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Arab Academy for science,� technology and maritime transport

Hydraulic Test Rig

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Supervised by:�Dr. Ahmed Khalifa,� Dr. Aly Batran�

Presented by:

Valerio Samy

Mohamed Amr Lotfy

Abdullah Elwan

Mohamed Osama

Mohamed El Sayed Ali

Mohamed El Dkak

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Introduction

  • Hydraulic test rig project’s primary function is to simulate physical loading situations that occur in real world applications and it will be used for educational purposes.

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Components of The Project

  1. Oil tank
  2. External gear pump
  3. Valves
  4. Actuators
    1. Hydraulic cylinders
    2. Hydraulic motors

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4.I

4.II

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1. Oil Tank

  • The proper design.
  • Function.
  • The construction features.

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Reservoir (Oil Tank)

  • The proper design is essential to
    • the overall performance
    • Life of Individual components

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Function

  • Storing oil.
  • Cooling oil.
  • Draining of impurities from the bottom of tank.
  • Separation of air from oil.

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  • The Construction Features.

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The capacity of reservoir

80

Liter

Oil volume

66

Liter

The clearance volume

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5.4

Liter (15% of whole capacity)

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Dimension

50 x 40 x 40

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cm

The material used in

Steel

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2. Pump

  • External gear pump

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  • Mechanism of external gear pump

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Advantages

    • Offer ease Maintenance.
    • Steady flow.
    • Less expensive to buy and repair.
    • High speed and pressure.
    • Relatively quiet operation.

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3. Valves

  • Pressure relief valve:

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  • Directional control valve:

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Pressure Relief Valve.

  • Function

Is to limit the pressure to a specified maximum value by diverting pump flow back to the tank

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Directional Control Valves

  • Function
    • To start, stop, decelerate and change the direction of motion of a hydraulic actuator
    • To permit the free flow from the pump to the reservoir at low pressure
    • To isolate certain branch of a circuit
  • Manual actuated
  • 4 ways and 3 positions

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4. Actuators

  • Hydraulic cylinder.

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  • Hydraulic motor

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Hydraulic Cylinder

  • Function.
    • Get their power from pressurized hydraulic fluid.
    • Produce liner motion and force.
  • Types
    • Single acting hydraulic cylinder.
    • Double acting hydraulic cylinder.
      1. Double-acting cylinder with a piston rod on one side.
      2. Double-acting cylinder with two piston rod on both side.

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Hydraulic Motors

  • External gear motor.

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  • How gear motor work.

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Advantages Of Gear Motor.

    • High overall efficiency to optimized hydraulic compensation.
    • Optimum quality to price ratio.
    • Low maintenance requirements.
    • Easy to serve.

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Theoretical Analysis: (Pump)

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Double Acting Hydraulic Cylinder

  • Hydraulic cylinder 1
  • Measured dimensions:
  • Stroke Length = 45 cm
  • Cylinder Diameter = 60.73 mm
  • Rod Diameter = 30 mm
  • Cylinder Length = 57 cm

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Theoretical Analysis: (Hydraulic cylinder 1)

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Double Acting Hydraulic Cylinder

  • Hydraulic cylinder 2
  • Measured dimensions:
  • Stroke length=35 cm
  • Cylinder diameter= 4.2 cm
  • Rod diameter=1.9 cm
  • Cylinder length=44 cm

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Theoretical Analysis: (Hydraulic cylinder 2)

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External Gear Motor.

  • Hydraulic motor 1

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Theoretical Analysis: (Hydraulic motor 1)

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External Gear Motor

  • Hydraulic motor 2

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Theoretical Analysis: (Hydraulic motor 2)

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Measured Analysis

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Measured Analysis

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Measured Analysis

  • Hydraulic Motor 1
  • Revolution per minute (N) = 268 rpm
  • Volt (V) = 5.5 volt
  • Current ( I ) = 70 m ampere
  • W = (2 * Pi * N) / 60 = rad/sec
  • Electrical power = I * V = kw
  • Mechanical power = T * W = kw
  • Torque = N.m

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Measured Analysis

  • Hydraulic Motor 2
  • Revolution per minute (N) = 24.7 rpm
  • Volt (V) = 0.5 volt
  • Current ( I ) = 0.7 m ampere
  • W = (2 * Pi * N) / 60 = rad/sec
  • Electrical power = I * V = kw
  • Mechanical power = T * W = kw
  • Torque = N.m

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Conclusion

  • A hydraulic test rig demonstrates the components of a hydraulic system, including a tank, hydraulic fluid, electrical motor, external gear pump, actuators, and valves. Each component serves a purpose, and they all work together to show the power that the oil delivers through the system.

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Recommendations & Future work

  • Change the pump
  • Check the valves
  • Check hoses and connections

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Thank you.