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Fluid Power Systems
Principles learned in fluid dynamics are the
foundation for fluid power systems
Pascals Law
Pressure exerted anywhere in a confined
incompressible fluid is transmitted equally in all
directions throughout the fluid such that the pressure
ratio (initial difference) remains
Additional concepts
Static pressure, viscosity, conservation of mass,
momentum, continuity, Bernoullis equation, head loss
Gage
pressure
Pressure
Atmospheric pressure
Barometric Absolute or
Pressure Total Pressure
Absolute reference
Reduce oxidation
Keep sources of oxygen out of the system
Remove particulates with a good filtration system. These
particulates can act as sites for the oxidation reaction to
occur
Avoid the use of cadmium, zinc, and copper in contact with
hydraulic oil. For example, never use galvanized pipe or
fittings. These metals can react as catalysts that promote
the oxidation reaction.
Properties
Compatibility
The oil should not react chemically with any other
materials used in the system, including bearings,
seals, paints, etc.
Should also be compatible with materials which will
come into contact with leaked oil (electrical lines,
mechanical components, etc)
Acidity
Ideal hydraulic liquid should be free from acids (may
become this way as it deteriorates)
Toxicity
Manufacturers try to produce liquids without toxins
May cause sickness or death
Some fire-resistant liquids are toxic
Corrosion and Rust Resistance
Corrosion:
Chemical reaction between the fluid and a metal
surface
Rust:
Oxidation of a ferrous metal
Typically takes place in the reservoir above oil level
Foaming
Mineral-based oil can contain up to 10% dissolved air
Dissolved air is liberated as discrete bubbles
Liberation increases with increased temperature or
decreased pressure
Most hydraulic fluids contain foam-depressant
additives that cause rapid breakdown of the foam
Cleanliness: Air Contamination
Free air bubbles passing through a pump
T1 = 288 K, P1 = 100 kPa (abs), k = 1.4
Bubbles/Air in Hydraulic Systems
Causes/Sources
Liberation of air (formation of bubbles) due to local
pressure drop
Air leakage in suction lines, connections, etc.
Free air entrained at reservoir (splashing at reservoir)
Low fluid reservoir levels
Bad design of tank/reservoir
Improper fluid maintenance
Effects of air on hydraulic systems
Spongy control: reduction in
stiffness
http://gpmhydraulic.com/hydraulicsystemflushing/
Why Water and Oil Dont Mix
This graph shows the effect of water concentration on bearing life. Bearing
life is normally derived assuming lubricating oil contains 100 ppm of water.
Reducing water concentration to 25 ppm increases bearing life by nearly
150%
Understanding hydraulic fluid contamination
Vacuum distillation
Water boils at 56 oC under partial vacuum (846 mbar)
water can be removed without damaging oil
Thermal Properties
__________ the temperature 3 oC above the
temperature at which the fluid ceases to flow
Disadvantages
Flammability
Excludes them from use in hazardous areas like in molding, coal
mines, and near furnaces
Increase in viscosity at high pressures
M.G.Rabie
Fire-Resistant Fluids
Oil-in-Water Emulsion
Consists of tiny droplets of oil dispersed in a
continuous water phase
Advantages
Extremely fire-resistant
Highly incompressible
Good cooling properties
Disadvantages
Poor lubricity
Low viscosity
Fire-Resistant Fluids
Water-in-Oil Emulsion
Most popular fire-resistant fluid
Advantages
Very low flammability characteristics
Suitable for low-temperature applications
Disadvantages
Cannot be used at high temperatures
Attack most paints
Fire-Resistant Fluids
Synthetic Oils
Good fire-resistance properties
Lubricating ability is similar to that of mineral oil
Certain metals and most paints are susceptible to attack for some
synthetic oils
80%biodegradablewithin21days
ISOVG 32/46 Viscosityat100oC 7.3cSt
Viscosityat40oC 40.1cSt Viscosity Index(VI) 149
SpecificGravity 0.965 FlashPoint 256oC
FirePoint 282oC PourPoint 56oC
Example
VG32 VG68
Density(at15oC),kg/m3 869 878
Pourpoint,oC 45 36
Flashpoint,oC 212 252
Minimumstartup temperature,oC 32 21
Estimatedoperatingrange,oC 14to67 0to87
Kinematicviscosity, at 40oC 32.2 67.9
cSt at 100oC 6.4 10
Viscosityindex 156 132
Hydraulic fluids incorporate fluorescent safety additive
July 16, 2015: Spectronics Corp. and Quaker Chemical Corp. have signed a strategic
supply-and-market-development agreement for the global expansion of Quakers fire-
resistant hydraulic fluids that incorporate FluidSafe, Spectronics unique fluorescent
safety additive. Along with the new partnership, Spectronics is merging its Alerton
subsidiary with the parent company and adopting FluidSafe under its Spectroline
brand
Image: FluidSafe confirms a fluid injection injury by its bright fluorescent glow under
blue light, minimizing surgical intervention
Temperature&HeatTransfer
Temperature Control
Keep oil temperatures below 160 oF to prevent
Deterioration of seals
Loss of lubricity
Changes in viscosity
Temperature Control
Design to remain below 140 oF
Characteristics:
Temperature Control
Article
Article
Heat Transfer Cundiff
Thereservoirisconstructedfrom0.125in.thickmildsteelandisrectangular,6 30 36in.The
specificgravityofthehydraulicfluidis0.85,andthespecificheatis1.5Btu/lbmF.Maximum
fluidtemperatureis140F,andmaximumambienttemperatureis95F.
Thevarioussubsystemsonthemachinearewidelyseparated;thus,therearesomelongrunsof
hydrauliclinesthatprovideampleopportunityforheatexchangefromthePumpBandPumpC
circuitstothesurroundings.
ThefunctionalrequirementofthePumpBcircuitwasanalyzed,andtheoperatingpressurewas
calculatedtobe400psi.Itisestimatedthatthepeakpressurerequirementwillbeperhaps2.5
timesthenormalpressure,or1000psi.Thispeakisexpectedtooccuronly10%ofthetotal
operatingtime.
AnalysisofthePumpCcircuitrevealedthatnormaloperatingpressurewouldbe650psi.Peak
pressuresupto1500psiareexpected,anditisestimatedthatthesepeakswilloccur20%ofthe
operatingtime.
Design Example Notes Cundiff
Reevaluate Pump A
Pump A is a variable displacement axial piston pump that delivers flow to
an axial piston motor. Pressure in the main circuit will generally be less
than 2000 psi, so the overall efficiencies of both pump and motor will be
greater than 90%. The volumetric efficiency of both pump and motor is
95%. The displacements of both pump and motor are 2.3 in3/rev.
PumpA: FlowRate:
Pressure:
TotalInputPower:
Design Example Cundiff
PumpAinputpowerconvertedtoheat
Outputpowerofmotor(neglectotherlosses)
Motorpowerconvertedtoheat
Totalheatgenerated(pump&motor)
Design Example Cundiff
Whatamountofflowisdeliveredtotheloopduetoleakage?(RecallQcharge =2.69gpm)
Leakageofpump(95%volumetricefficiency)
Leakageofmotor(95%volumetricefficiency)
Flowacrosschargereliefvalve
Heatgenerateacross150psireliefvalve
Design Example Cundiff
TotalheatgeneratedfromPumpAclosedcircuit:
Totalheatgeneratedfromthesystem:
Assume50%dissipatedforB&C(opensystems)and25%dissipatedforA(closedsystem)
Design Example Cundiff
Additionalcoolingneeded:
Forexample:
Obtainafinnedtubeheatexchangerratedat9500BTU/hat24gpm withT=45oF
Contamination&Filtration
Contamination
There are three types of failure in a fluid power
system.
Table2:Effectsofparticulatecontaminationandwateronhydraulicfluids
Fluidbreakdown Cause Effectonsystem
a. Agglomerationandprecipitationof componentwear
particulatecontamination cloggingofjets,nozzles,and
Physicalproperties b. Oxidation/hydrolysisproducts orifices;valvejamming
c. Reactionsinvolvingadditives systemmalfunctiondueto
d. Freewater icingoffreewater
Basestock a. Oxidation corrosionandsurface
degradation b. Hydrolysis degradationofcomponents
a. Precipitationofadditives
lossofcomponentprotection
b. Adsorptionbyparticulates
Additivedepletion increasedcomponentwear
c. Reactionsinvolvingadditives
andcorrosion
d. Abnormaldegradationofbasestock
Understanding hydraulic fluid contamination
Monitoring contaminants
On-line monitors
Particle counters particle size distribution
Contamination monitors operate on principle
of mesh blockage
Humidity monitors water sensors
Rangecodeat4m/6m/14m
NOT:15m/5m/2m(inCundiff)
Contamination: Pumps Cundiff
Contamination: Pumps Cundiff
Contamination: DCV
Contamination
Pressure Controls
Flow Controls
Cleanliness Level Cundiff
Cleanliness Level
From Target ISO Cleanliness Codes
Cleanliness Level
Step One
Use cleanliness code chart to determine the cleanest
fluid required for any component in the system
Step Two
Set one code lower if the fluid is not 100% petroleum oil
Step Three
Set one code lower if one or more of the following
conditions are experienced by the system:
(i) Frequent cold starts (0 oF);
(ii) Intermittent operation with fluid temperatures over 160 oF;
(iii) High shocks to the system;
(iv) Critical dependence on system operation sequence, ex:
manufacturing;
(v) Malfunction will endanger to operator or others
Filter Efficiency Cundiff
Filter Efficiency Cundiff
Filter Efficiency
under system operating conditions
Filter Location
Pressure Line
Filter Location
Return Line
Filter Location
Off-line
Filter Location
Additional Protection
Servo valves, and other close-tolerance spools
Filter Location
Closed Circuits
When to change a filter
After a certain number of hours?
Filters
www.daerospace.com
Return Line Filter
1. Housing
2. Cover
3. Connection to clogging
indicator
4. Filter element
5. Contamination retaining
basket
6. Clogging indicator
7. Bypass
CourtesyofBoschRexrothAG.
High Pressure Filter
1. Filter heat
2. Filter housing
3. Filter element
4. Clogging indicator
5. Bypass valve
CourtesyofBoschRexrothAG.
Contamination
Keep a record of filter performance/lifetime
Relatedconcept:
Application: Hydroforming
Sheet or Tube hydroforming
http://www.totalmateria.com/
Conservation of Energy
Continuity equation
Bernoulli's equation
Bernoullis Equation: Venturi
Consider a venturi nozzle
For the hydraulic system shown, the following is given
The pump is adding 5 hp to the fluid
The pump flow is 30 gpm
The pipe has a 1 inch inside diameter
The specific gravity of the oil is 0.9
Find the pressure available at the inlet to the hydraulic motor (station
2). The pressure at station 1 in the hydraulic tank is atmospheric. The
head loss due to the friction between stations 1 and 2 is 30 ft of oil
Bernoullis Equation
Torricellis Equation
Fluid Dynamics
Minor Losses
Results from rapid variation of magnitude or
direction of the oil velocity
Expansions and Contractions
Loss in Pipe Flow
MoodysDiagram
Losses: Roughness
For turbulent flows, f is a function of Reynolds number
and the relative roughness of the conductor
Relative roughness = (/ D)
= surface roughness
Head Loss Cundiff
Fitting K Factors
Standardtee 1.8
Standardelbow 0.9
45o elbow 0.42
Return bend(Uturn) 2.2
Q = flow (in3/s)
C = orifice coefficient (unitless)
A = area (in2)
= specific weight of fluid (lb/in3)
g = gravitational constant (386 in/s2)
p = upstream pressure downstream pressure (psi)
2 /
Allvalvesformsometypeoforificeintheline
Manufacturerstypicallysupplyacurve(p vs Q)
Orifice Equation
Pressurized Reservoir
Bootstrap Hydraulic Reservoir
Military and commercial aircraft
21.5 to 3119 in3
System pressures 3000 to 5000 psi
Operation
Pump supplies system pressure
High pressure piston conversion to low pressure
application in reservoir
Ex: 3000 psi to 85 psi
Bootstrap Hydraulic Reservoir
Bootstrap Hydraulic Reservoir
www.daerospace.com
Piston Spring Type
Spring provides a fairly constant (low) reservoir
pressure
www.daerospace.com
Emergency Reserve
Emergency reserve (feed backup/critical system)
www.daerospace.com
Two System Feed
Feed two systems (ex: if one leaks)
www.daerospace.com
HydraulicTransmissionLines
Transmission Lines
Performance:
Selection:
Recommendations
Rigid Pipes
2 to 6 m/s for pressure line
0.6 to 1.6 m/s for suction, return, and low pressure lines
Hose
2.1 to 4.6 m/s for pressure line
0.6 to 1.2 m/s for suction, return, and low pressure lines
Inner diameter
Tube: Nomogram (Fig. 3.1)
Hose: Nomogram (Fig. 3.5)
Working pressures
Pipe: Table 3.1
Hose: Table 3.2
Cundiff
100SUSfluid
0.5intube/hose
Saybold universalsecond:
Time60cm3 toflow
throughcalibratedtube
at38oC
100or400SUSfluid
0.5intube/hose
Pipe Cundiff
Hydraulic Tubing Cundiff
Pressure Ratings
SAE Standard J1065 Jul95
Table 9.4: Service Ratings
Appendix A9, Table A9.1 based on A Service Rating
Design Factor
Ratio of (Burst Pressure) / (Working Pressure)
Derating Factor
Based on working conditions
Value less than 1.0
(Burst Pressure) / (Working Pressure) / (Derating Factor)
i.e. increases overall factor
Cundiff
A press is used to form bladders for truck brakes. Sheets of reinforced elastomer
material are placed in the mold and the press closes. A combination of pressure and
temperature is used to form the part. The procedure calls for a bump cycle where
pressure is cycled for several cycles. Operating temperature is 320 F. The relief
valve for the press circuit is set on 2000 psi, and 0.75 OD carbon steel tubing has
been selected. Find the wall thickness required.
1. Innersyntheticrubbertube,resistanttooilsandhydrocarbons.Theoperating
temperaturerangesfrom40C to120C andthehosemayhaveaninternal
dressinglayerofViton.
2. Highabrasionresistantmetallicscreenlayers.
3. Closelybraidedhightensilesteelwirelayersseparatedbyantifrictionrubber
layer.
4. Abrasionresistantsyntheticrubbercover.
5. Textilelayer.
Hydraulic Hose Cundiff
Hydraulic Hose Cundiff
Pressure Ratings
Table A9.2
Hose Fittings
Hydraulic Tubing Cundiff
Vonberg flowregulatingvalves,directionalvalves,
velocityfuses,flowlimiters,pressurecontrols,
hydraulicmanifolds
Quick Disconnect
Single shut-off
Double shut-off
Installation of Lines
Influence of line choice:
Friction factor
Cost
Heat exchange
Compliance
Actuator movement (rigid vs. flexible)
External vibration
Design Life
Environmental
Corrosion, UV light, temperature, etc.
Failure
Routine
Pinhole
Burst