Fluid Power and Control:lts Applications and Future Development i n Hong Kong

Authors: T.P. Leung, Principal Lecturer, Dept. of Mech. & Mar. Eng. Hongkong Polytechnic B. Yam, Managing Director G.L. Rexroth Ltd. (Hongkong).

1. I ntroduction Fluid power is the form of power that is transmitted by a pressurised liquid or gas. It can be categorised into hydraulic or pneumatic. This paper will only discuss about hydraulic power and control since pneumatic power and control is generally integrated into low cost automation.
Hydraulic power is now indispensable as a modern method of transferring energy. It is widely used in machine tools, plastic machinery, heavy machinery, steelworks, presses, ship building, offshore and onshore industries, agricultural machinery, mobile equipments, civil engineering, mechanical handling equipments, aircraft and military defence equipments. With hydraulics, it offers the following:-

torques, stroke force etc., can be achieved simply. Simple overload protection. Suitable for controlling fast movement process and for extremely slow precision movement. Relative simple accumulation of energy by means of gas. Combined with decentralized transforming of the hydraulic energy back into mechanical energy, si mplified central drive systems are possible, giving a high degree of economy.

DISADVANTAGES:
High initial investment compare to other means of conservation of energy. When hydraulic systems leaks, it pollutes environment and become costly for oil. Hydraulic means of transferring energy are usually slower when compared to pneumatics or electrics. Flexibility may not be as good as pneumatics or electrics, i.e. additional function may not be so easily to add on at a later stage due to influence of circuit design and source of power supply. Hydraulic components which are commonly used in i ndustries can be classified into the following main categories

ADVANTAGES: - High forces (torques) with compact size, i.e. high

power density. - Automatic force adaption. - Movement from standstill possible under full load. - Stepless change (control or regulation) of speed,

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PUMPS r VARIABLE DISPLACEMENT

FIXED DISPLACEMENT

GEAR PUMPS FROM 1.5 c.c. TO 200 c.c./rev PRESSURE UP TO 250 BAR

VANE PUMP FROM 10 c.c. TO 125 c.c./rev PRESSURE UP TO 160 BAR

VANE PUMPS FROM 3 c.c. TO 400 c.c/rev PRESSURE UP TO 210 BAR

AXIAL PISTON PUMP FROM 10 c.c. TO 2000 c.c./ rev PRESSURE UP TO 400 BAR

RADIAL PISTON PUMP FROM 0.6 TO 20 c.c./rev PRESSURE UP TO 700 BAR

AXIAL PISTON PUMP FROM 10 c.c. TO 2000 c.c./ PRESSURE UP TO 400 BAR

VALVES
DIRECTIONAL CONTROL - simple check valves - pilot operated check valves - prefill valuves - directional poppet valve -directional spool valve METHOD OF OPERATION - manually operated - electrically operated - mechanically operated - hydraulical operated - pneumatically operated SPECIFICATION - pressure max: 630 bar - flow Q max: 7000 1 /min PRESSURE CONTROL - relief valve - sequence valve - reducing valve - back pressure valve - counterbalancing valve METHOD OF OPERATION -direct operated - pilot operated SPECIFICATION - pressure max=630 bar -flow Q max=3500 1 /min FLOW CONTROL - throttle valve - deceleration valve - fine throttle -flow control valves METHOD OF OPERATION - manually operated - mechanically operated -electrically operated SPECIFICATION - pressure max=315 bar -flow Q max=3000 1 /min - pressure and viscosity related - pressure related, but i ndependent of viscosity - independent of pressure, but viscosity related - independent of pressure and viscosity

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VALVES PROPORTIONAL

D =ECTIONAL PR_PCRTIONAL ' i.,ALVE METI-::0 OF OPERATION - pig- ::cerated - ele_-~c hydraulic operated - by -eans of pressure co =i valve with pr--ccrtional solenoid

PRESSURE PROPORTIONAL VALVE

FLOW PROPORTIONAL VALVE

- pressure relief - pressure reducing METHOD OF OPERATION - pilot operated - operated by means of proportional solenoid

- 2 directional flow control valve METHOD OF OPERATION - operation by means of DC servo motor

SPECIFICATION - P rax = 350 bar - Q max = 1200 1/min

SPECIFICATION - P max = 315 bar - Q max = 600 1 /min

SPECIFICATION - P max = 315 bar - Q max = 160 1/min

ACTUATORS
ROTARY

LINEAR

- double acting cylinders - single acting cylinders - telescopic cylinders

FIXED DISPLACEMENT - gear motors - vane motors - radial piston motors - axial piston motors

VARIABLE DISPLACEMENT - axial piston motor

SPECIFICATION - bore from 25 mm-1000 mm - stroke up to 10 meter - pressure up to 400 bar

SPECIFICATION - displ.from 3-10000 c.c./ rev. depending type - pressure up to 400 par

SPECIFICATION - displ. 12 c.c. to 1000 c.c./rev - pressure up to 400 bar

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HYDRAULIC ACCESSORIES

filters (suction, return line) pressure switches pressure indicating units pressure gauge isolator heat exchangers (oil coolers) air breathers l evel & temp indicator hydraulic flexible hose and fittings hydraulic pipes and fittings accumulators (bladder type, membrance type and piston type) drive couplings.

Hydraulic Circuitry
Design of hydraulic circuitry is a combination of technology and art. There may be more than one circuit that can solve a specific problem. Some points that require special attention are: 1. Load cycle Should know the load requirement and the

change of load with respect to time -this determines pressure of system. 2. 3. 4. Speed of actuator - this determines flow-rate. Sequence of operation

Accuracy requirement Some standard basic hydraulic circuits are available for simple applications. They are:

Circuit 1. Two-pump unloading system

Function to have larger flow at low pressure and smaller flow at high pressure operation to obtain different system pressures

2.

Two pressure-settings plus relief valve venting Regenerative circuit

3.

to have large flow during extension stroke for the sequence control when more than one actuator is involved to hold a load in the neutral position of directional control valve without creeping movement

4.

Sequence circuit

5.

Counterbalance circuit

6.

Brake circuit for hydraulic motor

to brake a hydraulic motor without i ncurring high system pressure

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Circuit

Function

7.

Meter-in flow control

to control in-coming flow-rate

8.

Meter-out flow control

to control out-going flow-out

9.

Bleed-off flow control

to dump part of the pump flow back to tank

10.

Deceleration circuit

to advance the initial extension stroke rapidly, then slow it down at the end

11.

Open circuit hydrostatic transmission

to drive a hydraulic motor through directional control valve

12.

Closed circuit hydrostatic transmission

to drive a hydraulic motor directly

13.

Electro-hydraulic servo control

to infinitely vary the position or speed of actuators

2.

Applications of Fluid Power

and injection of plastic material. I n plastic injection moulding machines, a carriage cylinder is used to move the carriage for the purpose of setting the correct distance between the mould and clamp. The use of variable displacement vane pump with HP-control (horse-power control) obtains a very simple and energy saving hydraulic system. The pressure controlling is done directly on the pump. Directional control valve 1.2 is provided for pressure unloading, i.e. zero flow of pump. The pressure relief valve item 1.4 is limiting the maximum pressure. By connecting further pressure control valves, being controlled by means of directional control valves, whatever pressure value can be obtained (i.e. with digital pressure controls) I nfinite pressure displacement is achieved with the use of proportional relief valve. For the controlling of closing the injection speed a throttle/check valve is provided, for the speed control of the hydraulic motor a flow control valve is employed. The back pressure control is done by means of a pressure control valve, item 2.8.

Hydraulic power and control is extremely useful for heavy load applications. In Hong Kong, hydraulic power is integrated into heavy machinery when they are bought from foreign countries. However, there are quite a few areas that design and build hydraulic circuits into their machineries. 2.1 Plastic Injection Moulding Machines I n Hong Kong, there are quite a number of plastic injection moulding machine manufacturers producing 2-3 thousand machines annually. Hydraulic power is used to drive the various operations. A typical plastic injection moulding machine operates basically on a four-step cycle: a. plasticizing of the solid raw plastic usually in granular form b. close mould and clamp c. inject d. open mould A screw rotating inside a barrel shears the raw material, heating it and softening it to its plastic (gently flowing) state. This operation is usually done with a low speed high torque hydraulic motor. Hydraulic cylinders are used for mould clamping 62

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OF PLASTIC

INJECTION MOULDING MACHINE

OT

DIGITAL

PRESSURE CONTROL UNIT

(31 PRESSURE SETTINGS ARE AVAILABLE CAUSE THERE ARE (2 s -1) COMBINATIONS) 2 .2 Machine Tools energy saving and smooth control of each machine operation . The working pressure still is between 25-5O bar, heat generation is kept to minimum, with variable displacement pumps. The need of an heat exchanger/oil cooler can be eliminated .

Hydraulic power is widely used in almost all kinds of modern machine tools such as grinding machines, copying machine, milling machines, shaping machines and etc., Variable displacement, pressure compensated vane pumps are normally used for such application for

One interest application example is the copying machine for making parts in local industry .

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SCHEMATIC DIAGRAM OF HYDRAULIC COPYING MACHINE

a Press with Prefill Valve High forces and therefore large volume cylinders are generally required for presses. So-called 'prefill valves" are used, in orfer to avoid using expensive large volume pumps for the fast movements of the press piston . In principle, these are large size pilot operated check valves . The method of of n is as follows

large press plunger follows from a high tank 3 via the pilot operated check valve 4. After the press beam touches the workpiece, the resistance increases and pressure in the system rises. The adjustable pressure sequence valve 5 opens and fluid reaches the large cylinder chamber of the press ram. All three piston areas are now affected by full pressure . The prefill valve is held in closed position towards the high tank . At return stroke, the piston chambers (A) of the fast forward cylinder are unloaded and the chambers (B) filled with fluid. At the same time, the pressure at port X of the prefill valve is effective by means of the control line . The main poppet is opened and the oil pushed back to tank by means of a control cylinder .
continued

me that the press rare is in its upper end and that the downward movement is actuated by means of the 4/3 way directional valve 6 (crossed arrow position) when pressure affects both fast forward cylinders 1 . The fluid required for the

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ont
Continued

HYDRAULIC CIRCUIT FOR HYDRAULIC COPYING MACHINE

2.4 Material

The circuit shown is designed as a control block.

Example of a fork lift control :

and l Handling

travels to the stroke cylinder via the bypass line . The flow divider is then outside the oil circuit. Brake Valve for Forward Tilting (tilting valve) A built-in brake valve can be fitted to port A2 or B2 of the control valve 2 . It prevents undesirable acceleration of the load during forward tilting. The brake valve spool allows the oil under load pressure to flow to the tank, as soon as pressure corresponding to the brake valve spring (approx. 30 bar) is available in the supply line . Control pressure on starting decreases if more oil flows to the tank than corresponds to the supply quantity . The valve spring pushes the brake valve in closing direction, until there is a state of equilibrium . This control circuit compensates the influence of the load size on the lowering speed. The brake valve therefore regulates the lowering speed independent of load, corresponding to the oil supplied . Secondary pressure relief valves are fitted to the user ports of valves 1 and 3 in the example shown .

The block contains 3 directional valve control spools in parallel switching series. Directional valve 1 for stroke cylinder Directional valve 2 for tilting cylinder Directional valve 3 for additional hydraulics . When the control elements (6 way valves) are in outlet position, there is bypass flow without pressure from pump connection P to tank connection T. The users mentioned above are controlled by operation of the individual control elements (1, 2 and 3) .

A type of flow divider is fitted additionally in the P line . It meters a preferred flow independent of load to the valves 2 (lowering) and 3 (additional hydraulics) at the set value. This guarantees, for example, an exact lowering speed, even at high strokes. Flow reduction is low toss by means of flow control using the flow divider, since the pump pressure is only minimally higher than the user pressure . The remaining flow is available for valve 1 (stroke cylinder) via a separate line (parallel switching) . It flows to the tank when valve 1 is not actuated .

I n order to operate the control elements, the spool ends on connection side A or B are fitted with a clevis or tongue piece, so that switching rods can be fitted . If levers are to be used, these pieces can be equipped with switching knobs. A lever system can be fitted to the control spool to operate an electro switch, e .g. to switch on the el . motor on electro trucks . When the valves are operated, the oil motor and thus the pump are switched on .

If valve 1 is actuated simultaneously with valve 2 or 3, the flow divider prevents the oil flows from influencing one another when user pressures differ .

If only valve 1 is actuated, the complete pump flow

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Check vlave Wake vabe

Ti\t!ngve!ve Flow chvider

HYDRAULIC CIRCUIT FOR FORK LIFT TRUCK

Systems
Hydraulic clutches are used for vehicles where the clutch is remotely located or when the load is of medium duty, Hydraulic power-steering systems are commonly give assistance in steering whereas hydraulic brakes assist in vehicle braking.

2,6 Deck Machineries and marine applications

and

Nowadays, most of the ships built are fitted with hydraulics for the operation of winches (cargo, guy
topping), windlass drives, mooring controls,

steering gears, deck cranes, butterfly valves and etc. In some cases, hydraulic energy is used for engine . start-ups

Apart from deck machinery applications, hydraulics are commonly used for offshore equipments, drilling rigs, jack-up systems, split barge controls and shiplifts. In Hong Kong, some fishing trawlers have converted mechanical driven winches into hydraulic winches for retrieving the net. Typical hydraulic circuitry is shown below for this particular requirement .

2.7 Aircraft
Hydraulic actuators are used to drive all control surfaces of aircrafts. The surfaces include flap, ailerons, elevators, rudders, spoilers, slats . Landing gears and brakes are also operated hydraulically .

For the sake of safety, the hydraulic system in an aircraft is a mu!ti-system . In large aircrafts, triplex systems are used .

3.

Oil Cleanliness

Large proportions of hydraulic system failures are due to contaminants of hydraulic oil, e.g . clogging of small holes, wearing of corners or moving components. System failures cause loss !n time, money and business prestige . Also the increasing reliabilities required for hydraulic systems due to the following factors: 3 .1 Great sophistication of the hydraulic system, e.g . in N/C machine tools. 3 .2 Need for greater reliability, e .g . aircraft systems control.

3.3 Need for increased life and durability to compete with electrical systems. 3.4 The use of smaller clearances for high pressure systems in order to reduce leakage and achieving high power to weight ratio.

Contaminants generation HYDRAULIC CIRCUIT FOR TRAWLER WINCH 68 4.1 Built in contaminants in the form of debris

resulting from manufacturing processes of hydraulic components or being introduced during their assembly stages. 4.2 System-generated particles as the result of abrasive wear, erosion or cavitation. 4.3 Environmental contaminants entering the system through air breathers or seals. 4.4 Contaminants resulting from the hydrolysis of oil additives or oxidation of the hydrocarbons. 5. Methods for Measuring the Cleanliness of Hydraulic Oil

5. Hydraulic pump should not be too high above the reservoir and restrictions should be reduced to a minimum to avoid pump cavitation. 6. Correct direction of rotation of pump. 7. Correct setting of relief valve. 8. Filters must be used, where applicable, clogging indication is necessary. 9. Load is not excessive.

10. It is necessary to flush the hydraulic system after i nstallation to ensure trouble free operation at the l ater stages. Future Trends of Fluid Power Applications and Development 1. Hydraulic Compenents in Modular Block Form

Among all the contaminants in hydraulic systems, soilid contaminants are the most disastrous. Methods of measuring the oil cleanliness are: 5.1 Counting of particle number Contaminants are extracted by passing a volume of oil (normally 100c.c.) through a fine filter disc of controlled pore size. The paticles trapped on the filter disc are examined by a microscope and projected on a screen. The particles are then counted by an automatic counter. 5.2 Method of comparison Standard slides of filter elements with trapped particles are prepared to indicate the tolerable degrees of cleanliness for various types of application. On comparison with 'standard slides under microscope, the condition of oil can be obtained. In case the oil is not up to standard, it may be necessary to use a portable filtration kit in addition to the i n-circuit filters to clean the oil, or when the condition is really bade, to clear out all the contaminated oil and replace with clean oil. 5.3 Measurement by weight This method is to find the weight of the trapped particles on the filter element. Oil contamination i s proportional to the weight of the trapped particles. Because of the small magnitude of the weight, very accurate weighing equipment must be used. 6. Some Precautions in Handling Hydraulic Systems

To reduce the size and price of hydraulic components, they are made in the form of blocks which perform certain functions. Several of these blocks, or modules, when assembled together would perform certain desired control function. Hydraulic integrated circuits (11 using screw-in cartridge valve elements enable the most complex circuit to be incorporated i n a single block. This trend is in fact following the same route as the electronic system's development which proved to be successful. The main advantages of modular blocks are: a. Very compact and space saving, thus making it possible to mount them close to the actuator, facilitating short connecting pipes and increased drive stiffness. b. Better function: lunge or jump-free motion, smaller pressure losses, built-in unloading valves, adequate ports for pressure switch and gauge connections. c. Free of pipe work, eliminating chances of oil l eakage. d. Simple block-building method makes it easy to enlarge the basic control for more sophisticated control. e. Easy replacement of components and convenient to carry out maintenance or service work. 2. Noise

Hydraulic systems can be troublesome if they are not dealt with properly. The following points may be useful to give a system of longer durability: 1. Care must be taken to keep hydraulic oil clean. 2. Temperature of oil must not be too high otherwise the oil would deteriorate through oxidation of i ts additives. Water cooling may be required for systems that create excessive heat. 3. There should be enough oil in reservoir and the oil is of the correct type. 4. Alignment of electric motor and hydraulic pump shafts must be correct.

Besides reducing the size of components, environmental considerations have to be taken care of. This is because of the tendency that environmental control would impose a restriction on the products of i ndustry in the future. Hence the development of low noise fluid power system is inevitable. Research work has been carried out in Europe and U.S.A. and considerable success is achieved to manufacture quiet hydraulic systems. Continued

Fluid Power & Control

Continued

space shuttle is going to be subjected to during its flight [7]. The less expensive micro-processors will be more suitable in general industrial applications. Attempts have been made to use micro-processors for the control of hydraulic-operated machines, e.g. injection moulding machines for plastics.

3.

Electro-modulated Components

The development of electro-moduIated/proportional directional, pressure and flow control valves plays an i mportant role in the development of fluid power systems. It has a combination of the merits of both electronics and fluid power, using electronics as the 'brain' and fluid power as the 'muscle'. Existing servo-valves provide a means of converting electrical signals to flow but the delicate and expensive nature of the servo-valves makes it unsuitable for general industrial usage. To produce a less expensive and not so delicate valve would increase the flexibility of fluid power system. One manufacturer has been successful in producing a valve whose flow orifice can be varied in proportion to the force i nduced by an electric signal applied to the solenoid [2]. Another valve uses the principle where an electric current proportional to the desired flow is applied to the pilot force motor which displaces the pilot spool to change the flow, and a negative feedback signal from a flow sensor keeps the spool i n position to give the desired flow (3). There is a third kind of flow control valve (4] which uses a set of valves connected in parallel. The smallest valve, when open, would give a flow-rate which provides the lowest speed ever required by the actuator on the smalles, increment. The other valves give flow-rates i n geometric progression to the smallest valve. This system hence requires on-off control which can be achieved by a binary-natured computer or microprocessor. A fourth kind of valve has a piezo-electric sleeve in an orifice [5]. When voltage is applied to the piezo-electric sleeve, the material stretches, becoming longer and thinner. This forms a gap between the sleeve and the inner rod which acts as a variable orifice. Apart from the flow-rate, the other parameter which characterised a fluid power system is the pressure. One valve is to use a flapper valve in which the position of the flapper is altered by a magnetising coil [6). The movement of the flapper change the pressure inside the pressure controlled chamber which connected to the system through a fixed orifice and to the drain through the flapper valve.

5.

Electronic Position Sensors

Some sequential hydraulic operation machines are normally controlled by means of micro-switches. Micro-switches suffer from their low reliability and adjustments required for each change of work programme. Static electronic position sensors are superior in reliability and easier in the pre-setting operation.

Conclusion
With the further improvement and diversification of local industries, there is bound to be more machines or equipment actuated by hydraulic power. Furthermore, there may be a tendency for some large hydraulic manufacturers setting up factories in Hong Kong or some local firms would like to start one themselves. Up to now, the correct handling of hydraulic equipment and systems is generally neglected though there are usually one or two hydraulic machines in the majority of factories. It is well recognised that much longer durability of operation can be achieved with the correct methods of handling. It can be foreseen that when more design work is carried out in the future, hydraulic system design will become necessary for heavy duty applications.

References
1. I ntegrated Hydraulics, I PHEX78, Pneumatic Mechanical Power, March 78. Hydraulic

2. ABEX Denison Ltd., IPHEX78, Hydraulic Pneumatic Mechanical Power, March 78. 3. P.M. Hamey, Electrically modulated actuator control, National Conference on Fluid Power, 1974. 4. Victor S. Strarodubov, Norman H. Beachley, and John G. Bollinger, Direct digital speed control for a hydraulic motor, National Conference on Fluid Poer, 1971. 5. Hydraulic Pneumatic mechanical Power, March 1978. 6. K.F. Martin, C.S. Ong, B.L. Tee, and E. Little, Dynamic analysis of an electrically operated PRV, Paper A2, 5th International Fluid Power Symposium 1978. 7. R.A Meyer and W.R. Sage, Hydraulic & Pneumatics, December 1978. 8. G.L. REXROTH GmbH. The Hydraulic Trainer R E00301 /6.78

4. Computer Control
I n some complicated and advanced hydraulic systems, computers or micro-processors can give an overall control especially when the valves are of the electromodulated type. Lockheed has employed a testing system which uses computer to control hydraulic cylinder motion and analyse feedback data in testing a space shuttle's orbiter. This system simulates the stresses that the

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