This script shall give you a basic idea of a simple hydraulic
system ( also known as fluid power system ) for single engine hovercraft.
The hydraulic system is used for separate lift fan operation.
It is not a working copy to set up any system and shall provide you
only with the basic idea and some tips in the layout - please consult a
hydraulic specialist for detailed calculations and project specific layout.
You will find some required calculations and formulas in
the linked pdf files.
The basics :
A hydraulic system consist of a hydraulic pump and motor.
The pump is attached to the main
engine. The shaft of pump is connected to the engine shaft via reduction
or belt drive.
With each revolution of your main engine, the hydraulic pump is brought
into pumping motion.
It is important to take care of the pump max. rated RPM which in most
cases, will require a reduction drive. Hold in mind that you will need
adequate RPM for your lift unit before you reach high RPM on your thrust
output shaft. As well as max. thrust shaft RPM should not exceed max. rated
pump RPM.
The pump is connected via hydraulic fluid
line to the hydraulic motor. This is your high pressure line.
For further reference please use : Eaton
Pressure-Flow Compensated Piston Pumps all credits to the original
source.
The motor most likely will be attached
to the fan shaft directly or in the shortest possible way. As the
hydraulic pump builds up pressure with each rotation, the high pressure
line transfers this pressure to the intake side of the motor which will
start turning in a nearly equal manner ( minus loss of friction in the
line,...). For further reference please see : Eaton
Medium Duty Piston Motor - all credits to the original source. The
low pressure line is attached to the motor's exit port and it will transfer
the hydraulic fluid back to the pump as seen in layout 1.
Alternative supplier are :
POCLAIN HYDRAULICS
INDUSTRIES
Sauer-Danfoss
CROSS Manufacturing, Inc.
KNF Neuberger, Inc. (USA)
Parker
Mobile Hydraulics
This is the most simple set up of fluid power in a closed system. Kind
of stripped down basics which will work on very low hp application
and with generally no major control over your system.
To set up your system you need to know the max. HP and RPM on your
motor side - once this is known you can work yourself to the pump side.
I hope you could still follow so we can start to complicate this quite
simple system a bit.
Lets start with the motor - what else is there to take care of besides
low weight and long lifetime for a reasonable price?.... Most motors won't
be sitting on the shelf and have a 8 - 10 week delivery time - so it is
wise to get the right unit in the first place. Make sure you know the shaft
turning direction, location of the motor and most appropriate ( high pressure
and low pressure ) port direction so you can reduce 90 degree elbow on
the high pressure side. Make sure your drain port point's up to drain air
from your hydraulic system. Last but not least motor attachment is important.
Filter:
Once we have this selected it is wise to think about the most important
medium in the system and that is your hydraulic oil ( try to use a good
non foaming oil ) . With the use of pump and motor you will get small amounts
of abrasion particles in your hydraulic oil - these tiny buggers surf your
oil and get pumped in equal manner through your system as the oil it is
in - so the use of a filter unit will increase the lifetime of your hydraulic
pump and motor and allow these buggers to get out of the system. The filter
unit will provide a certain amount of resistance to your hydraulic oil
flow.
For further reference please see : Low,
Medium & High Pressure Filters from Eaton Hydraulics - all credits
to the original source.
Your filter unit should be on the low pressure side - as seen
in Layout 2 - and is most likely close to the pump. Make the filter unit
easy accessible to change filter cartridges on a regular basis. As your
filter clogs up over time, resistance will increase in your system.
Other aspects you want to know about your hydraulic oil is hydraulic
oil pressure, hydraulic oil flow rate and the temperature of
your hydraulic oil.
In general - the more you know about your hydraulic oil the easier
it is to avoid expensive components failure.
Alternative supplier :
HYDAC TECHNOLOGY
So we covered motor aspect, oil and some means to hold it clean ...
now lets look at the
hydraulic hoses ... somehow we
need to get the hydraulic oil from point A ( pump ) to point B ( motor
) and again back through a few obstacles. Hydraulic hoses need to have
adequate cross section to reduce friction in the line ( friction = resistance
= heat build up in your oil) For further reference please see : Velocity
and Pressure drop in pipes and especially at the section : FLOW / VELOCITY
NOMOGRAM - as well as : SAE
Hydraulic hose specifications (SAE J517) . Select the appropriate cross-section
from your motor's maximum required GPM. and PSI range. Try to lay the high
pressure line as straight as possible from pump to motor. Try to avoid
90 degree elbows in your high pressure line. Now you have the theoretical
location of your hydraulic line - so check if the hydraulic hose will be
able to flex around all corners it is laid - some high pressure lines have
quite big minimum radius. You can bend them but do not underestimate this
and try to take care of it before hand. A Hovercraft specific problem in
the layout of your hydraulic system is the balance of your craft ( CoG
). As your hydraulic pump will be attached by some means to your main engine,
it is most likely off center. Your motor on the other hand will be either
on Centerline or off centerline - all are fixed weights which won't change
during operation - the location of the hydraulic lines allows you to compensate
your balance to a certain extent - low pressure lines are lighter and more
flexible than the high pressure lines. Last but not least the common sense
suggestions - don't run your hydraulic lines under your fuel tank
since hydraulic oil warms up quite considerable and it is not the safest
way to fly with hot fuel ...but who knows some might enjoy an extra boost.
So far we have a system which has no leaks. But over the service life
of your system, this might change. As well as for hovercraft applications
you will run on high RPM = high GPM. = relatively high PSI level which
will break down your hydraulic oil ... - the means to increase the lifetime
of your pump and hydraulic oil is a hydraulic
oil reservoir tank. This tank holds an amount of hydraulic oil
and is vented to the atmosphere. Unfortunately in a weight sensitive Hovercraft
this tank is dead weight and not appealing et all. Also it is a fact that
custom made tanks are not cheap. A good holding tank needs to have
certain features. The return line fitting which is attached to your hydraulic
hose, an internal extension which should extend in the tank to the
bottom of the tank to reduce foam build up. Internal thread on the oil
pick up side to attach a filter cat ridge, as well as external threaded
fitting to attach your hydraulic line feeding your pump. As seen
in figure Layout 3. The tank has to be located above the pump to
allow a gravity feed of hydraulic oil to the hydraulic pump. An inspection
hatch big enough to pass your hand through ( a bit bigger would be handy
so you don't loose your skin if you clean your tank ). A vent on its highest
point . And if you want to go fancy, a thread to attach an oil level /
temperature sensor would make it safer. So you see we ask for a lot from
the poor builder of these tanks.
You can use an alternative with a basic factory tank which has inline
filter on the pick up side. But this will reduce the life span of the tank.
You must also discharge all the build ups from the tank in an environmentally
safe manner.
The sender unit in your tank is
more or less nothing more than an electric switch .
You have to determine first hand if the switch shall interrupt the
circuit ( as it would be useful if you run your ignition system over the
switch ) or close the circuit ( which is the case for a dashboard emergency
light or sound which should be activated when your level goes low ) .
The appealing version is that in case the oil level drops ( the system
has a leak ) the sender unit would stop the main engine and damage could
be reduced to a minimum ... or you can run a red light to your dash board
...... glue your eyes to it and hope you react quicker as your pump is
pumping the left over hydraulic oil out the leak..
Alternative supplier :
Temposonics -
Even if our basic system got now quite complicated and fancy - we still
have no means of actual control of the system = any difference in the
RPM on the hydraulic pump shaft equals to equivalent RPM change on
the hydraulic motor shaft. The only means of control in this aspect is
a
Valve in the high pressure line
which regulates the fluid flow. For further reference please use
Vickers
valves file - all credits to the originator.
The valve - as seen in Layout 4 -should be the only component
between pump and motor in the high pressure side of the system. All the
valve does is to reduce or open the fluid flow to the hydraulic motor but
it cannot increase the flow beyond the pump capacity according to it's
input shaft RPM. The excess hydraulic fluid will be returned into the holding
tank. This process will heat up your hydraulic oil considerably and more
or less you burn unnecessary HP into heat. An alternative is to use a pressure
flow compensated pump with a load sensing line as described in :
Eaton Pressure-Flow
Compensated Piston Pumps pages 25 and down - which will
adjust fluid output according to system requirements. But this variation
exceeds the basic layout of this file and might just complicate it unnecessarily.
Alternative supplier :
Marwin Valve
Flow-Tek
Conbraco
Kepner Products Company
As you have seen in the description of most components - they all have
the nasty habit of changing a small amount of energy into heat -for further
reference please see : COOLING
AND HEATING - from friction in the lines to resistance in the filter
units - your hydraulic oil will heat up considerably if you have the system
running on high RPM. This heat needs to be anticipated to the environment
via an adequate heat exchanger which
will hold your hydraulic oil temperature as low as possible. For further
reference see : Heat
Exchangers for small systems or: Heat
exchanger for bigger systems The heat exchanger will be located in
the low pressure side of your system and either you have to use a heat
exchanger with relief valve as seen in Layout 5 - in case the unit clogs
up - or two units in parallel. All heat exchangers need direct airflow
= airflow through the unit and not over the unit which is something we
do not really like to provide in Hovercraft where we try our best to produce
the highest mass flow of air we can achieve with our HP.

Distributor for hydraulic components :
Small HP ratings :
Northern Tool
General aspect / high Hp ratings :
Motion Industries
Unfortunately their web site is as useless as their service and staff
is useful - so just look up your nearest Service center and get "hands
on" with them.
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