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Zeenni Technology Center for Engineering and Industrial Research
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Hydraulics
 
This module covers the applications of hydraulics in the domain of the modern technical automation. Starting from the physical basics of hydraulics, it treats in detail the components and architecture of a hydraulic circuit, safety measures and fault-finding. It describes the structure and operation of the components used in an electrohydraulic command, and illustrates the procedure to follow during the design and implementation of such commands. It then explains how to attain speed control, position uphold, leaks prevention and finally how and where is it possible to save energy.

 

The Hydraulics module consists of the following courses:

TP501- Hydraulics, Basic Level
Prerequisites: Technical Understanding
Contents:
Characteristics of valves and other components.
Uses of individual valves and other components.
Comparison of uses and functions of different valves and other components
Measurement of variables such as pressure, flow rate and time.
Control of pressure and speed.
Calculations of area ratios, forces, power and speed.
Basic physical principles of hydraulics.
Use of basic hydraulics equations.
Understanding and drafting of circuit diagrams.
Drafting of displacement/step diagrams.
Assembly and commissioning of control circuits, including faultfinding
Assessment of energy consumption.
Basic hydraulic circuits such as a pressure sequence circuit, a bypass circuit to the pump, a differential circuit, circuits with flow control valves in the inlet,  outlet and bypass, circuits with counter-holding and bypass circuits with a non-return valve.
 
 
TP502- Hydraulics, Advanced Level
Prerequisites: TP501
Contents:
Hose-reel drive system for tanker truck - Hydraulic motor
Table feed for a rough-grinding machine - Bypass with 2-way flow control valve
Lifting device with two cylinders - Flow divider
Rapid-traverse feed device for a drilling machine - Rapid-traverse feed circuit
Control system for a scrap press - Differential circuit
Clamping a gearbox casing - Accumulator
Plastic injection-molding machine - Dual pressure circuit
Pipe-bending machine - Rectifier circuit
Single-column press - Flow control valves in inlet and outlet lines
Machining center - Sequence control with two cylinders
Magnetic crane - Tractive load
Folding machine - Pressure regulator
Earth drill - Rapid-traverse circuit with accumulator
Machining centrer- Electrical sequence control
 
 
TP601- Electrohydraulics, Basic Level
Prerequisites: Technical Understanding
Contents:
Basic physical principles of electrical engineering and hydraulics
Function and use of electrical and electro-hydraulic components such as switches, pushbuttons and solenoid valves
Naming and identifying electrical and hydraulic symbols
Development and reading of standard circuit diagrams
Representation of control exercises as function diagrams
Drafting, assembly and commissioning of basic circuits
Direct and indirect activation of cylinders
Activation of a hydraulic motor
MANUAL and AUTOMATIC modes
Position and pressure dependent control circuits
Interlock circuit
Rapid-traverse circuit
Fault-finding with simple electro-hydraulic control circuits
 
 
TP602- Electrohydraulics, Advanced Level
Prerequisites: TP601
Contents:
Function and use of electronic sensors, hydraulic motors and hydraulic accumulators
Complex sequence controls
Combination position and pressure dependent control circuits
Electrical control circuit with several actuators
Sequence controls with MANUAL/AUTOMATIC EMERGENCY STOP and SETTING modes,
Circuit with hydraulic accumulator
Position and time dependent control circuits
Systematic fault-finding in electro-hydraulic control circuits
Development of sequence controls from a function diagram
Controls with timer relays with pick-up and drop-off delays
Counter controls with predetermining counters
 
 
TP701- Proportional Hydraulics
Prerequisites: TP602
Contents:
Introduction to proportional hydraulics
Hydraulic feed drive with manual and electrical control
Signal flow and components of proportional hydraulics
Advantages of proportional hydraulics
Proportional valves: Design and mode of operation
Design and mode of operation of a proportional solenoid and pressure valves
Design and mode of operation of proportional flow restrictors and directional control valves
Design and mode of operation of proportional flow control valves
Proportional valves: Characteristic curves and parameters
Characteristic curve representation
Hysteresis, inversion range and response threshold
Characteristic curves of pressure valves
Characteristic curves of flow restrictors and directional control valves
Parameters of valve dynamics
Application limits of proportional valves
Amplifier and setpoint value specification
Design and mode of operation of an amplifier
Setting an amplifier - Setpoint value specification
 
 
TP702- Advanced Proportional Hydraulics
Prerequisites: TP701
Contents:
Pressure sensor - Characteristic line, binary and analogue signal
Temperature sensor -Temperature monitoring control
Displacement sensor - Sensor characteristics - basic control using displacement sensors
Curing press - Accelerating, decelerating, velocity stages
Hydraulic lift - Interrupt positioning
Drawing press - Drive acceleration by means of Proportional pressure relief valve
Honing machine - Oscillation of hydraulic drives
Mold closing device - bypass circuit, Soft stop
Injection molding machine - Simulation of complex injection molding processes
Injection molding machine with mold - closing device - Overall process, Proportional flow control valves
Fault finding
 
 
P Checkpoint – Learning Outcomes
Upon completion of this training, the participant will be able to:
îdesign, assemble and test basic hydraulic circuits
îmaintain and troubleshoot basic hydraulic control systems
îidentify and describe the construction, design features, technical data and operation of hydraulic components
îperform simple calculations of pressure, flow and force
îidentify the components and explain their functions in a given mobile hydraulic circuit
îbuild and test hydrostatic transmissions, working hydraulics and steering circuits
îexplain load sensing functions and other efficiency components
îmake adjustments to the control parameters of mobile hydraulics
îmeasure the required parameters in a mobile hydraulic circuit
îsystematically troubleshoot and explain maintenance procedures
îexplain safety measures
îexplain the structure and mode of operation of proportional, way, pressure and flow control valves
îinterpret the characteristic data of proportional valves
îchoose the right proportional or servo solution for the application
îdevelop, read and interpret proportional hydraulics circuit diagrams
îexplain the principles of servo valve technology and control
îexplain the difference between open- and closed-loop controls
îidentify and solve the most common faults in proportional and servo hydraulics systems
 
The simulation software used for this module are FluidSIM & FluidLab