Advanced Hydraulic: Theory and Applications

Day 1

The Laws and Principles of Hydraulics              

• An Overview of Hydraulic Principles, Maintenance and Application

• Pascal’s Law

• Computing Force, Pressure, and Area

• Bernoulli’s Principle

• NASA Aircraft Example

• Advantages of Hydraulic Systems

Causes of Hydraulic Failures              

• Common System Faults

• Wear in Hydraulics

• Hydraulic Leaks

• Preventive Maintenance of Hydraulic Systems

• Finding Root Causes

Physical basics of hydraulics and the design of simple hydraulic cylinder system                   

• Categories of actuators; including Rotary and Linear Actuators

• Hydraulic cylinders classifications; including Single and Double acting cylinders

• Pistons

• Cylinder mountings

Calculation of a hydraulic motor application

• Hydraulic motors

• Limited rotation hydraulic motor

  • Hydraulic motor performance

  • Mechanical efficiency

  • Overall efficiency

• Electro-hydraulic stepping motors

• Pumps

• Hydraulic pumps

  • Hydraulic pump types; including Gear, Rotary vane, Screw and Radial piston pumps

  • Pumps for open and closed systems

• Multi pump assembly

• Hydraulic pumps, calculation formulas; including Flow, Power Mechanical and Hydraulic efficiency

Theory of Fluid, Pressure, Force & Air                

• Fluid

  • Characteristics of Fluids

  • Movement of Fluid Under Pressure

  • Mechanical Advantage

  • Handling of Fluids

  • Fluids used in Hydraulics

• Flow, Force, Pressure and Air

Theory of hydraulic filters and cleanliness control

• Filter; including Micron, Beta ratio and Filter location

• Filters and Contaminants

• Cleaning Maintenance practice

• Cleaning of parts; including Cleaning of seals, Oil seal installation, Inspecting castings and machined surfaces, Gaskets, seal rings and 0-rings

• Cleaning and Flushing Basics for Hydraulic Systems

• Inspections:

  • Daily and Monthly Checks

  • Hydraulic Systems Inspection and Service

• Start up and Maintenance of Hydraulic System

• Maintenance and Watchkeeping: Simple Maintenance Hints

Day 2

Thermal control of hydraulic systems   

• Define and explain Heat Exchangers

• Heat dissipation heat exchangers:

  • Air-cooled and Water Cooled

  • Advantages & Disadvantages

Hydraulic components and Valves         

• Pressure­control valves; incl. Pressure­Relief Valve, Simple Pressure­Relief Valve and Compound Pressure­Relief Valve

• Directional Control Valves; including Complex Valves, Poppet Valve, Sliding­Spool Valve, Two­Way and, Four­Way Valves.

• Control Valve Repair

• Proportional valves; including Proportional Control Valve Circuits and Circuits with proportional throttle valves

• Typical conventional valve circuit with resistive load

• Cartridge valves; including slip-in cartridge valves

• How to Monitor A Hydraulic Machine’s ‘Vital Signs’

Hydraulic Accumulators, Circuits and Control Theory           

• Accumulators – selection of and calculation of size; including Weight-loaded-type, Spring-loaded-type, Gas-loaded-type, Non-separator type, Piston-type separator gas-loaded and Bladder-type separator gas-loaded accumulators

• Accumulator applications

• An auxiliary power source

• Leakage compensator

• Hydraulic shock absorber

Step-by-Step Building of a Hydraulic system         

• Step 1: Understand how a hydraulic system works

• Step 2: Determine what type of power source your hydraulic system will require

• Step 3: Look at some simple, everyday hydraulic systems to help you become familiar with their function.

• Step 4: Plan your hydraulic system project with the design parameters you will require.

• Step 5: Determine the amount of work your system will do to allow you to size the components

• Step 6: Choose the appropriate container for your hydraulic fluid reservoir

• Step 7: Pick a suitable material to plumb up your hydraulic circuit

• Step 8: Find a suitable valve system for your task

• Step 9: Select the type of and capacity of your hydraulic pump

• Step 10: Pair up a suitable motor to your pump

• Step 11: Hook up your power application component

• Step 12: Build a support frame that will position each component in a position where it will perform it’s task

• Step 13: Fill the system with the hydraulic fluid you choose, bleed the air out of it, then pressurize it to check for leaks

Hydraulic control theory

• Pressure compensation and load sensing, closed loop and open loop

• Control valves

• Control components in a hydraulic system

  • Centering washers

  • Simple pressure relief valve

  • Pressure-compensated flow control valves

  • The Hydraulic Lever