Linkping University Design task 1(7)

IEI TMHP02
Fluid and mechatronic systems VT 2014

Design of a hydraulic system for a

lorry crane
Design task in the course Fluid Power Systems,
TMHP02, VT 2014
Linkping University Design task 2(7)
IEI TMHP02
Fluid and mechatronic systems VT 2014

Introduction and advisements for design task in the course Fluid

Power Systems
The aim of the design task is to illustrate some of the problems as engineers will be
confronted with at construction of hydraulic systems for fork lifters. The work shall
give training in problem solving related to hydraulic system design.
The lorry crane, you have to work with is a commonly used medium size crane. The
crane is equipped with a hydraulic motion control system, which has very high power
density and provides excellent controllability. In this task you shall work with a real
application and treat problems, which are very realistic according to system design and
development.
To perform the work in a convenient way there are some important directions:
I. General requirements: The design task is performed in groups of three (3)
students; possibly a group may consist of two (2) students. Each group must
sign up for the task on the homepage of the course. All students who will do the
design task must be registered on the list by Thursday, February 6, 2014.
II. Report requirements:
Well-structured and well written report.
Full solutions shall be presented.
Excel- or Matlab-file shall be enclosed to the report.
The report can be handed in max two times, which means one
completion.
Any return of the report shall be delivered at given time.
All group members must sign the report.
Use the report front page that you can find on the course homepage.
All reports should be submitted to your lesson assistant.

Think about the reasonableness of all calculations. The report shall include
a discussion about the system and components.
During the work, it is preferable to use the lesson times for questions and
discussion of your problems with your assistant. You can also discuss your
problems at other times.
III. Submissions:
Submission 1: Monday 17 February 2014, the report's sections about
lifting and lowering movements should be submitted which means that
force, cylinder pressure, lifting height and flow to be calculated.
Submission 2: Monday 3 Mars 2014, the reports sections about the
control of the crane should be submitted, i.e. symbol circuit of the
hydraulic system.
Final report: Last handing in day of the report is Sunday 16 mars 2014.
Linkping University Design task 3(7)
IEI TMHP02
Fluid and mechatronic systems VT 2014

Design of a hydraulic system for a lorry crane

In a lorry crane, hydraulics mostly is used for controlling lifting and lowering of the
load. With hydraulic cylinders it is possible to design a compact and regarding to the
lifting capacity a very effective system solution. The controllability of the hydraulic
system is also very good.
The lorry crane, which will be studied are shown in Figure 1. The crane structure
consists of three parts: crane pillar, lifting arm and tilt arm.

Figure 1: A lorry crane and its main components.

The aim of the design task

The major goal for the task is to design a hydraulic system for control of the two arms
on the crane. Basically the hydraulic system should include a supply unit (pump unit)
and valves for controlling the two cylinders shown in figure 1.
The hydraulic system shall be dimensioned for lifting a load with the total mass Mt a
vertical distance h at the time t. The hydraulic system should be designed with respect
to energy consumption and safety aspects.

Crane geometry and load specification

Figure 2 shows the crane with the parameters and variables needed for describing the
geometry and the vertical motion of the load.
Linkping University Design task 4(7)
IEI TMHP02
Fluid and mechatronic systems VT 2014

Figure 2: The crane structure and parameters.

In figure 2 the crane is loaded by the mass mt, which is assumed to be concentrated to
the crane tip. The lifting motion is vertical and starts at the point Z1. The lifting height h
has been reached at Z2. The lifting arm has the length L1 and the tilt arm has the length
L2. Both of the arms have constant lengths.
Besides, the crane geometry is defined by the angles of the arms related to the
horizontal plane, 1 and 2, and arms of the lever for cylinder torque, e1 and e2. The
velocities of the cylinder pistons are vp1 and vp2 respectively.
Actual values for the relative cylinder piston velocities (vp/vp0), arms of the lever for
cylinder torque and angles for the crane arms are shown in the figures 3 to 5.

Figure 3: Relative cylinder piston velocities versus time for vertical crane tip motion.
Linkping University Design task 5(7)
IEI TMHP02
Fluid and mechatronic systems VT 2014

Figure 4: Arms of lever for cylinder torque versus time (vertical crane tip motion).

Figure 5: Angels for the crane arms versus time (vertical crane tip motion).

Parameter values
The given parameters are as follow:
Total load weight: Mt = kg Lifting arm length: L1 = m
Tilt arm length: L2 = m Ref. cylinder velocity: Vp0 = m/s
Ref. time for lifting: t0 = s Cylinder efficiency: c1 = c2 = -
Max system pressure: psmax = MPa
The leakage flow in valves and cylinders can be neglected. During lifting motion the
pressure in the cylinder return side are assumed to be constant and equal to 1,0 MPa.
Pressure losses in hoses and valves shall be considered, which means that the inlet
cylinder pressure (load pressure) must be lower than max system pressure (psmax).
Observe that max system pressure is equal to max pump pressure in this application.
Efficiency models for actual pumps can be taken from Appendix 1.
Linkping University Design task 6(7)
IEI TMHP02
Fluid and mechatronic systems VT 2014

Tasks
Design a safe and well working hydraulic system for a cranes lifting and lowering
movement. References for components can be found on the course homepage. Task 1
and 2 below is connected to submission 1 and 2, see page 2.
1. Analyse of the cranes movement and calculate how force, cylinder pressure and
flow are varied during lifting movement.
2. Draw a symbol circuit of the hydraulic system which control the crane. Think
about the safety and controllability of the crane. The final report should include
analysis and discussion about different design possibilities.
3. Calculate the overall system efficiency when the load lifts from Z1 to Z2. The
efficiency shall be calculated in at least 5 different points. Pump losses, pressure
losses in the system and cylinder losses shall be considered.
4. Add cooler and filters to the circuit drawing (task 2).
Cooler design: Calculate approximately the hydraulic power losses that have to
be cooled out from the system for a full cycle, lifting and sinking motion. An
average value of power losses is dimensioning for the cooler.
Filter selection: Determine a suitable filtration grade for the hydraulic oil and
select filters.
(Suitable references for the design and component selection can be found on the
course webpage.)
Linkping University Design task 7(7)
IEI TMHP02
Fluid and mechatronic systems VT 2014

Appendix 1
Efficiency models for hydrostatic machines
The efficiency models below are developed for machines with fixed or variable
displacement. The relative volumetric and hydro-mechanical losses (Av and Ahm), which
are assumed to be valid for both pumps and motors will be expressed as:
p n k (1 )
Av = cv Ahm = k p + k v e
n p

Volumetric (v) and hydro-mechanical (hm) efficiencies for pump and motor
respectively are represented by the following equations:
1
Pump: vp = 1 Av hmp =
1 + Ahm

1
Motor: vm = hmm = 1 Ahm
1 + Av
For fixed displacement machines the displacement setting value is = 1 and for
variable machines the displacement setting must be in the range 0 < 1.
Units for shaft speed (n) and pressure difference (p) are [rev/s] and [Pa] respectively.
The dynamic viscosity of the oil, , is assumed to be constant for all working
conditions and its value can be set to = 0,03 [Ns/m2].
The loss coefficients values for cv, kp and kv can be derived from efficiency diagram.
However, for this task "mean-values" are given below, which can be used for all kind of
piston machines.

Coefficient values for pumps

cv = 1,310-9 [rev] kp = 5,410-2 [-] kv = 6,510-5 [1/rev]

For variable pumps the displacement setting coefficient is, k = 0,3.

Coefficient values for motors

cv = 1,310-9 [rev] kp = 5,410-2 [-] kv = 6,510-5 [1/rev]
For variable motors the displacement setting coefficient is, k = 0,3.