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Monitoring pressure and temperature in addition to lubricants and components are all important parts of maintaining any hydraulic system. If you don’t perform these then you are likely to get issues with failures.
Unfortunately this is the type of information that can get lost amongst productivity numbers and data. It’s known as in-attentional blindness and it can happen regularly. Unfortunately it’s also the type of human behaviour that can cause fatal incidents.
It’s something that can and does occur, even to people like airline pilots who can become so fixated on why something isn’t happening, that they don’t realise what is happening. When they finally catch on to what’s going on, then it might be too late and their plane’s nosedive is no longer recoverable. In fact, there is a case of a plane going down due to the failure of one light on the dashboard. The commercial pilots became so interested in why it wasn’t working that they came to a sorry end with over 100 passengers.
This is why visual inspections are important. Lights can get burnt out and gauges can get stuck. Oil levels need to be seen and in many cases an attentive individual can prevent a failure from occurring.
No matter how sophisticated your hydraulic machine is, there needs to be some scheduled and documented procedures established as part of the monitoring program.
Now that we know that engineers can get transfixed on one issue, even when the root of the problem lies elsewhere, it’s important to know that sometimes just a fresh set of eyes on the matter is enough to solve it. Some failures that are just about to happen, just need fresh eyes on them to prevent them from occurring.
Developing systems for better monitoring and maintenance is never something that is wasted time. It is something that can avoid hydraulic breakdown and component failure.
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.
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.
After years of working in and supplying to the hydraulic power industry, we have accumulated extensive knowledge and experience of how hydraulic units work, what can go right and of course what can go wrong. In this post we are now going to share with you the 7 most common issues that we have seen when it comes to maintaining hydraulic power equipment.
Generally, premature hydraulic system failure can be traced to one of the following deficiencies:
1. Insufficient fluid level
Lack of oil in a system may not stop it from operating, but it may result in increased contamination, increased temperatures and poor oil lubrication.
2. The presence of air in the system
A sure sign of this is foam and air entrained in the oil. Air dissolved in the darkened oil will cause oxidation of the oil and foam will often be evident in the reservoir. Both of these cause failure of oil lubrication performance.
3. Oil Contamination
Hydraulic filters must be monitored in an effective manner so not to either waste money by changing them too early or risk contaminating the system by changing them too late. Filters that are clogged will stop holding any dirt particles; this allows dirt to circulate in the system. This will then decrease the life of each component in the hydraulic unit – resulting in more expense than necessary.
4. Incorrect system design and commissioning
Filters fitted in the wrong locations can be problematic. In fact two locations for hydraulic filters that will cause no end of problems are the pump inlet and the pump drain lines. Wrongly adjusted valves can cause excessive heat and noise, leading to valve wear and oil failure.
5. Fluid leakage
Where oil escapes from a system, air or other contamination can enter. As we have said contamination causes many early failures.
6. Wrong fluid type or viscosity
The quality of the oil is vital to the operation of the hydraulic system as it not only transfers the power; it also lubricates the entire system. The viscosity and therefore, effectiveness will depend upon whether the system is running at the correct parameters. Poor oil selection can result in premature degradation of oil properties and in turn excessive wear of the system components.
7. Excessive temperatures
Excessively high running temperatures can be easily detected in engines or electric motors, but not so in many hydraulic systems. Quite often there is no method of recognising overheating, but this is the single most effective way of damaging hydraulic oil and the system components. Constant high temperature lowers oil performance and diminishes lubrication. Premature wear is often a result of poor lubrication.
These are the issues that we’ve most commonly seen with operating hydraulic power units. You may want to share this with your less experienced colleagues and employees, so they may avoid them.
Throughout the history of automotive development hydraulics have played a critical role in the engineering of brakes, steering and gears, as well as suspension. Specialist functions on road going vehicles as well as vehicles designed for non-road use, such as tractors, other agricultural machinery and military vehicles, also use hydraulic power to effect movement of harvesting machinery, aerial ladders and artillery. Hydraulic engineering offers a tested and trusted way of effecting actions with a quick response time and most importantly, it is reliable, efficient, and easier to fix than electrical systems designed to do the same.
Electrical systems are becoming more commonplace in road going vehicles, as the move to all electric or hybrid powered cars starts to take off in the mainstream. Electric actuators are starting to replace their hydraulic equivalent in some systems, especially those from manufacturers who are pro-actively making advances in alternative car design; self-driving cars and fully electric vehicles are pushing electric actuators to the fore of the minds of automotive designers. The appeal to designers is the easy integration of electrical components into an existing electrical system; if most of the controls are electric rather than mechanical it makes sense to extend the same technology as far as possible. Electric actuators are cheaper, easier to control and generally last as well as hydraulic actuators, and it is far easier to work these into the wiring and software system of a vehicle than to install a separate hydraulic system just to run the brakes, or the gearbox.
Advanced braking systems are one of the more important uses of hydraulics in motor vehicles. Hydraulically operated brakes are much more responsive and deploy very quickly compared to electric brakes. Although there is an argument for electric motors being used to achieve regenerative braking in electric and hybrid vehicles, these systems still use hydraulics for the quick action that is required when the brake pedal is pressed. ABS systems also rely heavily on the speed with which hydraulic brakes act; a miniature hydraulic power pack controls the system to deploy the brakes up to sixteen times per second in a skid situation, a speed which cannot be achieved by electric actuators. Mechanical brakes have a strong future in motor vehicles for safety reasons, and this will remain the case until electric actuators can replicate the speed at which a hydraulic system can function.
Gearboxes have been hydraulically operated since the early 1940s, when General Motors introduced the technology to its range. Although they were first developed in the 1920s, it took a while for the new design to be accepted and fitted in the new cars they were producing, but very little has changed since, apart from the introduction of solenoid valves in the early 2000s. Electric systems are now integrated into the control of the gearbox, especially for the twin clutch, but the mechanics at the centre of gearbox function are still hydraulic. This is one of the areas in which electrics will really have to try hard to oust hydraulics, and the only way hydraulics will be replaced here, may be if an engine can be developed where a gearbox is no longer needed.
Motor vehicles have used hydraulic dampers in suspension systems since the humble leaf spring fell out of favour. Even though some modern suspension systems (which allow the driver to adjust the settings for a particular driving style or road type) use electrics to adjust the shock settings, it is still hydraulics that effects the suspension action. Even electric vehicles use hydraulic suspension, as it is the best solution, and despite some manufacturers looking to recover energy from bumps in the road through an electrical suspension system, the complexity of such a system is not worth the small amount of energy that may be recovered, and certainly not at the cost of replacing a very capable suspension solution with something more expensive and difficult to fix.
Power steering used to be a hydraulic aid to assist drivers in steering and parking; right up to the 1990s there were still cars on the road that did not have power steering and anyone who has ever driven one, will attest to the huge difference that power steering makes to the driver. The first power steering systems used hydraulic pumps to provide the driver with extra power, but these have long since been replaced with electric motors. Self-parking cars are already widely available and these would not be possible without electrically operated steering. Power assisted steering is one area where hydraulics has already fallen out of favour and electrics have taken over.
Hydraproducts' miniature and micro hydraulic power packs are ideal for the automotive industry, and are perfectly suited to use in suspension, braking and power steering systems. Although there are some areas of automotive engineering where electrics have taken over, the key areas mentioned above are safe for now. Other areas have seen a better integration of electric and hydraulic systems, with the benefits of each being user harmoniously to affect the best system possible. As new designers emerge into the automotive market and look to shake things up, we may see electrics replacing hydraulics at least in the design and testing stage, but the reliability and relative simplicity of hydraulics means it will always have a place in the automotive industry.
Hydraulic pumps, one of the more common mechanical applications of hydraulic technology, use fluid to push an arm a set distance forwards and backwards (or up and down). One example is the mechanical arms of a digger or other ground-working machinery. A hydraulic pump is perfect for this use, as the machinery works using the set distances between the components of the arms.
A hydraulic gear motor uses fluid to power movement for a much longer distance (or to put it another way, for an unspecified length of time). The motor works by running fluid through a chamber containing two cogs. One is linked to the drive shaft and transfers the power to the component that needs to move, and the other is idle, existing only to complete the mechanism. The same fluid is pumped through the motor chamber for as long as the power is needed, and it works in a similar fashion to an electric motor, but is much smaller and can be used in places where electricity is not safe or viable to use. It is a natural development of the waterwheel that was commonplace in the UK during the Industrial Revolution, powering cotton mills, woodworking and even bellows for blacksmiths forges.
A hydraulic gear motor is more appropriate than a pump for any piece of machinery that needs continuous power in a simple mechanism; a series of hydraulic pumps, arms and cogs can be used to create continuous power, but the resulting apparatus is bulky and made up of several components, which increases the likelihood of mechanical failure. A hydraulic motor, by comparison, can be very small and portable, meaning it is ideal for any application that is a long distance from traditional power sources and remote areas of the planet where other forms of energy are not viable. They are also reasonably simple in construction, so parts and maintenance are not an issue.
Hydraulic motors are ideal for use underwater and in dangerous places like mines and gas works, where the spark from an electric or petrol motor poses a serious fire risk. They are also good for any task where the motor is operated remotely, as the fluid can be pumped a long distance to the motor using comparatively little power and the only connection needed is piping, compared to more expensive electrical cable for running a remote electric motor. What is the most ingenious application of a hydraulic motor you have ever seen? Let us know in the comments below.
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