1.

0 INTRODUCTION :

Force/torque applied by drives is a function of differential pressure across the oil hydraulic actuators and is effectively controlled by adjusting
PRV and/or RV settings. Functions like speed and direction selection are achieved through flow limiting valve and directional control valve
respectively. This report covers design calculation for arriving at the operational parameters e.g. pressure and flow settings for the following
actuators

2.0 INPUT DATA AND ASSUMPTIONS:

2.1 Requirements of Torque/Force and speed for the various oil hydraulic devices on Equipments along with actuator details are given This forms
the basis for determining the operating pressure and flow setting for the oil hydraulic actuators.

2.2 Pressure drop calculations include tube, hose and component pressure drops which are required over and above the differential pressure
required across the actuator.

2.3 Various assumptions and references made in calculations are given below:

2.3.1 Running torque requirement = 2/3 of Starting torque (assumed for motor loads)

2.3.2 Break-away pressure not considered for motors.

2.3.3 PRV setting = 'Reqd. DP across motor-start' or 'Total reqd. pressure - run' (Rounded-off), whichever is greater.

2.3.4 Hose drop= Estimated from Aeroquip catalogue.

2.3.5 Break-away pressure not considered for stall force calculation of cylinder circuits, as this much pressure out of total PRV supply pressure is
 expected to be consumed across cylinder piston seals, during stall.

2.3.6 Values for actuator Torque constant and Displacement constant have been taken from Rexroth catalogue for A2FM type axial piston motors.
For pressure drop across various valves, Rexroth catalogues have been referred.

2.3.7 Efficiency of motors considered based on earlier correspondence with motor suppliers.

2.3.8 The formula used for pressure drop for tube is :

Pressure drop tube = (0.125x Q x L)/ 3d4, where

Q= Flow through tube in LPM

L= Length of tube in meters

d = Inner dia. of tube in cm.

Above formula is derived for laminar flow of fluid having specific gravity of 0.89 and viscosity of 68 mm2/second.

2.3.9 Smaller area of Ram-CE considered for flow calculations. Higher area would have given higher flow for a given speed. And this flow, while
moving smaller area cylinder would have given, higher than allowed speed.

2.3.10 For calculation of pressure required to move the load, smaller area has been considered for Ram-CE. This pressure when acting on bigger area,
will give higher force output which is to be ensured to be within allowable limits. If the pressure is calculated with bigger area, it will not
generate enough force to move the load, when acting on smaller area of cylinder.

2.4 All the settings/data given below are tentative/estimates and will be used for procurement of various oil hydraulic valves such as flow control
valves, pressure reducing and pressure relief valves. Actual flow setting and pressure setting will be adjusted at site so as to get the desired
speed, force and torque.

3.0 DETAILED PRESSURE& FLOW CALCULATIONS FOR ACTUATORS:

3.1 Motor flow setting

3.1.1 Flow settings:

Selected oil hydraulic motor = Rexroth :A2F5/W 6.0 B 3

(with worm gear drive)
Gear ratio=3000:1
Volumetric efficiency of motor = 90%
NFM ‘High’ linear Speed = 75 cm/min
NFM motor rotary speed corresponding to = 1250 rpm
this speed
NFM ‘low’ linear Speed = 6 cm/min
NFM motor rotary speed corresponding to = 100 rpm
this speed
Displacement of the motor M-1 = 4.93 cc/rev
FCV-2 setting required for ‘high’ speed = (1250rpm x 4.93 cc/rev) / 0.9
= 6.85 LPM
FCV-1 setting required for ‘low' speed = (100 rpm x 4.93 cc/rev) / 0.9
= 0.55 LPM

3.1.2 Pressure settings:

Torque required by NFM(Start) = 2.32 N-m

Torque required by NFM(Running) = 1.55 N-m (refer section 2.3.1)
Torque constant of the motor = 0.076 N-m/bar
Starting torque efficiency of the motor = 75%
Running torque efficiency of the motor = 80%
Differential pressure required across the = (2.32/(0.076*0.75))*1.02
motor(starting) = 41.52 Kgf/cm2
Note: 1.02 has been used for ‘bar’ to
‘Kgf/cm2’ conversion.
Differential pressure required across the = (1.55/(0.076*0.80))*1.02
motor(running) = 25.95 Kgf/cm2
Line and component pressure drop = 1.97(Tube drop)+(0.5(MVD-31) +
0.25(MVD-34) +11.5(FCV-2) +
1.5(POCV-131) + 2(Power Pack))
= 17.72 Kgf/cm2
 Pressure required at PRV-61 outlet = 25.95+17.72
= 43.67 Kgf/cm2
Hence, PRV-61 setting = 44 Kgf/cm2
Stall torque at motor shaft = 2.51 N-m
3.2
3.3 Cylinder setting caln

3.3.1 Flow settings:

No. of cylinders = 1
Cylinder bore = 4.0 cm
Rod diameter = 1.8 cm
Bore Area(A1) = π * (4)2/4
= 12.56 cm2
Differential area (A2) = π * ((4)2-(1.8)2) / 4
= 10.02cm2
Linear speed (advance/retract) = 96 cm/min.
Flow on cylinder ‘cap’ side = 96 x 12.56
= 1.21 LPM
Flow on cylinder ‘head’ side = 96 x 10.02
= 0.96 LPM
Hence FCV-12 setting = 1.21 LPM (on ‘cap’ side)
0.96 LPM (on ‘head’ side)

3.3.2 Pressure settings:

Force required (advance & retract) = 60 Kgf

Pressure required for cylinder movement = 60  12.56 = 4.78 Kg/cm2 (advance
direction)
= 60 10.02 = 5.99Kg/cm2 (retract
direction)
 Total pressure required for advance motion = ∆P(actuator advance)+ ∆P (line+component drop-head
side) )* A2/ A1+ ∆P (line+component drop-cap side)+
break away pressure
= 4.78+(0.92(line)+0.25(MVD-41)+
2.5(FCV-12)+2.0(PP))*(10.02/12.56) +
(1.15(line)+0.25(MVD-41) +2.5(FCV-
12))+ 0.8
= 14.00 Kg/cm2
Total pressure required for retract motion = ∆P(actuator retract)+ ∆P (line+component drop-cap
side) )* A1/ A2+ ∆P (line+component drop-head
side)+break away pressure
= 5.99+(1.15(line) +0.25(MVD-
41)+2.5(FCV-12)+2.0(PP))*
(12.56/10.02)+(0.92(line)+0.25(MVD-
41)+2.5(FCV -12))+1
= 18.06 Kg/cm2
Hence, Pressure setting required for = 18 Kg/cm2
PRV-69
Stall force (advance) = 216 Kgf
Stall force (retract) = 170 Kgf

4.0 CALCULATION FOR PUMP PRESSURE AND FLOW SETTINGS:

4.1 For Pump P-5 / P-6 (Ref. Fig. 1):

A. Maximum flow requirement of pump P-5/P-6 consists of the following simultaneous demands:

9.35 LPM –for Loading Ram-CG motion, plus

9.8 LPM – for MTM X-drive high speed, plus

8 LPM – leakage flow of 16 nos. of PRVs connected to these pumps, plus

 1 LPM – leakage flow of two nos. of 3 position, spring centred direction control valves (MVDs),

0.4 LPM – leakage through two ball valve actuators, plus

1.8 LPM – leakage through various cylinders (14 nos.) connected to pumps via two position direction control valves (MVDs).

Hence Pump (P-5/P-6) flow requirement = 9.35 + 9.8 + 8+1+0.4+1.4= 29.95 LPM

Pump flow setting = 35 LPM

B. Maximum pressure setting requirement is 82 Kg/cm2 (for MTM 900 swing rotary actuator PRV-73.)

Hence, Pump (P-5/P-6) pressure setting = 90 Kg/cm2

Power pack (35216-PL-1) RV-80 setting = 95 Kg/cm2.

4.2 For Pump P-7 / P-8 (Ref. Fig. 8):

A. Maximum flow requirement of pump P-7/P-8 consists of the following simultaneous demands:

6.3 LPM - for TLM high speed, plus

1 LPM - Leakage flow of 2 nos. of PRVs connected to these pumps, plus

0.2 LPM – Leakage through ball valve actuator via 2 position MVD

Hence Pump (P-7/P-8) flow requirement = 6.3 + 1.0 + 0.2 = 7.5 LPM

Pump flow setting = 10 LPM

B. Maximum pressure setting requirement is 50 Kg/cm2 (for TLM-drive PRV-79).

Hence, Pump (P-7/P-8) pressure setting = 60 Kg/cm2

Power pack (35216-PL-3) RV-81 setting = 70 Kg/cm2.

5.0 ELECTRIC MOTOR POWER CALCULATION:

5.1 For Motor PM-5/PM-6:

Power (KW) = {Pressure (Kg/cm2) x Flow Rate (LPM) x 0.00164}/Efficiency

(Calculation for unit conversion factor .00164 is given separately)

OHPP (35216-PL-1) RV-80 Setting = 95 kg/cm2

Max. flow setting of pump P-5/P-6 = 35LPM

Pump overall efficiency = 75%

Hence, Power (in KW) = 95 ∗ 35 ∗ 0.00164

0.75
= 7.27 KW

Hence, a 9.2 KW (11 HP) electrical motor has been selected for PM-5/PM-6.

5.2 For Motor PM-7/PM-8:

OHPP (35216-PL-3) RV-81 Setting = 70 kg/cm2

Max. flow setting of pump P-5/P-6 = 10 LPM

Pump overall efficiency = 75%

Hence, Power (in KW) = 70 ∗ 10 ∗ 0.00164

0.75
 = 1.53 KW

Hence, a 2.2 KW (3 HP) electrical motor has been selected for PM-7/PM-8.

Calculation for constant factor:

1 Kgf/cm2 x 1 LPM = 1.00 Kgf/sq.cmx1000cc/min.
= 1000 Kgf cm/min.
= 10.00 Kgf m / min.
= 10.00 x 9.81/60 N m/s
= 10.00 x 9.81/(60x1000) KW
= 1.64 x 10–3 KW
6.0 TYPICAL CYLINDER CIRCUIT: PRESSURE AND FLOW EQUATIONS: