BENHA UNIVERSITY BANHA FACULTY OF ENGINEERING MECHANICAL ENGINEERING DEPARTMENT

M578 HYDRAULIC POWER SYSTEMS 5 YEAR PRODUCTION ENGINEERING DR. H. EL-BATSH | ENG. ABDALLA MOHAMED
TH

SHEET6: HYDRAULIC SYSTEM DESIGN

PROPLEMS 1. Design a hydraulic circuit to lift a guided load of 4 tones vertically for a stroke of 0.5 m. The retract speed of the load is 6 m/min. The hydraulic cylinder is mounted by its front flange and the piston rod is rigidly fixed. The system pressure is limited to 300 bar. a) Construct the hydraulic circuit with its accessories and explain the function of each element. b) Design the actuator. c) Estimate the pump type, its flow rate in liter per minute, and the extending speed. d) If you connect a hydraulic motor instead of the hydraulic cylinder, calculate the torque produced if the load will be driven with 30 rpm. (Hint: take into your consideration the volumetric and mechanical efficiencies) 2. It is required to design a big hydraulic crane is used to lift a mechanical load of about 10 tons vertically for a distance of 1 meter with a speed 3 m/min. The system must provide locking for the cylinder position in any position, and gives 8 different speeds. a) Draw the hydraulic circuit with its accessories and explain the function of each component. b) Design the hydraulic actuator i. Select its type. (Write your reasons) ii. Find its dimensions. iii. Estimate the best method for mounting. (Draw a free-hand sketch for it) c) Select the hydraulic power unit i. Select the pump type. (write your reasons) ii. Which type of displacement is it? iii. Calculate the input power required at the pump shaft in kilowatts.

3. In a given hydraulic system, the hydraulic cylinder is 12 cm inner diameter which drives a load of 200 kN with a speed of 8 cm/s. The pump overall efficiency is 0.85. Determine a) The pump exit pressure and the pump flow rate. b) The power and the torque required to drive the pump if the pump is driven by an electric motor with speed of 3000 rpm. c) The maximum possible cylinder load and corresponding pump driving power if the relief valve is adjusted at 30 MPa. 4. A hydraulic cylinder is to compress a car body down to a bale size in 10 seconds. The operation requires 13.05 m stroke and 35520 N force. If a 68 bar pump has been selected and assuming the cylinder is 100% efficient, find the following: a) The required piston area. b) The necessary pump flow rate. c) The hydraulic power delivered to the cylinder. d) Solve parts a, b, and c assuming frictional force of 444 N and a leakage of 0.776 lpm. Then determine the efficiency of the cylinder with the given friction force and leakage. 5. A sequence valve is used in a hydraulic press with two cylinders. The first cylinder exerts 10 kN to move and hold the work piece while the other cylinder is used to perform the pressing job with 180 kN. Both cylinders have bore diameter of 150 mm and a 100 rod diameter. Both cylinders have to move at velocity of 5 m/min. Draw the circuit using symbols [2 marks] and then determine: a) Pump pressure during work piece movement. b) Pump pressure during pressing. c) The capacity of the pump. d) Select appropriate pressure to set the sequence valve. 6. A machine tool cylinder gives a rapid approach speed of 10 m/min for a stroke of 1.0 m with a thrust of 2.5 tones. It then switched to give a pressing speed of 0.25 m/min for a 0.5 m with a thrust of 10 tones. The system working pressure should not exceed 200 bar. Draw a hydraulic circuit which can satisfy these requirements and obtain the following: a) Suitable size for the cylinder. b) The pressure setting for switching the circuit. c) The circuit efficiency for rapid approach and for final pressing. 7. The cylinder shown in figure has to apply extend force of 80 kN and retract force of 10 kN. The retract speed should be 5 m/min using full pump flow. The maximum pump pressure is 150 bar and the pressure drops over the filter is 3 bar and over the directional valve (for each path) is 2 bar.

Determine the cylinder size (assuming 2:1 ratio piston area to piston rod area). Determine also the pump size and circuit efficiency during extend and during retract.

8. A sequence valve is used in a hydraulic press with two cylinders. The first cylinder exerts 10 kN to move and hold the work piece while the other cylinder is used to perform the pressing job with 180 kN. Both cylinders have bore diameter of 150 mm and a 100 rod diameter. Both cylinders have to move at velocity of 5 m/min. Draw the circuit using symbols and then determine: a) Pump pressure during work piece movement. b) Pump pressure during pressing. c) The capacity of the pump. d) Select appropriate pressure to set the sequence valve. 9. A hydraulic power system has cylinder piston diameter = 20.3 cm and piston rod diameter = 10.2 cm. the cylinder extending speed is 7.6 cm/s. the external load of the cylinder during extend = 178 kN. The pump mechanical efficiency =90 % and the pump volumetric efficiency = 92%. Pump speed = 1800 rpm. The total pressure drop in the line from pump discharge to the cylinder is 5.2 bars and the pressure drop in the return line from the rodend of the cylinder is 3.5 bar. Draw the circuit using standard symbols and determine the following: a) Pump volumetric displacement. b) Input power to drive the pump. c) Input torque to the pump. d) Circuit efficiency during extend. 10. A press cylinder having a bore of 140 mm and a 100 mm diameter rod is to have an initial approach speed of 5 m/min and final pressing speed of 0.5 m/min. The system pressure for rapid approach is 40 bar and for final pressing 350 bar. Two pumps (high and low) are used in the system. Both pumps may be assumed to have volumetric and mechanical efficiencies of

0.95 and 0.9, respectively. Draw the circuit using symbols and then determine: a) The flow to the cylinder for rapid approach and final processing. b) Suitable deliveries for each pump. c) Each pump displacement if the drive speed is 1800 rpm. d) The pump motor power required during rapid approach and during final pressing. 11. A hydraulic power system has cylinder piston diameter = 20.3 cm and piston rod diameter = 10.2 cm. the cylinder extending speed is 7.6 cm/s. the external load of the cylinder during extend = 178 kN. The pump mechanical efficiency =90 % and the pump volumetric efficiency = 92%. Pump speed = 1800 rpm. The total pressure drop in the line from pump discharge to the cylinder is 5.2 bars and the pressure drop in the return line from the rod-end of the cylinder is 3.5 bar. Draw the circuit using standard symbols and determine the following: a) Pump volumetric displacement. b) Input power to drive the pump. c) Input torque to the pump. d) Circuit efficiency during extend. 12. Shown is the load-lifting mode of a hydraulic system having the following parameters: Pump: a swash plate axial piston pump, with piston diameter = 8 mm, pitch circuit diameter = 3 cm, swash plate inclination angle = 20, mechanical efficiency = 0.9, total efficiency = 0.81, number of pistons = 7, pump speed = 3000 rpm. Relief valve: preset at a relief pressure of 10 MP, with zero override pressure. Hydraulic cylinder: an ideal cylinder, loaded by a constant load of 60kN; the piston and piston rod diameters are 10 cm and 7 cm, respectively. Check valve: of zero cracking pressure. Throttle valve: sharp-edged with a 3 mm2 cross-sectional area. Hydraulic oil: a 850 kg/m3 density. (a) Explain the function of the system. (b) Calculate the piston speed and pump driving power at each of the two positions of the DCV if the pressure in the pump delivery line does not reach the preset relief pressure. Neglect the losses in lines and DCV.

13. For the following system, calculate the pump exit pressure, and the override pressure of the relief valve, given: Pump: pump speed = 1000 rpm, volumetric efficiency = 0.95, and pump displacement = 8 cm3 Relief valve: Pr = 22.5 MPa, andQr = K(Override pressure) ; K = 1013 where Pp is the pump exit pressure and (Pp Pr ) is the override pressure Throttle valve: throttle area a = 1 mm2 and Qm = 0.029a . Hydraulic motor: motor displacement Vm = 80 cm3/rev, total efficiency = 0.68, volumetric efficiency = 0.93, and loading torque = 200 Nm.

14. A 50-kN hydraulic press performs pressing and clamping actions. The clamping cylinder force is 4 kN. The pressing cylinder stroke is 30 cm and its extension speed is 8 cm/s. Design the hydraulic circuits, perform the preliminary calculations, and select the needed hydraulic elements. Then, calculate the different operating modes of the system. Assume, always, reasonable values for any missing data.

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