Fluid Power (System Design Concepts) MODULE TITLE Nominal Duration Module Code or Number Purpose FLUID POWER

(SYSTEM DESIGN CONCEPTS) One Module EB 723 This module aims to allow the students to produce a feasibility study for a fluid power system using a combination of hydraulic, pneumatic and PLC/electrical/electronic areas of study. This module will be modified in line with the requirements of the National Metals and Engineering Standards when they become available. The module contains the knowledge and skills identified and agreed by all state/territories. It has been developed on the assumption that these will be reflected in the Standards. Prerequisites NM59 Hydraulics 4 NM62 Pneumatics 4 NM63 Control 3

Relationship to Competency Standards

Summary of Content 1. Specification 1.1 Final product 1.2 Machine Needs Forces and torques Speeds Accuracy Types of load 1.3 Safety Types of load Load in relation to people Guarding Interlocking Load control

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) 1.4 Type of control PLC, electrical, pneumatic, hydraulic Automatic Manual 1.5 Life Number of cycles per year Number of cycles total Maintenance time available Allowance for downtime 1.6 Reliability 1.7 Services available Electric power 3 Phase Single Phase Compressed air Water and air Cooling Size of location Access Lifting equipment Communication systems 1.8 Environment Temperature Humidity Hazards Contamination Dust Chemical Flammable liquids Flammable gases or vapours Acceptable noise levels Oil leaks 1.9 Standards AS3900 AS standards in fluid power Local standards DLI, OH & S

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) 2. Mechanical calculations 2.1 Identify worst conditions 2.2 Components of forces Horizontal and vertical components 2.3 Acceleration and deceleration 2.4 Friction 2.5 Winch drives Line pull Line speed Effective radius 2.6 Vehicle drives Rolling resistance Grade resistance Drawbar pull Rolling radius 2.7 Gear, chain and belt drives Ratios Efficiencies self locking gearboxes 3. Design philosophy 3.1 3.2 3.3 3.4 3.5 4. Pressure selection Quality of components Lubrication or non lubricated pneumatics Maintenance Cost

Initial design 4.1 4.2 4.3 4.4 Pressure, force, area Area, speed, flow rate Pressure, flow rate, power Air consumption

5.

Comparison of methods 5.1 5.2 5.3 5.4 5.5 5.6 High - low Regenerative Accumulator Single pump Multi pump Kicker cylinder

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts)

6.

Optimising 6.1 6.2 6.3 6.4 Reduce flows, pressures and powers Change the design parameters Change times Compromise

7.

Control requirements 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Position Force and torque Speed Acceleration/deceleration Constant power Decompression Documentation Solenoid charts PLC logic statements

Delivery

This module draws on the calculations and design carried out in previous hydraulic and pneumatic subjects. Instructions will be required in the fields of determining the system specification; advanced calculations and system control; optimising and summarising the results. It is suggested that this subject be carried out immediately preceding Fluid Power (Component Selection and Sizing For Design), and that the design project be a combination of the two subjects. The design project for this subject will require a specified system using a combination of hydraulic, pneumatic and PLC/electrical/electronic complex which interact with each other and to be sufficiently complex to require a detailed analysis. This includes: High forces and torques High speeds Accurate control requirements Interaction between some of the functions and the quality of the manufactured product.

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) A new design project will need to be set yearly. It is suggested that all participating TAFE colleges agree to a roster for setting the design project for all states each year, to ensure that a national standard is set and adhered to. The design project will need to cover as wide a range of design criteria as possible, However, it must be recognised that all of the topics detailed in the outlines cannot be covered in a realistic system. The system will need to address the important safety, end user and local environment needs to enable a practical system to be designed. Learning outcomes Learning Outcome 1 On completion of this module the learner will be able to: Write a specification for a complete manufacturing system to enable the design for the system to be carried out, taking into account all variables which will effect the design. Identify the details of the final product which will effect the system design. Identify the customer requirements in terms of cost, life of machine, safety, type of control and details of the proposed location of the system, which need to be considered when designing the system. Conditions Assessment methods Written summary of parameters which will be considered during the writing of specification. the

Assessment criteria

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts)

Learning Outcome 2

Calculate the actuator forces and torques over the whole speed range from the mechanical specification, taking into account the machine variables. Identify the mechanical variables which must be considered in the design. Calculate the acceleration and deceleration, friction, components of forces and moments of forces. Calculate the ratios and efficiencies of any mechanical drives in the design. Calculate the actuator forces and speeds.

Assessment criteria

Conditions Assessment methods Learning Outcome 3 Written answer test of a mechanical design involving friction, components of forces and moments of forces. Choose the design parameters to suit the requirements of the end user, related to the specification for the system. Use manufacturers catalogues to select the quality of components to be used and the working pressures in relation to the rated pressures, to allow the design to meet the cost reliability and life requirements of the system.

Assessment criteria

Conditions Assessment methods Brief written preliminary report stating the reasons for making the selections.

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) Learning Outcome 4 Calculate the actuator sizes, pressures, flow rates, and powers for the system, based on the system specification and the design parameters. Calculate the actuators, sizes using forces or torques and working pressures. Select the actuators, using standard sizes from manufacturers catalogues Recalculate the maximum working pressure for each actuator selected. Calculate the flow rates, based on the actuator sizes and speeds. Calculate the power required to supply the flows and pressures for the system to meet the specified cycle time. Conditions Use manufacturers catalogues, charts, computer spread sheets or nomographs to allow this learning outcome to be performed as effectively and efficiently as possible. Written answer questions of typical calculations used in this learning outcome. Select the type of system which best suits the pressures and flows of the design. Select the actuators where there is high flow and/or power during the cycle. Compare the flows, powers, size of components and circuit requirements using different design methods. Select the most suitable design method to meet the system requirements. Condition Assessment method Written answer questions

Assessment criteria

Assessment methods

Learning outcome 5 Assessment criteria

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) Learning outcome 6 Optimise the system to reduce flows, pressures and powers. This may require some changes to the design parameters, changes to cycle times or methods of operation to optimise the system. Calculate the pressures, flows and powers for different pressures, cycle times or methods of operation to optimise the system. Select the most suitable parameters to optimise the system design. Condition Assessment method Learning outcome 7 Written answer test Determine the control requirements for the hydraulic pneumatic and PLC/electrical/electronic system to meet the needs of the system. Identify the parameters which will determine the control requirements for the system. Determine the control needs for the hydraulic and pneumatic circuit, as well as for the PLC to meet the control parameters. List the inputs and outputs required for the PLC Draw the solenoid energising chart Write logic statements which will allow the PLC programme to be written Condition Assessment method Written answer test

Assessment criteria

Assessment criteria

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) Learning outcome 8 Summarise the system design, and use this summary to select the type of system to be used, and the control requirements. Use this summary to determine the feasibility of the proposed design. Draw a step/time diagram and flow/time diagram for the system. Summarise the calculations onto a chart to show all forces, times, strokes, pressures, flow rates and actuator sizes. Determine the feasibility of the design to meet the specification and design parameters. Conditions Assessment method A minor written report, which should include a summary of the calculation results and a feasibility statement for the system.

Assessment criteria

Suggested Learning Resources Design Engineers Handbook Parker Hannifin Corporation. Analyzing Hydraulic Systems Parker Hannifin Corporation. Hydraulics. Theory and Application Robert Bosch. Gmbh. Industrial Hydraulic Control Peter Rohner - AE Press Pneumatic Control for Industrial Automation Peter Rohner - A E Press Using Industrial Hydraulics T.C. Frankenfield - Rexroth. The Hydraulic Trainer Volume 2 Mannesman Rexroth. GMBH

Actrac Products Ltd/ Australian National Training Authority 1997

Fluid Power (System Design Concepts) The Hydraulic Trainer Volume 3 Mannesman Rexroth. GMBH The Hydraulic Trainer Volume 4 Mannesman Rexroth. GMBH Electronically Controlled Proportional Valves Michael J. Tonyan - Marcell Dekker Inc. Hydraulic Systems Analysis George R. Keller Fundamentals of Control Engineering Festo Didactic Simple Memory and Logic Circuits Festo Didactic Introduction to PLCs Festo Didactic Power Trains F.O.S. John Deere Industrial Fluid Power Volume 3 Womack Educational Publiations Fundamentals of Fluid Mechanics James A.Sullivan, Reston Publishing Company. Hydraulic Control Systems - Design and Analysis of Their Dynamics Peter Dransfield Springer - Verlag. Fluid Power - Systems and Circuits Russell W.Henke. Basic Principles of Proportional Valves Vickers Systems. Basic Electronics for Hydraulic Engineers Vickers Systems.

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Actrac Products Ltd/ Australian National Training Authority 1997