Bosch hydraulics, physical principles and calculations 1. Unit of the S! measuring system (ontract, As from 1-1-1978, the St Units standardised by ISO became law. The most important units required in the calculations needed tor hydrauile aystome are presented in the following tabi, (physica principles Calculations for hydraulic systems | Sate rin! aan Sombot [SRE Sparnite [Comers nah rpm al decimal as os a |e sl cecal aves votune vf ot ecimal aes tne 1a inna vetocty vf me wn vn scesaaton 2 |e inset > [wo teca + | meewtom) | at docs vate wokoneny w | sou) | deca vats pow: P ‘W (Watt) | all decimal values temperate + fram |e we ~27095K pressure P Pa bar, N/m? 1 Pa = 1 Nim= 10-* bar tow a | mu vin 1 mys = 60000 nin ayramicviconty = fn pee | AE finamatcvecony |v | mee mma | 498 = 1 mm For rotational motion, the following apply ano ehy |e mpeaiene | id jecea as angular velocity ° rads ols | 1916 ° - 0.0175 rads mass moment of inertia | J kgs me (@dtis forbidden) “m4 Fis eS ise ue|| 12. Boseh hydraulics, physical principles and calculations 2. Basic laws of mechanics In general (extract) Teele rt re mas Velocity 2 Acceaton, [ant | @2 ae va Newton tow al ace Nha Accloation due to © gravity >. Work Wert] J=n-m energy: Energy and work have identical units. One differentiate ee ie of river core EESTI ose ci qalantet tina wok egiematconrans [ua prme] 1 =H peut of acceraon wort fc] =Nem a po rer Ee a = Between straightsine mation ang rotational motion, there apply the following analogies: Distance traveled 1 m Angle * ved Vetocity . F Anguarvelosty wf ae Ei “petatonel speed n) sal Acceleration a FE Angular acceleration y —% 8d > Force F N Torque Meet Nem ai ie eat pem-oMim wiiess ™ kg Massmoment = J. = kgm? orinentia, Bt ih erBosch hydraulics, physical principles and calculations 43. Basic laws of hydromechenies 3:1 Pressure p (extract) 3.1.1 Pascal's theorem: It force Fis In all the formulae given in thie see- applied through an area A to an en tion, the relevant numbers are to be closed tui, there results a pressure p substituted forthe basic quantities. which is cistbuted uniformly Formulae for use in calculations for throughout the entire fluid. The fol Practical systems are to be found on lowing law applies: Page 22. this page also contains cor rection factors tor agaptation to the Units commonly usee In he fel, as [o=E] unis: 1po= well as data on efficiencies. (Please si refer ote Basch Hye Side Fut) 1 pa= 10% tar 21.2 When applied toa hydrauie, |< oyinaer Wen his laws aooed toa mau | Icylnder i goveme te relationship bation pressure p ynder force F 4 and efectve cylinder sttace A Bopenaing upon the quantity rete, the forlecen be wane boned as folows 3.1.3 When applied to a hydraulic, =| ‘motor and hydraullc pump ‘Analogous to the hydraulic eyinder, the following quantities appiy to the hydraulic motor and the hydraulic pump: ‘Area. A-~ Swept volume V aiven in SIU or omvut Force F ~ Torque M given in Nn ‘This means that Pascal's theorem e o-- ‘an also be applied here analogously, ™ poe) unite: 1 Pam Depending upon the quantity required, the theorem can be transposed as follows Gara] [3] ‘Note: 1U 2 360° 2 628 red aaI] 14 Bosch hydraulics, physical principles and calculations J 4 4 a a Ie 1 r Pcgpiarcutig 3.1.4 Pressure ranges in hydraulics Each of the branones of industry in which hydraulics are used has its own particular pressure ranges, The com- ‘mon pressure ranges can differ const {erably from each other. The relatvaly law pressure range machinery | Combines [Agricultural [Tractors which is’common to metalcutting to increase the power efficiency of machines for instance is due to the the hydraull system. The upper pres fact that in the interests of a constant sure imitis determined by the reste: rate of feed, oll compression must be tango to pressure ofthe various com= {voided as far as possible. As regards ponents, particulary the pumps. The ‘the remaining epplications,@higher economically viabla maximum pres: ‘ange of pressure is chosen inorder sure at the present time is about ‘315 bar. Higher pressures, such as are ‘needed for prasses and for clamping functions, are generated ty means of pressure intensifier, Construction | Excavators, graders, loaders, ‘machines and | cranes, winches, hydro public service | transmissions I vehicles Fee Plastic Blow-molding machines, manufacturing | injection-molaing machines machines Heavy | Stee! mils eee industees | continuous-easting plant | non-cutting | ceramics and plastics 1 chine ote, Clamping devices Machine tools, | Materale-testing presses, presses, telding and bending Dresses’ drawing presses planers andsotting machines lathes, criling and turning | See sere ; Ee ee 8.1.5 Pressure scales In practice the atmospheric alr pros- ‘ure (approx. 1 barat sea level) must be added to the hydraulic overpres- sure. in the medium and high-pres Operating pressure bar storing sil agi toa teen Ohh se to Sn ae stoner elton SEScn cus teats tron ma? fr Ns ssesoc pat cae ime teen so pone fetooace ne auteinet sae ft Et? Extabecine manne sbieacion ntsc ot Paani ie ante rome Sareea ‘terhais nena pore Reena scale p= ~0.3 bar files 1 = atsoa level Say tsar vec | one t ° nettve Aste poorer are dle 2: CeeBosch hydraulics, physical principles and calculations 8.4.6 Hydraulic presses and pressure conversion In hydraulic presses, the forces F and the areas A bre equated as follows: es Roa ‘The langths of piston travel are inver ‘ely proportional tothe areas A This principe ie utilised in pressure intensifiers (converters) These are components in which, or example, high clamping pressures are gene rated Pressure intensification also occurs in aifferentaleylindars with a one-sided Piston rod whan, for instance, the out Tots vesticted This fact must be taken into account when determining the dimensions of pipes, fitings and vaives, 3.1.7 Pressure measurement The pressure gauge (manometer is used for this purpose. In genera Bourdon-tuba pressure gauges ere utlized. Piston-iype manometers and electrical pressure pickups find appl- cation in recording manometers, Pieton-type manometer3.2 Volumetric flow (2) 3.2.1 Equation of constant flow: it liquid flows through 2 pipe of variable Crass section, then the following applies Warm va A where ¥'= flow valocity } [A= pipe cross sactional area ‘The product vA corresponds to the volumetric flow and is constant. 2 d J 3.2.2 When apalied to the hyde 7 entinder J When applied to the hycrauliceylin dor, thaw ial for entra ‘ionaip betwean volumetric flow © 1 gender velocity ane east oy yfisirretsre Dapeng von the nny required, tha folowing (Biota Jie J sasynennieai te haat motor and hydraulic pump ‘Analogous tothe cylinder, tha fllow= ] ing quantities apply to the motor and puma Area A—volumeV—miut ql orem a Velocity v — rational speed n Ula fis rears tat the formula =A Pir bo tanetered anlogous}y a Waa] unt ee ou Depending upon the quantity required, te following transposition ‘can be made: 4 Note: 2 360" 6.28 rad co 1% 16 Bosch hydraulics, physical principles and calculations inde —— A] nits = 2 mt a a, =a WA EAD In practice, the common units t'min 1 seo \ 1 an3.2.4 When applied to the cross sec tional area of flow lines In practice, certain have proved to be the most sutable for hydraulic flow lines. Here, the aim 's primarly to achieve laminar flow. (Refer 10 33), Assuming this fac, it Is possible to utilise the formula Q = "A for the ealoulation of flow lines il-fow velocities Suction lines Return lines: Pressure lines: P< sober: P= 50.. 100 bar: P= 100. 200 bar: p >200 bar: 3.2.5 Measurement of the volumetric flow ‘The simplast method of measuring the volumetric flow is by means of a ‘meacuring glass and a timer. The most practical way of carrying os. 2 18mis 3 ms me mis me fut Continuoue menourements = Using measuring turbines, the rota tional speed of which is used as the imension for the volumetric flow. The pressure drop across an orifice can also be utlised for such measure- ments. Here, though, tne influence ‘xerted by the viscosity ofthe liquid isto be taken into aecount Bosch hydraulics, physical principles and calculations” 696 Measuring glass Measuring turbine ana timer Pressure line Suction line 4 h I f i | ar r [ I i Onis18 Bosch hydraulics, physical principles and calculations 19.8 Friction in low lines and rostrietione Piping and tubing, as well as reste tions in valves, tings and deflection components et. represent hyaraulc resistances for the volumetvie flow. Frictional losses are generated at these resistances, These losses become apparent in th form of pres: sure lose and heat. Inactual practice, there is no com ‘mon unit for hydraulic resistance such 8s the unit of ahmi resistance in the flection flld. One is forced to mea: Sure hydraulic resistance theretore by rmaang of the pressure drop referred to the volumetric flow. 3.3.1 The taw of flow The pressure losses incurred at a restriction depend upon: “flow velocity (and therefore upon the reationship between the volumetric flow an the cross-sectional area) {jplenath af the flow line or rastiction '8cnape of the restriction the viscosity of the liquid lowing the density of the liquid flowing «the type af flow (laminar or tur bulent) ea: u L eu Hagen-Poiseuile’s law spacities the interrelatonships. A genaral formula Which can be used hera sas follows: ‘Tho type of flow changes trom lami- rar to turbulent ata certain entioal Velocity, This velocity is given by the Roynold's Number Re, For cylindrical flow lines applies: J ] J] ssatis ot tom ] t nere v= velocity (ms) ‘di= flowiina internal Me diameter tm) v= kinamatic viscosity (o/s) [As soon as the value for Re exceeds 2300, the laminar flow changes fo fur Dulent flow. For restrictions, tne crt cal value lcs considerably below 4} 2300. tiow ines, the aim ito achieve laminar flow. Turbulent ow is + usually encountered in valves. J Dap | QnwA whereby: «: flaw factor 0.6.0.9 (fakes into account the viscosity ofthe quia ‘and the shape of the ‘estiction) AA: restriction area m2 Ap: pressure drop Pa 1p: density ofthe liquid in kam Extensively simplified, the formula can be reduced to This means: the flow at restriction Sepends upon the ctference In the brossuras before and after the restrc- tion point The interrlationship is {quadratic and can be represanted by a parabolic curve ‘This law fs used on the one hand for determining the volumetric flows oF Yelocities resulting fram changes in te restriction section, On the other hand, it can be used to caloulate the prassure losses in flow lines (Feter to Section 34). Itis preferable to deter mine the pressure lossos in valves by ‘experimentation, turbulent easBosch hydraulics, physical principles and calculations 19 3.4 Hydraulic power hydraulic systems Ina hydraulic system, mechanical ower (generated trom thermal of blectical power ie transformed into hydraulic power. The power iz then transported inthis state, itis con- trolled and routed, and is finaly vans formed back again into mechanical power. The various forms and classifi Cations of power ara presented in the fecompanying ilustration from which itcan be seen that the power i always comprised of two aitferent components. Hydraulic powar is the product of the pressure'p and the volumetsc flow 0. Nom? PQ] uUnts1 w= Nem 1w= 3.4.2 Power input of a hydraulic ump The power input of a hydraulic pump is caleulated using the above formule ‘The pressure p corresponds to the maximum valve eet at the prassure- {olla valve, or the pressure regulator, by the variable-capacity hydraulic pump, 3.4.3 Power losses at restrictions and pressure valves. ‘The above formula is also used for the calculation of the power losses due to the pressura drop rosulting from tr ‘ion in low linas and at restriction points. Losses also occur when pres Sure-roliof valves respond and tha ‘bump delivery flow is diverted in part, fr completely through these valves. Electrical Mechanical | “Hydraullo | Mechanical power power power power UxJ PaMxe Wav Weim? + P=axp3.44 Ettcloncy losses Efficiency losses occur when powet transtorm 9d in nydraulie motors, Pumps aud cylinders. Etficiency losses differ as folows: Leu 20 Bosch hydraulics, physical principles and calculations ‘Tho individual efficiencies are heavily |S dependent upon the different operat- ing parameters ang ean be optimised by selection of the most favourable Dimension for working point. These fects are to be {akan into account when earrying out practical calculations for hyaraulle, ystems. ] Take into account during transformation | efficiency m, internal and external leakag in pumps and motors (for eytinders = 100%) ‘of a rotational speed n (ora velo ‘ity v) Into volumetric flow Q, and conversely citer friction losses in pumps, motors and exlinders ‘of 8 torque M (or a fore F) into Dressure p, and conversaly Overal otticioncy y= Wy Fn the total losses in pumps, motors and eviinders| from mechanical power into hydraulic power. and conversely. isaac systems he term “Energy” Wi closely con: s9ct0d tothe term “Power” Pin jecordance witn the formula is Eneray conservation in ‘other wercs energy conservation ‘equates £0 mervmizing the loss in hydraulic power roterted to time. The lowing aseects must Be cons lore: 9 ] Power transformation ower transportation The consumption of excess power during cosed-ioop and open-loop control processes. (Rotor to Page 224)Bosch hydraulics, physical principles and calculations planning of hydraulic systems for practical applications. ‘The following formulae are based on the laws of genaral mechanics and hyoromechanies. They slready in clude correction factors for adepte- tion to the units commonly used in practice, Furthermore, these formulae fake efficiency factors into account, ‘Thete mathematical carelations aro also gwen on the Bosch Slide Rule. ‘The corresponding scales ere identi fied inthe formulaeby maens of 20. 4 Formulae and calculations for the HJ0 Bosch hydraulics, physical principles and calculations — M= 1.50: Vip thaw 10% ° 10. Hydraulic motor v=628 10 Q=V inna 10 aa J] Daoscement on pum Spaceeat motor aaa oo ang Vena 0 Fawerinput a — Op TP sia to @Hydavi oyindore (@ (aaa =P a0? J Ane a F-0*| pa P10 4) = piston dia: in rn oa is ® to & Specific pressure drop in traight low ines is ae J. [una -ioean] | 1-090 Rarer = Hasina = PSE 97 9.81 mie? J er Bie tha J etverew wisi tow ss 4 weg he ; ‘Note: In ll formulae, sto be entered in % ] t 9 J J 3Bosch hydraulics, physicaf principles and calculations Hydraulic pumps and motors Hydraulic oylinders Explanation: fom Inbar © min ® Ovi omPirev nw in min Onin revsmin ® Ainom? © bq inbar OF ny @ Q intimin ev @n In mimin @v in @t ins @ 2 intimin Torque of hydraulic motor ‘Operating pressure before hydraulic motor Hydro-mechanical sfficiency of hydraulic motor Dispracoment ot hydraulic pump of moter, Rated values Volume etfciency fof hydraulic pump or motor Flow rate of tho hydraulic pump or motor Flow lines Drive speed for hysraulic pump er ‘output speed of hydraulic motor Internal diameter (1D) (of hydraulic eyindor. Standard sizes ‘secording to DIN Piston area or annular area of hhydraulle cylinder = tn 107 Product of the ‘operating pressure at inlet to hydraulic cylinder and hydro-mechanical cfciency of the covlinder Piston fore Flow rate betore hydraulic cylinder ‘Stroke velocity ‘stoke of hysraulic cylinder, Standard strokes according to DIN ‘swept volume of hydraulic eylinder ‘Tims for complete ‘stroke of hydraulic, exlinder Flow rata before hydraulic cylinder Powe ae @ ® @ inmm y inmms 2 inumin ¥ inmmes vy inmmils ‘ap Inbar ¢ iam sp iar @ inmm w inmis 2 intimin P inbar a ine P inkw 23 intemal diameter (0) ‘of the flaw line Kinematic viscosity (est = Imms) Hydraulic tow Kinematic viscosity with laminar iow Kinematic viscosity, with turbulent flow Specific pressure lass in 1 m straight flow-ine with laminar flow (y= 028 giem) Intomal diameter (1D) of the flow tr Spent pressica Rom tmanaan — @ fone win o toon ow ase OF ings rater 0) ofthe tow Flow velocity inflow fine Hydraulic tlow rato inthe flow line ot oliver of hydraulic pump Operating pressure ater the hydraulic pump or before the hydeaulle motor Overall ficiency of hydraulic pump or motor Power input of hydraulic pump or power output of hydraulic motor