Study on hydraulic powerpack

Study of Hydraulic Power pack
Department of Mechanical Engg. ADCET, ASHTA. Page 1
A
Seminar report on
“Study of Hydraulic Power Pack”
Submitted in the fulfillment of the requirement for The Degree of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
OF
SHIVAJI UNIVERSITY,KOLHAPUR.
By
Mr. Shreyas Suresh Pandit
Under the Valuable Guidance of
Asst .Prof.K.J.BURLE
DEPARTMENT OF MECHANICAL ENGINEERING
Sant Dnyaneshwar Shikshan Sanstha’s
Annasaheb Dange College of Engineering And Technology, Ashta.

Sant Dnyaneshwar Shikshan Sanstha’s
Annasaheb Dange College of Engineering And Technology, Ashta.
CERTIFICATE
This is to certify that for Seminar on
“Study of Hydraulic Power Pack”
Submitted by
Mr. Shreyas Suresh Pandit
Submitted in the fulfillment of the of the requirement for The Degree of
BACHELOR OF ENGINEERING
(MECHANICAL ENGINEERING)
SHIVAJI UNIVERSITY,KOLHAPUR.
In the academic year 2015-2016, is a record of
His own work carried out under my direct supervision and guidance.
Prof. K J. BURLE Dr. S. S. AHANKARI
Guide H.O.D

AKNOWLEDGEMENT
I would like to Express My Deep Sense of Gratitude to Asst. Prof. K.J. Burle for
His Valuable Guidance and Co-operation through This Seminar Work .I Feel Proud to
Present my Seminar Under His Guidance.
Last but not the Least, We Would like to Thanks to all my Concerned Faculty and
Friends who Supported and Help us Through the Development of Seminar Either
Directly or Indirectly.
Place: ADCET, Ashta (Mr. Pandit Shreyas Suresh)
Date:

ABSTRACT
This study is about Hydraulic Power pack and its application in hydraulic system
Hydraulic drives and controls have become more important due to automation and
mechanization. Many of the modern and powerful machinery are controlled partly or
completely by hydraulics. Hydraulic system is less complicated and has less moving
parts. Today drive and control system engineering is inconceivable without hydraulics..
Hydraulic Power pack provides energy for the operations of the hydraulic system, also
moves the fluid through the system, provides a safe maximum system operating pressure,
and also assists in maintaining the fluid temperature and cleanliness.
Hydraulic Power pack is selected according to Pressure range, nominal power and
Size of tank other parameters.

Contents
Title page 1
Certificate 2
Acknowledgement 3
Abstract 4
List of Figures 5
Chapter 1 Introduction to Power pack 8
1.1 Construction 9
1.2 Working 9
1.3Types and applications of
Hydraulic power pack 10
1.3.1 Types 10
1.3.2 Applications 10
Chapter 2 Selection criteria 12
2.1 Selection of components 12
2.2 Price 13
Chapter 3 Components of Hydraulic power pack 14
3.1 Hydraulic Filters and strainer 14
3.2 Hydraulic pumps 14
3.2.1Classification of hydraulic pump 15
3.2.2Selection of hydraulic pump 16
Chapter 4 Advantages and limitations 17
4.1 Advantages 17
4.2 Limitations 18

Chapter 5 Case study 19
5.1 Interface between Controller and Hydraulic
power pack 19
5.2 Technical specifications 19
Conclusion 21
References 22

List of Figures
Figure No. Description Page no
1.1 Hydraulic Power pack 8
1.2 Circuit Diagram of Hydraulic system 8
1.3.2.1 Machine tools 11
1.3.2.2 Elevators 11
3.2.1.1 Centrifugal pump 15
3.2.1,2 Gear type power pump 16
5.1.1 KH Compact power pack 19
5.1.2 Mechanical dimensions 20

Chapter 1
Introduction to Power pack
A hydraulic power pack offers a simple method of introducing hydraulic
Operation to individual machines, with flexibility of being adaptable to other duties.
Power packs offer capacities, control options and configuration for virtually any
application requirement. A wide variety of manifold options and choice of pumps enables
customers to match any application requirement with a power pack that meets his system,
at the same time ensuring cost effective operation and optimum productivity.
Figure 1.1 Hydraulic power pack
Figure 1.2. Circuit Diagram of Hydraulic system

1.1 Construction:
It consists basically of an integral electrical motor, with associated tank. The pump or
motor unit may be mounted on the tank or separately and packs are usually available in
either horizontal or vertical configuration. Relief and check valves are normally
incorporated on the tank. The basic unit may be piped to the cylinders or actuators
through a suitable control valve. Hose assemblies are generally preferred to rigid piping
for connecting the power pack to actuators. The hydraulic power packs consist of a
reservoir / tank that house the hydraulic fluid, which is the working medium. The
capacity of the tank may vary accordingly to the requirements. The reservoir is also
equipped with an air breather at the top to maintain the pressure in the tank at the
atmospheric pressure and filters the oil to 40 microns.
1.2 Working:
The working of a power pack commences when the pump is initialized with the help of
an electric motor coupled to it. The oil is pumped from the reservoir along the suction
line through a suction strainer with a capability to retain the foreign particles up to 149
microns. From the suction line the oil is forced in to the pressure line through the pump at
35 bars. There is provision to measure the pressure, with the help of a pressure gauge. An
isolator is used to measure the pressure immediately in any line. When the set of pressure
is reached, the fluid moves to the cylinder present at the fixture (clamp). The hydraulic
energy of the fluid is converted back to the mechanical energy by the cylinder. According
to the direction of the energizing of the solenoid valve, the linear movement of the
clamps (clamping and unclamping) is controlled. When the solenoid valve is energized in
reverse, unclamping of the work piece occurs. There is a return line provided so that the
used fluid may be utilized again. Due to the friction losses, total energy is not converted
into the useful work so a part is converted into the heat. So, a heat exchanger is
incorporated. The return line filter has a return capacity of 10 microns.

1.3 Types and application of Hydraulic power pack
1.3.1Types
Standard hydraulic power pack
These are conventional hydraulic power units using a standard range of modular
components for easy specification, assembly and maintenance in the most demanding
industrial applications. With motors up to 30 kW, flow rates to 100 Litres/minute, tank
capacities to 180 litres and pressure capability to 250 bar, we can offer a standard power
pack to meet most industrial requirements.
Mini hydraulic power packs
These fit into the range between our micro and standard units for applications requiring
up to 5.5 kW. They offer a flexible platform of AC or DC hydraulic power unit for single
and double-acting applications to 30 litres/minute, with tank capacities between 1 and
100 litres and pressure to 250 bar.
Micro hydraulic power units
Initially designed for mobility applications, they are perfect wherever hydraulic power is
needed but space is limited. Designed around an 89 mm-square footprint, each micro
hydraulic power unit is available as an HPR reversible or HPU uni-directional build.
With 150–800 W DC and 150-375 W AC motors flow rates of 5 litres/minute are
possible, whilst pressures of 200 bar can be reached.
From the most compact unit to our largest standard AC hydraulic power unit, the
common denominators are the quality of in-house design and manufacturing, experience
in hydraulic power and the care with which every product in each hydraulic power pack
range is matched to your requirements.
1.3.2Applications
Hydraulic Power Units can generally be used in any application that requires heavy and
systematic lifting or other requirements for the repeated use of powerful and directional
force.

 Automation
 Aerospace
 Test Equipment
 Rolling Mill Machinery
 Material Handling
 Industrial Process
 Construction Equipments
Bull dozer, an excavator or even a skid steer
 Auto mechanic uses a hydraulic power unit to lift your car high enough to walk
around beneath it and make repairs.
 Modern auto braking systems rely on the power of hydraulics.
Figure 1.3.2.1
Machine tools Figure 1.3.2.2 Elevators

Chapter 2
Selection criteria
1. Space Available: The available physical-space with in which a hydraulic cylinder or a
fluid must be accommodates or dictates the size of cylinder or the fluid motor.
2. Force Required: Once the piston size is decided, the force required at the actuator
depends up on the working pressure of the system. Higher the working pressure, lower is
the size and weight of the actuator, for the same force. But it results in many
disadvantages. Systems working pressure are known the power of the prime mover can
be easily calculated. There by the size of the reservoir, the suction strainer, the pipelines
and all other valves are determined.
3. Flow Required: The speed of the actuator determines the flow capacity of the pump.
4. Environmental Conditions: This determines whether the system should have ordinary
or fire proof hydraulic fluid in hazardous condition, shock resistance on mobile use,
nonmagnetic construction in certain applications, noise elimination arrangement in noisy
atmosphere, more filtration arrangement in a dusty atmosphere and some special designs
of mountings or fittings in typical applications is required.
5. Economical Consideration: This is the most important factor, which must be kept in
mind while designing a hydraulic circuit. If a hydraulic machine is likely to operate only
a few hours in a month, no customer will likely to buy it, if its cost is very high. If a
hydraulic machine is likely to operate 24 hours a day, the life expectancy of each
component becomes an important consideration. The need of frequent replacement of
components will create maintenance problems and production losses.
2.1Selection of components
The answer must be that specific demands are made on all these components and since
none of them can be allowed to fail, they must all be equally important. Therefore
extreme care must be taken in all stages of their creation, selection and application. When
a hydraulic diagram is being prepared, the designer must have quality in mind, including
the quality of the drawing itself, so that any errors in interpreting the drawing are
avoided. It is a good idea always to use the correct ISO/CETOP-symbols.

All reputable hydraulic component manufacturers give real, usable values in their
catalogues, not just theoretical desired values. The technical data in Danfoss catalogues
always represents average values measured from a certain number of standard
components. In addition to these data, the catalogues contain a mass of useful and
explanatory information on selection, installation and start up of components, together
with a description of their functions. This information must, of course, be used as
intended in order to avoid overload, too high a wear rate, and consequent oil overheating
and to avoid an over-dimensioned system with poor regulation at too high a price
2.2Price
 1.5 HP single stage:
Ranges in 700-800
 5 Horse Power, Single Stage
Ranges in 800-1200
 5 Horse Power, Double Stage
Ranges in 1000-1300
 7.5 Horse Power, Single Stage
Ranges in 1200-1400
 10 Horse Power, Single Stage
Ranges in 1400-1700
 10 Horse Power, Double Stage
Up to 1800

Chapter 3
Components in Hydraulic Power Pack
3.1 Hydraulic Filters and Strainers:
1. Filters: Filters are used to pick up smaller contaminant particles because they are able
to accumulate them better than a strainer. Generally, a filter consists of fabricated steel
housing with an inlet and an outlet. The filter elements are held in position by springs or
other retaining devices. Because the filter element is not capable of being cleaned, that is,
when the filter becomes dirty, it is discarded and replaced by a new one. Particle sizes
removed by filters are measured in microns. The smallest sized particle that can be
removed is as small as 1μm.The smallest sized particle that can be removed by a strainer
is as small as 0.15mm or 150μm.
2. Hydraulic strainers: A strainer is a coarse filter. Fluid flows more or less straight
through it. A strainer is constructed of a fine wire mesh screen or of screening consisting
of a specially processed wire of varying thickness wrapped around metal frames. It does
not provide as fine a screening action as filters do, but offers less resistance to flow and is
used in pump suction lines where pressure drop must be kept to a minimum. A strainer
should be as large as possible or wherever this is not practical, two or more may be used
in parallel.
Maintenance of Filters
Maintenance of filters is relatively easy. It mainly involves cleaning the filter and element
or cleaning the filter and replacing the element. Filters using the micron-type element
should have the element replaced periodically according to applicable instructions. Since
reservoir filters are of the micron type, they must also be periodically changed or
cleaned. For filters using other than the micron-type element, cleaning the filter and
element is usually all that is necessary.
3.2 Hydraulic Pump:
The combined pumping and driving motor unit is known as hydraulic pump. The
hydraulic pump takes hydraulic fluid (mostly some oil) from the storage tank and delivers
it to the rest of the hydraulic circuit. In general, the speed of pump is constant and the

pump delivers an equal volume of oil in each revolution. The volumetric efficiency which
is the ratio of actual volume of fluid delivered to the maximum theoretical volume
possible. Second is power efficiency which is the ratio of output hydraulic power to the
input mechanical/electrical power. The typical efficiency of pumps varies from 90-98%.
3.2.1Classification of Hydraulic Pumps
These are mainly classified into two categories:
A. Non-positive displacement pumps
B. Positive displacement pumps.
A. Non-Positive Displacement Pumps
These pumps are also known as hydro-dynamic pumps. In these pumps the fluid is
pressurized by the rotation of the propeller and the fluid pressure is proportional to the
rotor speed. These pumps can not withstanding high pressures and generally used for
low-pressure and high-volume flow applications. The fluid pressure and flow generated
due to inertia effect of the fluid. The fluid motion is generated due to rotating propeller.
These pumps provide a smooth and continuous flow but the flow output decreases with
increase in system resistance (load). These pumps are primarily used for transporting
fluids and find little use in the hydraulic or fluid power industries. Centrifugal pump is
the common example of non-positive displacement pumps.
Figure 3.2.1.1 Centrifugal pump

B. Positive displacement pump
These pumps deliver a constant volume of fluid in a cycle. The discharge quantity per
revolution is fixed in these pumps and they produce fluid flow proportional to their
displacement and rotor speed. These pumps are used in most of the industrial fluid power
applications. The output fluid flow is constant and is independent of the system pressure
(load). The important advantage associated with these pumps is that the high-pressure
and low-pressure areas (means input and output region) are separated and hence the fluid
cannot leak back due to higher pressure at the outlets. The important advantages of
positive displacement pumps over non-positive displacement pumps include capability to
generate high pressures, high volumetric efficiency, high power to weight ratio, change in
efficiency throughout the pressure range is small and wider operating range pressure and
speed. The fluid flow rate of these pumps ranges from 0.1 and 15,000 gpm, the pressure
head ranges between 10 and 100,000 psi and specific speed is less than 500.
It is important to note that the positive displacement pumps do not produce pressure but
they only produce fluid flow. The resistance to output fluid flow generates the pressure.
Figure 3.2.1.2 Gear type power pump
3.2.1 Selection of pump
a) Safe and maximum system working pressure
b) Allowable pump speeds
c) System flow requirement
d) Leakage loss
e) Hydraulic oil characteristics
f) Heat, noise and vibration generation
g) Power-to-weight ratio

Chapter 4
Advantages and limitations
4.1 Advantages of power pack
 Allow easy speed and position control.
In Hydraulic power pack through their various types it is easy for
controlling the speed and position. Also devices like regulator help for
speed and position control.
 Easily change direction of motion.
Through DC valves incorporated it is easy to change the direction of
motion of the fluid in the system for performing operations.
 Capable of easy energy conversion.
Power pack converts electrical energy from motor to hydraulic energy of
fluid and then to mechanical energy of cylinders.
 Smoothly provides safety operations.
Hydraulic power pack are included with regulators like relief valve,
pressure regulators etc . for smooth functioning of system and also
provides safety.
 Allows for combination with electric control.
Hydraulic power pack shows interrelationship with electric control , which
controls all the operations of the power pack by the microcontroller.
 Compact
Hydraulic power pack is compact in size as compared with total hydraulic
system.

4.2 Limitations
 Cost.
Hydraulic power pack comes with wide range of types including their
cost. Power packs are costlier compared to other hydraulic components as
it consists filters, regulators pump, tank.
 Failure of pressure.
In the high pressure power pack, there may be failure arise due to
excessive rise of pressure.
 Losses during energy transformation.
As hydraulic power pack converts electrical energy to hydraulic energy
into mechanical energy, there is a loss of energy it may be hydraulic,
electric, or mechanical losses.

Chapter 5
Case study
Fluitronics Gmbh KH compact power packs
In recent times, the noise emission from hydraulic drives has increasingly become a topic
of interest in various sectors. Some applications or operating times only become possible
in the first place because of extremely silent power packs
Thanks to a significant increase of operating hours and lower cost, owners and machine
manufacturers alike achieve a competitive advantage.
For this reason, Fluitronics has systematically analysed the subject in recent years and
defined the procedure for the development and layout of noise-reducing mobile and
stationary hydraulic power packs in the framework of a project promoted by the BMWi.
This know-how is of advantage to every hydraulic power pack developed at Fluitronics.
5.1 Interface between Controller and Hydraulic power pack
5.2 Technical specifications
Figure 5.2.1 KH compact power packs
Controller Microcontroller Relay
Solenoid valveOperations
performed by power
pack

 Nominal Power rating :- 0.5 to 4.5 KW
 Nominal voltage :- Versions with direct current (12V, 24V, 48V)
3-phase alternating current (230V and 400V) are available.
 Frequency :- 50 Hz .
 Maximum Pressure:- 250 bar.
 Maximum tank size:- range upto 15lits.
 Pump Design:- External gear pump.
 Flow rate : 20-30 lit/min
Mechanical dimensions
Figure 5.2.2 Mechanical dimensions
Advantages of Fluitronics power packs and system solutions
 Systematic reduction of the noise emission matched to your requirements
 Use of very silent and highly efficient components
 Combination of the know-how from hydraulics and electronics
 All the required measurement and analysis facilities on-site
 Co-operation with universities and other research institutions

Chapter 6
CONCLUSION
1. In this report Study of various parameters for selection of Hydraulic Power pack
was done. Also different types and application of hydraulic Power pack was
studied.
2. Interface between electric microcontroller and Hydraulic power pack was studied
with help of Case study.

REFERANCES
[1]. A textbook of “Fluid mechanics and hydraulic machines”, by Dr.R.K.BANSAL,
LAXMI PUBLICATION,2012
[2]. “Design of Hydraulic Power Pack for Vertical Turret Lathe” by
M. Rama Narasimha Reddy, D. Sreenivasulu Reddy, P. Sundera, S. Madhusudhana
in International Journal of Research in Mechanical Engineering
Volume-2, Issue-2, March-April, 2014
[3]. “Study of an open circuit hydraulic power system with compact cooler-reservoir
unit”, By Ibrahim Subhi Al-Natour, Scientific Studies and Research Centre
DAMASCUS-SYRIA,2012 .

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