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chapterfive [Autosaved].ppt
1. Overview
Types of Cylinders
Construction and Operation
Cylinder Ratings
Formulas for Application
Cylinder Features
Installation and Trouble Shooting
2. 1. Hydraulic pump unit : in an actual hydraulic system a pump converts
mechanical power into fluid power.
2. Control valve : the flow of pressurized liquid discharge by the pump is
controlled by valves.
Pressure control valves- control the liquid pressure .
Flow control valves : control the liquid flow rate.
Directional control valve : control the direction of flow of the liquid.
3. Hydraulic motor/cylinder
The liquid discharged by the pump is directed to hydraulic motors or cylinders
by control valves.
Motors are used where rotory motion is desired and cylinders are used where
linear motion is necessary.
3. Hydraulic system
Hydraulic systems are used to control & transmit power.
•A pump driven by prime mover (electric motor) creates flow of fluid
5. Function of components
1. The hydraulic actuator is a device used to convert the fluid power
into mechanical power to do useful work. The actuator may be of the
linear type (e.g., hydraulic cylinder) or rotary type(e.g., hydraulic motor) to
provide linear or rotary motion, respectively.
2. The hydraulic pump is used to force the fluid from the reservoir to
rest of the hydraulic circuit by converting mechanical energy into hydraulic
energy.
3. Valves are used to control the direction, pressure and flow rate of a
fluid flowing through the circuit.
4. External power supply (motor) is required to drive the pump.
5. Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.
6. Con.
6. Piping system carries the hydraulic oil from one place to
another.
7. Filters are used to remove any foreign particles so as keep the
fluid system clean and efficient, as well as avoid damage to the
actuator and valves.
8. Pressure regulator regulates (i.e., maintains) the required
level of pressure in the hydraulic fluid.
7. Pneumatics
Uses pressurized air to transmit and control power. Air is used as
the fluid because:-
It is safe.
It is less expensive and readily available
It can be inducted and exhausted directly to the atmosphere and
return line is not necessary as with hydraulics.
11. Actuators
What is an actuator?
Actuators are devices used to produce action or motion.
Input(mainly electrical signal , air, fluids)
Electrical signal can be low power or high power.
Actuators output can be position or rate i.e. linear
displacement or velocity.
Actuation can be from few microns to few meters
14. Hydraulic actuator.
The hydraulic actuator is a device used to convert the
fluid power into mechanical power to do useful work. The
actuator may be of the linear type (e.g., hydraulic cylinder)
or rotary type(e.g., hydraulic motor) to provide linear or
rotary motion, respectively
15. Linear actuator (hydraulic cylinder)-
Provides motion in straight line.
Linear displacement depends on stroke length.
Usually referred to as cylinders, rams (single
acting cylinders) or jacks.
Rotary actuators (Hydraulic motors)-
Produces continuous rotational motion.
Pump shaft is rotated to generate flow.
A motor shaft is caused to rotate by fluid being
forced into the driving chambers.
Semi Rotary actuators
Produces non-continuous rotational motion
Limited to less than one revolution (<360)
Used to produce oscillatory motions in
16. Types of Cylinders
Ram
Single Acting
Telescopic
Spring Return
Double Acting
17. Ram Cylinders
The simplest single acting cylinder
One fluid chamber
Exerts force in only one direction
Mounted mostly vertically
The cylinder retracts by the force
of the load due to gravity
18. Ram Cylinders
Ram cylinders are most
commonly used in
elevators, jacks, and
automobile hoists.
Can also be used on a
scissors lift like the one on
the loading dock of KL.
19. Single Acting Cylinders
Acts much like a ram cylinder
Main difference is that the single acting
cylinder uses a piston. The leakage flow that
goes past the piston is ported the tank.
20. Telescopic Cylinders
Mostly a single acting cylinder
Series of rod segments called sleeves, most
common to only have 4 or 5 sleeves in each
cylinder
The sleeves work together to provide a longer
stroke
The maximum force is at the collapsed position
The speed will increase at each stage, but will not
allow as much force.
22. Spring Return Cylinders
Considered a single acting cylinder
Pressure applied to the cap end pushes the spring down as
the rod is extending
When the pressure is removed the spring force allows the
cylinder to retract
The drain is in the spring chamber and allows the leakage
flow past the piston seal
23. Double Acting Cylinders
Types
Basic double acting (differential
cylinder)
Double rod cylinder (nondifferential
cylinder)
Tandem cylinder
24. Double Acting Cylinders
Most common type of cylinder
Pressure is applied to both rod end and
cap end
The majority of the cylinders are basic.
This means that there is unequal areas at
either end.
25. Double Acting Cylinders
Rod extension is slower because has a larger
area, but allows a greater force because of
the bigger area.
Retract is faster because of the smaller area,
but the force allowed is smaller because of
the smaller area.
27. Double Acting Cylinders
Double Rod Cylinder
Nondifferential type cylinder
Same areas at both ends of the cylinder if the rods are the
same size
Provides equal force, and equal speed in both directions
28. Double Acting Cylinders
Tandem Cylinder
Two pistons in line with a common rod
This allows you to have a greater forces without increasing
the size of the cylinder bore
Tandem cylinders are used in places where there is
insufficient space to increase the size of the cylinder bore.
30. Cylinder Actuation
Fluid routed to and from cylinder through
ports in each of the heads
Cylinder retracts from pressure to rod end
port and the other port connected to tank
Cylinder extends from pressure to cap end
port and rod end port connected to tank
31. Cylinder Mounting
Main function to anchor the cylinder
Mounting methods include tie rod, bolt
mount, flange, trunnion, side lug and side
tapped, and clevis
Tie rod is most common
34. Cylinder Ratings
Ratings include size specifications and pressure
capability
Size specifications
- piston diameter (bore)
- rod diameter
- stroke length
Pressure capability
- pressure rating established by manufacturer
- rating limits maximum force capability
35. Formulas For Applications
V (in/min) = GPM x (231 / Area (in²))
Q (flow) = Area (in²) x V (in/min) / 231
F (lbs) = Pressure (psi) x Area (in²)
P (psi) = Force (lbs) / Area (in²)
38. Cylinder Features
Basic size and pressure ratings are not the only things that define a
cylinder
Features such as:
- seals
- cushions
- stop tubes
- rod spacers
- ports
- bleed ports
-limit switches
39. Seals
Cast iron is most common piston seal
Long service life is most important characteristic
Rubber-like materials are the most common rod seal
Rod wiper or scraper keeps foreign material from entering
the cylinder and the hydraulic system
40. Cylinder Cushions
Used to slow down the piston at the end of its
stroke
Basic elements include the plunger,
adjustable cushion orifice, and a check valve
41. Stop Tubes
Metal collar that fits over piston rod next to piston
Used primarily on long stroke cylinders
Provides better cylinder rod support
Majority of applications do not require a stop tube
42. Tie Rod Spacers
Tie rod spacers and center supports improve rigidity of long
stroke tie rod cylinders
Spacer keeps proper position and prevents excessive deflection
Tie rod center support has side mounting lugs and serves as
additional mounting location
43. Ports
Internal or external opening in a cylinder or a valve
Designed to allow the passing of fluid into or out of
the component
Wide variety of port type configurations
Straight thread O-ring fittings are highly
recommended for leak-free connections
Poor installation of tubing or hose to port causes
leakage
44. Bleed Ports
Usually cylinders bleed air when ports are
vertical on top
Bleed ports are necessary to remove trapped
air when the ports are installed on the bottom
of the cylinder
Desirable on high speed, high performance,
heavy load applications
45. Limit Switches
Signal rod position to a control circuit or a safety circuit to limit end of
travel
Common types
-mechanical = mechanical actuation of electrical switch when switch is
activated by lead angle on a hardened cylinder cushion
- proximity = activated when metal cushion passes close to magnetic
pickup of the switch
* becoming increasingly popular due to simplicity
46. Cylinder Installation and
Troubleshooting
Cylinder application design » hydraulic
engineers
Installation » hydraulic technician
Proper installation and maintenance is crucial
to all components to achieve max efficiency
Recognizing and controlling potential
problems is purpose of troubleshooting
47. Design Problem
A dump truck to lift 5 ton. Specify a cylinder.
Velocity in retract is 15 in/sec
Stroke = 18 in
P = 2000 psi