An Overview of Hydraulic System
for Special Course on Duomatic ,
WST/VPR
Hyd pump
The hyd pump in a hyd. System converts mechanical energy in a
drive unit in to hydraulic energy (pressure energy).
The pump draws in the hyd fluid and drives it out in to a system
of lines. The resistances encountered by the flowing hyd fluid
cause a pressure to build up in the hyd system.
Thus the fluid pressure in a hyd system is not predetermined by
the pump. It builds up in accordance with the resistances – in
extreme cases until a component is damaged. In practice it is
prevented by installing a pressure relief valve directly after the
pump or in the pump housing at which the max operating
pressure recommended for the pump is set.
Hyd. Pump types
» PUMPS
NON POSITIVE DISPLACEMENT PUMPS POSITIVE DISPLACEMENT PUMPS
CENTRIFUGAL PROPELLER
PUMP PUMP
VANE GEAR GEROTOR LOBE SCREW RECIPROCATING RADIAL AXIAL
PUMP PUMP PUMP PUMP PUMP PISTON PISTON
PUMP
PUMP PUMP
Contd.
• Hydrodynamic or non-positive pumps
– They are used for low-pressure, high-volume flow
applications.
– Normally their maximum pressure capacity is limited to
250-300 psi.
• Hydrostatic or positive pumps (Gear, vane, piston pumps)
– High pressure capability (up to 10,000 psi or higher)
– Small compact size
– High volumetric efficiency
– Small changes in efficiency
– Great flexibility of performance
Displacement of pump
• The flow capacity of a pump can be expressed as
displacement per revolution or output in GPM. Displacement
is the volume of liquid transferred in one revolution. It is
expressed in cubic inches per revolutions. In practice, the
pump is rated in terms of how much fluid is supplied per unit
of time, and expressed in terms of: Gallons per minutes
(GPM) liters per minutes(L/min).
• Pumping theory:
Due to partial
vacuum oil is
rushed towards
the pump.
Vane pump
• It is widely used on Track machines.
• On many industrial installations with a maximum pressure of
about 200 bar, vane pumps are applied.
Piston pumps
• It is mostly used in driving circuits.
• Piston pumps offer more pressure capabilities compared with
the vane and gear pumps.
• Piston pumps all have closer internal tolerances.
• Because of these close tolerances, piston pumps operate at
higher efficiencies than are possible with the vane and gear
pumps.
Contd.
PISTON PUMP PRINCIPLE
VARIABLE DISPLACEMENT PUMP - MAX FLOW
STROKE
Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)
VARIABLE DISPLACEMENT PUMP - REDUCED FLOW
STROKE
Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)
VARIABLE DISPLACEMENT PUMP - ZERO FLOW
STROKE
Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)
VARIABLE DISPLACEMENT PUMP - REVERSED FLOW
Q
Troubleshooting
PROBLEM CAUSES REMEDIES
1. Pump not delivering 1. Pump driven in wrong 1. We can check the pump rotation
oil. direction. by hand priming, pour the oil in
intake port and rotate the shaft and
see if the oil is coming from outlet
or not. If not change the direction
by repositioning the cam ring
turned by 90 0.
2. Intake filter or pipe 2. Clean or replace the faulty one.
\ choked.
3. Oil level too low in the tank. 3. Fill the tank with
hydraulic oil. 4. Pump shaft or rotor broken 4. Replace
the pump shaft or rotor
5. Air traps in suction line. 5. Check the suction line and replace
.
2). Pump making noise- 1). Oil level too low. 1). Fill the tank with hydraulic level
that more air influence is prevented.
2). Restricted or partially 2). Clean or replace the intake
clogged intake filter or filter or line. Suction filter should
line. be changed in time.
3).Tank is not vented 3).Air breather screening element
properly. should be cleaned regularly, so that
atmospheric pressure exert effectiv-
ely on the oil surface in tank and
good suction may take place
4).Viscosity of oil too 4).Use proper grade oil. In winter
high. Season oil becomes thick so no free
flow takes place, warm up the oil
by starting pump for few minutes.
5).Air leak at pump 5).Check for any loose connection or
intake pipe joints. joint and tighten them.
Relief valve
• Function: It is found in virtually every hydraulic
system. It is a normally closed valve connected
between the pressure line and the tank. Its purpose is
to limit pressure in the system to a preset maximum
by diverting some or all of the pump’s output to tank
when the pressure setting is reached.
DIRECT ACTING PROPORTIONAL RELIEF VALVE
1) Proportional valves can also be used to control pressure. In this case a
proportional solenoid is used to push a poppet against a seat via a spring. The
greater the solenoid force the greater the pressure required to push the poppet
off its seat and open the valve.
DIRECT ACTING PROPORTIONAL RELIEF VALVE
1) Proportional valves can also be used to control pressure. In this case a
proportional solenoid is used to push a poppet against a seat via a spring. The
greater the solenoid force the greater the pressure required to push the poppet
off its seat and open the valve.
2) This provides a direct acting relief valve
function but like most such valves, it is
only possible to pass small flow rates
through the valve.
TWO-STAGE PROPORTIONAL RELIEF VALVE
To control higher flow
rates, the proportional
direct acting relief valve
can be used as the pilot
stage of a two-stage
relief (or reducing valve).
TWO-STAGE PROPORTIONAL RELIEF VALVE
To control higher flow
rates, the proportional
direct acting relief valve
can be used as the pilot
stage of a two-stage
relief (or reducing valve).
Pressure control valves on machine
Direction control valve
• Directional control valves are used to control fluid
flow in hydraulic lines, to start, to stop or change the
direction of motion of hydraulic cylinders and
motors. Directional control valves can be manually
or automatically operated such as by push button,
lever, mechanical action, electrical signals, hydraulic
power or compressed air.
Direction control valve
DIRECTIONAL VALVE
DIRECTIONAL VALVE
DIRECTIONAL VALVE
DIRECTIONAL VALVE
symbol
4/3 way valve
Working of 4/2 way valve
Direction control valve used on machine
Proportional valve
• Proportional valves control and vary pressure,
flow,direction,acceleration and deceleration .
• They are adjusted electrically are actuated by
proportional solenoids.
• Output flow is proportional to the input signal
• By varying the input signal solenoid adjusts the spool
movement to vary the flow through the valve.
• To control the speed of the spool a gradually
increasing or decreasing signal (a ramp function) is
fed to the control amplifier and thus we get a smooth,
shock free movement.
Proportional valve contd.
• Used for Tamping unit lifting-lowering and satellite
drive.
• Maximum voltage 24V DC, current range-250mA to
750mA
• For Tamping Unit Lowering current-650mA
• For Tamping Unit Lifting current-600mA
Proportional valve
TWO-STAGE PROPORTIONAL VALVE
Thirdly, the main spool
springs are replaced with
just one spring. This means
that the same spring is
compressed whichever side
of centre the main spool is
moved thus avoiding the
need for two accurately
matched springs.
SWITCHING SOLENOID VALVE
A conventional solenoid valve can be
thought of as a simple switching valve.
It is controlled by some form of electrical
device which simply switches the electrical
current on or off.
SWITCHING SOLENOID VALVE
A conventional solenoid valve can be
thought of as a simple switching valve.
It is controlled by some form of electrical
device which simply switches the electrical
current on or off.
SWITCHING SOLENOID VALVE
A conventional solenoid valve can be
thought of as a simple switching valve.
It is controlled by some form of electrical
device which simply switches the electrical
current on or off.
PROPORTIONAL VALVE
A proportional directional valve however
will be controlled by an electrical device
more like a dimmer switch.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied
and hence the amount of flow through the
valve can be controlled.
PROPORTIONAL SOLENOID
I
F
The solenoid is designed so that the
relationship between the solenoid
force (F) and the coil current (I) is a
linear one. This means that the
solenoid force depends only on the
coil current.
Servo valve
• Servo valve is a directional valve that may be
infinitely positioned to control of both the
amount and the direction of the flow. A servo
valve coupled with the proper feedback sensing
devices provide very accurate control of the
position, velocity, or acceleration of an actuator.
• Small input signal causes a large output of hyd.
Power.
• A low power control signal can produce output
of several hundreds horse-power.
• In aeroplanes, jet planes servo valves are used
for fast response.
servo valve contd..
• Used in lifting and lining circuit in 09 csm, 09-3x,
unimat-3s, new duomatic.
• For track lifting – 2nos and for alignment – 1no servo
valve is provided.
• Voltage – 3v. DC
• Current – 15 mA.
• Contaminated oil is not desirable.
• Maintain the oil cleanliness to NAS-5 class.
• Before installing the servo valves flush the system.
• Filter should be replaced in time.
• Do not open the valve in contaminated atmosphere.
• Null should be adjusted properly, if null gets
disturbed.
Servo valve
SERVO VALVE
The tilting of the
armature causes the
flapper to move closer
to one nozzle and
further away from the
opposite nozzle.
SERVO VALVE
... causing the main spool
to move and flow to
pass through the valve.
As the main spool
moves, the flapper is
dragged back to the
centre of the two
nozzles when the pilot
pressures equalise and
the spool stops moving.
SERVO VALVE
Flow control valves
• By controlling the rate of flow in a hydraulic circuit,
it’s possible to control the speed of hydraulic cylinder
or motor. A more typical method is to use a flow
control valve. By varying the size of opening, one can
vary the amount of oil entering the cylinder and thus
control its speed. Three factors affect flow rate:
pressure, fluid temperature, and orifice size. If any
one of these factors is increased, the flow rate
increases.
