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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