F8 Hydraulic Systems 2017 - Session 2 · • Proper Design: Regulates or alters the behavior of all the components in the system for the desired behavior. – Actuators (cylinders

Training

Mobile Fluid PowerAfternoon Session

2017 FTTC

F8 – Hydraulic Systems

Mobile H

ydraulic

s Manual

Chapter 16

Hydraulic Fluids

John Hart – DTS Fluid Power, LLC

1:00

Hydraulic Fluid

• Means of Power Transmission

– Largely incompressible (stiffness)

• Lubrication

– Inherent property

• Sealing

• Cooling

• Contamination Removal

COPYRIGHT (1998) VICKERS, INCORPORATEDC 16-1

16-2COPYRIGHT (1998) VICKERS, INCORPORATEDC

Compressibility


Full-Film Lubrication


Boundry Lubrication


Sealing


4

1000

6

2000

8

3000

10

4000

12

5000

14

6000

16

7000

18

8000

20

9000

22

10,000

24

26

22.7

16.8

9600

12.9

4800

5.7

12009.6

2400

Summer Winter


10

20

30

40

50

60

70

80

90

100

110

120

110

90

74.8

61.2

50.6

41.4

35.2

28.8

24.2

19.8

KinematicViscosity

cSt @ 40 deg. C.


Eaton / Vickers Vane Pump Viscosity Recommendations



Fluid selection is an educated tradeoff!

Consult the experts before initial

selection or changing fluid from

recommendation!

Mobile H

ydraulic

s Manual

Chapter 17

Fluid Conditioning


1:15

Cooling & Contamination Removal

Introduction to Mobile Fluid Power

• Fluid Conditioning

“Cooling & Contamination Removal”

Contamination Definition

• Contamination: “anything that’s not supposed to be in the fluid.”

• Common contaminants: Solid particles (visible and microscopic), entrapped air, bacteria, water, ferrous and non-ferrous silt & incompatible fluids.

• Solid particles are measured in micrometers

(.0000394 inch.) There are 25,400 microns/ inch

Built-In Contamination

Component manufacturing processes

– Cast components: casting process material

– Machined components: machine chips, burrs and large other particles from milling, drilling and threading.

Fabricated components: weld slag, die grinding, cut scrap

Hose and tubing/ pipe cut-off: rubber carcass,

braid, carbon, rust, scale and tailings

Other debris: shop towels, tools, fasteners…

External Contamination

• Contamination

entering from the

environment

– Airborne dirt,

moisture, metal

particles, industrial

pollutants and

bacteria

• Ingression points:

Reservoir breather and

cylinder rod seals,

pump suction ports

and pump shaft seal

17-11

A: Full-Film Lubrication B: Boundary Lubrication

C: Mixed Film LubricationCOPYRIGHT (1998) VICKERS, INCORPORATEDC

COMPONENT MICRONS INCHES

Gear Pump

CLEARANCELOCATION

Gear to side plate

Gear tip to case

1/2 - 5

1/2 - 5

0.00002-0.0002

0.00002-0.0002

0.00002-0.0002

Vane Pump

Piston Pump

Servo Valve

Control Valve

Actuators

Hydrostatic Bearings

Antifriction Bearings

Slide Bearings

Tip of vane

Sides of vane

1/2 - 1

1/2 - 1

5 - 13

0.00002-0.00004

0.00002-0.00004

0.0002-0.0005

Piston to bore

Valve plate to cylinder

5 - 40

1/2 - 5

0.0002-0.0015

Orifice

Orifice

Flapper wall

Spool sleeve

Spool sleeve

130 - 450

18 - 63

1 - 4

0.005-0.018

0.0007-0.0025

0.00005-0.00015

Disk type

Poppet type

130 - 10,000

1 - 23

13 - 40 0.0005-0.0015

0.00005-0.0009

0.005-0.4

50 - 250

0 - 25

1/2

1/2

0.002-0.01

0.00005-0.001

0.00002-

0.00002-


17-1

Component Micron

100 mesh screen

Grain of table salt

Smog particle

Machining particle

200 mesh screen

Human hair

Pollen

Fog droplet

Particle visible to unaided eye

White blood cell

Grinding particles

Red blood cell

Honing particles

Yeast cells

Bacteria

Viruses

159

100

90

80+

74

70

60

50

40

24

10+

6

2+

1

0.2+

0.1+

COPYRIGHT (1998) VICKERS, INCORPORATEDC

Particle nearclearance size

Silt particlesParticle largerthan clearance


In both rolling and siding contact bearings, a thin oil film separates the ball from the race or the journal surfaces from the shaft. In most bearings, particles as small as 3µm can have a negative impact on the life of the bearing or system.



11-22

Normal Wear Wear OutBreak In

Time

Number Of Contamination Particles


1-50 Hours

5,000 10,000 20

RangeCode

Number of particles per1 ml of fluid

More than Up to =

20

40 12

19

18

17

16

15

14

13

11

10

9

8

7

6

5

4

3

2

1

5,0002500

25001300

1300640

640320

320160

16080

8040

10

105

52.5

2.51.3

1.3.64

.64.32

.32.16

.16.08

.08.04

.04.02

.02.01

RangeCode

Number of particles per1 ml of fluid

More than Up to =

80,000 160,000 24 20

40,000 80,000 23

22

21

20

20,000 40,000

10,000 20,000

10,0005,000


Filtration Rating

System

Sample number

Particle Count / Milliliter

> >10 micron5 micron

1

2

3

4

5

6

7

8

9

10

180 20

21401 4087

1703 342

11230

309

2303

1933

2437

3342

963

3209

63

406

313

183

419

155

Average of all Samples 4580 920


RangeNumber

80k40k20k

10k5k

2,500

1,300640320

1608040

20105

2.51.30.64

0.320.160.08

0.040.020.01

160k80k40k

20k10k5k

2,5001,300640

32016080

402010

52.51.3

0.640.320.16

0.080.040.02

242322

212019

181716

151413

121110

987

654

321

k = thousand

ParticleSize'x'in

micrometers

No. ofParticles

> 'x'in 1ml

sample

2510

152550

1,800390114

658.50.6

2 m 5 m 15 m


ISO 4406:1999

17-16

Fixed Gear 20/18/15 19/17/15Fixed Vane 20/18/15 19/17/14 18/16/13

1000 PSI 2000 PSI 3000 PSI+PUMPS

Fixed Piston 19/17/15 18/16/14 17/15/13Variable Vane 18/16/14 17/15/13Variable Piston 18/16/14 17/15/13 16/14/12

Directional (solenoid) 20/18/15 19/17/14Pressure Control (modulating) 19/17/14 19/17/14Flow Controls (standard) 19/17/14 19/17/14Proportional Directional (throttle valves) 17/15/12 15/13/11*Check Valves 20/18/15 20/18/15Servo Valves 16/14/11* 15/13/10*Cartridge Valves 18/16/13 17/15/12H.R.C. 18/16/13 17/15/12Proportional Pressure Controls 16/14/12* 15/13/11*Flow controls (pressure compensating) 17/15/13 17/15/13Proportional Cartridge Valves 17/15/12 16/14/11*

Cylinders 20/18/15 20/18/15 20/18/15Vane Motors 20/18/15 19/17/14 18/16/13Axial Piston Motors 19/17/14 18/16/13 17/15/12Gear Motors 21/19/17 20/18/15 19/17/14Radial Piston Motors 20/18/14 19/17/13 18/16/13Cam Wave Motors 18/16/14 17/15/13 16/14/12*

Hydrostatic Transmissions (in loop fluid) 17/15/13 16/14/12* 16/14/11*

Ball Bearing Systems 15/13/11*Roller Bearing Systems 16/14/12*Journal Bearings (high speed) 17/15/13Journal Bearings low speed) 18/16/14General Industrial Gearboxes 17/15/13

*Requires precise sampling practices to verify cleanliness levels.

VALVES

ACTUATORS

HYDROSTATIC TRANSMISSIONS 4000 PSI

BEARINGS


FILTER

TYPES

Full flowpressure

or return line

Full flowpressure

and return line

Pressure lineand recirculating

loop a 20% system volume

per minute

Pressure lineplus return

line plusrecirculating

loop

Recirculatingloop at 20% of system

volume

Recirculatingloop at 10% of system

volume

Recommendedfor high

ingressionsystems with fixed volume

pumps

Recommendedfor high

ingressionsystems with

variable volumepumps

Recommendedfor systemswith fixed

volume pumps

14/12/10

15/13/11

16/14/12

17/15/13

18/16/14

19/17/15

Ta

rge

t C

lea

nlin

ess


Beta Ratio Efficiency

1

2

5

10

20

75

100

200

1000

5000

0%

50.00%

80.00%

90.00%

95.00%

98.70%

99.00%

99.50%

99.90%

99.98%


Down-streamParticleCounter

Up-streamParticleCounter

Known contaminant


Zinga – AE Filter Elements (Cellulose Media)

Zinga – ZAE Filter Elements (Z-glass Media)

Other Considerations

� Pressure Rating of the Filter

�Pressure Drop Across the Element

�Dirt Holding Capacity

�Commonly expressed in “grams of dirt”

�Collapse, or “Crush” rating of the filter

�Pressure differential across the filter

SUPPORTMESH

SUPPORTMESH

DIFFUSERLAYER

DIFFUSERLAYER

MEDIA


WELL SUPPORTED ELEMENT POORLY SUPPORTED ELEMENT

FULL FLOW LIMITED FLOW PLEAT FAILURE

FLOW FATIGUE FAILURE ISCOMMON AT ROOT OF PLEAT


Supported fiber matrix after repeated stess

Inadequately supported matrix after repeated stress


Supported fiber matrix after repeated stess

Inadequately supported matrix after repeated stress


Mobile H

ydraulic

s Manual

Chapter 18

Circuits

Brian Burgess – DTS Fluid Power, LLC

1:35

Circuits Review• Proper Design: Regulates or alters the behavior of

all the components in the system for the desired behavior.

– Actuators (cylinders & motor)“provides the muscle”

– Directional Controls

“the command center

of the fluid power system”

– Control Valves

“the brains of the fluid power system”

Circuits Review

• Proper Design: Regulates or alters the behavior of

all the components in the system for the desired

behavior.

– Hydraulic Fluid

“transmits the power…”

– Fluid Conductors & Connectors

“connects the system together”

– Fluid Conditioning & Aux. Components

“keeps it running”

Typical Systems

• Pulling it together!

COPYRIGHT 1998 VICKERS, INC.C 1-6


SERIES -VS-PARALLEL

PARALLEL CIRCUITRY

SERIES -VS-PARALLEL

PARALLEL CIRCUITRY

Basic Hydraulic Principles

• Prior Discussions Open

Loop Systems

• Closed Loop

COPYRIGHT C 2-19(1998) VICKERS, INC.

COPYRIGHT C 2-20(1998) VICKERS, INC.

Basic Hydraulic Principles• Fluid Power component: Other controls

• Motion control, load holding and special

cases, variations will be covered later

Fluid Power Controls Circuits

• Integrated function blocks (manifolds)

8-9


To circuit

Orifice sized fordesired flow

Variable displacementpump with pressurelimiting and loadsensing compensator

Load sensingspring

PTDR

C1

S1

C2

DRLS

HRC

Pilot Pump

Boom Cylinders

EmergencyLowering Valve


Auger DriveMotor

Valvistor proportionalflow control valve

Variable displacementpressure compensated,load sensing pump

Pressure reducingvalve

Prime Mover


To temperature sensorand controller

Variable displacementpressure limiting, loadsensing pump

0.030 inchdiameterorifice


PTDR

C1C2

DRLS

Pilot Pump

Boom Cylinders

Float Valve

18-5

S1


Pump 1

LoadSense 1

LoadSense 2

Pump 2

X

X

HRC

HRC

CONTROL 1

CIRCUIT 1 CIRCUIT 2

CONTROL 2

CircuitSelector

Valve

CircuitCombining

ValveLoad Sense

SelectorValve


T P

LS

To Actuator

1:2

Load SensingValve Manifold



To lift, tilt,auxiliary System

C1 C2

Forward

Reverse

Left Propel

TractionControlValve

Right Propel

ParkingBrake

Propel SpeedControl

PowerSteering

Motor

X

SteeringCylinders


Power SteeringMotor

T P

Steering ModeSelector Valve

Articulated/Conventional/Crab

Left Front

Left RearRight Rear

Right Front


18-11

WaterPump

Water PumpFlow Adjustment


PT DR

C1C2

DR

LS

A

B

ToActuator

MomentaryHighPressureSwitch

Set toOperatingPressure

Set toIntermittentHighPressure


VelocityController

SpeedSensor

Valvistor

AC Generator


1:2

RegenerationSelectorManifold


PT DR

C1

C2

DR LS

PropelMotor

Creep ControlForward, Reverse


Applications & Capabilities

• From individual products to complete designs Fluid Power Specialists have products and expertise to provide complete fluid power system solutions.

Circuits Review


2:15

Item Description - See attached Spec Sheet

M +

_

1

Item Qty Description

1 1 12 VDC Power Unit

Title

Part Number

Drawing Number Rev.

Scale: Size: C

DRWN

AP'D

Material Spec.

Heat Treat

Finish

N/A

N/A

Std Black

12VDC Cab-Tilt Power Unit

DTS-CT101

JGH 02/18/10

N / A

P7


M +

_

1

2 2

3 3

4

4



2 2 Cab-Tilt Cylinder

3 2 Velocity Fuse

4 2 Customer Supplied Cab Latches

Title

Part Number

Drawing Number Rev.

Scale: Size: C

DRWN

AP'D

Material Spec.

Heat Treat

Finish

N/A

N/A

Std Black


DTS-CT102

JGH 02/18/10

N / A


M +

_

1

4

2 2

3 3

5

5

Optional Hand Pump



2 2 Cab-Tilt Cylinder

3 2 Velocity Fuse

4 1 Optional Back-up Hand Pump

5 2 Customer Supplied Cab Latches

Title

Part Number

Drawing Number Rev.

Scale: Size: C

DRWN

AP'D

Material Spec.

Heat Treat

Finish

N/A

N/A

Std Black


DTS-CT103

JGH 02/18/10

N / A

Circuits Review

Brian Burgess – DTS Fluid Power, LLC

Aerial Circuit

3:00

Meet outside @ 3:45 pm

3:30

Documents

F8 Hydraulic Systems 2017 - Session 2 · • Proper Design: Regulates or alters the behavior of all the components in the system for the desired behavior. – Actuators (cylinders