كتاب Fluid Power Engineering

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Fluid Power Engineering
M. Galal Rabie, Ph.D.
Professor of Mechanical Engineering
Modern Academy for Engineering and Technology Cairo, Egypt

و المحتوى كما يلي :

Contents
Preface xix
1 Introduction to Hydraulic Power Systems . 1
1.1 Introduction 1
1.2 The Classification of Power Systems . 2
1.2.1 Mechanical Power Systems . 2
1.2.2 Electrical Power Systems . 3
1.2.3 Pneumatic Power Systems 4
1.2.4 Hydrodynamic Power Systems 5
1.2.5 Hydrostatic Power Systems . 6
1.3 Basic Hydraulic Power Systems . 8
1.4 The Advantages and Disadvantages of
Hydraulic Systems . 9
1.5 Comparing Power Systems . 10
1.6 Exercises . 11
1.7 Nomenclature . 13
2 Hydraulic Oils and Theoretical Background . 15
2.1 Introduction 15
2.2 Basic Properties of Hydraulic Oils . 16
2.2.1 Viscosity . 16
2.2.2 Oil Density . 25
2.2.3 Oil Compressibility 30
2.2.4 Thermal Expansion 37
2.2.5 Vapor Pressure . 38
2.2.6 Lubrication and Anti-Wear
Characteristics 39
2.2.7 Compatibility . 39
2.2.8 Chemical Stability . 39
2.2.9 Oxidation Stability 39
2.2.10 Foaming . 39
2.2.11 Cleanliness . 40
2.2.12 Thermal Properties 45
2.2.13 Acidity . 452.2.14 Toxicity 45
2.2.15 Environmentally Acceptable
Hydraulic Oils 46
2.3 Classification of Hydraulic Fluids 46
2.3.1 Typically Used Hydraulic Fluids . 46
2.3.2 Mineral Oils 47
2.3.3 Fire-Resistant Fluids . 47
2.4 Additives . 49
2.5 Requirements Imposed on the Hydraulic
Liquid 49
2.6 Exercises . 50
2.7 Nomenclature . 53
Appendix 2A Transfer Functions . 54
Appendix 2B Laminar Flow in Pipes 55
3 Hydraulic Transmission Lines . 59
3.1 Introduction 59
3.2 Hydraulic Tubing 59
3.3 Hoses 64
3.4 Pressure and Power Losses
in Hydraulic Conduits 68
3.4.1 Minor Losses . 68
3.4.2 Friction Losses . 70
3.5 Modeling of Hydraulic Transmission Lines 72
3.6 Exercises . 76
3.7 Nomenclature . 77
Appendix 3A The Laplace Transform . 77
The Direct Laplace Transform . 77
The Inverse Laplace Transform 77
Properties of the Laplace Transform . 77
Laplace Transform Tables . 78
Appendix 3B Modeling and Simulation of
Hydraulic Transmission Lines . 79
The Single-Lump Model 79
The Two-Lump Model . 80
The Three-Lump Model 81
The Four-Lump Model . 81
Higher-Order Models 82
Case Study . 82
4 Hydraulic Pumps . 89
4.1 Introduction 89
4.2 Ideal Pump Analysis 91
4.3 Real Pump Analysis 94
4.4 Cavitation in Displacement Pumps 97
x C o n t e n t sC o n t e n t s xi
4.5 Pulsation of Flow of Displacement
Pumps . 98
4.6 Classification of Pumps 100
4.6.1 Bent Axis Axial Piston Pumps . 100
4.6.2 Swash Plate Pumps with
Axial Pistons 103
4.6.3 Swash Plate Pumps with
Inclined Pistons . 105
4.6.4 Axial Piston Pumps with Rotating
Swash Plate-Wobble Plate 106
4.6.5 Radial Piston Pumps with Eccentric
Cam Ring 106
4.6.6 Radial Piston Pumps with
Eccentric Shafts . 108
4.6.7 Radial Piston Pumps
of Crank Type . 109
4.6.8 External Gear Pumps 109
4.6.9 Internal Gear Pumps . 114
4.6.10 Gerotor Pumps . 115
4.6.11 Screw Pumps . 117
4.6.12 Vane Pumps 117
4.7 Variable Displacement Pumps . 122
4.7.1 General 122
4.7.2 Pressure-Compensated
Vane Pumps 123
4.7.3 Bent Axis Axial Piston Pumps with
Power Control 125
4.8 Rotodynamic Pumps . 128
4.9 Pump Summary . 130
4.10 Pump Specification 134
4.11 Exercises . 134
4.12 Nomenclature . 137
5 Hydraulic Control Valves . 139
5.1 Introduction 139
5.2 Pressure-Control Valves 141
5.2.1 Direct-Operated Relief Valves . 141
5.2.2 Pilot-Operated Relief Valves 144
5.2.3 Pressure-Reducing Valves 147
5.2.4 Sequence Valves . 152
5.2.5 Accumulator Charging Valve . 155
5.3 Directional Control Valves 157
5.3.1 Introduction 157
5.3.2 Poppet-Type DCVs 157
5.3.3 Spool-Type DCVs . 1585.3.4 Control of the Directional
Control Valves 161
5.3.5 Flow Characteristics
of Spool Valves 167
5.3.6 Pressure and Power Losses in the
Spool Valves 169
5.3.7 Flow Forces Acting on the Spool . 170
5.3.8 Direct-Operated Directional
Control Valves 172
5.3.9 Pilot-Operated Directional
Control Valves 173
5.4 Check Valves . 175
5.4.1 Spring-Loaded Direct-Operated
Check Valves . 175
5.4.2 Direct-Operated Check Valves
Without Springs . 176
5.4.3 Pilot-Operated Check Valves
Without External Drain Ports . 176
5.4.4 Pilot-Operated Check Valves with
External Drain Ports . 178
5.4.5 Double Pilot-Operated
Check Valves . 178
5.4.6 Mechanically Piloted Pilot-Operated
Check Valves . 179
5.5 Flow Control Valves . 179
5.5.1 Throttle Valves 180
5.5.2 Sharp-Edged Throttle Valves 180
5.5.3 Series Pressure-Compensated Flow
Control Valves 181
5.5.4 Parallel Pressure-Compensated Flow
Control Valves—Three-Way FCVs . 184
5.5.5 Flow Dividers . 185
5.6 Exercises . 188
5.7 Nomenclature . 190
Appendix 5A Control Valve Pressures and
Throttle Areas . 191
Conical Poppet Valves . 191
Cylindrical Poppets with
Conical Seats . 192
Spherical Poppet Valves 193
Circular Throttling Area 196
Triangular Throttling Area 197
Appendix 5B Modeling and Simulation of a
Direct-Operated Relief Valve 198
xii C o n t e n t sC o n t e n t s xiii
Construction and Operation
of the Valve . 199
Mathematical Modeling 199
Computer Simulation 201
Static Characteristics . 201
Transient Response 202
Nomenclature . 204
6 Accessories 207
6.1 Introduction 207
6.2 Hydraulic Accumulators . 208
6.2.1 Classification and Operation 208
6.2.2 The Volumetric Capacity
of Accumulators . 210
6.2.3 The Construction and Operation
of Accumulators . 211
6.2.4 Applications of Hydraulic
Accumulators 216
Energy Storage 216
Emergency Sources of Energy . 219
Compensation for Large
Flow Demands 221
Pump Unloading 224
Reducing the Actuator’s
Response Time 224
Maintaining Constant
Pressure 225
Thermal Compensation 226
Smoothing of Pressure
Pulsations 227
Load Suspension on Load
Transporting Vehicles 231
Absorption of Hydraulic
Shocks . 232
Hydraulic Springs . 235
6.3 Hydraulic Filters 237
6.4 Hydraulic Pressure Switches 238
6.4.1 Piston-Type Pressure Switches 238
6.4.2 Bourdon Tube Pressure Switches . 239
6.4.3 Pressure Gauge Isolators . 240
6.5 Exercises . 241
6.6 Nomenclature . 243
Appendix 6A Smoothing Pressure
Pulsations by Accumulators 243Appendix 6B Absorption of Hydraulic
Shocks by Accumulators 246
Nomenclature and Abbreviations . 249
7 Hydraulic Actuators 251
7.1 Introduction 251
7.2 Hydraulic Cylinders . 251
7.2.1 The Construction of Hydraulic
Cylinders . 252
7.2.2 Cylinder Cushioning 253
7.2.3 Stop Tube 256
7.2.4 Cylinder Buckling . 256
7.2.5 Hydraulic Cylinder Stroke
Calculations 258
7.2.6 Classifications of Hydraulic
Cylinders . 258
7.2.7 Cylinder Mounting 261
7.2.8 Cylinder Calibers 262
7.3 Hydraulic Rotary Actuators . 264
7.3.1 Rotary Actuator with Rack and
Pinion Drive 264
7.3.2 Parallel Piston Rotary Actuator 264
7.3.3 Vane-Type Rotary Actuators 265
7.4 Hydraulic Motors 265
7.4.1 Introduction 265
7.4.2 Bent-Axis Axial Piston Motors 266
7.4.3 Swash Plate Axial Piston Motors . 267
7.4.4 Vane Motors 268
7.4.5 Gear Motors 269
7.5 Exercises . 269
7.6 Nomenclature . 271
Appendix 7A Case Studies:
Hydraulic Circuits . 272
8 Hydraulic Servo Actuators . 281
8.1 Construction and Operation 281
8.2 Applications of Hydraulic Servo Actuators . 283
8.2.1 The Steering Systems of Mobile
Equipment . 283
8.2.2 Applications in Machine Tools 284
8.2.3 Applications in Displacement
Pump Controls 285
8.3 The Mathematical Model of HSA 286
8.4 The Transfer Function of HSA . 289
8.4.1 Deduction of the HSA Transfer Function,
Based on the Step Response 289
xiv C o n t e n t sC o n t e n t s xv
8.4.2 Deducing the HSA Transfer
Function Analytically 289
8.5 Valve-Controlled Actuators . 292
8.5.1 Flow Characteristics . 292
8.5.2 Power Characteristics 295
8.6 Exercises . 296
8.7 Nomenclature 297
Appendix 8A Modeling and Simulation
of a Hydraulic Servo Actuator . 298
A Mathematical Model
of the HSA . 299
Simulation of the HSA . 300
Nomenclature 303
9 Electrohydraulic Servovalve Technology 305
9.1 Introduction 305
9.2 Applications of Electrohydraulic Servos 306
9.3 Electromagnetic Motors 306
9.4 Servovalves Incorporating Flapper
Valve Amplifi ers . 311
9.4.1 Single-Stage Servovalves . 311
9.4.2 Two-Stage Electrohydraulic
Servovalves . 313
9.5 Servovalves Incorporating Jet
Pipe Amplifi ers 324
9.6 Servovalves Incorporating Jet
Deflector Amplifiers . 327
9.7 Jet Pipe Amplifiers Versus Nozzle
Flapper Amplifi ers . 330
9.8 Exercises . 331
10 Modeling and Simulation of Electrohydraulic
Servosystems 333
10.1 Introduction 333
10.2 Electromagnetic Torque Motors . 333
10.2.1 Introducing Magnetic Circuits . 333
10.2.2 Magnetic Circuit of an Electromagnetic
Torque Motor . 336
10.2.3 Analysis of Torque Motors 337
10.3 Flapper Valves 340
10.4 Modeling of an Electrohydraulic
Servo Actuator 342
10.5 Exercises . 347
10.6 Nomenclature . 348
Appendix 10A Modeling and Simulation
of an EHSA . 349xvi C o n t e n t s
Numerical Values of the Studied
System . 350
Torque Motors 351
Single-Stage Electrohydraulic
Servovalves . 352
Two-Stage Electrohydraulic
Servovalves . 354
Electrohydraulic Servo
Actuators (EHSAs) . 358
Appendix 10B Design of P, PI, and
PID Controllers . 361
11 Introduction to Pneumatic Systems . 367
11.1 Introduction 367
11.2 Peculiarities of Pneumatic Systems . 367
11.2.1 Effects of Air Compressibility . 367
11.2.2 The Effect of Air Density 372
11.2.3 The Effect of Air Viscosity . 372
11.2.4 Other Peculiarities of Pneumatic
Systems 372
11.3 Advantages and Disadvantages of
Pneumatic Systems 373
11.3.1 Basic Advantages of Pneumatic
Systems 373
11.3.2 Basic Disadvantages of Pneumatic
Systems 373
11.4 Basic Elements of Pneumatic Systems 374
11.4.1 Basic Pneumatic Circuits 374
11.4.2 Air Compressors 374
11.4.3 Pneumatic Reservoirs 378
11.4.4 Air Filters . 378
11.4.5 Air Lubricators 379
11.4.6 Pneumatic Control Valves 379
11.5 Case Studies: Basic Pneumatic Circuits . 385
11.5.1 Manual Control of a SingleActing Cylinder . 385
11.5.2 Unidirectional Speed Control
of a Single-Acting Cylinder . 385
11.5.3 Bidirectional Speed Control
of a Single-Acting Cylinder . 385
11.5.4 OR Control of a Single-Acting
Cylinder 386
11.5.5 AND Control of a Single-Acting
Cylinder 387C o n t e n t s xvii
11.5.6 AND Control of Single-Acting
Cylinders; Logic AND Control 387
11.5.7 Logic NOT Control 387
11.5.8 Logic MEMORY Control 388
11.5.9 Bidirectional Speed Control of a
Double-Acting Cylinder 388
11.5.10 Unidirectional and Quick Return
Control of a Double-Acting
Cylinder 389
11.5.11 Dual Pressure Control of a DoubleActing Cylinder . 391
11.5.12 Semi-Automatic Control 392
11.5.13 Fully Automatic Control of a
Double-Acting Cylinder 392
11.5.14 Timed Control of a DoubleActing Cylinder . 392
11.5.15 Basic Positional Control of a
Double-Acting Cylinder 392
11.5.16 Electro-Pneumatic Logic AND . 396
11.5.17 Electro-Pneumatic Logic OR 396
11.5.18 Electro-Pneumatic Logic MEMORY . 397
11.5.19 Electro-Pneumatic Logic NOT . 398
11.6 Exercises . 398
11.7 Nomenclature . 399
References . 401
Index

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