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Basic Hydraulics: Basic Hydraulic Circuits Basic Hydraulic Circuits
Basic Hydraulics: Basic Hydraulic Circuits Basic Hydraulic Circuits
LEARNING
HYDRAULICS ACTIVITY
PACKET
TM
BB831-XA02XEN
LEARNING ACTIVITY PACKET 2
INTRODUCTION
This LAP will explore two new components: motors and needle valves. Both of
which are often used in hydraulic circuits.
The first segment will continue to discuss hydraulic pumps, and the last segment will
explain the interpretation and creation of hydraulic schematics. These are important skills
to know when working with fluid power.
ITEMS NEEDED
You will need the following items in order to perform this LAP.
Amatrol Supplied
1 85-BH Basic Hydraulic Training System
1 85-HPS Hydraulic Power Unit
School Supplied
1 Allen Wrench Set
1 Stopwatch
1 Measuring Container (1-5 gal./3.78-18.9 liters)
Shop Towels or Rags
SEGMENT 1 PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OBJECTIVE 1 Define flow rate and explain how it can be measured
OBJECTIVE 2 Describe the operation of two types of flowmeters and give their schematic symbol
SKILL 1 Connect and read a flow meter
Activity 1 Flowmeter accuracy
OBJECTIVE 3 Describe the operation of a fixed-displacement pump and give its schematic symbol
Activity 2 Fixed-displacement pump operation
OBJECTIVE 4 Describe the operation of three types of fixed-displacement pumps and give an application
of each
The flow rate of a fluid indicates the amount of fluid that flows past
a point in a certain amount of time. This amount can be measured as a
weight or volume. In hydraulics, flow is most often measured by volume.
The most common flow rate units of measure are gallons per minute
(gpm) in the U.S. Customary system and liters per minute (lpm) in the
S.I. metric system.
POINT A
VOLUME OF FLUID
Rotameter
The rotameter consists of a transparent tube which contains a
movable piston. The tube and piston are constructed so that the fluid
flows through the tube and around the piston, as shown in figure 2. The
flow rate is determined by measuring the height to which the piston is
raised by the force of the fluid flow.
This type of flowmeter must be oriented in a vertical position and is
usually rated for low pressures. This means it can only be used in a return
line.
OUTLET
TAPERED GLASS
METERING TUBE
INLET
Figure 2. Rotameter
MAGNETIC
PICKUP
TURBINE
WHEEL
Procedure Overview
In this procedure, you will connect the flowmeter to the
outlet of the pump and measure its flow rate.
IN
SUPPLY
MANIFOLD
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
SHUTOFF
VALVE
RETURN
MANIFOLD
IN A
OUT B
IN
OUT
SMALL CYLINDER
❑ 11. Turn on the power unit and adjust the pressure to 500 psi/3447 kPa.
❑ 12. Open the shutoff valve.
❑ 13. Now cycle the cylinder and observe the flowmeter reading.
Record the flow rate when the cylinder extends, retracts, and stops.
Extending
Retracting
Stopped
Did you notice that the flow rate is different when the cylinder
extends and retracts? The rate you measured should have been
approximately 2.5 gpm/9.5 lpm extending and 2.7 gpm/10.2 lpm
retracting. You will learn in the next LAP why there is a difference
between retracting and extending flow rates.
❑ 14. Reduce the relief valve setting to its minimum.
❑ 15. Close the shutoff valve and turn off the power unit.
❑ 16. Move the DCV handle back and forth to remove all pressure.
❑ 17. Disconnect the hoses and proceed to the activity.
Procedure Overview
In this procedure, you will verify the accuracy of the
flowmeter by comparing the flowmeter’s reading at several
flow rates to the actual flow rate measured using a
container and a stopwatch.
OUT
IN
SUPPLY
MANIFOLD
SUPPLY
LINE OPEN END
FITTING
CAP
FILLER/
BREATHER
OPENING
POWER MEASURING
UNIT CONTAINER
OPEN-END
FITTING
SHUTOFF
VALVE
MEASURING
CONTAINER
RETURN
MANIFOLD
❑ 11. Close the shutoff valve, empty the container back into the power
unit tank through the filler-breather opening, and place the
container next to the reservoir.
❑ 12. Again, while directing the open hose end into the filler-breather
opening, slowly open and adjust the shutoff valve to set the flow to
1.0 gpm/3.8 lpm through the flowmeter.
❑ 13. Switch the hose back to the container and again measure the time
required to fill it. Direct the hose back to the filler-breather
opening and record this time in the chart.
❑ 14. Repeat steps 11, 12, and 13 for the other two flow rates listed in
the chart.
❑ 15. Close the shutoff valve and reduce the power unit relief valve
setting to minimum (turn fully CCW).
❑ 16. Turn off the power unit.
❑ 17. Empty the container back into the power unit tank through the
filler-breather opening.
❑ 18. Replace the filler-breather cap on the reservoir and clean up any
spilled oil, using clean shop rags.
NOTE
Seconds must be converted to minutes for this formula.
❑ 20. Using your data from step 19, calculate the difference in flow rate
between the flowmeter reading and the actual. Record in the chart
in step 19.
None of your differences should exceed 0.25 gpm/0.95 lpm for
this flowmeter. Slight differences exceeding the stated accuracy of
±5% of full flow could be attributed to measuring and timing
inaccuracies.
PUMP
PARTIAL
VACUUM PRESSURE
LINE
TO SYSTEM
INLET OUTLET
SUCTION
LINE
ATMOSPHERIC
PRESSURE
30 in Hg
RESERVOIR
In order for the pump to supply flow to the system, oil must flow
from the reservoir to the pump’s inlet. The pump causes this oil to flow
through the suction line by creating a partial vacuum at its inlet. This
allows the atmospheric pressure pressing on the oil in the reservoir to
force oil through the suction line into the pump’s inlet port. The pump
then pushes the oil through to the outlet and discharges it into the
pressure line.
PUMP
ELECTRIC
MOTOR OUTLET
SOLID ARROW INDICATES
MEDIUM IS LIQUID
INLET CIRCLE
INDICATES
COUPLING ROTATING DRIVE
SUCTION
FILTER
RESERVOIR
Procedure Overview
In this procedure, you will show that a
fixed-displacement pump produces the same flow
regardless of pressure.
SUPPLY
MANIFOLD
SHUTOFF
VALVE FLOW
METER
RETURN
SUPPLY
MANIFOLD
LINE
RELIEF
VALVE
GAUGE
S
RETURN
LINE
M
200/1380 /
250/1725 /
300/2070 /
350/2415 /
400/2760 /
GEAR
PISTON
VANE
HOUSING IDLER
GEAR
INCREASING
VOLUME
ROTARY
DRIVE GEAR MOTION
SHAFT
CONNECTED TO DRIVE
(ELECTRIC MOTOR)
Vane Pump
Vane pumps have a rotor containing movable vanes that slide in and
out in radial slots of a rotor. As the shaft turns the rotor, the centrifugal
force throws the vanes out against a surrounding cam ring or housing.
The suction at the inlet is created when the vanes rotate around toward
the inlet. Because the rotor is positioned off center, these vanes create an
increasing volume at the inlet which creates a partial vacuum.
HOUSING
INLET OUTLET
INCREASED
VOLUME VANES
Piston Pump
Piston pumps use a number of pistons which each create a pumping
action. As the pistons are rotated by the barrel, they move in and out
because they are held on one end by an angled swashplate. This creates
an increasing and decreasing volume action similar to a syringe.
High pressure applications such as presses and molding machines
often use piston pumps. They are the most efficient but also the most
expensive.
BARREL
PISTONS
SWASHPLATE
SHAFT
VALVE PLATE
ADJUSTMENT
SCREW
PORT A
FLOW PORT B
VALVE BODY
SYMBOL EXPLANATION
VARIABLE
ORIFICE
PORT PORT
A B
ORIFICE
Procedure Overview
In this procedure, you will use a needle valve to control
flow rate through a flowmeter. You will also demonstrate
that the flow is controlled in both directions through the
valve.
SUPPLY
MANIFOLD
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
Figure 21. Pictorial of Circuit for Measuring Needle Valve Flow Rate
FLOW
METER
Figure 22. Schematic Diagram for Measuring Needle Valve Flow Rate
The long and short dashed lines drawn around the power unit
components tell you that these components are mounted together.
❑ 2. Perform the following checkout procedures for the power unit.
A. Check the oil level. Fill if necessary.
B. Press the stop push button on the motor starter to make sure it
is in the Off position.
C. Plug in the power cord to a wall outlet.
D. Reduce the relief valve to its minimum pressure setting (turn
CCW fully).
❑ 3. Open the needle valve by turning the adjustment knob fully CCW.
❑ 4. Close the shutoff valve fully.
❑ 5. Turn on the hydraulic power unit.
❑ 6. Increase the pressure setting on the relief valve to 500 psi/3447
kPa.
❑ 7. Open the shutoff valve and observe the flow rate through the
flowmeter.
Gauge S Pressure ________________________________(psi/kPa)
ADJUSTMENT KNOB
(TURNED IN)
FLOW RESTRICTED
HERE
Figure 23. Needle Valve Shown Controlling Fluid Flow by Restricting the
Passage
RELIEF LOW
VALVE PRESSURE
RESERVOIR
Figure 24. Relief Valve Closed, Flow Constant Through Needle Valve
HIGH LOW
RELIEF
PRESSURE PRESSURE
VALVE
RESERVOIR
Figure 25. Relief Valve Partially Open, Flow Reduced Through Needle
Valve
❑ 11. See if you can adjust the flow rate, using the needle valve, to each
of the following flow rates: 2.0 gpm/7.6 lpm, 1.5 gpm/5.7 lpm, 1.0
gpm/3.8 lpm and 0.5 gpm/1.9 lpm.
This will give you more experience with the adjustment of the
needle valve.
You should observe that the pressure continues to rise as the
needle valve’s opening gets smaller.
❑ 12. Reduce the relief valve to its minimum pressure setting (turn CCW
fully).
❑ 13. Close the shutoff valve and turn off the power unit.
❑ 14. Switch the hoses at the needle valve so that the supply hose
connects to port B and the hose to the flowmeter connects to port
A. This will allow oil to flow in the other direction through the
needle valve.
Procedure Overview
In this procedure, you will use a needle valve to control
the speed of a cylinder. This is a common task done every
day in industry.
SUPPLY
MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL SHUTOFF
3 3 VALVE
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
Figure 26. Circuit for Controlling the Speed of a Cylinder with the Needle
Valve
OUT B
SMALL BORE
CYLINDER
CYLINDER
RETRACTED
CYLINDER
EXTENDED
2 LITERS OF OIL
Procedure Overview
In this procedure, you will use the directional control
valve to control the speed of the cylinder by opening it
partially. This action causes the DCV spool to restrict the
flow similar to the needle valve. Hydraulic systems in
construction equipment such as backhoes often use this
technique.
❑ 1. Continuing from the previous skill, gently push the lever of the
DCV slightly off center so that the spool of the DCV is only
partially shifted. Observe the speed of the cylinder.
NOTE
Control of cylinder speed may be sensitive because this DCV
was not made with tapers on the spool.
ELEC.
LOAD
MOTOR
MOTOR MOTOR
DRIVES DRIVES
PUMP LOAD
IN OUT IN OUT
PRESSURE
LINE
PUMP MOTOR
SUCTION
LINE
RETURN
LINE
RESERVOIR
UNI-DIRECTIONAL BI-DIRECTIONAL
IN
OUT
Procedure Overview
In this procedure, you will set up a basic hydraulic
circuit that will allow you to stop, start, and operate a motor
in both directions of rotation. This circuit uses a 4-way,
3-position DCV to control a bi-directional motor.
SUPPLY
MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL SHUTOFF
3 3 VALVE
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
IN A
SHUTOFF
VALVE OUT B
TEE
GAUGE A
RETURN
MANIFOLD
FLOW
METER
NOTE
Verify that the flywheel has been removed from the motor’s
shaft before continuing. This flywheel is shown in figure 35. If it is
attached, ask your instructor to assist you in removing it.
You should observe that the motor runs in the opposite direction
for each position of the handle.
0.75 / 2.8
1.0 / 3.8
1.5 / 5.7
2.0 / 7.6
1.0 / 3.8
❑ 13. Now adjust the circuit using the following substeps so you can
observe the effects of rapidly reversing motor rotation.
A. Push the lever of the DCV in and hold it so the motor runs.
B. Adjust the needle valve so that the flow rate is 0.75 gpm/2.9
lpm.
❑ 14. Now test the ability of the motor to be quickly reversed by shifting
the lever of the directional control valve quickly from a full-in
position to a full-out position. Record the peak pressure reading on
Gauge A when you do this.
No flywheel, moderate speed:
NOTE
For safety and proper operation, the flywheel must be locked
firmly to the motor shaft. As shown in figures 37 and 38, the
flywheel is locked using slots in the flywheel, a slot in the shaft,
two set screws, and a key.
A. Locate the flywheel and remove the first set screw using a
3/32-inch Allen wrench, as shown in figure 36.
There are two set screws in the flywheel. One tightens against
the shaft. The other (the one you are removing) holds the
second set screw in place.
Figure 36. Removing a Set Screw from the Flywheel Using a 3/32-inch
Allen Wrench
SET SCREW
ACCESS HOLE
HYDRAULIC
MOTOR
KEY SLOTS
KEY
FLY WHEEL
HYDRAULIC
MOTOR
FIRST
SET
SCREW
SECOND
SET
SCREW
KEY
FLYWHEEL
Gear Motors
There are two types of gear motors available: standard gear motors
and gerotor motors. A standard gear motor uses two meshing spur gears
that rotate inside a housing. This design is so similar to its pump
counterpart that many gear motors can be used as pumps.
The gerotor motor, shown in figure 39, uses an internal gear that
rotates inside a ring gear similar to planetary gears. Gerotor motors are
generally less efficient than other types of motors but they are very
inexpensive and highly durable under extreme environmental conditions.
Gerotor motors are very popular for light-duty mobile applications
including agriculture, mining, and construction.
BENT AXIS
INLINE RADIAL
INDICATES THAT
RETURN LINE GOES
TO THE RESERVOIR
M
SUPPLY FROM
PUMP
RETURN TO
RESERVOIR
Procedure Overview
In this procedure, you will draw schematics by looking
at actual circuit connections on pictorials. This is a
common requirement in industry because the schematics
are not often readily available.
❑ 1. On a copy of figure 47, draw the circuit schematic for the pictorial
shown in figure 46. Start from the supply and return manifold
connections as shown. You may show flexible hoses as rigid
connectors (i.e. a straight line) and omit all quick-connect symbols.
SUPPLY
MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3
3
#1 #2
A A
NEEDLE
VALVE
A B
B B RETURN
MOTOR MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
❑ 2. On a copy of figure 49, draw the circuit schematic for the pictorial
shown in figure 48. Start from the supply and return manifold
connections as shown. You may show flexible hoses as rigid
connectors (i.e. a straight line) and omit all quick-connect symbols.
SUPPLY
MANIFOLD
SUPPLY
MANIFOLD
SUPPLY
MANIFOLD
1 1 SHUTOFF
2 2 VALVE
FLOW FLOW
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
Procedure Overview
In this procedure, you will draw pictorials of the
hydraulic trainer’s actual circuit connections given
schematics. This will help you develop your skills in
reading schematics.
SUPPLY
MANIFOLD
1 1 SHUTOFF
FLOW FLOW 2 2 VALVE
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
GAUGE A
GAUGE C
SUPPLY
MANIFOLD
1 1
SHUTOFF
FLOW FLOW 2 2 VALVE
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
GAUGE B GAUGE A
SUPPLY
MANIFOLD
1 1
SHUTOFF
FLOW FLOW 2 2 VALVE
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
Procedure Overview
Now that you have learned how to draw schematics,
you will get a chance to combine this skill with your
creativity to design a more complex hydraulic circuit.
H. HYDRAULIC MOTOR
A. HYDRAULIC G
DRIVE
CLAMP
CYLINDER B D
C
N
F
L J
CLAMP
CYLINDER
MOTOR