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As you are aware we love hydraulic power, we wouldn’t do what we do if we didn’t. But, today we wanted to write an article on some of our favourite machines that are powered by hydraulic powerpacks. We have told you before that the world is a better place because of hydraulic powerpacks, and today we are going to prove it.
Firstly we have chosen to look at how hydraulic powerpacks help the everyday mechanic.
In the UK, there are as many as 36 million cars registered on the roads. At many points during a cars life, they will need to visit a garage. Hydraulic lifts are vital for mechanics to see and get under your car and our hydraulic powerpacks can easily connect to your mechanics lift, providing all the power it needs to lift up your car. This in turn not only makes a mechanics job much easier, but it also means your car has been thoroughly checked over. Thanks to hydraulic power your car will spend a minimal amount of time out of action.
In this article we want to explain the ins and outs of hydraulic powerpacks. A vital piece of equipment that is used with so many machines we see every day.
In a nutshell, hydraulic powerpacks are self contained units that are used instead of a built in power supply for hydraulic machinery. Hydraulic power uses fluid to transmit power from one location to another in order to run a machine. It really is as simple as that.
So what do they look like?
In order to recognise and better understand hydraulic powerpacks, it is a good idea to get to know the key components. Hydraulic powerpacks come in many different shapes and sizes, some are very large and stationary whereas others are much smaller and more compact. In fact, some hydraulic powerpacks are so compact that they can easily be transported in a small van or even an estate car.
The only real way to identify hydraulic powerpacks is through its main components. No matter the size of the unit, all power packs will have the following; a hydraulic reservoir, regulators, a pump, motor, pressure supply lines and relief lines.
What do these components do?
It may be obvious to some but in this post we wanted to explain every hydraulic power pack component as simply as possible. So here goes.
First up is the hydraulic reservoir which quite simply holds the fluid. Reservoirs will come in different sizes.
Then we have the regulators. Regulators are vital as they control and maintain the amount of pressure that the hydraulic powerpack delivers.
Thirdly we have the pressure supply lines and relief lines. The supply line simply supplies fluid under pressure to the pump and the relief lines relieve pressure between the pump and the valves. The relief lines also control the direction of flow through the system.
Finally we have the pump and a motor. We will begin with the simpler component of the two, the motor. The motor is simply there to power the pump. Easy as that. Now the pump generally performs two actions. Firstly, it operates as a vacuum at the pump inlet and through atmospheric pressure forces fluid from the reservoir into the inlet line and then to the pump. It then delivers the fluid to the pump outlet and pumps it into the hydraulic system. We did warn you that the second part would be slightly more confusing.
So what is the function of hydraulic powerpacks?
Hydraulic powerpacks deliver power through a control valve which in turn runs the machine it is connected to. Hydraulic powerpacks come with a variety of valve connections. This means that you can power a variety of machines by using the appropriate valves.
Hydraulic powerpacks are relied upon by a range of different machines that use hydraulic power to do its work. If a machine is required to carry out heavy or systematic lifting then its likely it would need help from a hydraulic powerpack.
To make it easier for you to understand, we have included a list of trades that regularly rely on our powerpacks. On a building site you will see machines like bulldozers and excavators, which both need hydraulic powerpacks. But, it is not just on building sites that you will find these types of machines. Fishermen and mechanics both need hydraulic powerpacks too. If we did not have them then how would fishermen lift their nets or how would mechanics lift our cars?
When picking a hydraulic powerpack there are a variety of pumps and options to pick from and it is important to pick the right pack to meet your machines needs. It is also important to consider a pack that will help maximise productivity and minimise cost.
Many people will overlook the necessity of hydraulic powerpacks, but they really are vital to ensuring our society runs efficiently.
Do you need to maintain hydraulic powerpacks?
Yes you do and this is hugely important! Hydraulic powerpacks require regular maintenance to ensure they are working properly and safely and to help extend their life. Maintaining hydraulic powerpacks is relatively simple and includes checking the tubing, this can be for any noticeable problems such as dents or cracks. It is also vital to regularly change the hydraulic fluid and look at the reservoir to check for any corrosion or rust in hydraulic power packs.
What hydraulic powerpacks do we provide?
Generally we provide four different types of hydraulic powerpacks. You can pick from a standard powerpack, a mini powerpack, a micro powerpack or a bespoke powerpack.
The standard hydraulic powerpack uses a standard range of modular components and is ideal for the most demanding industrial applications. The mini powerpack is ideal for applications requiring up to 5.5kW. The micro hydraulic powerpacks were originally produced for mobility applications, so are great for when space is limited. Finally, if none of these seem to fit your needs then we offer bespoke hydraulic powerpacks ensuring your application gets the hydraulic powerpack it requires.
Finally, who is the genius behind hydraulic powerpacks?
The man behind hydraulics was Laissez Pascal. A French mathematician, physicist and religious philosopher who lived in the mid seventeenth century. Pascal made observations about fluid and pressure which led to Pascal’s law. Pascal's law states that when there is an increase in pressure at any point in a confined fluid, there is an equal increase at every other point in the container. Hydraulic powerpacks have been designed based on Pascal's law of physics, drawing their power from ratios of area and pressure.
So, interested in our Power Packs? Come on over to the main website and see what we can do for your Hydraulic Power Pack Needs .
Hydraulics has been around for a very long time. But are you aware of how far it has actually come? You wouldn’t be alone if you responded with no. It is a very technical subject that can be quite difficult to understand, but in this article we want to tell you the story of hydraulics! We want to share with you who discovered hydraulics, what it was originally used for and how hydraulic power got to where it is today.
So why don’t we start at the beginning! Where does the word hydraulic come from?
The word hydraulic originates from the Greek word ‘Hydros’ which means water. Why water? Well, this is because water was the first liquid to be used in the hydraulic system. Today, hydraulics includes the physical behaviour of all liquids, not just water.
Although using high-pressure hydraulic systems is considered to be one of the safest methods of applying force, there are still some important factors to take into account. They are powerful tools and can take on any bending, lifting, pushing or pulling work that you need performed, but there are some important safety factors that need to be observed.
Surprisingly, one of the weak points of the hydraulic system when it comes to safety is that it is very easy to use. This can lead to complacency and in some cases abuse. As with any type of equipment use, there are rules to be followed and disciplines to observe in order to get the best from these machines whilst keeping yourself and others in the vicinity of the equipment safe from harm. Following these guidelines can also often ensure longer lifespan and greater efficiency of the machinery.
In the following passages we look at the different areas of safety that will need to be taken into consideration when dealing with high pressure hydraulic tools.
Just as with any equipment, it’s necessary to observe standard safety rules. This means that gloves, safety glasses, boots or safety shoes and a hard hat all need to be worn. As in any environment that can be hazardous, these should be considered fundamental necessities.
Although most engineers will take the most obvious precautions to avoid accidents whilst taking the longevity of the equipment life into consideration, most mishaps and issues will come from either not operating the equipment properly or not assembling it in the right way. It’s important to understand each function in addition to being clear how it works. Take time out to learn your machinery and how it works.
Lifting of loads that are over capacity is something that can result in trouble. Not only will the cylinders be at risk of damage but it can also result in bent plungers and blown seals.
Keep in mind the following points:
- Take an estimate of what you think the load will be, then apply a suitable safety factor.
- Keep in mind that some of your pumps will be equipped with relief valves whilst others won’t be.
- The use of a gauge will help to give an indication of which operating loads are safe.
- Your gauge should also be used to determine whether there is any pressure in the system before you make any changes or breaks in the hydraulic connection.
- Check your environment before you either advance or retract a cylinder.
Fundamentally, two types of cylinders are used in hydraulic systems. The single acting and the double acting.
Single acting cylinders may be any of these types:
· Spring return
· Load return
Double acting cylinders work with the use of hydraulics and advance and retract.
It’s important that you follow these safety guideline rules for cylinders:
- If you need to position the cylinder on the ground, ensure that the base is able to bear the weight of it. It wouldn’t be funny to watch your hydraulic cylinder disappear into soil. A jacking based should be used, or at least a steel or timber plate that will enable the load to be spread.
- The saddle should have the load spread across it, and not be point loaded.
- Stay clear of and be careful around any areas that are directly below a load that the hydraulic cylinder is supporting.
- Situate your cylinders in order to give enough clearance space for extension of them.
- Excessive heat is any heat that is above and beyond 65°C. This needs to be avoided otherwise packing will be softened and hoses weakened. If there is heat that is not avoidable, use either a piece of metal or a heat-resistant blanket to protect the cylinder.
- Keep oil connectors clean and wipe any couplers before they are connected. Dust caps are provided for a reason and that’s to keep dust and dirt out. If you choose not to use them, be aware that you’re likely to experience scoring of the cylinder walls and this can lead to the eventual failure of seals.
- Over-extending cylinders should be avoided as not all of them have safety stop-rings installed.
- If you need to add oil to the pump, check whether the cylinder is already extended, if it is be sure not to disconnect them. The trouble with having too much oil in the system is that your reservoir could become pressurised and blow. If it doesn’t blow it will rupture.
Hydraulic Hand pumps
Depending upon the speed and oil capacity of your system, there is likely to be a pump available for each cylinder. These may be power-assisted or they could be manual in nature. Those applications that are lower speed and where it’s necessary to have that added human ‘touch’ will usually have a hand pump. If the application needs faster movement, or the cylinder is particularly large, then it will use a power pump.
It’s essential that the pump valve is suitable for the cylinder. For example, with single acting cylinders, there is usually a pump that has a 2 way or a 3 way valve. This equates to one outlet. When it comes to double acting cylinders you’re likely to find a 4 way valve which means it has 2 outlets. It’s dangerous to use a 2 way valves in combination with a double acting cylinder.
Check the pump reservoir level before using. Fill using the correct procedures if necessary. Remember that pump hoses will shorten when they are filled with pressure, so ensure there is enough slack to handle this.
With regards to power pumps, you can expect to come across one of these types:
· Petrol / Diesel
It’s fairly obvious that hose failure can occur after heavy objects being dropped on the hose cause damage, but it’s surprising how this escapes the thoughts of many engineers. We often hear stories of how something was dropped but then it was a forgotten memory and the next thing the engineer knows, the hose has failed and there has been a hydraulics disaster.
Another strongly recommended tip is that hydraulic equipment should not be carried by the hose. Most of us are well aware of this, but you will need to keep an eye on any young apprentices who are as yet unfamiliar with the norms of operating hydraulic systems. There should also be an eye kept out for any sharp bends in the hose. The internal wire braids can be damaged from this type of event and this will weaken the set up and could result in leaks and at worst a lethal situation.
An essential fundamental when it comes to hydraulic system safety is to check all fittings, hoses and connections to ensure that they are tightened as they should be and that they comply with the amount of pressure that they will need to be able to handle with your specific system.
We generally recommend that hydraulic systems use oil that is suggested by the manufacturer. The system will usually have been manufactured around that oil and the creators know that it will perform best with that particular one. You will need to change the oil periodically. This will ensure that the system does not get damaged by dirty oil. Ensure that hydraulic oils do not touch your skin.
After you have finished using your hydraulic machinery, it’s time to get it ready for the next job. You will need to clean it before storing it. You can do this by wiping it down. You will also need to lubricate any parts that are exposed.
In conclusion, operating hydraulic systems safely entails using the right cylinder with the right pump and the right oil. Although these rules may seem obvious and safe, it’s surprising how many people fail to adhere to them and put themselves and others in danger. Hydraulic equipment is very powerful but it can also be very dangerous.
Hydraulic filtration is a vital component of keeping a system running smoothly.
For example, did you know that up to 75% of failures with fluid power can be attributed to contamination? With the use of hydraulic filters, contamination damage can be significantly lowered which can not only cut down on expense but lower that 75% drastically.
If you’re looking to save costs from less downtime then it’s also time you looked into what a difference hydraulics filtration can make for extending the life of your equipment. Running your system optimally is essential when it comes to cost saving, but protecting its longevity is also a critical element in running any business efficiently.
Muck and dust can destroy a hydraulic system, that’s why it’s essential to make the best use of hydraulic filters. You wouldn’t even be able to remove that dirt yourself, as it’s likely to be dust that is so fine that you won’t be able to see it without the use of a microscope. Dirt has the same detrimental effect as sandpaper or gravel and not only will generally deteriorate the system, but it could even destroy it.
However, through the use of a hydraulic filter system you will be able to maintain control over the level of contamination and by doing so reduce the failure of systems by as much as 75% just be removing that dirt.
Hydraulic parts are expensive. Combine that with down time and having to keep engineers on hand to fix worn components and that’s a lot of expense to deal with. Putting filters into place can even save costs by increasing how long the hydraulic fluid will last.
Degradation of fluid – hydraulic fluid that contains fine metallic particles can degrade rapidly through chemical breakdown. Without protecting against this, there could be issues such as slippage, internal leakage, corrosion or sticking parts.
Scoring of surfaces – this can occur when particles get trapped between surfaces of seals
There’s no doubt about it, but …
· System performance is affected by dirt levels
· Hydraulic filters can control levels of dirt. Without using this management method, the system will get dirtier and dirtier until it fails.
In fact, hydraulic filters are the only way to control how much dirt is in fluid. Without them you will be forced to change out the hydraulic fluid regularly, which can be a time consuming and costly event.
Hydraulic system dirt particles are incredibly small. In fact, they are so small that they cannot be seen by the human eye – and 98% of hydraulic fluid has some dirt in it.
Engineers have found that when it comes to size of particles in samples taken from operating systems, the smaller the particles, the more dirt there is in the system.
So where do these particles come from that we have to work so hard to deal with?
In order to have an idea of what goes on inside the closed system, let’s examine where these particles come from.
Instead of enjoying the typical 20 gpm that is the measurement of a pumped flow from a 2000 psi system, you can expect to see something in the region of just 10 gpm. Although your pump will still produce for you, you’ll discover that the degradation results in just 50% efficiency and you should als be prepared to experience extra heat and other unwanted issues.
As with any hydraulic system, there is an optimum level of cleanliness, but there is a point where you cannot get any better performance out of the system by improving the quality of the fluid. However, with the use of hydraulic filters you should be well set to extend the life of your machinery.
The street sweeper is a ubiquitous sight in cities across the country; once the preserve of Trigger et al, the humble broom was replaced by the compact mechanical sweeper which removes debris and dust from the streets using air, water and rotating brushes. Low pressure water jets spray ahead of the brushes to damp down the dust, thereby stopping it from rising into the air too much. The rotating brushes pick up the debris and it is collected into a hopper for emptying later on. Although harder to fix than a broom, which may only require a new head or a new handle, they are much more efficient at quickly cleaning streets and come into their own after events such as the Notting Hill Carnival or London Marathon.
The machines we see on the streets are designed specifically for the purpose of street cleaning, but there are also other locations where sweepers are used, such as on construction sites, at mines and even at waste processing and recycling facilities. At these locations, the sweeper normally takes the form of an attachment that can be fixed to a front-end loader or other hydraulic machine. This is done for cost and efficiency reasons, as it removes the need for a separate vehicle and allows an existing one to be used in a different way. These attachments use the auxiliary hydraulics of the machine to which they are fixed to provide power for the brushes, water sprayers and positioning system of the attachment. They too have used low pressure water jets up until now, but the drawback is that the reach of these jets is small, and because the water is concentrated on a relatively small area, it can end up creating a muddy paste which is then smeared on the surface rather than being cleaned up, and the dusty particles that do not get watered are then kicked up into the air to settle elsewhere.
Dynaset Oy have found a solution to this problem by using the hydraulics in sweeping attachments to power a hydraulically operated water intensifier. This addition pressurises the water creating a fine mist that contacts more of the dusty dirt without forming a paste. The system also uses far less water than a conventional sweeper attachment, so is better for the environment in that sense as well. The HPW Dust component can be fitted to any hydraulically powered machine that uses water, so can be used for pressure washing and other purposes that require high pressured water. It uses the power of the hydraulics to create the high pressure and does not need any additional power or electronics to work.
The resulting cleaning is much more effective; the water is still sprayed ahead of the brushes but damps down the dust more effectively, so the brushes can clean properly without sending that dust up into the air. The air quality post sweeping is visibly cleaner and this is important in routinely dusty environment such as mines and construction or demolition sites, especially if these are located in built up areas, where there is already an environmental concern over air quality.
This technology is not being used in city street sweepers yet, but it could make a very real difference to the air quality in urban areas if deployed in these machines. There is some development to do in order to make the water intensifier technology work in modern street sweepers as they are not hydraulically powered, but when designing new models hydraulic power could be an option to operate not only the high-pressure water delivery, but the brushes and collection method as well.
The reduction in the amount of water used, coupled with the superior cleaning could be incredibly useful in developing countries or very hot climates where water is at a premium. The applications of this hydraulically operated water intensifying system are numerous and will become apparent as the technology is deployed in other hydraulic machinery, or integrated into new designs of current machinery. Perhaps the most obvious application for this invention is the automatic car wash, which already uses hydraulic power to move and direct the water spraying components. If the amount of water needed could be reduced significantly by pressurising it with the HPW Dust it could make a huge difference to global water consumption.
Electrostatic charge builds when there are two bodies moving and creating friction. The fact is that this also occurs in hydraulic systems from the friction caused by system components with moving fluid.
Although we haven’t had a lot of situations that have involved electrostatic discharge, it is still something that every engineer should be aware of.
When an electrostatic discharge occurs, there is a clicking noise as charge increases and is then released. This is something that will often occur in a filter – leaving burn marks and potentially other damage.
With the increasing preference of using non-metallic additives in hydraulic oils the electrostatic charge could be on the increase. Those hydraulic oils that contain anti-wear additives that are zinc-based have considerably high conductivity.
Conductivity in hydraulic oils helps when it comes to moving electrostatic charge around the system. Although zinc-based additives will rarely collect enough charge to cause a big problem, synthetic oils can. This is because they have less conductivity and therefore will potentially accumulate more charge before discharging it.
Another change that could lead to an increase in electrostatic discharge is that there has been a change made to the materials that filter elements are made of. In order to make them easier to dispose of them in an eco-friendly way, they have more non-metallic material in the design, which lowers conductivity and therefore increases the capacitance.
The manufacturers of hydraulic filters are aware of these issues, and are looking into how they can minimise or even eliminate these issues.
However, if you come across a situation where there is electrostatic discharge in the meantime, then consider this:
By adding larger filter elements you can reduce flow density and therefore the amount of charge that is being generated. You might also want to consider increasing the tank size so that the time between charge generations increases.
This is one of the reasons why you shouldn’t skimp on tank size or on filter capacity.
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