basic

training
- Hydraulics 07.01.2015

Jrg Prezer

Seite 1

Hydraulic basics
topics:
- Hydraulic fluid
common sorce of contamination in a hydraulic system
filtration
oil analysis purity class of hydraulic fluid

- hydr. symbols according to DIN ISO 1219

types of valves

- Pump systems
- Tube coupling system
- Maintenance and Assembly
____________________________________________________________________________________________________________

- Introduction to the hydraulic control system of the WKP 600 S

reading and understanding the hydr. diagram
technical site visiting and operation of the WKP 600 S
07.01.2015

Jrg Prezer

Seite 2

Hydralic fluid
Function of the fluid in the Hydraulic system:
Transmit the force and movement
Hydralic power is defined as the product of pressure and flow rate

pressure
force
volume
speed
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Hydralic fluid
Subdivision of the hydralic fluid mineral oils :
According to DIN 51524 the hydraulic oil is subclassify into 4 groups.
These oils are determinated by the used additives:

Group H mineral oils without additional additives

Lubricating oils

Group HL improvement of the resistance to ageing and corrosion

used by system pressure to 200bar and normally thermal loads

Group HLP further improved of the resistance to wear and load

capacity, as well as improve the viscosity-temperature characteristics

Group HLPD additional properties as dispersing (water retaining

effect) and detergent (cleaning effect)

generally used in hydralic systems

07.01.2015

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Hydralic fluid
chem. characteristics:
corrosion protection
low viscosity changes
- viscosity pressure characteristics
- temperature-dependence of viscosity

compatibility with the system

- no swelling of the seal materials, paints,

flame-resistant - high flashing point

low thermal expansion coefficient
rule of thumb : oils increase in volume by 0,63..0,76 % of their total
volume for each 10C temperature increase
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Jrg Prezer

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Hydralic fluid
chem. characteristics:
oxidation resistance (no acid formation)
- ageing resistance

Less air input and good air output

- high temperatur makes the air release property significantly
worse

good dielectric (isolating) properties

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Jrg Prezer

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Hydralic fluid
mech. and phsical characteristics:
shear stability of a fluid
- mechanical load of the fluid at control edges and valve seats

lubrication ability
- is indicated by the Brugger-test according to DIN 51347-2

high density
- high density allow to transfer higher performances
low compressibility

07.01.2015

Jrg Prezer

Seite 7

Hydralic fluid
mech. and phsical characteristics:
low foam formation
high wear resistance to:
dirt (abrasion)
cavitation (fatigue)
corrosion (e.g. by water)

dirt removal
good filterability
- attention: by filteration with filterelements <2m additives can
also be filtered

07.01.2015

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Hydralic fluid
contamination
Reason of contamination:

07.01.2015

Jrg Prezer

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Hydralic fluid
contamination
Reason of contamination:
e.g. typical clearances on valves:
- Servo valve
=> 1..4m
- Prop. Valve
=> 1..6m
- Directional control valve
=> 2..8m

07.01.2015

Jrg Prezer

Seite 10

Hydralic fluid
contamination
Reason of contamination:
missing or
inadequate
maintenance
no filter replacement
filling with nonfiltered oil
lack of cleanliness
by component
replacement
lacking inspection of
the hydraulic fluid at
regular intervals
07.01.2015

Jrg Prezer

assembly
tinder,
welding spatter,
rubber particles,
liquid remaining,
grinding dust,
metal chips,
sand, fibres,etc.

Seite 11

Hydralic fluid
contamination
Reason of contamination:
plant operations
- inner system
influences

plant operations
- external
system
influences

inner contamination
accrue constantly

biggest dirt
ingress is coused
by cylinder
non-closed system
openings

07.01.2015

dirt particles will be

produced by wearness
or result by the aging
of the oil

Jrg Prezer

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Hydralic fluid
contamination
Consequences of wear:
Abrasion:

caused by particles between

reciprocating surfaces

effects:
increase in play, external oil leak, loss of holding ability and
additional wear and contamination of the fluid
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Hydralic fluid
contamination
Consequences of wear:
Erosion:

existing particles clash with high velocity against the corners

and edges of the system

effects:
increase in play, leaking/damaged seat and plug, piston jamming
and
additional wear and contamination of the fluid
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Jrg Prezer

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Hydralic fluid
contamination
Consequences of wear:
Deposition by adhesion:

excessive load and/or a reduction in

fluid viscosity can reduce the oil film
thickness

effects:
clamping of the materials (metal-to-metal contact)
malfunction of the componentes, e.g. piston jamming at valves
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Hydralic fluid
contamination
Consequences of wear:
Surface fatigue:

surfaces damaged by particles

are subjected to repeated stress

effects:
smallest cracks in the surface are
hollowed out this causing a break off the material and
additional wear and contamination of the fluid

Oil ageing:

leads to deposits, filter will clogging quickly

07.01.2015

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Seite 16

Hydralic fluid
oil analysis and care
Oil care by:

system filters

permanent offline filter units

mobile bypass filteration

07.01.2015

Stefan Hertel

Seite 17

Hydralic fluid
oil analysis and care
Overview system filters:
suction filters
=> pump protection

pressure filters
=> direct protection of the components

return line filters

=> filters the contamination which has
entered the system as a result of component wear

tank breather filters

=> protection contamination from entering the tank
during tank breathing
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Seite 18

Hydralic fluid
oil analysis and care
Oil analysis by:
oil sampling
for analysis in laboratory
- detailed analysis (viscosity, Brugger,
contained additives, wear components, water content, etc. )

for particle countint by oil diagnostic

device
- immediate particle counting at place

permanent oil analysis by

ConditionMonitoring system
07.01.2015

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Seite 19

Hydralic fluid
Brugger test

07.01.2015

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Seite 20

Hydralic fluid
Brugger test

Limits:
-

For general hydraulic:

>30 N/mm

- For fast and proportional hydraulic: >50 N/mm

(Water has an Brugger value of about 19 N/mm)
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Seite 21

Hydralic fluid
oil analysis and care
Cleanliness requirements for hydraulic components
classification of solid
particle contamination
follows ISO 4406/1999:
to determine the cleanliness
level the particles present in
100 ml fluid are counted,
sorted according to size &
quantity and classified into
particle ranges

07.01.2015

Jrg Prezer

Seite 22

Elements of hydraulic
circuits
mechanical
energy

hydraulic energy

pumps

energy converter

lines

control elements

hydraulic circuit =

07.01.2015

cylinder/motors/
rotary drives

valves

tranporter of
energy

electic control

mechanical
energy

actuators

- muscle

=
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- nervous system
Seite 23

Elements of hydraulic circuits

hydr. symbols (DIN ISO 1219)

07.01.2015

Jrg Prezer

Seite 24

Elements of hydraulic circuits

hydr. symbols (DIN ISO 1219)

07.01.2015

Jrg Prezer

Seite 25

Elements of hydraulic circuits

hydr. symbols (DIN ISO 1219)

07.01.2015

Jrg Prezer

Seite 26

Elements of hydraulic circuits

hydr. symbols (DIN ISO 1219)

07.01.2015

Stefan Hertel

Seite 27

Elements of hydraulic circuits

hydr. symbols (DIN ISO 1219)

07.01.2015

Stefan Hertel

Seite 28

Elements of hydraulic circuits

hydr. symbols (DIN ISO 1219)

07.01.2015

Jrg Prezer

Seite 29

Valves
Characteristics connection interfaces
Standardized connection interfaces (according to DIN 24340A6/
ISO 4401) allow worldwide replacement of valves by
independentce from manufacturer

07.01.2015

Jrg Prezer

Seite 30

Valves
direction valves - direct operated
Characteristics
the housing is mode of pressure-tight
hydraulic castings iron
the canals (P-T-A-B) are poured in with
the housing at the same time
main bore is lapped
the pistons ring groove serve as pressure balancing and for a
better the forming of a lubricating film

Important:
piston-sleeve-valves show a certain leakage
=> oil flow rate from range with high pressure to range with
low pressure e.g. canal P to A/B or canal A/B to T
07.01.2015

Jrg Prezer

Seite 31

Valves
direction valves - direct operated
Operation modes:

normal
position

electically
4/3 direction valve; direct operated

Solenoid "B" actuated

=> flow rate from P-A; B-T

07.01.2015

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Seite 32

Valves
direction valves - direct operated
Operation modes:
mechanically
activity takes a variety of forms. The returnes into
normal position achieved by a spring normally

activity by cam/roles

07.01.2015

activity by
hand lever

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Seite 33

Valves
direction valves - direct operated
Operation modes:
emergency actuation a special form
of mechanical actuation

in case of piston jamming or power failure, the valve

(piston) can be moved.
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Seite 34

Valves
direction valves pilot operated
Operation modes:
fluidic activity
because of the big actuation forces direct operating
over valve size NG 10 is not useful

Operation is made by
pressurisation the
auction cylinders of
the valve piston

07.01.2015

Jrg Prezer

Seite 35

Valves
direction valves pilot operated
Operation modes:
electro-hydraulic
valve is pilot operated by an NG6
valve witch is mounted on the main valve
internal pilot oil supply internal/external:

a minimum pilot pressure (7-15 bar) must be ensured for all operating
conditions of the directional valve
=> pilot pressure can be worn internal from the P-chanal or
external by the X-port
=> in case of high dynamic pressure in the return line (T-chanal)
external pilot oil drain, by the Y-port, is needed

a malefunction of pilot operated valves is often the result of

problems in pilot oil supply
07.01.2015

Jrg Prezer

Seite 36

Valves
direction valves pilot operated
Operation modes:

normal
position

electro-hydraulic
Solenoid A" actuated
=> flow rate from P-B; A-T

Solenoid B" actuated

=> flow rate from P-A; B-T

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Jrg Prezer

Seite 37

Valves
direction seat valves
Characteristics
piston-sleeve-valves show a certain leakage due to their play
between piston and housing
seat valves realised the leak-tight sealling of the ports by a
ball or conical shape and seat
seat valves require a highly operation force, this means
particularly stong solenoid
disadvantage of direct operated seat valves
is a small stroke and, as a result, the small oil
volume flow rates
large volume flow rates can be realized by
pilot control of the main stage
07.01.2015

Jrg Prezer

Seite 38

Valves
direction seat valves
Functional principle
direct operated

pilot operated

07.01.2015

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Seite 39

Valves
2 way slip-in cartridge
Characteristics
slip-in cartridge valves designed for compact block
installation
Leak-free valve charecteristic as:
- hydraulic controlled seat/check,
or pressure valve
=> depanding of pressure build-up in the
main ports A and B

- active pilot operated 2/2-way

cartridge valve
=> Pilot pressure actively opens and closes the
main poppet independent of pressure in the main ports
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Jrg Prezer

Seite 40

Valves
2 way slip-in cartridge
Functional principle
The varying of the valve elements;
slip-in cartridge, cover, and pilot system
permit combinations for single
and complex functions

07.01.2015

Jrg Prezer

Seite 41

Valves
2 way slip-in cartridge
Functional principle
normally open

normally closed

sleeve
cone
spring
spacer ring
cover
unit

07.01.2015

Jrg Prezer

Seite 42

Valves
check valves
Characteristics
component parts:
hardened ball or cone
seat
spring (generally 0,55 bar)

Leak-free valve charecteristic as:

- line mount check valve
- cartridge designe for
block installation
- flange design for directly mount on
surfaces
07.01.2015

Jrg Prezer

Seite 43

Valves
check valves
Functional principle
direct operated check valve
- provide free flow in one direction (1->2)
and block the flow in the counter
direction (2->1)

pilot operated check valve

- provide free flow in direction (3->2).
The flow in the counter direction (2->3) is
only given when pilot pressure is applied
on port 1

07.01.2015

Jrg Prezer

Seite 44

Valves
pressure valves
Function types
pressure relief valve
- primarily protection of system pressure
- pump control of variable displacenemt pumps
with pressure compensator

pressure reducing/control valve

- the secondary pressure is limited to the
preset pressure value independently of the input pressure

pressure switching valves

- a hydralic switching operation will be
triggered when it reaches the adjustable
pressure value
=> e.g. pressure dependent shut off valve,
pump venting valve,
07.01.2015

Jrg Prezer

Seite 45

Pumps
selection
The choise of a pump type depends on the application
and the cycle as well as:
combination of possible pump controller
necessity of simultaneous motions
-> pump controls with double pumps or pump
combination of different pump designs

system pressure
availability and ease of maintenance
maximal sound pressure level
price

07.01.2015

Jrg Prezer

Seite 46

Pumps
Overview pump types
Pump
design
external gear
pump

max. pressure
range
[bar]

160..250

internal gear
pump

160..210

vane pump

160..210

Flow rate
Displacement

fixed
fixed

Speed range
[U/min]

Sound pressure
level
[dB(A)]

800..3000

< 60

800..3000

< 50

fixed/
variable

600..3000

350

fixed/
variable

500..2500

< 75

Radial piston
pump

280/350

fixed/
variable

500..2500

< 70

screw pump

80

3000..5000

< 50

axial piston
pump

07.01.2015

fixed

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< 60

Seite 47

Pumpen
axial piston pump
9

Parker PVplus
1

component parts

1. servo piston
3

2. rolling bearing
3. shaft drive
4. drain port
5. swash plate
6. piston and slipper
7. barrel
8. pump body

7
5
10
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9. pump compnesator
10. servo spring

Seite 48

Pumpen
axial piston pump
Rotating group
valve plate
cylinder block
piston and
slipper

07.01.2015

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Seite 49

Pipe fitting system

Walterscheid flare tube fitting 37
the Walterscheid flare fitting design consists of four
components:
fitting body according to DIN 2353
centre unit
Ioose collar
nut
The centre unit - effects the
transition from the 24 taper of
the fitting body to the 37 flare
connection
24
taper

07.01.2015

37 flare
connection

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Seite 50

Pipe fitting system

Walterscheid flare tube fitting 37
The clear advantage for the user:
Higher assembly safety than cutting ring
Lower starting torque

High precision tightness due to elastomer sealing

for both points of separation

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Jrg Prezer

Seite 51

Maintenance and Assembly

The most important basic principles of a hydraulic
technician are:
pay attention to meticulous cleanliness in his surroundings and
during assembly work (even if it is sometimes difficult).
never install a component that is dirty or damaged.
never do any assembly work on a unit if the electric motor is
running (not even in bypass!!) or if the accumulator is filled.
never dismantle a component or loosen a screw connection if
the plunger is not supported mechanically, or if any other
dangerous movement can occur.
Never mix different media.
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Seite 52

Maintenance and Assembly

The most important basic principles of a hydraulic
technician are:

The first step when switching the electric motor on is to check the
direction of rotation while bleeding the pressure line simultaneously
using suitable connections (the pump can be damaged already by
running 10 sec in the wrong direction of rotation).

After that a static pressure test follows without activating valves and
without switching on the accumulator.

Then the air bleeding of the pipes and the components such as
cylinders and motors follows.

First start is always at lowest pressure (set pressure relief valve or

pump controller to minimum), slowest speeds (choke valves and set
values of prop. valves set at minimum) and always without the
accumulator being switched on.

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Jrg Prezer

Seite 53

Maintenance and Assembly

Avoid contaminations
In order to obtain perfect performance and the longest possible
life span of a hydraulic system, the assembly and
commissioning are of decisive importance, as well as perfect
project planning.
The component gap widths of sometimes less than 2mm
require the cleanest working manner during assembly.
Sources of contamination during interim storage are:
dust, shavings, fibers, remains of paint, sand, remains of
packaging, water, means of preservation, rust

Compulsory: Check every component visually before

installation and pay attention to the exact closure of the
connections.
07.01.2015

Jrg Prezer

Seite 54

Maintenance and Assembly

Avoid contaminations
Sources of contamination are:
During unit assembly (flexible tubes, piping, oil, cleaning rags
welding, grinding, drilling, etc.)
scaling, welding beads, rubber parts, caustic and flushing agents,
separating and wheel wharf, drilling chips, sealing component,
paint, fibers

Compulsory:
Connections of every component must be kept closed until they
are about to be installed.
No mechanical work during hydraulic assembly
Clean piping and flexible tube lines also when fitting and clean
thoroughly before final assembly
Use cleaning cloths that are free of fibers and fluff
Never do any subsequent welding on pipes or tanks
Clean oil tanks thoroughly before filling with oil
only fill in finely strained oil
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Jrg Prezer

Seite 55

Maintenance and Assembly

Avoid contaminations
Dismantling
Sources of contamination are: pipes and
connections left open

Compulsory: in the case of unit dismantling

the oil should be drained off
the oil tank should be cleaned thoroughly
change the filter elements (include spare elements in the list
of pieces)
close connections of every component immediately
do not do any more mechanical processing
close pipe and hose lines
never do any welding on pipes or tanks afterwards
pack the oil tank dust-free
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Seite 56