Latest Trends In Hydraulic Systems
Hydraulics is a matured industry, but still, it requires improvements to become a part of the digital world. The fact is, current hydraulic industry have several drawbacks. The hydraulic experts are working on these issues for improving energy efficiency, reliability, energy storage, and redeployment capabilities. So, the latest technology in hydraulics will focus on improvements in these areas by reducing the size and environmental hazards.
Today, most of the hydraulic systems are used to lift, pick or grasp things. Such systems have a wide range of application in various industries like construction, manufacturing, automobile, medical, etc. But soon the new hydraulic technology will bring advancements to these existing technologies and applications
Innovative new technologies are laying the foundation for the latest hydraulic systems and applications designed for construction, agriculture, mining, and power generation. From smart user interfaces to load sensing valve technology to hybrid actuation systems for renewable energy applications, these solutions lead to productivity increases, energy savings and maximized operational efficiency. Here are five key technology trends presented by Parker Hannifin that are shaping the future of hydraulics.
The latest hydraulics innovations are focusing on renewable energy applications, smart user interfaces, load sensing valve technology, and hybrid actuation systems. Some of the applications of these are mentioned below.
1.Innovative heavy duty vehicle technology
New generation load sensing valves: Parker’s EQA Eco Formance
electric flow amplifier technology is a significant advancement in load sensing
valves. By automatically adapting the meter-out pressure to the load conditions,
machine control is greatly improved. This is especially useful for functions
with slew or jib movements, or digger arms with over-Centre movement.
Electro-hydraulic control: Parker’s IQAN Connect is a
totally electronic approach that replaces mechanical and electromechanical
systems for controlling and monitoring hydraulics in mobile machines. This
digital ecosystem ties together Parker’s smart hydraulics and electronics
products, resulting in a synergy of intelligent components and customizable software
that delivers next generation connectivity while providing flexibility in
design and development.
Accurate mobile diagnostics: Abnormal temperature and pressure levels can adversely impact the function of hydraulic lines and pump systems in heavy mobile machinery. Parker’s SensoNODE BlueTM sensors give users an advanced condition monitoring solution that provides accurate readings without excessive wiring, allowing for mobile diagnostics with the cab door closed.
2. A smart user interface to improve machine efficiency
Parker has been building a new presence in industrial
Internet platforms and ecosystems by developing a software platform for
advanced and flexible user interface design. This enables machine manufacturers
to increase machine functionality and efficiency and to create new types of
business. Developing smart applications requires a robust software platform for
the HMI device. Parker’s UX Toolkit software tool enables easier development of
demanding applications for machine instrumentation, control and adjustment. The
applications can include supporting applications for core machine functions,
smart control systems, diagnostics or prediction applications that decrease
downtime, or GPS monitoring and navigation applications. Solutions helping
end-users to improve performance and efficiency include applications for mobile
hands-free devices, logbooks, usage monitoring, and task management (for
example managing bus lines).
3.Energy-saving hydraulic systems using drive
controlled pumps
Modern industrial machinery is creating ever-increasing
demands on hydraulics to provide more efficient and quieter solutions with a
smaller footprint, while maintaining the traditional benefits of hydraulic
systems such as high power density, precise control and enduring performance.
But these benefits come with the high cost of inefficient energy allocation,
heat generation and noise.
Conventional hydraulic power units require oversized pumps and motors to ensure performance during a system’s highest duty cycle demands. In today’s eco-conscious and globally competitive economic environment, a transition to systems in which power is precisely modulated to the requirements of specific tasks within highly complex hydraulic systems is essential. This is where drive controlled pump (DCP) technology can provide a solution to address the challenges of more demanding applications, rising energy costs and greater environmental requirements.
4.Variable speed drives become simpler and more efficient
Variable speed pump drives save up to 70% energy compared to
conventional drive solutions. Parker has developed a new, innovative variation
of its drive controlled pump. The combination of an optimized axial piston pump
with two displacement volumes and a very compact synchronous servo motor offers
decisive advantages over common variable speed pump systems:
• Low torque due to de-stroking in pressure holding,
resulting in reduced acquisition costs for the motor and frequency converter.
• High traverse speed through up-stroking when in rapid
drive mode.
• High operating pressure, high productivity and high energy
efficiency.
Parker has developed a hybrid actuation system (HAS) that is
ideal for renewable energy actuation applications such as those used with solar
panels, wind turbines and hydroelectric dams. The new hybrid design combines
the controllability of traditional electromechanical actuators with the power
density, longer life and resistive force capabilities of traditional hydraulic
systems. The result is an improved actuation system for wind and hydro and
other renewable energy systems, with a wider range of capabilities.
The hybrid design of this high efficiency, modular system is a fully self-contained system with no hydraulic hoses or power units. Hybrid hydraulics achieve exceptional economies of scale, with the ability to move over a megawatt from a single point. This makes HAS a good choice for large or small arrays.
6.Hydrostatic Transmission Fluid Engineered for Low Maintenance
Work in the turf industry can be tough, dirty and
unforgiving. The last thing you need is for the machine to fail in the midst of
a job. Machine failure leads to unscheduled maintenance and an increased amount
of time in the field. To prevent this costly downtime, it is essential that
fluids are routinely checked and replaced, namely transmission fluid.
Transmission fluid is the lifeblood of a hydraulic
system. Without transmission fluid, hydraulic pumps and motors cannot perform
the powerful tasks that are required for many different applications.
Unfortunately, most hydraulic fluids are merely repackaged mineral oils with
contaminants that reduce oil lubricity, high amounts of sulfur that accelerate
corrosion and unstable chemistries that lead to phase separation and
“gunked-up” gears. Coupled with a 500-hour maximum life, the current market of
transmission fluids provides hassle, downtime and uncertainty.
7. New Compact Design Solves for Typical Check Valve Challenges
Check valves are
commonly applied to a variety of load-holding applications that are found, for
example, in mobile equipment in mining, construction, or forestry. Typical
thread in cartridge style check valves are large and mount to the surface of a
manifold block. This surface mounting adds to the complexity and cost because
of the additional machining or drilling of internal passages required to
integrate the valve into the circuit. The compact design of Parker’s new
thread-in cartridge valve is an ideal solution because it allows for an
internal mount.
The CVH021 can be compact in nature because of its application; used
in circuits to isolate pressure signals to flow compensators and load sense
lines for pumps. Load sensing is a common methodology used for pump control on
many multifunctioning hydraulic circuits that use a variable displacement pump.
In load sensing circuits with two or more functions, it is important to use
check valves to isolate the signal from each function. This ensures that the
pump control is receiving the highest pressure signal in the circuit while
multiple functions are being used at the same time. (The pump control receiving
the highest pressure means the pump output is increased to meet the demand of
the highest demand function).
8. New Hydraulic Motors for Marine and Offshore Winches Exceed Performance Goals
Hybrid Actuation System (HAS) is ideal for harsh power generation environments such as those used with solar panels, wind turbines, and hydroelectric dams. HAS can be combined with an integrated Intellinder sensor, that eliminates the complexity of gun drilling and unprotected external sensors. This system improves efficiency without any complex maintenance.
The challenge
An offshore crane OEM identified the opportunity for
improved crane efficiency and partnered with Parker's Pump and Motor Division
(PMDE) to develop a new hydraulic motor to support their active heave
compensated winch system. Active heave compensated winches are designed for
crane load handling from a vessel or drill rig towards the seabed, underwater
installations or other fixed targets on the seabed. They reduce the influence
of waste upon offshore operations, keeping a load helped by equipment on a moving
vessel motionless concerning the seabed or another ship.
The new motor offers an extended speed range and
improved efficiencies, thus enabling the OEM to meet their performance goals in
the most severe weather conditions offshore. Other benefits of the new motor
are ease of installation and a simplified start-up procedure, contributing to
reduced overall installation costs.
Solution - V16
The solution was to increase the winch system's
speed and accuracy by developing the new V16 Variable Bent Axis motor. V16's
unique lightweight, spherical piston concept has a 30% speed capability over
competitors. This feature resulted in more excellent winch performance and
productivity. In terms of accuracy and controllability, the V16's world-class
displacement ratio (5,5:1) provides the winches with a high resolution,
resulting in better accuracy and controllability. The new V16 is an excellent
choice for offshore cranes and high-performance handling equipment requiring
precise operation and high power. Active heave compensated cranes, with their
strong demand for accuracy and high rope speed, are a typical example of such
an application. Heave compensation systems are vital for offshore
cranes, The motor development has been done in close cooperation with a major
marine OEM, thus ensuring a result aimed 100 % at marine applications, with
unsurpassed performance data. OEMs can install the V16 with a position sensor,
which provides the ability to monitor the motor displacement and make system
adjustments. Finally, with the V16's machined axial and radial main ports, an
OEM has both ease and flexibility in its installation of the V16.
Future of the Hydraulics Industry
A few years back, hydraulic was considered as a dying industry. Because nobody wanted to become a hydraulic professional due to the danger in that field. But now the situation has changed, this industry will be there in the next century also.
Hydraulics is there from the 17th century onwards. When you consider the applications of hydraulics from the past to the present, the growth of this industry will become clearly visible for you. The early inventions included piston pumps and water clocks and now it has reached on robotics and heavy equipment.
Recently most of the hazardous industrial applications use hydraulic power transmission method. Because electrical sparks will create accidents on potentially combustible atmospheres. Also, the advancements in reactance-based technology will create more vacancies in Hydraulic Job.
Authors -
Karansinh Gaware
Tanmay Kasliwal
Aditya Khabiya
Sushom Khaire
Amit Khare
Guide - Prof. Mangate Sir, VIT, Pune.
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