Editors:

Marcin Jakubowski

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Graphic Design:

Jean-Baptiste Vervaeck

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Version:

Date:

Hydraulics

v19.05

First Edition

Open Source Ecology Design Guide Series

Hydraulics - Table of Contents 1

Summary – How to generate toolpath files for automation and manufacturing applications. Manual generation of simple files, 3D printer slicers, and other open source g-code generators. Applications – Do you want to convert design concepts into machine instructions so that your CNC machine builds something for you? You will learn how to create these machine instructions for various machine types.

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1. What are hydraulics?
1. How it works
2. Why it works
3. Cost and performance vs electrical and mechanical systems
4. Basic components and circuit
2. Principles
• Hydraulics 101
• Continuity of fluid
• Modularity
• Valve design - Hydraulic Valve Symbols
• Hydraulic Motor design
• Open Source Cylinder Design
1. Universal Cylinder Builder
2. 3D Printed Seals
• Hydraulic diagrams
• Low pressure and high pressure hydraulics
• Working fluids - towards biohydraulics
3. Calculations
• Power, pressure, engine drive, hose sizes
• Measuring pressure and flow rate
4. Components and functional details
• Surpluscenter
• Gear pumps, multiple stage pumps
• Motor valve, cylinder valve - floating vs locking
• Spools and springs
• Hoses

Hydraulics - Table of Contents 2

• Components and functional details (continued)
• Check valves, manual valves, diverter valves, case drain
• Shafts and couplers for hydraulic motors
• Pump mounting to engines
• Solenoid valves - CEB press, automated controls
• Arduino-based controller design - diagram + real
• Starting gas engines
• System integration
• Power Cubes - gas engine, charcoal engine, electric
• Power Cube scalability
• Heavy machinery
• CNC machines, lathes, punch/shear
• Off-grid solar hydraulics
• Slow hydraulics on solar power - autonomous tractors + shredders
• Light hydraulics - the solar hydraulic car with Battery Pack
• Designing a hydraulic system
• Hydraulics Construction Set
• Hydraulic Fitting Library
• Hydraulics Visual Bill of Materials - parts and costs
• Design Diagrams
• Using an open source Circuit Symbol template
• Drag and Drop
• Using visual bills of materials for build transparency
• Open Source Hydraulic Design Software and Rendering
• Hydrology and fluids
• Range of motion simulation
• Ramge of motion in LibreCAD and in FreeCAD
• Motion simulation in Blender
• OpenFOAM
• Open Source Physics engine and game engine
• Design Checklist

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Hydraulics - Table of Contents 3

• Building a Hydraulic System
• 3D Printed, functional scale models
• Safety issues - hose protectors, bypasses, physical barriers, protective clothing
• Types of hydraulics fittings - o-rings and without
• Tightening fittings and measuring tightening torque
• Cylinder and motor mounting
• Hydraulic spindles for CNC machines
• Hose routing + hose protectors
• Pump mounting
• Power Source connection and stacking
• Test-driven design
• Build Checklist
• Hydraulics testing and measurements, flow, T, and pressure

Notes On Using this Guide

OSE work builds upon these great open source projects:

ABOUT: This is part of a design series on general machine design aimed at basic competency in the design of all 50 Global Village Construction Set machines.

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HOW TO USE: You can use a QR code reader to scan the bar codes to access content online.

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COLLABORATION: This is a collaborative effort. You are invited to help edit this guide. You can edit this document or make a copy, make your edits, and email us describing your proposed changes. To join our open source product development effort, join our Developer Team, or get hands-on experience in our Workshops. Email us at info@opensourceecology.org

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1. Hello

Subtitle

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Time Estima

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Use magn

[6] Frame

[2] 14” Rod

[4] Magnets

[1] 16” Rod