DesignofaHydraulicPress

1. SimpleHydraulicPressDesign:

Basedonareliefvalvesettingof3000psi(20.7MPa),calculatetheareaofthecapside
ofthecylinder.
A
1
=
F
MAX
P
S
=
9u 1u
3
N
2u.7 1u
6
N
m
2
= 4. 35 1
-3
m
2

Calculatetheborediameterofthecylinder.
A
1
=
n
2
4
- =
_
4A
1
n
=
_
(4)(4.SS 1u
-3
m
2
)
n
= u.u744 m = 7.44 cm
Theneareststandardsizeis3inches(7.62cm)thereforerecalculatetheareabasedon
this.
A
1
=
n
2
4
=
(n)(u.u762 m)
2
4
= 4. 5 1
-3
m
2

Basedonthiscylinderarea,calculatetherequiredpumpflowrate.

P
= I
1
A
1
= [u.7S
m
min
(4.S6 1u
-3
m
2
) = 3. 42 1
-3
m
3
m|n
= S.42
l
min

Calculatethedisplacementofthepumpbasedona3phaseinductionmotoroperating
at1750RPM.Assumeavolumetricefficiencyof0.85.Notethatthepumpmustdeliver
sufficientflowtoadvancethecylinderatthemaximumspeed,

P
=

P

p
vP
=
_S.42 1u
-3
m
3
min
]
[17Su
rc:
min
(u.8S)
= 2. 3 1
-
m
3
reu
= 2.Su
cm
3
rc:
= u.14
in
3
rc:

Calculatethetorquerequiredtodrivethepumpatthesystempressure.
I

=

P
P
p
MP
=
_2.Su 1u
-6
m
3
rc:
] [
rc:
2n roJ
[2u.7 1u
6
N
m
2

(u.8S)
= 8.91
N m
roJ

Calculatethepoweroftheelectricmotor.
P
M010R
= I

= _8.91
N m
roJ
] [17Su
rc:
min
_
2n roJ
rc:
] _
min
6u s
] = 133 W

P
M010R
= 1.6SS kw
Ep
u.74S6 kw
= 2.19 Ep
2. ThermalEquilibrium

Calculatetheincreaseinoiltemperatureforonecompletecycleassumingthatthe
volumeofoilinthereservoiris20liters.

Theincreaseinoiltemperatureisduetotheflowthroughthereliefvalveasthecylinder
advancesslowlyagainsttheloadfor150seconds.

E =
Rv
P t
Theflowthroughthereliefvalveisequaltothepumpflowlesstheflowrequiredfora
cylinderadvanceof0.1m/s.

Rv
=
P
- I
2
A
1
= _S.42 1u
-3
m
3
min
_ -[u.1
m
min
(4.S6 1u
-3
m
2
)

Rv
= 2. 94 1
-3
m
3
m|n

The quantity of energy that contributes to an increase in the oil temperature for one
cycleofthepresscanbecalculatedasfollows:
E =
Rv
P t = _2.964 1u
-3
m
3
min
__2u.7 1u
6

N
m
2
] _1Su
s
cyclc
] _
min
6u s
]
E = 153, 387
]
cyc|e
= 1SS
k[
cyclc

Theincreaseinthetemperatureoftheoilpercyclecanbecalculatedasfollows:

E = p
0IL
I
0IL
C
0IL
I
I =
E
p
0IL
I
0IL
C
0IL
=
1SS,S87
[
cyclc
_848
kg
m
3
] (2u l) _
m
3
1uuu l
] _21S4
[
kg C
]
= 4. 238
C
cyc|e

3. TwoPumpSystem

Basedonthesameforceandvelocityprofiles,designamoreefficienthydrauliccircuit
basedontwopumpsandahydraulicunloadingvalve.

Startbysizingthelowflow,highpressurepump(Pump1).Thispumpisusedtoslowly
advancethecylinderat0.1m/min.

P1
= I
2
A
1
= [u.1
m
min
(4.S6 1u
-3
m
2
)

P1
= . 45 1
-3
m
3
m|n
= u.4S6 IPH

Notethatinthisdesignthereliefvalveshouldneveropen.Sincethecylinderwassized
togenerate90kNat20.7MPa,thereliefvalveshouldbesetsomewhathigher(say23
Mpa). The other option is to size the cylinder slightly larger so that the pressure
requiredtoadvanceunderloadisbelow20.7MPa.Forsimplicityassumethattherelief
valvesettingisincreasedto23MPa.

CalculatethedisplacementofPump1.

P1
=

P1

p
vP
=
_u.4S6 1u
-3
m
3
min
]
[17Su
rc:
min
(u.8S)
= . 37 1
-
m
3
reu
= u.Su7
cm
3
rc:

CalculatethetorquerequiredtodrivePump1atthesystempressure.
I
P1
=

P1
P
p
MP
=
_u.Su7 1u
-6
m
3
rc:
] [
rc:
2n roJ
[2u.7 1u
6
N
m
2

(u.8S)
= 1. 19
N m
rad

CalculatethepowerrequiredtodrivePump1.
P
P1
= I
P1

= _1.19
N m
roJ
] [17Su
rc:
min
_
2n roJ
rc:
] _
min
6u s
] = 218 W

P
P1
= u.218 kw
Ep
u.74S6 kw
= u.292 Ep
Sizethehighflow,lowpressurepump(Pump2).Bothpumpsareusedtoslowlyadvance
thecylinderat0.75m/min.

P2
= I
1
A
1
-
P1
= [u.7S
m
min
(4.S6 1u
-3
m
2
) -_u.4S6 1u
-3
m
3
min
_

P2
= 2. 94 1
-3
m
3
m|n
= 2.964 IPH
CalculatethedisplacementofPump2.

P2
=

P2

p
vP
=
_2.964 1u
-3
m
3
min
]
[17Su
rc:
min
(u.8S)
= 1. 99 1
-
m
3
reu
= 1.99
cm
3
rc:

Calculate the pressure required to advance the cylinder against an opposing force of 5
kN.
P
2
=
F
L0w
A
1
=
Suuu N
4.S6 1u
-3
m
2
= 1. 9 1

Pa = 1.u96 HPo = 1S9 psi

CalculatethetorquerequiredtodrivePump1andPump2atthispressure.
I
P12
=
(
P1
+
P2
)P
p
MP
=
_2.297 1u
-6
m
3
rc:
] [
rc:
2n roJ
[1.u96 1u
6
N
m
2

(u.8S)

I
P12
= . 471
N m
rad

CalculatethepowerrequiredtodrivePump1andPump2atlowpressure.
P
P12
= I
P2

= _u.471
N m
roJ
] [17Su
rc:
min
_
2n roJ
rc:
] _
min
6u s
] = 8 W

P
P12
= u.u86 kw
Ep
u.74S6 kw
= u.116 Ep
SincethisiswellbelowthepowerrequiredtodrivePump1 underfullload,thepower
requirementoftheelectricmotorissimply:

P
MOTOR
= . 218 kW = . 292 Hp