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Simo SinkkoSaimaa UASLappeenranta, Finland
International Engineering Week in Schmalkalden 2017– IEW SM17
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Saimaa University of Applied Sciences
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3100 students and 300 experts form an innovative and open higher education team
High quality education, modern study environment and RDI support the internationalization and development of the area
Saimaa UAS is specialized in Russian business
Studying, teaching and research in five fields
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Understand the basic rules of hydraulics what are the things that affects the speed of an actuator
To know what different ways there areavailable for controlling the speed
To understand what are the advantages and disadvantages of each controlling method
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Hydraulics Pneumatics Electrical Mechanical
Linearmovement
Easy, highforce, accurate, cheap
Easy, butonly smallforces
Complicatedand expensive
Complicated
Rotary movement
Easy, highpowerdensity
Not suitablefor commonuse
Easy,efficient, (cheap), notreally limited
Belts, chains, gearboxes.Complicateto transferlong distances
Efficiency Poor Poor Good Good(excellent)
Controllability Easy Poor Excellent Limited
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Actuator can be either hydraulic cylinder orhydraulic motor. In this lecture, we will mainlyconcentrate into cylinder.
Force: F=pA
Speed: v=Q/A
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Single acting vs. doubleacting
Piston diameter D
Rod diameter d
Different force & speedin extending vs. retracting.
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There is a simplehydraulic system with pump, directionalvalve and a cylinder.
Calculate maximumforce and speed for both operating directions.◦ System max. pressure:
190 bar◦ Flow rate: 25 l/min◦ Piston diameter: 40 mm◦ Rod diameter: 20 mm
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Hydraulic cylinder speed is adjustedby throttles (one way flow controlvalve)
Flow through throttle can becalculated with Poiseuille’s formula:
α = Flow reference number= 0,611 (approx.)
A = Throttle cross-section [m2] Δp = Pressure drop [Pa] ρ = Density of the oil [kg/m3] Q = Volumetric flow rate [m3/s]
pAQ
20
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Restrictor is onlyeffective in one direction
Flow is throttled only in flow direction AB
Flow goes through non-return valve in flowdirection BA
Source of the picture: Merkle D., Schrader B., Thomes M., Festo Hydraulics Basic Level
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Hydraulic power canbe calculated with formula:
P = Qp
If speed is adjustedwith simplethrottling, whathappens to flow rateand pressure?
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Sometimes rapid motion is needed before the actual work begins. By guiding returning oil (from rod side) to pressure line, we can get boost for speed but reduction to force.
Counterbalance valves with regenerative function
Applied e.g. in woodcleaving machines
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Calculateextending speed of the cylinder (sameinitial values as earlier), with rapidmotion valve activated (returningoil is directed backto piston side).
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With regulating flowcontrol valves somebenefits can beachieved.
Due to pressurecompensation, flowrate through valve remains constanteven if external loadis changing
2-way flow controlvalve
3-way flow controlvalve
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Regulating restrictor finds hydraulicequilibrium which makes flow controlindepent from load.
Power consumption?
Complete symbol
Simplified symbol
Source of the picture: Merkle D., Schrader B., Thomes M., Festo Hydraulics Basic Level
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3-way flow regulator has tank connection where extra oil is directed oil doesn’t have to go through pressure relief valve lower pressure level less heat better efficiency compared to other flow control valves
Source of the picture: Kauranne H., Kajaste J., Vilenius M. Hydraulitekniikan perusteet
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If piston moves faster than 0,1 m/s, end position cushioning is normally needed to avoid heavy impacts
Suggested max. velocity for hydraulic cylinders is 0,2 m/s
End postion cushioning brakes piston speed just before collision to the end
With non-return valves it is possible to get non-cushioned start
Source of the picture: Merkle D., Schrader B., Thomes M., Festo Hydraulics Basic Level
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Theoretical flow rate:
Q=nVrev / Q=ωVrad
n=rotating speed of the pump [rps or rpm]
Vrev=pump displacement volume per one revolution [m3/r]
Vrad=pump displacement volume per one radian [m3/rad]
ω=2πn
Vrad=Vrev/2π
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By adjusting displacement volume of the pump we can adjust flow rate and thus the speed of the actuator
Both electric control and manual control arepossible
Q=nVrev
Bosch Rexroth hydraulic pumps
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Frequency converters are built for controllingthe speed of electric motors.
If we have fixed volume hydraulic pump thatis rotated by electric motor, we can adjust the hydraulic cylinder speed by adjusting the rotating speed of the electric motor
Q=nVrev
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Possibility to control flow same way as in the case of cylinders
Variable displacement motors (compare to pump) easy speed control
revnVQ
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Different ways to control actuator speed◦ Throttling easy and cheap but consumes energy
◦ 2-way regulating valves constant flow, butconsumes energy
◦ 3-way regulating valves load independent and low energy consumption
◦ Variable volume pumps easy, load independent, low energy consumption
◦ Hydraulic pump speed control with electric motor & frequency converter load independent, lowenergy consumption