Design of Hydraulic systems

In spite of being subject to the laws of science the flexibility of hydraulic systems is what makes the application one of the more favoured in industry.

Flexibility of design will allow hydraulic systems to be created to serve a specific purpose.

Design Parameters

• Is hydraulics the correct application for the desired result?
• Flexibility of hydraulic system and of assisted function
• Longevity
• Expected load bearing
• Operational requirements, eg. hours equipment runs at a time
• Temperature of equipment
• Maintenance requirements
• Pump configuration
• Displacement
• Weight
• Mass Moment of Inertia

Operating Parameters of Hydraulics

System Pressure

The lifespan of a hydraulic unit is determined by the pressure placed on the unit during operation. A high pressure load will reduce the longevity of a hydraulic unit.

Application Pressure

This is the applied system pressure at which maximum calculated torque is applied with in the unit.

Maximum working Pressure

Given the sizing of the component, maximum working pressure is the height of pressure at which a unit can operate. This is however not a constant rate. Operation at a lower rate will be more suited to efficiency and longevity.

Maximum Pressure

This is the highest allowable pressure under any circumstance and should not be maintained for any period.

Minimum low loop pressure

Must be maintained under all operating conditions to avoid cavitation.

Pump life

The life of a hydraulic pump is dependent on the efficient design and a continuous inlet pressure. Inlet pressure is determined by the adequate design of the inlet filter. If pressure within the hydraulic equipment is low, performance will be sub-par and possibly non-existent. Low pressure can occur at cold start of equipment but this should improve as the fluid warms.

Sizing correct companion motors and equipment can be guided by the expected or required function of pump displacement.

Hydraulic life is equal to the life expectancy of it's components. It is a function of speed and system pressure

Safety

Safety of any equipment should be a first line consideration in the design thereof. Consider the type of equipment being designed and its application to determine the various safety factors. because hydraulic equipment includes motion and works under pressure there are two concerns which cannot be overlooked in the design process.

Brakes

The loss of hydrostatic drive line power in any mode of operation may cause the system brakes to fail. You will need to provide an independent braking system with the capacity to stop and hold the machinery or equipment in question.

High Pressure Relief valves

These valves are designed as protection against over pressure on the system and not as continuous pressure control. Inappropriately used there is a risk of damaging heat build-up and increased pressure levels which may result in damage to the system.

Once the system has been designed and is fully operational there are certain maintenence levels which need to be adhered to in order for the equipment to operate at the favoured levels.

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