Basic Course

Hydraulics & Electrics

(24 February 2010)

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Hydraulics
The word "hydraulics" originates from the Greek words (hydor, water) and (aulos, meaning pipe). Science of Hydraulics concerns itself with flowing liquids Hydraulic fluid in modern machinery is in most cases oil
Archimedes of Syracuse (287 BC 212 BC) was a Greek mathematician, physicist, engineer, inventor, and astronomer. Among his advances are the foundations of hydrostatics. He is credited with designing the screw pump that bears his name. This pump is known from many Roman sites as having been used for raising water.

Archimedes (278 B.C. - 212 B.C.)

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Hydraulic Principles
1.
2.

Liquids are (almost) incompressible

Pressure exerted anywhere in a confined incompressible fluid is transmitted equally in all directions throughout the fluid (Pascals Law)

Blaise Pascal (1623 1662)

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Hydraulic Principles
3. Liquids can transfer force

4.

Liquids can multiply force

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Hydraulic Principles
5.
6.

A fluid under pressure takes the path of least resistance

The energy in a hydraulic system (flowing liquid under pressure) is ultimately transformed into work or heat Flow through an orifice will create a drop in pressure

7.

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Early applied hydraulics

Hydraulic Press (1795)

Tower Bridge (1886), originally used water as hydraulic fluid

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Example: Hydraulic Jack

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Hydraulic energy
Hydraulic fluid can be transmitted through pipes, similar to electric current through wires Hydraulic energy can be used to actuate cylinders, hydraulic motors and valves

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BASIC COMPONENTS OF HYDRAULIC SYSTEM

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How can we operate this cylinder by means of hydraulic oil?

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We fill a tank with hydraulic oil

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We add a pump

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We add a switch or directional valve

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We add a return line to tank

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We add connections to the cylinder

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The valve controls the direction of the oil flow to the cylinder

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What determines the pressure in the system?

External load Resistance of pipes and hoses Resistance of the control valve Resistance of the cylinder How can we prevent overload of the system?

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Safety valve

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Safety valve
Limits the maximum pressure in the system

Closed

Open

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Hydraulic sytem in short:

Oil tank Pump Control valve Pipes & hoses Cylinder(s) Safety valve

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HYDRAULIC EXCAVATOR

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Hydraulic Excavator
Engine powers hydraulic pump Pump creates oil flow Oil flow actuates cylinders, swing motor, etc.
Diesel Engine
Hydraulic Pump Hydraulic Cylinders & Motors

Power

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Hydraulic Excavator/ Crane

Pumps
Diesel Engine Hydraulic Tank

Control Valve Cylinders

Swing Motor
Travel Motors

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Hydraulic pump
Translates mechanical energy in hydraulic energy Generates an oil flow Hydraulic pump does not create pressure! Pressure is caused by the load on the system (for example: actuator, friction)

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Hydraulic pumps
Gear Pump

Gear Pump
Plunger Pump

Vane pump

Plunger pump (variable volume)

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Hydraulic motor
Converts hydraulic energy into mechanical energy Gear box to create low speed and high torque Various designs (e.g. plunger or trochoid) Often has variable swash plate for two travel speeds (e.g. travel motor)

Plunger Motor

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Hydraulic cylinder
Converts hydraulic energy into mechanical energy Seals very important

Connections

Cylinder Bottom side Piston

Cylinder rod side Cylinder rod

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Cylinder
Seals

Connection Connection
Seals

Cylinder rod side Cylinder rod Cylinder Bottom side

Piston

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Center Joint
Allows for turning the upper structure on the under structure without twisting hoses.

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Directional valve
Controls oil flow to cylinders or hydromotors Determines direction of oil flow High tolerance

Spool

Connections

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Directional valve: cut-through

Spring Spool

Spring

Oil channels

Cap

Relief valve

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Control valve: Several directional valves together Controls oil flow to cylinders, travel motors, or swing motor. High precision (Main) overload relief: protects the system

Mini

Mid size

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Operation of directional valves

With lever or joy stick With pedal

Pilot Valve

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Hydraulic oil tank

Storage Cooling Elimination of foam Deposition of dirt Air pressure inside tank Approximately 0.2 bar Avoids cavitation Reduces condensation inside oil tank

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Oil Filter
Keeps oil clean Suction filter High pressure filter Return filter Regular Maintenance

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Oil Cooler
Keeps hydraulic oil within acceptable temperature range (50 80 deg. C)

Oil Cooler

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ENERGY LOSS, CAVITATION, HYDRAULIC OIL, SAFETY

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Energy Loss by Resistance

Higher resistance in system:
High oil flow Long pipes and hoses Small diameter of pipes and hoses High viscosity

Lower resistance in system:

Small oil flow Short pipes and hoses Large diameter of pipes and hoses Correct viscosity

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Pump effectiveness
Pump is designed to leak for lubrication Due to normal wear leakage will increase Efficiency of pump will decrease slightly over life time

Leak line

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Cavitation
Under-pressure at suction side Air bubbles Bubbles implode at pressure side Cavitation Vibration, noise, damage to pump Or hydraulic components

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Cavitation
Damage to valve plate of pump Air bleeding was not done correctly ZX140W-3

No damage

Damage: scratches

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Prevent Cavitation
Sufficient diameter of suction lines Slight over-pressure on hydraulic oil tank No sharp turns of suction lines Prevent damage of suction lines Correct viscosity of oil

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Hydraulic oil
Main functions: Transport of energy Lubrication
Requirements: Good lubrication Stable Protection against corrosion Non foaming Water repellant Correct viscosity

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Oil Contamination
70% of hydraulic problems caused by incorrect or contaminated hydraulic oil Dirt & dust Metal particles Cotton particles Water Air (water, dust)

Each contaminating particle is the seed for new contamination

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Oil Contamination
Contamination from outside: System (oil tank, pipes, hoses) open during maintenance or repair Contaminated oil drums, funnels, tools, cloths By cylinder rods, by hammer attachment

Contamination from inside: During break-in period Normal wear (metal on metal) By packings (dirt, paint particles) Formation of Oil sludge

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Oil Contamination
Consequences: Early wear Jamming, Stuck valves Clogging of filters Leaks Solutions: Prevent contamination Work in a clean way! Limit air to oil contact Clean cloths, tools, end nuts Correct filters, regular maintenance

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Advantages hydraulic system

Compact components Simple transfer of forces Small system can generate large forces Easy protection against overload Self-lubricating Low noise level compared to cable or gear systems Easy operation

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Disadvantages hydraulic system

Sensitive to contamination Possibility of leaks Correct assembly very important Regular maintenance needed Temperature sensitive Cause of problems can be difficult to find

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Health & Safety

What are the dangers of working with hydraulic oil? Oil can be hot (burns) High pressure Skin penetration blood poisoning Flamable

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Health & Safety

Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a Do Not Operate tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. 11. Use correct torque values 12. Do not use damaged parts

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HYDRAULIC COMPONENTS & SYMBOLS

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VALVES

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Check valve

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Safety valve
150 100 200

200 bar Tank

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Advanced

Safety valve (with pilot pressure)

HP HP

Animation

Tank (LP)

HP LP

HP Orifice

LP

LP

Reaches set pressure (small spring)

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DIRECTIONAL VALVES

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Directional valves
Control oil flow to actuators Control direction of oil flow ON/OFF type Proportional type Tight tolerances

(4/2) Valve

(6/3) Valve

(8/3) Valve

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Directional valve (4/2)

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Directional valve (4/3)

Valve closed Valve open

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Directional valve (4/3)

Opposite direction Valve open

Control Valve

Valve closed

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OPERATION OF DIRECTIONAL VALVES (WITH ELECTRICITY OR PRESSURE)

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Pilot pressure operated valve (4/3)

Pilot pressure Valve closed Valve open

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Pilot pressure operated valve (4/3)

Pilot pressure Valve closed Valve open

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Solenoid valve
Electrical current

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Solenoid valve

Animation

Electrical current disconnected

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READING HYDRAULIC CIRCUIT DIAGRAMS

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Mini excavator ZX10U-2

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Hydraulic Diagram: ZX10U-2

Hydraulic diagram ZX10U-2

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Hydraulic Circuit Diagram

International symbols Shows function and connection of hydraulic components Does not show exact position of components on machine

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Subway diagram
Distance between stations and exact position does not correspond with geographic reality This makes the diagram easy to understand

Subway diagram London (1931)

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Hydraulic Diagram: Oil Tank

Oil tank

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Hydraulic Diagram: Pumps

Engine and Pumps

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Hydraulic Diagram: Pumps

Main Pumps

Pilot Pump

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Hydraulic Diagram: Pilot Filter

Pilot filter

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Hydraulic Diagram: Pilot Filter

Filter

By-pass valve

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Hydraulic Diagram: Two spool solenoid

Solenoids

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Pilot relief valve

2 Speed Travel Solenoid valve

Pilot Shut-off Solenoid valve

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Purpose: to purge air from pilot circuit when pilot shut-off safety lever is in UP position. Reason: Pilot gear pump of ZX10U-2 is mounted above hydraulic tank (engine rear side)

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Hydraulic Diagram: Pilot Control Valves

Pilot valves

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Pilot Valve

Variable Pressure reducing valves

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Hydraulic Diagram: Multi Way Valve

Multi way valve

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Hydraulic Diagram: Multi Way Valve

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Control valve

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Control Valve
Main Proportional Valves (Spools)

Pilot controlled

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Control Valve

Check Valves

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Control Valve

Main relief P2 (17.7 MPa)

Main relief P1

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Control Valve

Overload Relief Valves Arm, Boom: 20.6 MPa Swing: 7.5 MPa

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Overload relieves
Relieve valve

Make-up valve

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Hydraulic Diagram: Cylinders

Cylinders

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Hydraulic Diagram: Swing Device

Swing Motor

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Swing Device

Make-up valves

Swing Motor

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Hydraulic Diagram: Center Joint

Center joint

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Hydraulic Diagram: Travel Device

Travel motors

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Travel Device
Counterbalance Valve

Travel Mode Selector Valve

Travel Motor Reduction gear

Control Piston

OIL FLOW IN NEUTRAL CIRCUIT

Start animation

NEUTRAL CIRCUIT PARALLEL CIRCUIT

NEUTRAL CIRCUIT

PARALLEL CIRCUIT

Start animation

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NON-OPERATION

NEUTRAL PASSAGE

OPERATION

PRIORITY CIRCUIT

PARALLEL CIRCUIT

Operation of SIDE FRAME EXTEND cylinder

Start animation

Parallel circuit

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HYDRAULIC DIAGRAM EXAMPLE & EXERCISES

Examples

Examples: In the following examples we will indicate the oil flow in the hydraulic diagram with the three colors

Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Example: Boom Swing (spool up boom swing clock wise)

Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Example Boom Swing clock wise

Example: Boom Swing

Example: Boom Swing

Example: Right Travel Motor (spool upwards)

Example: Right Travel Motor (spool upwards)

Example: Right Travel Motor

Exercises

Exercises: Please indicate the direction of the oil in the hydraulic diagram in the following exercises
Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Exercise #1: Blade cylinder

Please draw oil stream in hydraulic diagram for operation of BLADE down Spool up = Blade cylinder out = Blade down

Exercise #1: Blade cylinder (spool upwards blade moves downward)

Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Exercise #1: Blade cylinder out

Exercise #2: BUCKET in

Please draw oil stream in hydraulic diagram for operation of BUCKET in Bucket in = Bucket cylinder out

Exercise #2: BUCKET in

Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Exercise #2: BUCKET in

Exercise #2: BUCKET in

BUCKET in

Bucket spool

Pilot pressure for Bucket spool up

Exercise #2: BUCKET out

BUCKET out

Bucket spool

Pilot pressure for Bucket spool down

Exercise #3: Travel speed selection with solenoid

Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Exercise #3: Travel speed selection with solenoid

Exercise #3: Travel speed selection with solenoid

Exercise #4: Swing (clock wise)

Pilot circuit: Main circuit (high pressure): Main circuit (low pressure):

Exercise #4: Swing (clock wise)

Exercise #4: Swing (clock wise)

Swing spool

Advanced: 100% spool operation

Tank

100% spool operation

Advanced: 50% spool operation

Tank

50% spool operation

Boom Spool ZX14-3 (cross section)

Load check valve Neutral passage Port B to cylinder Parallel passage Port A to cylinder

Spool

Tank

Boom Spool ZX14-3 (neutral circuit)

Section AA

Multiple Spools (neutral circuit)

Boom Spool ZX14-3 (cross section)

Port B

Port A

Pilot pressure

Boom Spool ZX14-3 (cross section)

Port B

Port A

Pilot pressure

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BASIC FORMULAS

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Basic Formulas
PRESSURE: p(N/m2) = F(N) A(m2) 1 N/m2 = 1 Pa 100.000 Pa = 1 bar 1.000.000 Pa = 1 MPa = 10 bar

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PUMP FLOW:
Q(l/min) = V(cm3/rotation) x n(rpm) 1000
Question: What is the maximum theoretical oil flow of an hydraulic pump that has a displacement of 100 cm3/rotation when the maximum engine speed is 2000 rpm? Answer: Q(l/min) = 100x2000 = 200 (l/min) 1000

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TORQUE:
T(Nm) = V(cm3/rotation) x p(bar) 20 x
Question: What is the Torque of an hydraulic pump that has a displacement of 100 cm3/rotation when the delivery pressure is 200 bar? Answer: T(Nm) = 100 x 200 = 318 (Nm) 20 x

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MECHANICAL POWER:
P(kW)= 2 x x T(Nm) x n(rpm) 60 x 1000
Question: How much power is produced by an engine that delivers a Torque of 200 Nm at 2000 rpm? Answer: P(kW) = 2 x x 200 x 2000 = 42 (kW) 60 x 1000

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HYDRAULIC POWER:
P(kW)=p(bar) x Q(l/min) 600
Question: How much power is at least required for a hydraulic pump that delivers 200 l/min at a delivery pressure of 150 bar? Answer: P(kW) = 150x200 = 50kW 600

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PQ-DIAGRAM

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HYDRAULIC POWER:
P(kW)=p(bar) x Q(l/min) 600

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Hydraulic Power:
P(kW) = p(bar) x Q(l/min) = 240 x 100 = 40 kW 600 600 When a pump delivers 100 L/min at 240 bar, this pump requires 40 kW of hydraulic power

Exercise: Calculate hydraulic power in the table below Draw the answers in the diagram
Pressure Flow Power (bar) (L/min) (kW) 240 100 40 300 20 10 400 60 40 100 240 40 150 160 40 300 250 125 250 180 75 300 80 40 160 150 40 400 150 100 120 200 40 100 120 20 200 120 40 50 60 5
300 300

P(kW) = p(bar) x Q(l/min) 600

PQ Diagram (kW)
250 250

200 200
Flow (L/min)

Flow (l/min)

Line of constant power

150 150

100 100

50 50

0 0 0 0

50 50

100 100

150 150

200 200

250 250

300 300

350 350

400 400

450 450

Pressure (bar) Pressure (bar)

PQ-diagram (ZX60USB-3)

Max. pump flow

Engine Power
(constant @ fixed rpm)

Requested pump power must remain below Engine Power

Pump flow reduces when pressure increases

Pump flow reduces when pressure increases

Max. pressure

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OPTIONS

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Use of an excavator
Most common usage: Digging, truck loading

Usage with attachments: Cutting up material (hammer, breaker) Demolition work (crusher, pulverizer) Material handling (grapple) Mowing grass (cutter)

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Hammer/ breaker
Cutting up of concrete or rock Uses oil from single pump (P2) Oil flow needed in 1 direction only
Additional Components needed: Three way valve + solenoid Secondary relief + valve + solenoid 2 Accumulators + valve + solenoid 1 Pilot valve (Auxiliary) 2 Overload reliefs (Auxiliary) Extra piping

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Crusher or grapple
Demolition Material handling Oil flow needed in 2 directions (open/close)
Additional Components needed: Three way valve + solenoid 1 Pilot valve (Auxiliary) 2 Overload reliefs (Auxiliary) Extra piping

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Crusher or grapple
additional components

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Option: pilot accumulator

Provides possibility to relieve pressure from hoses (quick couplings) without need to start engine. Additional components: Pilot Accumulator Check valve

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Option: Double flow or 2 speed flow

Will give auxiliary port oil from both pumps Makes quick opening/closing speed of crusher or grapple possible
Additional components needed: Flow combining valve already built in c/v Solenoid A1 to control combining valve Solenoid A2 for flow control valve Reducing valve

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Option: Two piece boom

Ability to work closer to machine Wheeled excavator: improved visibility, improved stability while driving
Additional components needed: Extra boom + extra boom cylinder Extra pilot valve (Auxiliary 2) PTO valve + 2 overload reliefs Shuttle valve Extra piping/ hoses

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Option: Hose Rupture Valves

Prevents sudden fall of boom or arm in case of hose rupture Safety feature
Additional components needed: 2 HRV (boom 1) 1 HRV (boom 2) 1 HRV (Arm)

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Option: Extra gear pump

For operation of extra functions: Grass/weed cutter Rotation of grapple Blade Quick coupler Component: Extra gear pump

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ELECTRICS

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Electrics
From Latin word lectricus An electric circuit is a combination of electric components to perform a useful task Electric Current flows from Plus to Minus
Long before any knowledge of electricity existed people were aware of shocks from electric fishes. Texts from 2750 BC by the ancient Egyptians, referred to these fish as "thunderer of the Nile", and were seen as the "protectors" of all the other fish.

Basic electric circuit

What is missing?

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Electric Components
Battery Wires (not connected) Wires (connected) Earth or Mass

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Electric Components
Fuse Switches Diode Transistor

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Diode

_ +

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Transistor

C: Collector E: Emitter B: Base NPN type

PNP type

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Transistor: How it works (NPN type)

Main Electrical current Main Electrical current Steering Electrical current

+
_

+
_

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Electric Components
Key Switch

Monitor
Light Relay

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Key Switch: How it works

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Key Switch: How it works

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Key Switch: How it works

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Key Switch: How it works

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Relay: How it works

Steering Electrical current Main Electrical current

+ +

_ _

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Electric Components
Solenoid

Integrated Circuit
Connector Resistor

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EXERCISE: Similarities between Electric and Hydraulic components

What is the comparable hydraulic component of the following electric components?

Electrics Diode Diode (Zener) Resistor Potentio meter

Hydraulics Check valve Overload relief Orifice Variable orifice

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Safety Devices

Electrics: Fuse When activated current will stop

Hydraulics: Relief When activated oil flow will continue

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Electric wires: color coding

AEX Heat Resistant

Number Code

Wire Cross Area Color

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Electric wires: color coding

Excercises:

Wire Code AEX 2 RW :

Heat Resistant, 2 mm2 , Red/White Wire Code 0,5 G :

0,5 mm2 , Green

Wire Code 0,85 Y : 0,85 mm2 , Yellow

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READING ELECTRIC CIRCUIT DIAGRAMS

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Electric Circuit Diagram

International symbols Shows function and connection of electric components Does not show exact position of components on machine

Exercise 1: Please study the electric components in this diagram

Exercise 2: Please indicate which components are connected to the Battery when Key Switch is in OFF position (use red color). Which components are connected?

Exercise 3: Please indicate how the glow plugs are operated (use blue). Exercise 4: Please indicate how the travel speed solenoid is operated (use green).

Exercise 5: Please indicate how the horn and work light are operated (use blue). Exercise 6: Please indicate when hour meter is enabled (use green).

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End
Thinking is the hardest work there is. That is why so few people do it. Henri Ford