valve.
Sections are spring centered and manually controlled type. Each section
has a separate valve spool with a separate control and can act
independently from the others. In the neutral position, the pressure line is
bypassed to the reservoir. When flow is required, the hydraulic pump starts
to deliver flow first and then the plunger moves to redirect the flow through
the valve. Shifting the spool opens the ports to the hydraulic actuators and
at the same time closes the bypass line.
The first section is for lifting and it has only one pressure outlet. Each of the
other three sections has two outlets. The fourth section has two quick
connect/disconnect connectors for utilization of additional power
consumers. The manual control is acting only on one side of the spool by a
lever. When the lever is pushed forward, it shifts the spool in one direction.
When the lever is pulled back, it shifts the spool to the other direction.
When the lever is released, the spring returns the plunger to its neutral
position. This type of control allows us to have infinitive positioning of the
spool. When we move the plunger slightly, it opens the pressure port
partially and divides the pump flow sending part of it to the actuator and the
rest of it back to the reservoir. Valve sections are connected in parallel.
When all sections are fully open at the same time (require flow in all four
139
outlets), the fluid will not go to all of them. The reason for this is that the
system has different pressures in the different branches and when the
operator shifts two or more sections at once, the fluid always takes the
lowest resistance path and goes to the outlet with the lower pressure first.
But, if the operator opens the ports, just a little, and creates back pressure
from each spool, then two or more sections can operate at the same time.
Orifice (7a) role is to restrict the flow from the lift cylinders to the reservoir
during lowering of the load. When lifting, the fluid going to the cylinders
passes through the check valve (7b). The check vale has very small
pressure losses and it allows more energy efficient lifting. When the
cylinder is lowered, the check valve (7b) closes and fluid is forced to pass
through the orifice (7a). The orifice cross section diameter has to be
calculated and properly selected in order to create enough back pressure to
achieve the desirable lowering speed.
Single-acting ram type cylinders (8 & 9) lift the payload to the designed
preset height. Cylinders (8) are called main-lift cylinder and their function is
lift the movable sections of the mast. They are mounted on the side or
behind of the mast. Both cylinders (8) are connected via a rigid cross bar so
that they always work together in tandem. Cylinder (9) is called free-lift
cylinder. Its function is to lifts the fork carriage without lifting the sections of
the mast. If there is only one free-lift cylinder, it is mounted in the middle of
the mast. The piston area of the free-lift cylinder (9) is larger than the
combined piston area of both main-lift cylinders (8). Therefore, when oil
pressure is applied, the pressure creates higher force (F= p*A) in the
middle cylinder and this cylinder starts to lift first. Free lift does not increase
the overall truck height and allows the truck to transport the load through
doors. This feature also allows faster lift speeds and requires less power.
When the cylinder (9) finishes its stroke, the flow starts to lift cylinders (8)
together. When the cylinders lower the load, their function is similar to a
weighted (gravity) accumulator. The pressurized fluid holding the load
accumulates potential energy which has to be released in a way that will
absorb the shock waves and provide a smooth lowering piston movement.
As we mentioned in chapter 2, when compressing and decompressing
large fluid volumes in hydraulic cylinders, we have to consider the
compressibility of the fluid factor. Compression of the hydraulic fluid
accumulates potential energy similar to the potential energy accumulated in
a compressed spring. Fluids that are less compressible absorb less energy.
When the fluid is decompressed, it releases this energy creating noise. We
have to control the decompression process otherwise the released energy
140
141
the hoses attached to the lift cylinders. They are designed to be inserted
into a hydraulic cylinder. The flow limiting fitting has a built-in valve which
restricts the flow in the event of a hose failure. The hose failure is detected
when the fluid flow exceeds a specified value. This fitting can control the
flow in one direction- when the flow exits the cylinder during lowering. The
flow is uncontrolled when it enters the cylinder.
Two double-acting cylinders (10) are used to tilt the load by tilting either
the mast or the carriage. The cylinder body is mounted to the chassis while
the piston rod end is mounted to the pivoted mast. These cylinders can
have built-in flow restrictors (10a) which limit the speed. Limiting forward tilt
speed is very important because a high tilt speed leads to instability of the
forklift truck. When the tilt cylinders dont have built-in restrictors, an in-line
orifice or flow control is used to control the tilt forward speed.
142
Filter selection
The life of the whole system depends on the life of each individual
component. The biggest contributor for component failures in the system is
the number and the size of contaminants (dirt, dust, hard particles, etc) in
the hydraulic fluid. The filter function is to limit the contaminants to an
acceptable level. There are two steps of filter selection. The first step is
selecting the location. Based on the location, the filter can be: suction,
pressure or return. Selecting the location of the filter is based on the
considerations described in chapter 3 (filters). The second step is sizing the
filter which is done at components selection level.
Filter sizing
Filter sizing is based on four main parameters:
1) Maximum flow rate through the filter.
For suction filters it is the maximum pump flow rate.
2) Maximum pressure across the filter.
Suction and return filters do not experience high pressures. For calculation
purpose, we accept that the filter collapsed pressure is at least 1.5 times
143
higher than the crack pressure of the bypass valve. Filters without bypass
valves should have pressure switches which disable the system when the
filter is plugged and yield a replace filter message.
For a pressure line filter, designers have to select pressure ratings higher
than the maximum pressure setting of the relief valve. This higher pressure
rating is needed because of the pressure fluctuation in the fluid.
3) Fluid viscosity
Fluid viscosity depends on temperature. Temperature range for the filter
and the fluid should be the same. If a hydraulic system starts working at
cold conditions, increased fluid viscosity puts extra pressure on the filter
and can damage filtering element. If this risk exists, the filter has to be
tested at cold conditions.
4) Filter retaining efficiency
In the past, we worked with absolute rating and nominal rating. But these
ratings did not describe the likelihood of particles larger than the rating to
go through the filter.
A better measure of filter retention efficiency is the Beta rating (Beta
number) which shows the filter efficiency to capture specific size particles.
Most manufacturers provide three beta ratings: 75, 100 and 200. Beta
ratings (ISO 16889) are a measure of the number of particles greater than
X microns entering the filter divided by the number of particles greater than
X microns exiting the filter. Different Beta values are given in table 3.2,
chapter 3.
A procedure for filtration selection in order to maximize the life of a
hydraulic system is described below.
Determine minimum component clearance
We look at all components in the system and identify the components with
the minimum clearances between their moving surfaces. These
components require the highest fluid cleanliness. The first step is to collect
information for all components, put it in a table and compare the data.
There are two sources for this information: 1) component manufacturers
and 2) standards. Clearances between moving surfaces is a mirror of
quality of the product. It depends on the manufacturing technology, process
144
control and process quality. The component with the least clearance I am
going to refer as: the most sensitive component.
If we do not have data from the manufacturer, we will determine the most
sensitive component based on ISO minimum cleanliness code. For the
hydraulic system shown in Fig. 5.3 we will use the ISO guidelines. First we
will use tables 3.6, 3.7 and 3.8 (chapter 3) and list all the components and
the corresponding cleanliness code for 25 MPa (250 bar) pressure. The
first number of the code is more relevant to precise servo systems and will
be omitted.
System components
__/16/13
Check valves
__/18/15
__/15/12
__/17/14
__/17/14
Hydraulic cylinders
__/18/15
Table 5.1
From the table 5.1 we see that the most sensitive component to
contamination is the directional valve.
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75
100
200
Microns
8.7
9.6
12
System Efficiency
The ultimate measure for system efficiency is the total pressure drop from
the pump to the hydraulic actuators. A large pressure drop in the hydraulic
components results in a requirement for higher input pressure. This
increases the load on the hydraulic pump and requires more power from
the drive motor. Even properly working pump loses its efficiency gradually
so, the efficiency loss must be considered then the system is designed.
146
Calculations
Select hydraulic components
Usually the first selected components are the pump and the actuators.
From the initially selected maximum pressure and payload we determine
the diameter of the lift cylinders. First we determine the diameter of the two
main-lift cylinders and then we select the diameter of the free-lift cylinder so
that the piston area of the free-lift cylinder is larger than the combined areas
of both free-lift cylinders. The cylinder diameters are calculated from the
formula:
LT
kASC =
5.1
p MAX CYL
Where:
ASC =
d 2
[m2]
LT [N]
p MAX [Pa]
CYL
d=
2 LT
p MAX CYL
[m]
5.2
pCYL =
LT
2 ASC CYL
[Pa]
5.3
147
Q=
ASC m 3
n s
5.4
Where:
n = 2 is called polyspast number (or mechanical advantage of pulley
operated mast mechanism) and it is the ratio:
n=
V
load _ lifting _ speed
= C
cylinder _ lifting _ speed Vd
dP =
Q P cm 3
n V rev
5.5
Where:
QP [cm3/min] is the flow rate.
n [rev/min] is the shaft input rotational speed
V is pump volumetric efficiency.
The next step is to determine the volume requirements of the system and to
select the components per these requirements. The components that most
affect the required fluid volume are the lift cylinders. As mentioned, for
lifting we use single-acting ram type cylinders; for tilting we use differential
(double-acting) cylinders; for a side shift we can use either differential or
non-differential cylinders.
148
S CYL =
H a+
[m]
n
5.6
Where:
H [m] is the height of the mast
149
l q
=
d 2 S
q
S
l 2
V
d 2
5.7
150
p LOC =
V2
5.8
5.9
Where,
p6 are the losses in the directional valve (6) and
p7b are the losses in check valve (7b).
Losses in the components at defined pressure and flow are given by the
component manufacturers.
8. Total pressure loss from the pump to the lift cylinder is:
p SYS = p LIN + p LOC + pCOM
Calculate the pressure requirements at the pump discharge port
p PUMP Q
60 PUMP
[kW ]
Where:
5.10
151
T=
pd P
m ( Nm )
2
Where:
Next, the electric motor is selected from the power and torque requirements
of the system.
A calculation of the parameters of the hydraulic system, described in fig. 5.3
and using the elevating section shown in fig. 5.2, is given in Appendix F.
152
After the pressure drop p reaches 2 MPa, the valve closes and maintains
relatively constant flow. When the pressure drop across the valve
increases, the valve has to compensate more which produces a tailing off
effect. The tailing off effect tilts the graph up or down off its horizontal line.
Since constant flow maintains almost constant lowering speed, when a
constant lowering speed is required, we use a flow regulator. The flow
regulator does not maintain a constant flow only in the first part of the graph
for pressure drop where (p) < pmin.
The orifice characteristic is a quadratic relationship between the pressure
drop (p) and the flow (Q). When the load is increased, p increases as
well. The valve has a high flow rate at high pressures (maximum load on
the forks) and a low flow rate at low pressure (no load). Orifice valve
characteristic provide high lowering speed when the lift truck is fully loaded
and low lowering speed when it is empty. The reduced lowering speed
reduces the overall truck productivity. The only advantage of using orifice is
its simple construction and low price. For this reason, orifice is used to
control lowering speed only in systems where the low cost of the system
outweighs the increased productivity.
60
50
Flow (l/min)
40
30
20
10
0
0
Flow Regulator
Orifice
10
15
20
25
153
Fig. 5.6
154
Components:
1. Reservoir assembly
2. Flexible line
3. Electric motor
4. Hydraulic pump
5. Pressure relief valve
6a. Proportional directional valve for lift and lower
6b. Proportional directional valve for tilt
6c. Proportional directional valve for side shift
7. Check valve
8. Flow control
9. Lift cylinders
10. Tilt cylinder
11. Side shift cylinder
12. Check valve
Principle of operation
The main difference between this system and the first one (Fig. 5.3) is that
the directional valves (6a, 6b, 6c) have electric controls. Lift and tilt valves
(6a and 6b) are proportional type valves controlled by proportional electric
signal while the side-shift valve (6c) has an ON/OFF control.
Unlike the mechanical type where the control lever is mechanically linked to
the valve, electrically controlled valves are connected to the controller with
wires. Connecting components with wires allows more design freedom
because the valves can be placed anywhere on the truck.
Electrically operated valves can be equipped with a manual override. A
manual override can be a screw or push-pull button. It is used to: 1) reset
the plunger in its neutral position when the plunger is stuck as a result of
contamination. Easy plunger movement shows that a plunger is not seized;
2) activate the valve and lower the load when power to the valve is lost. In
the hydraulic system shown on Fig. 5.6, the lift/lower directional valve (6a)
is equipped with manual push button.
155
A control lever (joystick) that includes buttons and switches can be used to
control the valves. Any movement of the joystick results in corresponding
movement of the work mechanism. Using a joystick design allows
designers to develop a more ergonomic operators compartment.
Solenoids of the proportional valves can be controlled either directly by a
potentiometer or by an electronic controller. The potentiometer is usually
placed inside the joystick. Joysticks can have a mechanical potentiometer
or solid state potentiometer (based on inductive technology) to translate
mechanical motion into electric signal output. In the last few years the trend
is to use joysticks that have a CAN bus interface. CAN bus technology
allows electronic communication with a minimum number of wires and
contactors.
When a programmable controller is used, the potentiometer sends a signal
to the controller which in turn sends a signal to the solenoid that controls
the valve plunger. The position of the plunger determines the flow rate
through the valve. The flow rate controls the position and movement of the
work attachment. In this case, the joystick is configured only to deliver
commands to the controller. Operators can activate two or more functions
by pressing two or more buttons simultaneously. The controller can be
programmed in such way that some commands are restricted when they
are in conflict with commands already taking place. These restrictions are
used for safety reasons.
There are two basic types of valve controls: electric and electronic:
An electric control is when the valve solenoid is controlled by changing the
input voltage by continuous analog signal directly from the control handle
(joystick). A potentiometer changes the value of the signal proportionally to
the handle movement. The solenoid armature motion is proportional to the
input voltage. Armature pushes the valve spool. Usually, proportional
valves have a voltage or a current control. Discrete (ON-OFF) valves have
a voltage control. Voltage is turned on and off by electric switch.
An electronic control is when a programmable electronic device controls the
input signal to the valve solenoids. Electronic control can be an analog or a
digital signal. Digitized signals have definite number of steps. For example
if the digital controller has eight-bit signal, there will be 256 (28 = 256) steps
available. The resolution of eight-bit controller will be 0.4% (1/256 =
156
Signal modulation
Pulse Width Modulation (PWM) is a method of controlling the signal. The
signal is controlled by a transistor. The transistor is an ON-OFF switch
which controls the average value of the signal by controlling the width of the
signal (the time signal is ON). Modulation time is the time (measured in per
cent) when the signal is on. One hundred percent (100%) is practically a
continuous signal and the voltage is equal to the maximum.
Signal
[Volts]
Signal
[V]
100% modulation
50% modulation
V = 24
V = 12
t [s]
t [s]
Switching frequency is the rate at which the signal is turned ON and OFF
and it is called PWM frequency. PWM frequency must always be higher
than the valve resolution. Then, the spool is too slow to respond to the
instantaneous ON-OFF switching and it responds to the average value.
Valve resolution is the smallest increment of input signal (input frequency)
at which the valve spool can respond.
The current to the valve solenoid will be:
I = V/R (amp)
Where: V is PWM average voltage and R is coil resistance
157
Dither signal
Dither signal is a high frequency input signal. Dither signal is added to the
control signal in order to achieve smooth spool motion. The dither makes
the valve spool vibrate at high frequency. This vibration makes the spool
movement smoother by diminishing sticktion in the valve. It is important to
choose a correct frequency and amplitude dither signal. Dithering reduces
the valve hysteresis and makes valve performance more consistent. The
minimum dither frequency is part of the valve specification and it is provided
by the manufacturer. Excessive dithering can negatively affects the static
and dynamic characteristics of the valve.
158
159
160
CF
EF
LS
P
Fig. 5.7b System with lowering directional valve which has a built-in check
valve and a manual override for emergency lowering
161
162
b) Reversible
pump and flow
c) Separate
pump and motor
163
Fig. 5.9
Principle of operation
Hydraulic pump/motor (4) is coupled with an electric machine (3) that can
work as a motor or a generator. The electric machine (3) always works in
the same direction. The relief valve (5) is placed between the pressure line
and the return line. The return line has a return filter (2) with a check valve
connected in parallel. This hydraulic system has three main branches that
support three functions: lifting/lowering, tilt and side shift. Directional valves
(6 and 7) have controls independent from each other which allows the
operator to activate each of them separately or at the same time. Each
three-position directional valve has a neutral middle position. The middle
164
position has a bypass passage which ensures free flow from the pump to
the reservoir. There are two ways to control the speed of the lift cylinder:
flow resistance control and pump control. With flow resistance control, the
flow rate to the cylinder is controlled by changing the opening of the
proportional valve (6 or 7). When the proportional valve is partially open, it
allows the excess flow to go for auxiliary functions. Pump control is when
the flow rate is controlled by changing pump rotational speed. Pump
controlled lifting is more energy efficient because there are less hydraulic
losses. Disadvantage of it is that it has a longer response time.
The unique feature of this system is the lowering branch configuration. One
end of it is connected to the lift cylinder (11) inlet and the other end is
connected to the suction line between the check valve (8) outlet and the
pump inlet. This way, all returned fluid during lowering goes through the
pump. Flow rate of the return fluid can be controlled either by the
pump/motor (4) or by a flow control (9).
In the case of motor controlled lowering, valve 9 and 10 can be replaced
with one proportional directional two-position valve (not shown). The motor
has a speed sensor (not shown) which sends actual rotational speed to the
controller (not shown).
The flow control (9) has a constant flow through the valve at different
pressures in the lift cylinder. This constant flow provides lowering speed
that is independent from the load. It also limits the rotational speed of the
pump (4) and the electric machine (3) because pump rotational speed is
proportional to pump volumetric flow.
When the return fluid is not needed for another function, the pump/motor
acts as a hydraulic motor and the electric machine works as a generator
and recharges the battery. The fluid goes thought the bypass passages of
the valves (7) back to the reservoir.
When fluid is needed to move tilt (12) or side shift (13) cylinders, one or
both valves (7) shift and redirect the flow to the auxiliary functions. Then,
part of the flow goes to drive the auxiliary cylinders while the unused part is
bypassed to the reservoir. If the tilt or side-shift actuators require more flow
and pressure than supplied from the return line during lowering, the electric
machine works as a motor and rotates the pump to create the necessary
flow. In this case, in addition to the return fluid, the pump pulls out fluid from
the reservoir.
165
In the energy recovery modes the return fluid is used for other functions
before going to the reservoir. If the fluid is too hot, it will have a negative
impact on its life and on the efficiency of the whole system. For this reason,
reservoir design that ensures proper cooling is essential for this design.
166
Reservoir
Filter with check valve
Hydraulic pump
Steering valve, type: Orbitrol (with built-in relief and check valves)
Steering wheel
167
168
Steering valve (4) is selected on the basis of the steering wheel number of
revolutions. Our goal, per design requirements, is four revolutions. The
valve has to ensure that four full turns of the steering wheel will result in
turning the truck wheels from full left to full right position.
The steering valve has a built-in relief valve. When steering is performed,
the relief valve is fully closed and all flow is circulated though the Orbitrol.
When steering stops, the pressure increases and the valve opens. Then all
flow from the pump goes through the valve to the reservoir. Some steering
control valves have a return-to-center feature. The valve returns the
steering control to neutral position when it is released by the operator. This
returns the tires automatically to their center position.
Steering wheel (5) is mechanically connected to the Steering valve
(Orbitrol).
Filter (2) is placed in the return line. It must have a check valve, connected
in parallel, which opens when the filter is plugged. The check valve will
ensure a continuous flow from the pump to the reservoir when the filter
fails. Continuous flow is necessary to guarantee truck steering.
Reservoir (1) is a vented type. It can be separated or combined with the
reservoir of the hydraulic system for the lift/lower and the auxiliary
functions.
Pump (3) is a fixed displacement pump.
Calculating the pressure requirement
Let us look at the system in Fig. 5.10. Pressure in the system is a result of
the steering force FS [N] acting on the piston in the cylinder. Steering force
is determined by the moment which is necessary to turn the wheels. The
pressure inside the cylinder is:
pCYL =
Where,
FS 1
[ Pa]
ACYL CYL
5.11
ACYL
169
D2 d 2
=
[m2] is the cylinder area on which pressure is acting.
4
CYL
p PUMP = p CYL + p H
5.12
Where,
p H
are the pressure losses in the hoses and the fittings from the
pump to the cylinder.
Calculating the flow requirement
A.
VCYL cm3
dS =
N rev
5.13
Where,
B.
VCYL
dS
QSP =
Where,
N MAX (d S ) l
min
K
Q SP
5.14
170
K = 1000
NMAX
N MAX = (1.5 2) N A
5.15
Example:
Determine the steering valve size and the required pump flow rate for a
steering system with a double-acting cylinder with piston diameter D = 80
mm and rod diameter d = 56 mm. The mechanism kinematics require a
cylinder stroke S = 140 mm. Design requirements specify from 3 to 5
steering wheel rotations from full left to full right turns.
Solution:
Cylinder volume V in cubic centimeters is:
VCYL =
(D2 d 2 )
4
S=
(80 2 56 2 )10 4
4
[ ]
cm3
358.9
= 89.7
dS =
4
rev
We select Orbitrol. For example: Danfoss 80 which has a displacement of
80 [cm3/rev].
Using this valve the steering wheel rotations will be:
[ ]
VCYL 358.9 cm 3
N=
= 4.5 [rev]
=
dS
cm3
80
rev
171
QSP =
N MAX (d S ) (105)(80)
l
=
= 8. 4
K
1000
min
Flow rate together with motor rotational speed are used to select the pump
displacement. The displacement is calculated from equation 5.5. The
process of pump selection is described in chapter 3 and in the example in
Appendix F (Hydraulic System Calculation).
172
173
174
175
176
Compact design
High work pressure (usually 25 MPa)
Operate in wide temperature range (-20 to +50 C)
Maintain static and dynamic sealing
177
load reaction and the inertia of the moving parts. Moving parts are the mast,
cylinders, carriage, the load and all chains and hoses attached to the mast.
The lifting force is:
Fd = pA
Where:
Fr = FL + Fi + F f
Where:
FL
Fi
Ff
F f = Fcyl + Fmech
Where:
Fcyl
178
Fig. 5.14
In the first speed range -I-, the friction force (FT) has its highest value. In the
second range -II-, FT is almost interchangeable and has its lowest value.
Within this speed range the hydraulic cylinder has its best performance in
terms of smoothness of motion and efficiency. When piston speed is in the
third range, we observe a gradual increasing of FT but the slope of the
curve is not as sharp as at the beginning. Lets look in detail at the first
section of this graph because the most vibrations appear in this speed
range.
After we open the directional valve, the flow starts moving the piston. When
piston speed reaches a value v1, friction force is FT1. If a pulsation from the
gear pump appears at this moment, additional kinetic energy will be added
to the fluid entering the cylinder. This momentary kinetic energy increases
the piston speed to v2, which in turn decreases the friction force to FT2.
When the speed reaches v2, the momentary energy finishes and the friction
force increases to FT1, reducing piston speed to v1. When a new pulsation
appears in the cylinder, this process will be repeated and will make the
piston speed vary between v1 and v2. This speed variation of the cylinder
piston (or plunger) causes the jerky motion of the elevating system.
There are two general ways to reduce the piston speed variation.
The first way is to minimize flow variations (increase the spring constant of
the system) by adding a hydraulic pulsation damper to the system. A
damper is a hydraulic resistance between the direction valve and the lift
179
cylinder. There are two types of damping: active and passive. Active uses a
programmable controller which uses a cylinder position feedback signal to
control the directional valve plungers movement. This method is expensive
and is not used for forklift truck applications. Passive damping uses flow
restriction to reduce pressure oscillations in the system. The most popular
and cost effective damping element is the flow restrictor. On the other hand,
its use is not energy efficient because it increases the hydraulic losses by
converting hydraulic energy into heat. Another more efficient solution is
using a pressure compensated flow control valve.
The second way to minimize the piston speed variation is to reduce the
mechanical friction between the piston and the internal cylinder surface.
The most effective way to reduce friction is to use sliding non-metal rings.
The use of non-metal sliding rings can reduce the friction force up to ten
times, which comes from the difference in the coefficient of friction, f.
f teflon 0.01 ,
f metal 0.10
Fcyl = nf teflonDLp
Where:
n is the number of sliding rings, usually n = 2
D is the outside diameter of the ring
L is the width of the ring
p is the pressure in the cylinder
Two main materials are used to manufacture sliding rings- teflon based and
thermoplastic polyurethane materials. Optimal design is a combination of a
seal, a scraper and a sliding ring.
B. Pressure and flow pulsations entering the cylinder
Flow and pressure variations in the pressure hoses are important to
consider. In addition to pump induced flow pulsations, there could be shock
waves after the directional control due to opening and closing of the valve.
Pumps flow rate irregularity is:
Q =
Q Qmin
Q
100 = max
100 _[%]
Qm
Qm
180
Where,
Pressure pulsations in the discharge port are created by the gear pump.
Every time the fluid, situated between two teeth, is pushed out of the pump,
a peak in the pressure appears. Pressure waves in the discharge port are
described in Chapter 3.7 (Hydraulic Pumps).
C. Compressibility of the fluid
When calculating the hydraulic system we treat the fluid as incompressible
but in reality it is not. Compressibility is characterized by Modulus of
Elasticity (Bulk Modulus) EV. The higher EV is the stiffer and less
compressible the fluid is. Fluids which have higher Bulk Modulus absorb
less energy.
Modulus of Elasticity depends strongly on the fluid temperature because
when the temperature rises, the fluid expands creating additional pressure.
Ev decreases when temperature increases. Experimental data are shown
on Fig. 2.2, Chapter 2.
Also, there could be small amounts of air (aeration) in the fluid. Aeration
reduces the value of EV and makes the fluid more compressible. At high
pressure, the air forms bubbles. When the pressure drops air bobbles are
released causing cavitation, vibration and noise. Usually the first step in
troubleshooting a jerky cylinder motion is to bleed-off the cylinders. For this
reason, all high lift cylinders have bleed-off plugs or fittings. Some systems
have automatic air bleed valves which allow air to escape from the
hydraulic line without bringing the truck in for service.
D. Dynamics of the valve
Fluctuation of both flow speed and pressure decrease with the increase of
the internal frequency of the directional valve. Higher frequency limits the
amplitude of the relevant variables velocity and pressure. Speed
fluctuations decrease with the increase of the switching frequency of the
valve. Pressure fluctuations also decrease with the increase of the
hydraulic capacity of the cylinder. Switching time of a normal solenoid valve
is in the range of 30 to 50 ms. Servovalves have a switching frequency of
10 ms from fully open to fully closed position.
181
Chapter 6
182
Fig. 6.1 Low-lift truck with manual steering and mechanical lift mechanism.
Fig. 6.2 Low-lift truck with power-assisted steering and hydraulic lift
mechanism.
183
An advantage of systems with two circuits is that the lifting circuit can be an
off-the-shelf power unit. Almost all hydraulic valve manufacturers offer such
power units, which contain an electric motor, a hydraulic pump, a manifold
with valves and a reservoir. When selecting a power unit, we look the
combined performance of the pump and the electric motor from the
manufacturer. Lift cylinders (12) usually are single acting. They are
184
Reservoir
Filter
Electric motor
Hydraulic pump
Check valve
Relief valve
b) lift circuit
7. Steering valve, type Orbitrol
8. Hydraulic motor
9. Gear
10. Flow control
11. Directional valve
12. Lift cylinders
Two circuits require two tanks, two electric motors and two
hydraulic pumps which take up more space.
Cost of the system is higher because more components are
used.
185
The steering circuit for low-lift trucks with a capacity below 3,000 kg is a low
pressure system- up to 5 MPa (50 bars) and for trucks with capacity above
3,000 kg it is a medium pressure system- from 5 to 15 MPa (50 150 bars).
The lifting circuit always has a normal high pressure from 15 to 25 MPa
(150 250 bars).
186
Reservoir
Suction filter with check valve
Pump
Load sensing priority valve (LSPV)
Lift power pack
Lift cylinders
Motor
Steering valve, type Orbitrol with LS feedback
Steering control
Hydraulic motor
Gear
187
188
Fig. 6.6 Hydraulic system with dual pumps and a priority valve
189
In some cases the cost of the electronic controller is too high and it is more
cost efficient to connect the electric motor directly to a battery. Then, the
motor will have only a high speed and it will deliver the maximum flow at all
times. When only steering is required, a lot of the power will be wasted. For
this reason, when a one-speed motor and a fixed-displacement pump are
used, energy efficiency can be achieved by using a dual pump (3) to split
the flow. Both pumps work continuously but only the flow from one will
circulate through the system to support steering. The flow from the second
pump is used only when a lift is requested. If these is no lift request, the
flow is bypassed through a valve (8) and returned to the reservoir (1). When
more flow is needed for lifting, the directional valve (8) switches and redirects the flow to the priority valve (4).
190
191
When the operator steps on the dead-man pedal, the parking brake is
released and the motor (7) is turned on. Then, the pump (3) starts to supply
flow to the system. If the accumulator (9) is empty, it will take a few
seconds to fill up. If there is a steering request before the filter is filled up,
the flow from the pump will go to both the orbitrol (10) and the accumulator
(9). As soon as the accumulator (9) is fully charged and the pressure
reaches a pre-set value, the pressure switch (8) is activated and it turns off
the electric motor. From this moment, the accumulator will supply the oil
flow for the steering. When the accumulator is discharged to a pre-set
minimum, the pressure will drop and the pressure switch (8) will turn on the
electric motor.
As mentioned above, steering and lift functions are rarely used
simultaneously therefore this design does require a variable speed motor.
Pump flow rate is selected to be a little more than the maximum required for
steering. This way even during steering, there will be extra flow for charging
the accumulator.
Example 1
Selecting an accumulator for the system shown in fig 6.7
Given (Engineering Specifications):
192
V = (dS)(revolutions)
V = (80)(4) = 320 m3
Where: V = V3 V2 is the difference in the volume of a fully charged
accumulator V3 (maximum pressure) and uncharged accumulator V2
(minimum pressure).
Then, the size of the accumulator, V1, is calculated by using formula 3.13
V1 = V
p3
p1
1/ n
p
1 3
p2
1/ n
1 / 1.4
10
9
= 320 1 / 1.4 = 1615 [cm3]
10
1
14
Where:
p2 = 14 MPa is the maximum pressure in the steering circuit (fully
loaded accumulator);
p3 = 10 MPa is the minimum pressure in the system;
p1 = 0.9 p3 = 9 MPa is the pressure in the bladder when the
accumulator is no loaded.
Based on the above calculation we are choosing a standard size of 2000
m3
Example 2
Calculate the energy saving
Calculate how much time the motor has to work in order to support the
steering during one work shift. Assume that one work shift consists of 400
TWC (truck work cycles).
Solution
An example of TWC is shown in fig. 6.8. In one TWC, the truck goes from
the load/unload area to the trailer (forks first), takes the load and drives
back (tractor first). The truck will make six turns (three in each direction).
193
Fig. 6.8 Steering duty cycle that requires three 90 turns in each direction
It is known that one 90 turn requires two steering revolution. One (TWC)
has six 90 turns = 12 steering wheel revolutions per truck work cycle or n1
=12 rev
It is estimated that in an 8-hour work shift an average operator makes a
maximum of 200 TWC (N = 200 cycles). Therefore, the total number of
steering wheel revolutions per 8-hour work shift is:
p.3
1
1.4
1
V := V .1
p.2
p.3
p.1
V = 396 cm3
1
1.4
The steering revolutions (nA) per one accumulator charge with the chosen
2000 m3 accumulator will be:
nA = V / ds = 2000/80 = 5
194
So, the total charging time per 8-hour work shift will be:
T = t x Nc = 4 x 480 = 1920 seconds = 32 minutes
Therefore the electric motor will work only 32 minutes to support the
steering. In systems without accumulator this time is about 7 hours because
the electric motor runs continuously regardless whether steering is required
or not.
195
For long attachments such design is not efficient because of the increased
cost and lack of space needed for the links. Also, the mechanical links have
to be different for each fork length. To eliminate these downsides, pallet
trucks with long forks have hydraulic cylinders pivoting the load wheel
downward. Such hydraulic lift system is shown in fig. 6.2 (component
layout) and in fig. 6.9 (schematics).
The system shown in fig. 6.9 has two main cylinders (5a and 5b) mounted
on the tractor and two slave cylinders (6a and 6b) mounted within the fork
profile and attached to the load wheels.
Fig. 6.9
196
A1
A2
197
Where:
6.1
A1
A2
tiller arm control and drive unit with horizontal motor (6.11a)
tiller arm control and drive unit with vertical motor (6.11b)
steering control with steering ratio rs 1 (6.11c)
a) steering ratio rs = 1
Fig. 6.11
b) steering ratio rs = 1
198
Components:
1.
2.
3.
4.
5.
6.
6.2
Where:
Nc is the number of revolution of the steering control
Nw is the number of revolution of the steered wheel
Steering ratio equal to one (rs = 1) means that the control (2) and the
steered wheel (6) rotate at the same time and at the same angles.
The hydraulic torque generator is activated mechanically by a steering
control. The rotation from the control (2) to the steered drive unit (3) is
transmitted through the input and output shafts of the torque generator (1).
Both shafts are mechanically linked inside the generator. The steering
control (2) is connected to the input shaft while the steered unit is
connected the output shaft. Connection to the shafts can be direct (6.11a)
or indirect by gear sets (6.11b and 6.11c). When both gear sets have the
same gear ration (6.11b), the design has a steering ratio equal to one (rs =
1). By changing the gear ratio, different steering ratios can be achieved.
The biggest advantage of using a hydraulic power steering over an electric
steering is that the truck does not lose steering if a failure in the power
system occurs. If there is no supply of pressurized fluid to port P, only
manual steering will be available. Manual steering will be more difficult but
will ensure control over the truck.
199
Fig. 6.12
Components:
1.
2.
3.
4.
5.
6.
7.
8.
Pump
Motor, electric
Priority valve with LS port
Relief valve
Gear
Tiller arm
Gear, ring
Torque generator with LS port
200
201
Chapter 7
5
2
1
3
202
The boom arm is pivoted at the rear side of the truck. It moves up or down
using the hydraulic cylinder (3). One end of the cylinder is attached to the
vehicle chassis and the other to the boom. Another hydraulic cylinder (4)
extends and retracts the boom. Cylinder (4) can be placed inside or outside
on the outer telescopic arm.
Examples of hydraulic circuits for lift mast fork attachments were shown in
chapter 5 (Hydraulic Systems for High Lift Trucks). In this chapter, we are
going to describe only hydraulic circuits for boom manipulation.
203
Fig. 7.2
204
Fig. 7.3 Hydraulic circuit for lifting and lowering a boom-type arm
1. Reservoir assembly
2. Hydraulic pump
3. Motor/ IC engine
4. Flexible line
5. Pressure relief valve
6. Directional control valve
7. Directional valve with a check valve
8. Directional valve
9. Accumulator
10. Double-acting cylinder (item 6 in fig. 7.1)
11. Load
205
206
turn minimizes the risk from breaking the connection. In most cases, metal
tubing is used to connect the accumulator to the cylinder.
Double-acting cylinder (10) is connected pivotally to the truck body on
one side and to the boom on the other side. A single-acting cylinder can
also be used.
Load (11) consists of the weight of the boom, the boom attachments and
the maximum payload.
Description of the hydraulic circuit operation
During lifting: the directional valve (6) is in position 1, valve (7) is deenergized and it has the check valve section connected to the line allowing
oil flow to the cylinder.
During lowering: the direction valve (6) is in position 3 and valve (7) is in
position 2 forcing the fluid through an orifice in order to create a back
pressure and smooth the lowering.
During lifting or lowering, valve (8) is not energized and the spring force
keeps the valve in closed position. Then, the accumulator (9) is
disconnected from the system because the built-in check valve does not
allowing flow to the accumulator.
During transportation (with or without a load): the control valve (6) is
switched to the neutral position, valve (7) is switched to position 1
preventing flow to the reservoir and valve (8) goes to position 3 connecting
the accumulator to the lift arm support cylinder. Now, the pressure in the
accumulator (9) will support the weight of the boom and will act as a
vibrations dumper. When the load bounces, it forces the fluid from the
hydraulic cylinder into and out of the accumulator. It is necessary for the
accumulator to have the same pressure as the lifting side of the cylinder at
the time it is connected to the system. To avoid pressure spikes, valve (8) is
constructed as a proportional type. The valve solenoid is energized
proportionally and it moves the plunger from position 1 to position 3 while
going through the orifice (position 2). Switching at a slow rate allows the
system to equalize the pressure before the valve is fully open. If the
pressure in the accumulator is lower, a sudden lowering of the boom may
occur. To avoid this effect, a small size accumulator is preferred for this
application.
207
Fig. 7.4 Hydraulic circuit (with an automatic shut-off valve) for lifting and
lowering a boom
1. Reservoir assembly
2. Hydraulic pump
7. Check valve
3. Motor
9. Accumulator
5. Relief valve
10. Cylinders
6. Directional valve
11. Load
208
Principle of operation
Directional valve (1) has three positions. Position 2 is neutral. When the
valve is in position 1, the cylinder extends and lifts the boom. When it is in
position 3, the cylinder retracts.
When the cylinder (4) is extending an unloaded boom, the pressure under
the piston will be low and the relief valve (6) will be closed. Then, the return
209
flow (Q1) will pass through check valves (5) and join the flow from the pump
(Qp). Combined flow (Q1 + Qp) will go through the check valve (3) to the
cylinder (4). When the boom is loaded, the pressure under the piston
increases and the valve (6) opens. Then the return flow from the cylinder
will go through the valve (6) to the reservoir (T).
During cylinder retraction, the flow from the pump goes through the check
valve (7) and enters the piston rod side of the cylinder. The return flow
passes through the pressure-compensated flow regulator (2). The flow
regulator (2) will maintain a constant lowering speed regardless of the load.
Fig. 7.5
The extension speed of an unloaded boom is:
E =
QP + Q1 m
s
A1
7.1
210
Where:
Qp [m3/s]
m3
Q1 = A2 E
s
A1 =
A2 =
D 2
4
[m ]
2
(D 2 d 2 )
4
[m ]
2
E =
QP
m
A1 A2 s
7.2
211
Chapter 8
Selected Topics
I.
In the last few years, the service sector has grown rapidly as more services
are offered by manufacturers and companies are focusing more on the
quality of the service. High quality service leads to customer perception of a
high quality product, which results in higher customer satisfaction and more
orders. The American Management Association has estimated that
companies lose as many as 25 percent of their customers each year
because of poor customer service. Also, service is a very big revenue
generator because it has higher turnover rate and higher profit margins
than the original equipment. Studies show that having loyal, long-time
customers can increase profitability by 100 percent even without increasing
the market share. For these reasons, all organizations have service
departments with trained professionals whose main objection is achieving
maximum customer satisfaction.
Service is an activity that does not create a new product. Its main function
is to repair, maintain or increase the life of the existing equipment.
For hydraulic systems, service means: 1) monitoring the system
parameters within pre-defined limits; 2) repairing and replacing failed
components and 3) preventive maintenance such as filter and fluid change.
Three service requirements must be met in order to achieve a service
excellence:
Efficient - repairs done correctly the first time.
Effective - repaired or replaced parts to last a satisfactory length of
time.
Economical - quick and cost efficient repairs.
Service excellence can only be achieved on the basis of good designs for
service and clear service procedures.
212
Troubleshooting principles
In order to perform effective troubleshooting, a number of hydraulic
principles must be known and followed. These principles are:
System life
As mentioned in the introduction of this book, one of the aspects of a good
system design is: design for service and inspection. The main goal of this
approach is to increase the overall life of the system and maintain a high
efficiency throughout its life cycle.
The expected life of individual components within a hydraulic system varies
and is influenced by a number of factors. These factors include the type
and construction of the component, circuit design, operating load and dutycycle. Forklift manufacturers determine the expected service life of
components within a particular system by considering these variables in
combination with historical data on achieved service life. Component life is
normally available from the manufacturers upon request. This information is
typically provided to long-term customers who have their own service
departments. To minimize the chances of hydraulic components failing
during service, the system manufacturers recommend expected service life.
The service life is used for scheduling component replacements.
All system components (valves, pumps, hydraulic lines) are flushed in order
to have a certain cleanliness level. But regardless this fact, in the first hours
after start up, the components continue to release small particles. In order
to protect the system from the initial contamination, it is recommended the
first filter change be done after 50 hour of operation.
213
Safety Rules
214
215
Abbreviations
TAN (Total Acid Number) measures the level of acid and acid-products
present in the oil.
KV (Kinematic Viscosity) is a measure of oil thickness. Viscosity is
considered abnormal when it has decreased by 10% or increased by 20%
of the base line value.
AF (Analytical Ferrography) is a method for visual observation of lubricant
degradation. When a lubricant works beyond its carrying capacity, friction
polymers are observed. When a lubricant is degraded, amorphous films are
observed.
216
Servicing filters
Pressure drop in the filter
When the filter pressure drop is measured, the fluid has to be at the
operating temperature. At the operating temperature, hydraulic fluids have
a lower viscosity than when they are cold. Pressure drop depends on the
exact temperature and the viscosity index of the oil. In addition, most filters
have bypass valves that are viscosity sensitive. Therefore, during a cold
start or other cold operating temperature conditions, some of the flow
passes through the filter through a bypass check valve. The fluid that goes
through the valve is not filtered at this time. As the oil heats up, a higher
percentage of the flow will pass through the filter. During bypass, a welldesigned filter will not permit particles from being pulled off the front side of
the filter.
Servicing reservoirs
The first requirement for having a clean reservoir is proper packaging and
capping all ports to prevent contamination from entering the reservoir
during storage.
Regular reservoir service includes: fluid level check, moisture check and
airflow around the reservoir check.
The water in the system comes from humid air entering the reservoir
through the breather. The temperature changes cause humidity to
condensate into water droplets on the inside reservoir walls. Moisture in the
reservoir forms rust on the inside metal walls. Vibrations, during operation
of the system, knock the rust particles into the oil, where they are picked up
by the pump and distributed throughout the system. New rust particles form
where the old ones fell off which makes the contamination an endless
process. Changing filters and off-line filtration are not solutions to the
problem. Flushing or replacing the reservoir is sometimes the most costeffective solution. When the reservoir is flushed, a turbulent flow is required
for more effective cleaning.
217
218
More than 90% of hydraulic pump failures can be attributed to the three
common causes listed below:
Mechanical: broken shaft, broken gear or cracked housing
Worn-out pump: worn-out pump has a high leakage path which
results in pressure losses.
Wrong fluid type: the fluid must be selected per outside temperature
conditions. Using a wrong type can cause premature pump failure.
Set up
Pressurize to maximum pressure
Hold the pressure for 1 to 2 minutes
De-pressurize
Check for leaks
When a cylinder leaks after being used, each part has to be checked in
order to find the cause of the problem. There are a few basic steps in the
troubleshooting sequence:
1.
2.
3.
4.
219
Servicing valves
The most common valve failures are: malfunction as a result of
contamination, spring failure and O-ring failure.
A typical contamination failure is a seizure between the spool and the valve
bore. This seizure is called: silt lock. Silt lock occurs when the silt force
exceeds the force available to actuate the valve. The most sensitive
hydraulic components to seize are components with small internal
clearances such as: priority valves and servo valves. In order to avoid
locking the valves, we can install a filter in the pressure line before the
valve.
Most failures of the pilot control valves are due to contamination. Pilot
(indirect) operated valves are less tolerant to contamination than directly
operated valves. If a pilot stage of indirect control valve is plugged by
contaminants, the failure can result in unintended fully open or fully closed
position. If directly operated valve is contaminated, it is more likely to have
an increased leakage or sticky plunger. For these reasons, every time a
valve is serviced because of contamination, the hydraulic fluid has to be
changed with new fluid.
All valves have to be properly marked and stored lubricated in plastic bags.
Sometimes the valves are performing normally but make excessive noise.
Most common reasons for noise in the valves are:
220
Servicing connectors
Usually hose assemblies fail without warning. They will age and harden
even under normal operating conditions. Therefore, they have to be
inspected regularly for cracks, leaks wear and excessive corrosion of the
fittings. Major causes for connectors failures are improper selection, use,
routing and assembly.
If hose failure occurs, the operator must immediately shut down the
machine, move away from it and call a mechanic to de-pressurize the
system. Then the hose is disassembled and examined for damages. A
failed hose must not be repaired; it must always be replaced with a new
one. Failures such as: high speed discharge of pressurized fluid, flying
connector or wiping hose can endanger a persons life or cause permanent
injuries.
Factors reducing hydraulic hose life are:
1.
2.
3.
4.
5.
6.
7.
221
Tubes are easier to service than hoses because they can be cut and flared
in the field.
Hoses have to be removed if welding or torch cutting is performed close to
the hose.
Cleanliness of the new hoses is very important. Replacement hoses must
have both ends caped. Any hose contamination decreases the life of the
other components.
Seals
Failures and causes
1. Damage during installation. The causes for this failure are: seal cuts
from sharp corners or threads, lack of lubrication and use of
improper tools.
2. Ware-out as a result of rubbing against seal groove surfaces in
dynamic sealing applications. The biggest contributor for this failure
is the roughness of the groove surface.
3. Extrusion is changing the shape of the seal as a result of pushing it
into the gap of the mating surfaces. This failure is common for seal
rings in high pressure applications.
4. Swelling is a result of absorbing fluid by the seal. The reason for this
failure is the use of incompatible fluid and seal material.
5. Loss of original shape. This is common for O-rings. The O-ring loses
its original shape and develops two flat surfaces. This is mainly
caused by excessive compression due to improper design or
working for a long time under high pressure at high temperatures.
6. Contamination. Seals start to leak when hard particles enter seal
contact surfaces.
222
Filters
Pumps
Valves
223
III.
Common Problems
Leaks
There are two types of leaks: external and internal. External leaks are easy
to see and repair. Internal leaks are caused by mechanical damage in the
hydraulic components, damaged seals or pressure buildup.
When fluid moves from an area of high pressure to an area of low pressure
without performing useful work, there is a pressure loss which decreases
the components efficiency and the component generates extra heat. This
means that any component in the hydraulic system that has abnormal,
internal leakage will increase the heat load on the system and can cause
the system to overheat. This could be anything from a cylinder that is
leaking pressurized fluid through the piston seal, to an incorrectly adjusted
relief valve. Any heat-generating components need to be identified and
changed. One way to quickly locate an internal leak is to measure the
temperature of individual components. The hottest component in the
system can lead us to the problem.
First, locate the leak and determine whether it is through the housing, seal
or thread. Second, look for things that may cause the leak. Leaks are often
caused by pressure buildup. Look for plugged vents, overfilling and
elevated heat levels.
224
Overheating
Any temperature above a specified limit is considered excessive heat.
Excessive heat for a system with one type of fluid can be normal heat for a
system with a different fluid. For this reason the first thing that a service
person needs to know is the maximum acceptable temperature.
Overheating causes fluid degradation and change in viscosity. Heat in the
hydraulic system is caused by pressure losses in the fluid. Pressure losses
are generated when fluid passes through the hydraulic components or any
restriction in the hydraulic lines. Heat is equal to the power loss and is
proportional to the pressure drop. Every component in the system, that
creates a pressure drop, generates heat. When we design a system, first
thing we have to calculate is the total power loss in the system (see chapter
5).
Together with the heat generation, the system has heat dissipation. The
amount of dissipation will determine the fluid temperature. If the
temperature goes above the design value we say the system is
overheating. To avoid overheating we should design a system with
minimum pressure losses and size the reservoir according to system power
loads. Design of the reservoir is described in Chapter 3, section 13.
225
226
227
Particles that are the same size as the internal clearances and are
passing through two surfaces. They cause scoring and heavy wear
of sliding surfaces damage. These particles are the main cause for
the abrasion wear.
228
There are three states of water when it enters a hydraulic fluid: dissolved,
emulsified and free. Usually all three states are presented at the same time.
Dissolved state is when a water molecule is captured by oil molecules and
becomes part of the fluid. Dissolved water can only be removed from the oil
chemically by using a Vacuum Dehydrator. A Vacuum Dehydrator machine
can remove about 80% of dissolved water. Dissolved water contamination
is the least harmful of the three states.
Emulsified state is when water and oil are homogenously mixed.
Emulsified water can be removed physically by using a moisture absorbing
filter.
Free water state is when water is in a free state. Because it is heavier, it
settles to the bottom of the reservoir. Free water is the most damaging of
the three states, because it can displace the oil and allow metal to metal
contact of sliding surfaces and cause hydraulic component mechanical
failure. Most of free water is settled on the bottom and can be removed
simply by draining it.
Water contamination accelerates the aging process resulting in oxidation,
hydrolyses, additive depletion, reduced lubricant film strength, corrosion
and damage to components. In addition it can cause cavitation. Hydraulic
and lubrication fluids are best operated with a water content of 50% below
the vapor tension.
Contamination in the fluid increases the pressure losses and it is one of the
most important factors negatively affecting the hydraulic system operation
and reliability. One method of evaluating fluid cleanliness is to measure the
motor current. The motor current draw will go up when the hydraulic system
has more pressure losses (lower efficiency) due to resistance in the fluid.
The environment contributes greatly to system contamination.
Contamination enters the system via the fluid reservoir (air breathers and
access covers), and any sealing pairs (cylinders seals, pump and motor
seals). It is estimated that about 50-60% of contaminants enter via the
cylinder seals and it can be expected that the amount of ingression will
increase with seal wear.
If we have a contamination problem, it is more cost effective to filter the oil
than to do frequent oil changes. Research has shown that maintaining fluid
cleanliness results in increasing the average time between system
breakdowns. Particle contamination reduces the service life of hydraulic
fluids by striping additives and promoting oxidation. When evaluating metal
229
wear trend, the fluid sample has to be taken after the valve (downstream of
the valve).
A measure for contamination is the clearance code of the fluid. It is
described in chapter 3, section 16.
For servo systems and high quality proportional valves, it is recommended:
V.
In the first half of the 20th century industrial trucks had mechanical elevating
systems. Then, within a period of 50 years the mechanical systems were
replaced by hydraulic systems. The first hydraulic systems were
mechanically controlled. Later, some mechanical controls were replaced by
electrical. Today, we have computer controlled systems. The performances
of mechanically and electrically controlled systems depend greatly upon the
system design and selection of the right components. Every year
manufacturers add more intelligence to the electronic controls to better
control the performance of hydraulic systems. By using computers, we can
change the performance of the system by simply changing the software.
230
Appendix A
Source: Industrial Truck Association
Class 1
Class 1
Lift Code - 1
Counterbalanced Rider Type, Stand Up
Class 1
Lift Code - 4
Three Wheel Electric Trucks, Sit Down
Class 1
Lift Code - 5
Counterbalanced Rider, Cushion Tires,
Sit Down
Class 1
Lift Code - 6
Counterbalanced Rider, Pneumatic or
Either Type Tire, Sit Down
A1
A2
Class 2
Class 2
Lift Code - 1
High Lift Straddle
Class 2
Lift Code - 2
Order Picker
Class 2
Lift Code - 3
Reach Type Outrigger
Class 2
Lift Code - 4
Side Loaders, Turret Trucks,
Swing Mast and Convertible
Turret/Stock Pickers
Class 2
Lift Code - 6
Low Lift Pallet and Platform
(Rider)
Class 3
Class 3
Lift Code - 1
Low Lift Platform
Class 3
Lift Code - 2
Low Lift Walkie Pallet
Class 3
Lift Code - 3
Tow Tractors (Draw Bar Pull
Under 999 lbs.)
Class 3
Lift Code - 4
Low Lift Center Control
Class 3
Lift Code - 5
Reach Type Outrigger
Walk behind operator
A3
A4
Class 3
Lift Code - 6
High Lift Straddle
Walk behind operator
Class 3
Lift Code - 7
High Lift Counterbalanced
Class 3
Lift Code - 8
Low Lift, Walk Behind (Walkie) or
Rider Pallet Truck
Class 4
Class 4
Lift Code - 3
Fork, Counterbalanced (Cushion Tire)
Load capacity above 8000 lb (3636 kg)
Class 5
Class 5
Lift Code - 4
Fork, Counterbalanced (Pneumatic Tire)
Load capacity above 8000 lb (3636 kg)
Class 6
Class 6
Lift Code - 1
Sit-Down Rider (Draw Bar Pull Over 999
lbs.)
Class 7
Class 7
Lift Code - 1
Variable Reach Rough Terrain Fork Lift
Truck
A5
A6
Appendix B
Approximate physical properties of common fluids
Fluids
Grade/
name
Temper.
Density
Specific
Weight
Kinematic
Viscosity
kg/m
kN/m3
cSt
-3
Air at 1 bar
20
1.21
11.8 x 10
15.1
Water
16
999
9.80
1.1
Gasoline
16
680
6.67
0.46
32 (Light)
40
870
8.53
160
46
(Medium)
40
876
8.59
227
68 (Med.
Heavy)
40
Hydrocarbonbased
hydraulic
fluid
Synthetic
hydraulic
fluid
Hydrostatic
Transmission
fluid
Automatic
Transmission
Fluid (ATF)
Synthetic
Automatic
Transmission
Fluid (ATF)
Steering fluid
Hydraulic
882
8.65
340
100 (Heavy)
40
887
8.7
490
150 (Extra
Heavy)
40
890
8.73
750
40
835
8.19
160
Mobile
HSC-824
Applications
&
Steering systems
Hydraulic
FIRLUBE
22
40
SAFETYTE
X 216
40
1145
11.23
230
32/46
40
887
8.7
195
46/68
40
893
8.76
267
100
40
911
8.93
533
32/46
40
867
8.5
185
1110
10.88
230
&
Steering systems
Hydrostatic
transmission
Automatic
transmission
Steering systems
AMSOIL
40
850
8.33
36.8
Automatic
transmission
MAX
40
835
8.19
58.8
Steering systems
5W20
40
859
8.42
33.4
PENNZOIL
40
874
8.57
37.3
Steering system
130 at
Brake fluid
Castrol SRF
16
1058
10.3
-40C
Brake system
3.5 at
100C
Engine oil
SAE 30
16
912
8.95
420
Engine
lubrication
A7
Appendix C
VISCOSITY CLASSIFICATION OF INDUSTRIAL FLUIDS
Kinematic Viscosity Limits
ISO
Viscosity
Grade
Mean Viscosity
at 40o C
Minimum
Maximum
2,2
1,98
2,42
3,2
2,88
3,52
4,6
4,14
5,06
6,8
6,12
7,48
10
10
9,00
11,00
15
15
13,5
16,5
22
22
19,8
24,2
32
32
28,8
35,2
46
46
41,4
50,6
68
68
61,2
74,8
100
100
90,0
110
150
150
135
165
220
220
198
242
320
320
288
352
460
460
414
506
680
680
612
748
1000
1000
900
1100
1500
1500
1300
1650
(cSt)
A8
Appendix D
Coefficients of Local Resistance
3000
3300
Our target
2
2
1
Benchmark values
30
30
3.6
min
3.7
cm/
s
2
2
2
2
33
33
cm/
s
3
2
2
Y/
N
55
60
cm/
s
Y/
N
2
2
3
1
1
1
1
1
Y/
N
3
1
min
min
kW
2
2
Y/
N
1
1
1
2
1
3
900
900
hour
2
1
3
60
80
dB
0.6
0.5
min
m2
2
2
2
70
80
3000 kg capacity
2
3
1
1
5
Stop lifting in case of failure
1
1
6
Limit lowering speed in case
of failure
1
1
2
2
2
2
2
2
2
2
1
10
11
Optimize system efficiency
12
Ergonomic controls
1
3
1
1
2
2
13
3
1
2
2
2
2
1
1
1
14
kg
10
10
10
10
10
10
10
8
8
7
7
7
6
5
5
16
15
Engineering requirements
Measurement unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Requirements
Customer
Table 4.1 QFD house with the relationships: 3 is strong, 2 is medium and 1 is weak
Appendix E
A-9
Competitor 1
Concept selection
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
3000 kg capacity
Lift/lower pallets at 3.6 m height
Stop lifting in case of failure
Limit the maximum lowering speed
Monitor load position, speed and weight
Minimize vibration during lifting
Minimize vibration during lowering
Lifting speed 30 cm/s +/- 10%
Lowering speed 33 cm/s +/- 10%
Tilt and side shift option
Optimize system efficiency
Ergonomic controls
System reliability (time between service calls)
Minimum system noise level
Open area between lift cylinders
Engineering Requirements
Total +
Total Overall total
Weighted total
10
10
10
10
10
9
9
8
8
7
7
7
6
5
5
Weights
I
II
III
Design Concepts
Datum
In the first column we can list the Engineering Parameters. In the second column we list the importance/ weight
of these parameters. In the last column we can list the points that our benchmark design has. For benchmark
we have an existing design. It could be our design or a design of a competitor.
Table 4.2
A-10
Appendix E
A-11
Appendix F
Calculate the hydraulic parameters and power requirement of a
hydraulic system (hydraulic circuit fig. 5.3) for the elevating system
shown in fig. 5.2
cm
s
cm
s
6
pmax := 26 10 Pa
Maximum payload
Lift speed with maximum load (+/- 5 %)
Lift speed empty (+/- 5 %)
Maximum pressure in the system
Mast construction- one free lift cylinder and two main lift cylinders
cyl :=
0.97
mast :=
0.98
n := 2
g = 9.807
m
2
s
Gravitational acceleration
Gcyl.m := 42 kg
Gpiston := 26 kg
Gfork := 63 kg
Gm.chain := 4 kg
Gmast2 := 158 kg
Gex.chain := 6 kg
A-12
Calculations
Selecting cylinders
1. Main lift (side) cylinders
Maximum load on cylinders is:
Lmax := n Gmax + Gcarrige + 2 Gfork + Gmast1 + Gcyl.m + 2 Gm.chain + Gmast2 + 2 Gpiston + 2 Gex.chain
3
Lmax = 7.076 10 kg
d1_min :=
Lmax g
pmax cyl mast
d1_min = 0.042m
We select standard size piston diameter bigger than the calculated minimum
d1 := 45 mm
2
d1
A1 = 1.59 10
d2_min = 63.6 mm
A-13
2
d2
4
3
A2 = 3.526 10
There are two main parameters which will be calculated first: follow and
pressure.
In order to have two lift speeds (one for empty lift and one for lift with
maximum load), the system requires two flow rates.
Mast construction has two stages (free lift and main lift) with different cylinder
areas which produce different pressures.
Therefore, the system has four main work points:
Work point 1. Free lift without load (Maximum flow - minimum pressure)
Work point 2. Free lift with maximum load
Work point 3. Main lift without load
Work point 4. Main lift with load (Minimum flow - maximum pressure)
Calculating required flow rate for desired lift speed
Work point 1 (Flow rate in free-lift cylinders, lift without load)
Q1 :=
A2 v2
n
Q1 = 42.3
L
min
Work point 2 (flow rate in free-lift cylinders, maximum load on the forks)
Q2 :=
A2 v1
n
Q2 = 31.7
L
min
A-14
Q3 :=
2 A1 v2
n
Q3 = 38.2
L
min
Work point 4 (flow rate in main-lift cylinders, maximum load on the forks)
Q4 :=
2 A1 v1
n
Q4 = 28.6
L
min
Calculate pressures
Work point 1 (pressure in free-lift cylinders, lift without load)
G0 := 0 kg
L1 g
A2
6
p1 = 2.38 10 Pa
p1 = 23.8 bar
A-15
p2 :=
L2 g
A2
6
p2 = 19.1 10 Pa
p2 = 191 bar
L3 g
2 A1
6
p3 = 3.3 10 Pa
p3 = 33 bar
p4 :=
Lmax g
2 A1
6
p4 = 21.8 10 Pa
p4 = 218 bar
A-16
Pressure (p)
bar
24
191
33
218
The system power requirements must be based on minimum two work points.
Work points one and four are both extreems. Therefore, in this example only
these two points will be considered.
Select components
Pump displacement
Pump displacement is function of pump flow delivery and shaft rotational
speed.
Gear pumps have best performance and reliability in the range of 1000 to
3000 rev/min.
Electric motors have best performance and reliability in the range of 1500 to
5000 rev/min
Based on this, we will target rotational speed of 2200 rev/min.
Given
Q3 = 38.2
Q2 = 31.7
n := 2200
vol :=
L
min
L
min
1
min
0.98
A-17
Q3
n vol
3
dmax = 17.7 cm
dmin :=
Q2
n vol
3
dmin = 14.7 cm
0.90
vol :=
0.98
Q3
dpump vol
ne = 2434
nl :=
1
min
Q2
dpump vol
nl = 2024
1
min
A-18
Q1
vs
2
AS = 470.1 mm
dS :=
AS
dS = 24.5 mm
ds := 25 mm
Pressure line
vp := 6
Ap :=
Q4
vp
2
AS = 470.1 mm
dP :=
Ap
dP = 10.1 mm
dp := 10 mm
Recommended diameter
Select 10 mm diameter for pressure line
A-19
Return line
vr := 2.5
Ar :=
Q1
vr
2
AS = 470.1 mm
dR :=
Ar
dR = 19 mm
dr := 20 mm
Hydraulic Losses
Calculate pressure losses in two work points of the system (WP1 and WP4)
Known
p4 = 218 bar
Q4 = 28.6
L
min
:=
p1 = 24 bar
Q1 = 42.3
L
min
2
32 10 stokes
A-20
p dc :=
0.08 10 Pa
p fc1 :=
0.26 10 Pa
p fc2 :=
1.5 10 Pa
p filter :=
0.07 10 Pa
:=
880
kg
m
Re := 1500
:=
Reynolds Number
64
Re
AH :=
2
ds
Q1
Ls
p s1 :=
2 ds
AH
p s1 =
0.005 bar
Q4
Ls
p s4 :=
2 ds
AH
p s4 =
0.002 bar
dp
Hose length
Q1
Lp
p p1 :=
2 dp
AP
p p1 =
12.11 bar
Q4
Lp
p p4 :=
2 dp
AP
p p4 =
5.54 bar
Lr := 900 mm
AR :=
dr
Q1
Lr
p r1 :=
2 dr
AR
p r1 =
0.04 bar
Q4
Lr
p r4 :=
2 dr
AR
p r4 =
0.02 bar
A-21
A-22
p L1 := p s1 + p p1 + p r1
p L1 =
p L4 =
12.15 bar
5.56 bar
2.1 10 Pa
p t1 := p dc + p fc1 + p L1 + p loc
p t4 := p dc + p fc1 + p L4 + p loc
p t1 =
3.66 10 Pa
p t4 =
3 10 Pa
Work poit 4
pp4 := p4 + p t4
6
pp4 = 24.81 10 Pa
Pressure in
pump outlet
bar
60.4
248
These two points (p.1 and p.4) will be used to determine the power
requirements of the system
A-23
work poit 4
( pp1) ( Q3)
Pmax :=
vol m
Pemp = 4.3 kW
pp4 Q4
vol m
Pmax = 13.4 kW
Pemp = 6 hp
Pmax = 18 hp
0.90
work point 1
work point 4
Te :=
Pemp
( ne) 2 m
Tmax :=
Te = 19 Nm
Description
Free lift empty
Main lift with
maximum load
Pmax
( nl) 2 m
Tmax = 70.4 Nm
Hydraulic parameters
Power requirements
l/min
42.3
Pressure in
pump outlet
bar
60.4
Pump
speed
rev/min
2434
Pump input
power
kW
4.3
Pump input
torque
Nm
19
28.6
248
2024
13.4
70.4
Flow (Q)
A-24
Notes
References
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Notes