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Required equipment when designing hydraulic systems

In the industrial sector, and others like maritime, aviation, aerospace, agricultural, military, construction, to name only few, hydraulic system engineering specialist companies are contracted to design hydraulic systems. This means the customer provides details about the industrial hydraulics application for which the hydraulic system is intended. Based on this, hydraulics engineers design a hydraulic system with specifications that will allow the system to reach that objective.

System design involves the selection of components and their sizing, establishing the operating pressure and flow rate of the system, and ensuring that component specifications meet the design objectives. Hydraulic tools are sometimes required when executing the system design.

The following hydraulic equipment is usually incorporated:

 

Hydraulic crane & hydraulic cutter use cylinders but can be powered by a hydraulic power unit.

Cylinders

Hydraulics cylinders create mechanical force in a linear motion. They are used in mobile applications due to their ability to lift practically any load, and because of their huge push and pull capacity. Hydraulic cylinder repair is conducted by Hytec Engineering.

Most mobile machinery, like bull dozers excavators, loaders, mine dump trucks & graders, for example, rely on hydraulic cylinders. In the industrial sector, they are used in a hydraulic press machine, compactors, injection moulding, forging presses, etc.

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Accumulator (Reservoir)

The hydraulic reservoir, also commonly known as hydraulic accumulators, holds the hydraulic fluids – usually hydraulic oil – in hydraulic machines.

More than just a hydraulic tank, the accumulator in hydraulic systems transfers heat from the system, settles solid contaminants, preventing contamination of the fluid, and assists with the release of moisture and air from the fluid.

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A hydraulic hand pump can be used with accumulators.

 

Pumps are used in both hydraulic and pneumatic systems, and Bosch Rexroth offers a hydraulic pump repair service.

Pump

The task of the pump is to conduct mechanical energy into hydraulic energy by forcing the transmission medium (fluid) from the accumulator (reservoir) to the rest of the circuit. This is done by creating a vacuum at the pump inlet.

Hydraulic pumps all work on the same principle – the displacement of fluid volume against a resistant load or pressure. There are various types of pumps in hydraulics: fixed displacement pumps, variable displacement pumps, electric hydraulic pumps & manual hydraulic pumps – and portable hydraulic pumps are also sometimes used.

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Filters

It is estimated that about one million particles measuring 1 μm (micron) or more enter a hydraulic system each minute. Hydraulic filters are therefore essential to continuously remove dirt and particles from the system, which may cause damage to your system components over time.

Selecting the most appropriate filter for the system and its application will contribute to longer component lifetime, reduced maintenance & downtime, and therefore costs.

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Our filters are designed to accommodate unique hydraulics and are ideal for hydraulic pneumatic machines

 

Regardless if a complex or simple hydraulic system, design by professionals is imperative

Motors

To get power to your hydraulic pump and ensure that the pump’s mechanical elements work, an electric motor is required. Its sole function is to power the hydraulic pump because, If the motor stops running, the hydraulic system will shut down. Power is also achieved via a hydraulics motor.

When selecting the motor, the following factors must be taken into consideration: horsepower, rotational speed (rpm), voltage & phase, frame size & configuration, and the enclosure.

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Valves

Poppet valves or spool valves are generally used in hydraulic systems to direct fluid flow as well as stop and start this flow, and to relieve disproportionate pressure from the system.

They are actuated by means of pneumatic, hydraulic, electrical, manual or mechanical means. These valve types can be pressure control valves (pressure relief valve, pressure reducing valve, sequence valve), flow control valves and directional control valves (check valve, spool-type valve, for e.g.).

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Even basic hydraulics require hydraulic valves.

 

If you are searching for actuators for hydraulic controls, look no further than Bosch Rexroth.

Actuator

Actuators convert hydraulic energy back into mechanical energy via a cylinder.

The cylinder converts hydraulic energy into linear motion, or a hydraulic motor can be used to convert hydraulic energy into rotary motion.

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Open & Closed Hydraulic Systems – a comparison

Open Loop System

  • Suitable for low-pressure applications (below 3000psi)
  • More control options & direction is reversible without using valves
  • More difficult to diagnose & repair compared with closed loop systems.
  • Continuous pressurisation eliminated.

Closed Loop System

  • Can operate under high pressure with less fluid flow
  • Valves required for reversible direction

  • Easier to diagnose & repair compared to open loop systems.

  • Continuous pressurisation

Hydrostatic drives are sometimes incorporated in closed-loop systems.

 

Hydraulic training courses

 

Bosch Rexroth South Africa offers comprehensive hydraulics training, which incorporates hydraulic system design.

Our fully accredited hydraulic training courses are aimed at varying degrees of specialisation.

Training courses enable you to work on hydraulic cutter and spreader, hydraulic winch, hydraulic control valves and hydraulic cylinder parts.

 

Frequently asked questions

What are the basic components of a hydraulic

  • Accumulator (Reservoir)
  • Hydraulics pump
  • Filters
  • Electric motor
  • Valves
  • Hydraulic actuator
  • Hydraulic piping

Where are hydraulic systems used

Wherever high power density is required or when load requirements change rapidly, a hydraulic system is required. Used across many industries, and for multiple applications, some application examples that use hydraulics systems are:

  • Hydraulic jacks 
  • Jack trolley
  • Aeroplanes
  • Hydraulic press
  • Bearing press machine
  • Heavy equipment
  • Hydraulic lifts
  • Truck hydraulics
  • Hydraulic shock absorbers
  • Excavator hammer / hydraulic hammer
  • Hydraulic scissor lifts
  • Hydraulic crane
  • Toe jacks
  • Hydraulic floor jack
  •  Please set across two columns.

What are the two types of hydraulic systems

The 2 different types of hydraulic systems are open loop and closed loop hydraulic systems. Both systems use an extra pump known as a feed pump.

Open loop system:

Closed loop system:

 

The Bosch Rexroth South Africa Group of Companies brings you the world’s leading hydraulics, pneumatics and automation brands for all your warehousing automation requirements.