Polytechnic Manufacturing and Automation

FLDS 385 EATON Industrial Hydraulics Manual Chapter 1 Introduction to Hydraulics

Ted Nelson A.Sc.T. Rm T409 403-284-8242 ted.nelson@sait.ca

Section1. Introduction to Hydraulics

Objectives:
1.1 Evaluate methods of providing mechanical power. 1.2 Describe the advantages and disadvantages of hydraulic power. 1.3 Examine the principles of hydraulic systems. 1.4 Explain simple circuit design. 1.5 Draw a simple circuit using appropriate schematic representation. 1.6 Build a simple hydraulic circuit. 1.7 Discuss and follow safety practices current in the hydraulic industry.

Introduction to Hydraulics
The study of hydraulics deals with the use and characteristics of liquids Early recorded history shows devices such as pumps and water wheels used in very ancient times Modern hydraulic systems are based on a principle discovered by Blaise Pascal
Hydraulic systems can transmit power, multiply force and modify motions with the use of a confined fluid

Introduction to Hydraulics
Pascals Law (simply stated):
Pressure applied on a confined fluid is transmitted in all directions, and acts with an equal force on equal areas, at right angles to the area
2. A 10 lb. force is appliedto the stopper with a surface area of one square inch

3. This results in 10 lb of force on every square inch of surface area in the container

1. The bottle is filled with liquid, which is not compressible

4. If the bottom has an area of 20 sq. in. and each square inch is pushed on by 10lbs. of force, the entire bottom of the container receives 200 lbs push

Methods of Providing Mechanical Power

Simple Hydraulic Press:
Joseph Bramah, a British mechanic, invented the hydraulic press by applying Pascals law to his design Below: the stopper has an applied force of 10 lbs on its area of 1 in2, 2 A. SIMPLE PRESS has an area of 10 in , therefore it can support a total theHYDRAULIC large piston weight or force of 100 lbs
10 lbs
1. An input force of 10 lbs on a one square inch area 3. This pressure will support a 100 lb weight if this is a 10 sq in piston

2. Develops a pressure of 10 pounds per square inch (psi) throughout the container

4. The forces are proportional to the piston areas

10 lbs

100 lbs

=
1 sq in 10 sq in

Methods of Providing Mechanical Power

Simple Hydraulic Press: contd
The forces or weights will balance using a simple press The forces are proportional to the piston areas If the output piston area would have been 200 in2, the output force would be 2000 lbs (with the same 10 lbs/ in2 input force)

(input pressure) x (area of output piston) = (output force)

10 lbs/ in2 x 200 in2 = 2000 lbs

This is the operating principle of the hydraulic jack, as well as the hydraulic press

Methods of Providing Mechanical Power

Simple Mechanical Lever:
The simple press and a mechanical lever are similar Below: the left side of the fulcrum must equal the right side of the fulcrum An applied force of 10 lbs on a length of 10 in, will balance 100 lbs at a length of 1 in
1. An input force of 10 lbs here
2. will balance 100 lbs here

100 lbs

3. if this arm is 10 times as long as

4. this arm

B. SIMPLE MECHANICAL LEVER

Pressure
Pressure Defined:
In order to determine the total force exerted on a surface, it is necessary to know the pressure or force on a unit of area Pressure is usually expressed in pounds per square inch (psi) It is also expressed in terms of Bar and kilopascals (kPa)

Force = Pressure x Area

Conversions from Eaton Textbook Appendix C page 557 1 kiloPascal = 100 Bars 1 Bar x 10-5 = 1 Newton/Sq. meter 1 Newton/Sq. meter = 1 Pascal 1 kilogram = 9.81 newtons

Conservation of Energy
Conservation of Energy Defined:
A fundamental law of physics states that energy can neither be created nor destroyed. The multiplication of force is not a matter of getting something for nothing, the large piston is moved only by the liquid displaced by the small piston What is gained in force is lost in distance
10 lbs 1. Moving the small piston 10 in displaces 10 cu in of liquid (1 sq in x 10 in = 10 cu in)

100 lbs
1 in

10 in

2. 10 cu in of liquid will move the larger piston only one inch (10 in sq x 1 in = 10 cu in)

4. The energy transfer here is also 100 in lbs (1 in x 100 lbs = 100 in lbs) 3. The energy transfer here equals 10 lbs x 10 in or 100 in lbs

Hydraulic Power Transmission

Hydraulic Power Transmission Defined:
Hydraulic Power Transmission is a means of transmitting power by pushing on a confined liquid. The hydraulic system is not a source of power
The power source is the prime mover (electric motor, or an engine) that drives a pump

A hydraulic system provides versatility and flexibility which is an advantage over other methods of transmitting power

Hydraulic Power Transmission

The input component of the system is called a pump
Most pumps have multiple pistons, vanes or gears as their pumping elements

The output components are called actuators

Actuators can be linear (a cylinder) or rotary (a hydraulic motor)
A. Linear Actuator

B. Rotary Actuator
Motor 4. Rotary actuators or motors give the system rotating output. They can be connected to pulleys, gears, rack and pinions, conveyors, ect.

2. Lines carry the fluid to actuators which are pushed internally to produce a mechanical output which moves the load

Load

1. The pump pushes the hydraulic fluid into the lines Piston & Rod To Reservoir

Electric Motor

Electric Motor

PUMP Pump
Pump
3. Some actuators operate in a straight line (linear actuators). They are called rams or cylinders. They are used to lift weight, exert force, clamp, ect.

Rotary Drive Shaft

Fig 1-4

(A) Linear and rotary actuator

Fig 1-4

(B) Linear and rotary actuator

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Advantages of Hydraulic Power

Variable Speed:
Most electric motors run at a constant speed It is also desirable to operate an engine at a constant speed An Actuator (linear or rotary) can be driven anywhere from a maximum speed to a reduced speed by varying a flow control valve
A. Maximum Speed
3. the piston will move this far on one minute

B. Reduced Speed
6. the actuator receives only 5 gallons and only travels half as far in one minute Flow Control Valve 5. but a valve restricts the flow to 5 gallons per minute Relief Valve 4. If the pump delivers 10 gpm, 5 gpm

2. and the volume is 10 gallons

Load

Load

1. If the pump constantly delivers 10 gallons per minute

Electric Motor

Electric Motor 7. Excess 5 gpm is diverted over the relief valve

Pump

Pump

Figure 1-5

(A) Hydraulic drive speed is variable

Figure 1-5

(B) Hydraulic drive speed is variable

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Advantages of Hydraulic Power

Reversible:
Few Prime Movers are reversible If they are reversible they must be stopped before reversing them Hydraulic actuators can be reversed instantly while in full motion without damage to the hydraulic system
A cross-port relief valve is used on a hyd motor to reduce pressure spikes

A four way directional control valve provides the reversing control

3. The piston extends 2. pump delivery is directed to the cap end of the cylinder

Load
Load
1. In this position of the directional valve

4. Exhaust oil is pushed out of the rod end and back to tank Electric Motor

5. In another position, oil is directed to the rod end of the cylinder Electric Motor 6. The piston rod retracts 7. Exhaust oil from the cap end is directed to tank 8. The relief valve protects the system by momentarily diverting flow to tank during reversing, and when the piston is stalled or stops at the end of stroke

Pump

Pump

Figure 1-6

(A) Hydraulic drives are reversible

Figure 1-6

(B) Hydraulic drives are reversible

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Advantages of Hydraulic Power

Overload Protection:
A Pressure Relief Valve protects the hydraulic system from overload damage due to excessive pressures When the load exceeds the valve setting, the fluid is directed back to the tank (reservoir) The Relief Valve also provides a means of setting a machine for a specified amount of torque or force (ie: a press or clamping operation)
3. The piston extends 2. pump delivery is directed to the cap end of the cylinder

Load
Load
1. In this position of the directional valve

4. Exhaust oil is pushed out of the rod end and back to tank Electric Motor

5. In another position, oil is directed to the rod end of the cylinder Electric Motor 6. The piston rod retracts 7. Exhaust oil from the cap end is directed to tank 8. The relief valve protects the system by momentarily diverting flow to tank during reversing, and when the piston is stalled or stops at the end of stroke

Pump

Pump

Figure 1-6

(A) Hydraulic drives are reversible

Figure 1-6

(B) Hydraulic drives are reversible

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Advantages of Hydraulic Power

Small Packages:
Hydraulic components provide high power output with very small weight and size
Due to their high speeds and high pressure capabilities

Can Be Stalled:
Stalling an electric motor will cause damage or blow a fuse A stalled engine will have to be restarted to continue an operation
A Hydraulic actuator can be overloaded and stall without damage, and will start up immediately when the load is reduced
During the stall, the relief valve dumps the fluid back to the tank The only loss is the energy lost in wasted horsepower

Advantages of Hydraulic Power

Hydraulic Oil:
Any liquid is essentially noncompressible and will transmit power instantaneously in a hydraulic system The most common liquid used in hydraulic systems is petroleum oil Oil is virtually incompressible
It will compress about 0.5% at 1000 psi (70 bar, 7000 kPa) This is a negligible amount in most systems

A hydraulic oils most desirable property is its lubricating ability

Moving parts in a system must be lubricated

With a hydraulic system you dont have to worry about lubricating components because it is done automatically

Pressure in a Column of Fluid

The weight of a volume of oil varies slightly as the viscosity changes Most hydraulic oils weigh from 55 to 58 lbs per cubic foot The weight of the oil is an important consideration on the pump inlet
1 cubic foot of oil weighs approximately 58 lbs 1. If this weight is divided equally over the 144 sq in the force on the bottom of each square inch is .4 lbs Thus the pressure at the bottom is .4 psi 0.4 psi

12 in 12 in

2 psi 12 in

Pressure =

Force Area

58 lbs = 0.4 psi 144 in2

Area = 144 in2 4 psi

2. If the fluid column height is 10 ft then the pressure at the base of the column will be 4 psi. It is the height of the column, not its volume that determines the pressure. Figure 1-7 Weight of oil creates pressure
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Oil Reservoir Location

Reservoir above the Pump Inlet:
When the reservoir oil level is above the pump inlet, a positive pressure is available to force the oil into the pump

Oil Reservoir Location

Reservoir below the Pump Inlet:
If the reservoir oil level is below the pump, a vacuum equivalent to 0.4 psi per foot is needed to lift the oil to the pump inlet Oil is actually forced by atmospheric pressure into the vacuum created at the pump inlet when the pump is in operation

Atmospheric Pressure Charges the Pump

A pumps inlet is charged with oil due to a difference in pressure between the reservoir and the pump inlet On the intake stroke, the piston creates a partial vacuum, and the atmospheric pressure in the reservoir pushes the oil into the pumping chamber vacuum In a rotary pump, successive pumping chambers increase in size as they pass the inlet, creating the same vacuum condition
3. Atmospheric pressure pushes the fluid into the pumping chamber to fill the void. Fluid is pushed, not pulled into a pump 2. A partial vacuum or void is created here 1. On the intake stroke, the pump piston moves out expanding the pumping chamber

Outlet

Atmospheric Pressure

Inlet

Problems with Vacuum at the Pump Inlet

Cavitation:
If it were possible to pull a complete vacuum at the pump inlet, there would be available some 14.7 psi to push the oil in Pump manufacturers recommend a vacuum of less than 12.2 psi (5 of mercury) absolute at the pump inlet

This leaves about 2.5 psi pressure difference to push oil into the pump
If there is too much of a pressure difference the liquid will vaporize in this vacuum, which in turn will put gas bubbles into the oil

Problems with Vacuum at the Pump Inlet

Cavitation:
When these gas bubbles get to the pump the higher pressure in the pump causes them to collapse (implode) against pump components with considerable force and cause damage, which impairs the pumps operation and reduces its life

Driving a pump at too high a speed increases fluid velocity which increases friction in the line, which in turn causes a lower pressure condition and will increase the possibility of cavitation

Problems with Vacuum at the Pump Inlet

Aeration:
If the inlet fittings are not tight, air can get into the inlet line and into the pump This air-oil mixture also causes trouble and noise, but not as much damage as cavitation This air is not dissolved in the oil and continues throughout the system as compressible bubbles causing erratic valve and actuator operation

Positive Displacement Pumps

Most pumps used in hydraulic systems are positive displacement This means that the pumps output is constant regardless of the pressure

The outlet is positively sealed from the inlet, so whatever goes into the pump is forced out of the pump through the outlet

The sole purpose of a pump is to create flow Pressure is caused by a resistance to flow
Pressure can be lost only by a leakage path that diverts all the flow from the pump

Positive Displacement Pumps

If a 10 GPM pump is used to push oil under a 10 in2 piston and raise an 8000 lb load, the pressure must be 800 psi while the load is being moved or supported by the hydraulic oil
A.
2. The area is 10 sq in 1. The load is 8000 lbs

Load
1000 750 1250 1500 500 250 1750 2000 0

8000 lbs

psi

Electric Motor

Pump

3. The pressure equals the force area equals 8000 lbs 10 in sq = 800 psi

P=FA

Figure 1-10

(A) Pressure loss requires full loss of pump outlet

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Positive Displacement Pumps

Even if a hole in the piston allows 9.5 GPM to leak at 800 psi, pressure will still be maintained. Only 0.5 GPM is available to move the load very slowly The pressure required to move the load still remains at 800 psi

Positive Displacement Pumps

Now imagine that the 9.5 GPM leak is in the pump instead of the cylinder There is still 0.5 GPM available to move the load and there is still pressure at 800 psi Thus, a pump can be badly worn, losing nearly all of its efficiency, and pressure can still be maintained

Pressure alone is no indicator of a pumps condition

Its necessary to measure the flow at a given pressure to determine whether a pump is in good or bad condition

Positive Displacement Pumps What will happen?

Scenario There is a hole through the piston Both the Rod end and Cap end ports are blocked off 2. 2. The The pressure pressure required required to to lift lift
the the load load equals equals the the load load divided divided by by the the piston piston area area

8000 lbs

LOAD

Will the load drop quickly? Will the load drop slowly? Will it stay in place? ??????????????????
Figure 1-20 Choosing Choosing cylinder cylinder size size Figure 1-20
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8000 lbs lbs 8000 10 sq sq in in 10

1. 1. If If the the piston piston area area is is 10 10 sq sq in in

Positive Displacement Pumps What will happen?

The load will stay in place!

If the load were lowered it would introduce more rod into the cylinder and none of the fluid can escape
2. 2. The The pressure pressure required required to to lift lift the load equals the load the load equals the load divided divided by by the the piston piston area area

8000 lbs

LOAD

8000 lbs lbs 8000 10 sq sq in in 10

The load may drop a very small amount due to the oil compressing
1. 1. If If the the piston piston area area is is 10 10 sq sq in in

Figure 1-20 Choosing Choosing cylinder cylinder size size Figure 1-20
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How Pressure is Created

Pressure is created whenever the flow of a fluid is resisted
The resistance may come from: 1) A load on an actuator or 2) A restriction (or orifice) in the piping

Below: Pressure is being created from the load on the actuator:

How Pressure is Created

Pressure created from a restriction (or orifice):

Below: No restriction causes No Pressure

How Pressure is Created

Pressure created from a restriction (or orifice):

Below: A small restriction causes an increase in Pressure

The restriction is not enough to limit the quantity of flow out of the faucet

How Pressure is Created

Pressure created from a restriction (or orifice):

Below: An increased restriction causes an increase in pressure up to the relief valve setting
The restriction limits the quantity of flow out of the faucet, the excess flow goes over the relief valve and back to tank

How Pressure is Created

Summary of Pressure created from a restriction (or orifice): As the faucet is gradually closed it resists flow and causes the pressure to build up on the upstream side

It takes more and more pressure to push the 10 GPM through the restriction
Without the relief valve there would be no limit to the pressure build up, until something breaks or stalls the prime mover (electric motor) Note: It is always advised to have a relief valve or some other pressure limiting device in a hydraulic system with a positive displacement pump

Parallel Flow Paths

Path of least resistance: Liquids will always take the path of least resistance When two or more parallel flow paths have different resistances, the pressure in the system will increase only to the amount required to take the easiest path (100 psi, path A) and no flow will go through path B or C

Parallel Flow Paths

Path of least resistance: If path A is blocked the next easiest path in this parallel system is path B, therefore the system pressure will be 200psi, and there will be no flow through path C

Parallel Flow Paths

Path of least resistance: Similarly, when a pumps flow goes to two actuators, the actuator which needs lower pressure will move first It is difficult to balance loads exactly, therefore cylinders are often physically connected to each other if they must move together

Series Flow Paths

Additive flow path: Pressures are additive when resistance to flow is connected in series Pressure in the line, at any given point, will be the pressure to open a valve plus the back pressure from the valve downstream The pressure at the pump is the sum of the pressures required to open each valve

Orifices
Pressure Drop through an Orifice: An orifice is a restricted passage in a hydraulic line or component, used to control flow or create a pressure difference (pressure drop) If there is no flow, there is no difference in pressure across the orifice

Orifices
Pressure Drop through an Orifice: Increasing the flow through an orifice will cause an increased pressure drop across the orifice A high flow causes a large 500 psi pressure drop

Orifices
Pressure Drop through an Orifice: Reducing the flow through an orifice will cause a reduced pressure drop across the orifice A medium flow causes a smaller 200 psi pressure drop

Pressure
Pressure Indicates Work Load: Pressure equals the force of a load divided by the piston area

Formula:

P= FA
Where: P = pressure (pounds per square inch (lbs/in2) or (kPa)) F = force (pounds (lbs) or (newtons)) A = area (square inches (in2) or (square centimeters))

Pressure
Pressure Indicates Work Load: An increase or decrease in the load will result in an increase or decrease in the operating pressure

Pressure is proportional to the load and the pressure gauge reading indicates the work load at any given moment
Pressure gauge readings (psig) normally ignore atmospheric pressure

A standard gauge reads zero at atmospheric pressure

An absolute gauge reads 14.7 psi (101 kPa) at sea level Absolute pressure is usually designated as psia (pounds per square inch absolute)

Force
Force is Proportional to Pressure and Area: Output force of a cylinder can be computed as follows

Formula:

F=PxA
Where: P = pressure (pounds per square inch (lbs/in2) or (kPa)) F = force (pounds (lbs) or (newtons)) A = area (square inches (in2) or (square centimeters))

Force
Force is Proportional to Pressure and Area: Below the hydraulic press has an operating pressure of 2000 psi The pressure is applied to a ram area of 20 in2, Find output force: F=PxA Substitute F = 2000 lbs/in2 x 20 in2 Therefore F = 40,000 lbs
1. This valve limits the maximum pressure in the system to 2000 psi. This controls the maximum force of the press
1000 750 1250 500 1500 250 1750 2000 0

psi

2. The force is 2000 psi x 20 sq in = 40,000 lbs or 20 tons of pressing force

Relief valve set at 2000 psi

750 500 250 0 1000 1250 1500 1750 2000

psi

Moving platen Fixed platen

Figure 1-15

Force equals pressure multiplied by area

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Area
Computing Piston Area: Formula:

A=x
4 = 0.7854

2 d

Where: A = area (square inches (in2) or (square centimeters (cm2)) d = diameter of the piston (inches (in) or centimeters(cm)) = pi (3.1416) Area of a piston can also be calculated with the formula A = r2 but pistons are measured by diameters so you would have to make sure to use the radius of the piston for any calculations

Formulas
Force, Pressure and Area relationships:

F=PxA P=FA A=FP 2 A=4xd

Speed
Speed of an Actuator: A. Speed of a piston or motor depends on its size and the rate of oil flow
1 gpm pump
75 0 50 0 25 0 0 10 00 12 50 15 00 17 50 20 00

A.

Below, both cylinders have the same volume, yet the piston in cyl B will travel twice as fast as cyl A because the flow from the pump is doubled If one of the cyl diameters were smaller its speed would be faster As long as the pump delivery remained constant B.
psi

Load

The cylinder has a 2 ft stroke

60

50

10

1 gpm pump
75 0 50 0 25 0 0 10 00 12 50 15 00 17 50 20 00

2. The 2 gpm pump will cause the cylinder piston to move 2 ft in 30 seconds
psi

3. The rate of fluid delivery and its area determine the speed of the cylinder

Load

2 gpm pump
75 0 50 0 25 0 0 10 00 12 50 15 00 17 50 20 00

psi

The cylinder has a 2 ft stroke

60

50

50

40

B.
2. The 2 gpm pump will cause the cylinder piston to move 2 ft in 30 seconds 2 gpm pump
75 0 50 0 25 0 0 10 00 12 50 15 00 17 50 20 00

Figure 1-16

Speed depends on cylinder size and rate of oil flow to it

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3. The rate of fluid delivery and its area determine the speed of the cylinder

psi

30

30

1. The one gpm pump will cause the cylinder piston to move 2 ft. in one minute

40

60 Seconds
60

30

1. The one gpm pump will cause the cylinder piston to move 2 ft. in one minute

40

60 Seconds

The cylinder has a 2 ft stroke

10

20

Load

20

10

30 Seconds

20

Speed
Speed of an Actuator: Formula:

speed (s) = flow (Q) area (a) flow (Q) = speed (s) x area (a)

area (a) = flow (Q) speed (s)

Where: Q = flow (in3/ minute or cm3/ minute) a = area (in2 or cm2) s = speed (in/ minute or cm/ minute)

Actuator Summary
From the previous formulas we can conclude:

1) The force or torque of an actuator is directly proportional to the pressure and independent of the flow
2) An actuators speed or rate of travel will depend upon the amount of fluid flow without regard to pressure

Velocity
Velocity in Pipes: The velocity at which hydraulic fluid flows is an important design consideration because of the friction developed by velocity Recommended Velocity Ranges: Pump Inlet Line = 2 4 feet per second (0.6 1.2 meters/second) Working Lines = 7 20 feet per second (2.1 6.1 meters/second)

Velocity
Velocity in Pipes: Doubling the inside diameter of a line will quadruple the crosssectional area This would mean that the velocity would only be one fourth as fast in the large line If you use half the size of pipe, the velocity will quadruple
1. The diameter of the large pipe is twice that of the smaller one 2. It would take four of the smaller pipes to equal the flow area of the larger one

1 in dia 2 in dia

Velocity
Velocity in Pipes: 1 in dia The velocity in the 2 dia line is 20 fps and the flow is laminar 2 in dia (smooth), as it flows into the smaller 1 dia pipe the flow is transitional (part laminar and turbulent), the velocity in the 1 dia pipe is 80 fps and the flow is turbulent Turbulent flow increases friction in the pipe and resists flow, which results in an increased pressure drop through the line 3. the through pipe is 4. Thefor same the flow will have to go through the 1 inch If Avelocity very lowthis velocity is recommended pump inlet line because 20 fps and the flow is laminar diameter portion of the pipe having only the (smooth) area of the 2 inch section. velocity will have very little pressure drop can be tolerated there, the The inlet lines are to be 80 fps to allow the fluid to pass usually one size larger than the outlet lines on a pump
2 in dia 1 in dia area

5. At this high velocit flow will be turbule (rough) this increa the frictional losse the pipe and is hig undesirable

Laminar flow

Transitional flow

Turbulent Flow

Pipe Sizes
Determining Pipe Size Requirements: Formula: (If GPM (l/m) and desired velocity are known)

Areapipe cross-section = GPM x 0.3208 Velocity (ft/sec) Velocity

(ft/sec) =

GPM x 0.3208 Areapipe cross-section

Typically increase the size of a pipe by 20% of the calculated size to account for inaccuracies, wear etc.

Size Ratings of Lines

Determining Pipe Size: In standard pipes, the actual inside diameter is larger than the nominal size quoted, so use a manufacturers chart to find accurate sizes
For steel and copper tubing, the quoted size is the outside diameter The inside diameter will be the outside diameter minus 2 times the wall thickness
Wall Thickness 1. Tubing size is quoted as outside diameter

Internal Diameter

2 in dia

2. To find the internal diameter, subtract two times the wall thickness from the quoted size

Work and Power

Work: Work is done whenever a force or push is exerted through a distance Formula:

Work = distance (ft) x force (lbs)

Where: Work units are foot-pounds (in metric it is joules) Work Example: A 10 lb (44.5N) weight is lifted 10 ft (3 m) Work = distance (ft) x force (lbs) Substitute Work = 10 ft x 10 lbs OR Therefore Work = 100 ft-lbs Work = 3m x 44.5 N Work = 135 J

Work and Power

Power: The rate of doing work is called power To visualize power, think of climbing a flight of stairs, It is more difficult to run up the stairs than to walk. When you run you are doing the same work but it is done at a faster rate (more power) Formula:

Power = distance x force time

OR

Work time

Where: Power units are horsepower (hp) (in metric its a watt (W)) 1 horsepower is equivalent to 33,000 lbs lifted 1 foot in 1 minute 1 watt is equal to 1 newton applied over a distance of 1 meter in 1 sec

Work and Power

Power: Formula:

1 hp = 33,000 ft-lbs minute

OR

550 ft-lbs second

1 hp = 746 watts (electrical power)

1 hp = 42.4 BTU/minute (heat power)

We convert hydraulic power to horsepower (watt) so that the mechanical, electrical and heat power equivalents will be known

HP in a Hydraulic System
Hydraulic Power: In the hydraulic system, speed and distance are represented by flow, and force is indicated by pressure, hydraulic power is expressed as: Formula:

Power = GPM x psi

Conversions: 1 gallon = 232 cubic inches (in3) 12 inches = 1 foot Thus: 1 gallon per minute flow at 1 psi equals 0.000583 hp

HP in a Hydraulic System
Hydraulic Horsepower Out of the Pump: The horsepower out of the pump is the exact power being used in a system Formula:

Hyd hpout = GPM x psi x 0.000583

OR

Hyd hpout = GPM x psi 1714

HP in a Hydraulic System
Mechanical Horsepower in to the Pump: The horsepower required to drive the pump will be somewhat higher than the pump puts out because the system is not 100% efficient If we assume an average efficiency of 83%, then power input requirements can be estimated using the following formulas: Formula: Imperial

hpin = GPM x psi x 0.0007

Metric

kW = L/min x bar x 0.002

Horsepower and Torque

General torque-power formulas for rotating equipment: It is desirable to convert back and forth from horsepower to torque without computing pressure and flow Formula: Imperial

torque = 63,025 x hp RPM hp = torque x RPM 63,025

Where: torque is in pound-inches

Horsepower and Torque

General torque-power formulas for rotating equipment: Formula:
Metric

kW = torque x RPM 9,550

Where: torque is in newton-meters

Designing a Simple Hydraulic System

Job to Be Done: All circuit design starts with the job to be done From this you can determine the actuator that will be used If you need to raise a load, a hydraulic cylinder would do the job The stroke length must be at least equal to the distance the load must 1. To raise an 8000 lb load 30 inches, be moved a cylinder with at least a 30 inch
stroke is required

Load
8000 lbs

30 in 30 in

Load
8000 lbs

Figure 1-19
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Use a cylinder to raise a load

Designing a Simple Hydraulic System

Size of Cylinder: The piston area is determined by the force required to raise the load and the desired operating pressure Assuming a weight of 8000 lb is to be lifted 30 in and the maximum operating pressure is limited to 1000 psi Cylinder stroke = At least 30 inches LOAD 8000 lbs Piston area = 8000 lb 1000 lb/in2 = 8 in2 This gives no margin for error 2. The pressure required to lift
the load equals the load divided by the piston area

By choosing a Piston area of 10 would have the capability of lifting up to 10,000 lbs The system pressure would only need to be 800 psi to lift the 8000 lbs 1. If the piston area is 10 sq in in2 we

8000 lbs = 800 psi 10 sq in

Figure 1-20 Choosing cylinder size

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Designing a Simple Hydraulic System

Size of Pump required: The rate at which the load must travel will determine the pump size The 10 in2 piston will displace 10 in3 for every inch it lifts the load Extending the rod 30 will require 300 in3 of fluid If it is to move at 10 inches per second, it will require 100 in3 of fluid per second or 6000 in3 per minute Pumps are rated in gallons per minute, so a conversion will be done Divide 6000 in3 per minute by 231 in3 per gallon to get GPM

GPM = 6000 in3/minute = 26 GPM 231 in3/gallon The pump required needs to be sized at 26 GPM

Designing a Simple Hydraulic System

Horsepower needed to drive the pump: Assume maximum operating pressure, therefore 1000 psi

hpin = GPM x psi x 0.0007 hpin = 26 gpm x 1000 psi x 0.0007 hpin = 18.2 hp
It will take 18.2 hp to operate the prime mover (electric motor) that drives the hydraulic pump

Designing a Simple Hydraulic System

Overload Prevention: To protect the pump and other components from excessive pressure due to overloads and stalling, a relief valve set to limit the maximum system pressure should be installed in the line between the pump outlet and the inlet port of the directional control valve
2. In this position of the directional valve 3. pump delivery is directed to the cap end of the cylinder 4. The piston rod extends

Load
1. The relief valve protects the system from over pressure by diverting the pump flow to tank when the maximum pressure setting is reached

Electric Motor

5. Exhaust oil is pushed out of the rod end and back to tank

Pump

Directional Valve

Figure 1-21
COPYRIGHT C (2001) EATON CORPORATION

Valving to protect and control the system

Designing a Simple Hydraulic System

Reservoir Size: The reservoir should hold approximately two to three times the pump capacity in gallons per minute Filters and adequate piping would complete the system
2. In this position of the directional valve 3. pump delivery is directed to the cap end of the cylinder 4. The piston rod extends

Load
1. The relief valve protects the system from over pressure by diverting the pump flow to tank when the maximum pressure setting is reached

Electric Motor

5. Exhaust oil is pushed out of the rod end and back to tank

Pump

Directional Valve

Figure 1-21
COPYRIGHT C (2001) EATON CORPORATION

Valving to protect and control the system

Any Questions?