Part 1 - Hydraulic systems design process

author:  MSc. Tobiasz Gola |  Sc. D Piotr Rosikowski 

At the beginning of the design process, the designer's task is to collect all the data necessary to design the hydraulic system, which then undergoes a detailed analysis. The next step is to prepare a hydraulic diagram of the designed system in accordance with the requirements of ISO-1219-1.
The designed diagram should include:

  • hydraulic fluid energy flow
  • adjustable pressures
  • piping dimensioning.

Figure 3 shows an exemplary hydraulic diagram of the prototype power unit used to power the Cutting and Extinguishing System.

On the basis of the previously prepared diagram, a preliminary specification of the elements is prepared. The list of elements should include all the elements and devices specified in the hydraulic connection diagram together with the exact type designation and the name of the supplier or manufacturer. After that the specification goes to the logistics department, where orders are processed.  

The next stage of the design process is the execution of an overall drawing for the customer. The designer places the most important overall dimensions, transport and connection elements on it. The technical person designated to contact the customer sends the diagram together with the dimensional drawing for an approval. 

With the use of CAD tools for spacial modeling, in the case of PONAR Wadowice it is Solid Edge, a 3D model of the designed hydraulic unit is made. Many representatives of companies involved in the production and / or distribution of hydraulic elements provide ready-made models on their websites or CDs, which can be easily imported into the designed set of hydraulic elements, which contributes to the acceleration of the entire design process. 

After making the model, the designer starts preparing the technical documentation. Drawings are made, among others elements requiring processing or welding drawings of steel structures. Appropriate surface roughness is selected, calculations of welded joints as well as structure strength calculations - FEM are performed. 

At the final stage, a full specification of parts is prepared, which is extended to include elements whose application is the result of 3D modeling, e.g., bolts, connectors, rigid pipes, steel profiles. The full list of parts is sent to the logistics department for ordering. 

Preparation of assembly documentation in the form of drawings is the next step that should be performed. In the last stage of the process, the designer is responsible for supervising the production process, and in the meantime, the 3D model is verified in order to eliminate possible errors.  

It is also worth remembering about the time pressure that the designer has to deal with in the design process. The implementation time is assigned to individual activities and it should be observed in order not to extend the time of the design and construction process.

Figure 3 An exemplary hydraulic diagram

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