Principles of Hydraulic System Design

Summary
1. Introduction
2. Major aspects in the selection of pumps and motors
3. Types of pumps and motors
3.1 Fixed displacement unit
3.1.1 External gear pumps/motors
3.1.2 Internal gear pumps
3.1.3 Vane pumps/motors
4. Variable displacement units
4.1 Vane pumps
4.2 Piston pumps/motors
5. Equations for pumps and motors
5.1 Flow and speed relationship
5.1.1 Volumetric efficiency
5.2 Torque and pressure relationship
5.2.1 Mechanical efficiency
5.3 Pump selection parameters
6. Low speed motors
6.1 Types of low speed motors
6.1.1 Radial piston motors
7. Some general considerations
8. Comparison of Motor Performance Characteristics Reference

CHAPTER THREE

HYDRAULIC ACTUATORS

Summary
1. Introduction
2. Linear actuators
3. Principle features
3.1 End covers
3.2 Mounting methods
3.3 Seals
3.4 Position transducers
4. Actuator selection
4.1 Actuator force
4.2 Cushioning
5. Rotary actuators
5.1 Actuator types and capacity range
5.2 Applications References

CHAPTER FOUR

PRESSURE CONTROL VALVES

Summary
1. Introduction
2. Relief valves
2.1 Single stage relief valve
2.2 Two Stage Relief Valves
3. Pressure Reducing Valves
4. Counterbalance Valves

CHAPTER FIVE

FLOW CONTROL VALVES

Summary
1. Introduction
2. Directional control valve
3. Restrictor valve
4. Pressure compensated valve
5. Central bypass valve

CHAPTER SIX

ANCILLARY EQUIPMENT

Summary
1. Introduction
2. Accumulators
2.1 Types
2.2 Performance
3. Contamination control
3.1 Components
3.2 Filters
4. Coolers
4.1 Cooler types
5. Reservoirs

CHAPTER SEVEN

CIRCUIT DESIGN

Summary
1. Introduction
2. Pressure and Flow
3. Directional control
3.1 Two position valves
3.2 Three position valves
4. Load holding valves
5. Velocity control
5.1 Meter-in control
5.2 Meter-out control
5.3 Bleed-off control
5.4 Four way valve restrictive control
5.4.1 Analysis of the valve/actuator system 5.4.1.1 Actuator extending
5.4.1.2 Actuator retracting
5.4.2 Valve sizing
5.4.3 Valves with non-symmetrical metering
5.5 Bypass control with fixed displacement pumps
5.5.1 Open centre valves
5.5.2 Closed centre valves with load sensing and pressure compensation
6. Variable displacement pump control
6.1 Load sensing
6.2 Power control
6.3 Accumulator charging
7. Hydrostatic transmissions
7.1 Pump controlled systems (primary control)
7.2 Motor brake circuit
7.3 Linear actuator transmissions
7.4 Motor controlled systems (secondary control)
8. Pilot operated valve circuits
8.1 Load control valves
8.2 Pump unloading circuit
8.3 Sequence Control
9. Contamination control

CHAPTER EIGHT

FLOW PROCESSES IN HYDRAULIC SYSTEMS

Summary
1. Introduction
2. Fluid properties
2.1 Fluid viscosity
3. Flow in pipes
4. Laminar flow in parallel leakage spaces
5. Orifice flow

6. Valve force analysis
6.1 Poppet valves
6.1.1 Momentum force
6.1.2 Valve flow
6.1.3 Valve pressure/flow characteristics
6.2 Spool valves
Appendix
Reference

CHAPTER NINE

OPERATING EFFICIENCIES OF PUMPS AND MOTORS

Summary
1. Introduction
2. Mechanical and volumetric efficiency
3. Analysis of the losses
3.1 Theoretical performance
3.2 Volumetric flow loss
4. Mechanical loss
5. Unit efficiency
5.1 Volumetric efficiency
5.2 Mechanical efficiency
5.3 Overall efficiency Reference

CHAPTER TEN

CONTROL SYSTEM DESIGN

Summary
1. Introduction
2. Simple valve actuator control
2.1 Open loop system
2.2 Closed loop system
2.3 System response
3. Fluid compressibility
3.1 Bulk modulus
3.2 Hydraulic stiffness
4. Valve actuator dynamic response including compressibility effects
4.1 Valve flow
4.2. Actuator flows
4.3 Actuator force
4.4 Comments
4.5 Actuator position
4.6 Valve selection
4.7 Pressure shock control in open loop systems
5. Frequency response
5.1 Simple actuator
5.2 Valve actuator system
6. Stability of the closed loop position control system
6.1 Stability criterion
6.2 System design
6.3 Steady state accuracy
6.3.1 Valve leakage
6.3.2 Valve hysteresis
7. The improvement of closed loop system performance
7.1 Position control
7.2 Velocity control
7.3 Pressure control
8. Compensation techniques
8.1 Integral plus proportional compensation
8.2 Proportional plus derivative control
8.3 Phase advance compensation
8.4 Proportional, Integral and Derivative (PID) control
8.5 Pressure feedback
9. System frequency response tests
10. Pump controlled systems

CHAPTER ELEVEN

PERFORMANCE ANALYSIS

1. Introduction
2. Meter-in control
2.1 The effect of load force changes
3. Valve control of a single ended actuator
3.1 Data
3.2 Actuator retraction
3.3 Actuator extension
4. Winch Application
4.1 Lifting the load
4.2 Lowering the load
4.3 Numerical Values
5. Hydraulic Motor for Driving a Winch
5.1 Gearbox ratio
5.2 Motor selection
5.3 Flow required
5.4 Minimum motor displacement
6. Hydraulic system for gantry crane
6.1 Gantry crane
6.2 Wheel drive
6.3 Pipe sizes
7. Pressure losses
7.1 Data
7.2 Pressure loss at 20 degrees C
7.3 Pressure loss at 60 degrees C
7.4 Pump requirements
8. Single stage relief valve
9. Simple actuator cushion
10. Central bypass valve
10.1 Flow analysis
10.2 Valve characteristics
10.3 Actuator force
10.4 Valve operation
11. Pump and motor efficiencies
12. Control System Design
13. Hydraulic system for injection moulding machine
13.1 System data
13.2 Injection moulding machine
13.3 Actuator
13.4 Motor
13.5 Volume required/cycle
13.6 Accumulator
13.7 Circuit
13.8 The prevention of pressure shocks
14. Oil Cooling
14.1 System data
14.2 Duty cycle
14.3 Heat generated
14.4 Heat loss to the surroundings
14.5 Pump efficiency
15. Vehicle Transmission
16. Pump Control Applications
16.1 Application of Pump Unloader Valve to Vehicle Crusher/ Refuse Vehicle Machines 16.2 Application of Pump Controls to Bending Machines

CHAPTER TWELVE

SYSTEMS MANAGEMENT
Summary
1. Introduction
2. Aspects of systems management
3. Systems management objectives
4. System cleanliness
5. Fault analysis
5.1 Fault Tree Analysis (FTA)
5.2 Failure modes effects analysis (FMEA)
6. General

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