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Industrial hydraulic power units help create and operate machines and tools in large manufacturing, construction, and shipbuilding industries. Several types of these hydraulic power units exist to help accomplish better productivity.
This type of power hydraulic unit is a versatile equipment capable of running various applications. Therefore, users can employ it to produce high-volume, high-demand production.
This power unit is used when a machine generates much heat and may affect its working environment. Like any other air conditioning system, a heat exchange system cools the fluid by passing it through coils and using air to remove the heat from the fluid.
This hydraulic power unit configuration uses a tank with a pump installed on top and separated by an adapter. It is common in self-contained systems where the hydraulic fluid's lowest level is above the pump.
This configuration fully submerges the pump into the fluid, making it function without any reliance on gravity to pull the fluid down to the pump level.
Ground-mounted units are used when the hydraulic fluids must be stored away from the area of operation. This device is any type of hydraulic power unit configured to be ground-mounted instead of mounted on top of a machine.
This hydraulic power unit, similar to the hydraulic power pack, uses a submersible pump installed on a platform with a floating frame for transportation. These devices drive motion-seeking machinery and are portable air conditioning systems.
This device operates the pump at different speed levels to regulate fluid flow as demanded. It uses a variable speed motor and is commonly used with electric motors.
Some factors that should be considered when purchasing industrial hydraulic units include:
Check the compatibility of the hydraulic fluid with the circulating element, such as the electric motor or pump. Ensure the components are constructed from durable materials to enable the unit to run successfully. Aluminium, stainless steel, and thermoplastic are the most common.
Choose hydraulic power units with a specific hydraulic power rating to meet the requirements of a certain operation. The power rating is commonly in kilowatts and horsepowers.
Hydraulic power units have primary and secondary control components and mechanisms. Primary controls include pressure and flow control valves, while secondary ones involve proportional solenoids. Mostly, proportional solenoids control more accurately than simple on-off solenoids. Still, they are expensive and require complex operation.
Sometimes, machines in an industrial setup are connected in series, making their pressure add up. Others could also be in parallel, increasing the flow rate. In such a case, one has to ensure the hydraulic power unit flow rate and pressure ratings are sufficient to match the system's requirements.
Consider the cost of installing and running the industrial hydraulic power system for a given system. The installation costs include labour and the number of days required to set up all the components. Another thing to reflect on is the cost of electrical power used to run the unit.
How much space is available in the workplace for installing the hydraulic power unit? Consider the limitations of height and width and ensure the unit fits tight spaces if needed.
In the automotive industry, hydraulic pumps are used to operate heavy machinery, such as hydraulic lifts, which help repair and transport fluid. Construction companies use them in excavators and bulldozers to move large quantities of dirt and other debris because they can help accomplish tasks much faster than other methods.
The chemical industry uses hydraulic oil pumps to move corrosive fluids and materials through pipelines. This movement is critical in fluid transmission within the chemical manufacturing industry. These pumps act as pipelines, providing strength and durability to transport chemicals such as acids, bases, and industrial solvents.
The manufacturing industry also uses hydraulic power units in metalworking, such as stamping, forging, metal surface treatment, etc. They are used in die casting to inject molten metal into the die, shaping the product.
Hydraulic power units are crucial in the marine industry for operating the rudder, lifts, and deck machinery. They are also employed in tensioners used to lay cables and other underwater tasks. Plus, since many marine components are subjected to corrosive environments, marine hydraulic pumps are designed with corrosion-resistant materials.
Hydraulic pumps, called venturi pumps, play a critical role in the mining industry, especially in hydraulic mining. They are used to extract valuable minerals and ores from deposits by high-pressure water, which will wash away the rocks and leave behind the minerals.
Hydraulic pumps in the pharmaceutical industry move lubricants and other mediums used to manufacture drugs, extraction, and other processes.
Pressure rating
Industrial hydraulic power units have different pressure ratings that determine the highest pressure level the units can sustain. Those commonly used in light-duty applications have pressure ratings of about 1000 psi. Meanwhile, the ones in heavy-duty applications, like mining and military, can be several thousand psi.
Power source
Electronic hydraulic power units run on electricity. On the other hand, pneumatically powered ones are powered by compressed air. Manual HPUs use hand pumps or lever systems. This power source determines how the hydraulic fluid is pumped through the system.
Hydraulic fluid
The fluid works as a medium for transmitting force in hydraulics and pneumatic systems. Most hydraulic power units use mineral or water-based fluids. While some industries prefer using synthetics or bio-based fluids, especially for environmental considerations or health reasons, mineral-based fluids are commonly used due to their better oil ownership and cost-effectiveness.
Reservoir size
This refers to the hydraulic fluid storage container's capacity within the power unit. The sizes of these tanks can range anywhere from a quart to several gallons. The reservoir size should fit the needs of the particular application in mind. Example: high-demand hydraulic systems need a large reservoir, while small systems can do with a small one.
Frame materials
The frame of industrial hydraulic power units is constructed from various materials like steel, aluminium, and plastics. Steel frames are preferred for heavy-duty applications due to their high strength and durability. Light-duty power units use aluminium because it is lighter and resistant to corrosion. Plastic frames are used in small power units that are lightweight and affordable.
Components and accessories
Industrial hydraulic power units consist of hydraulic fluid reservoirs, pumps, pressure valves, filters, heat exchangers, and hose/tube connection to the components. Most of these units are equipped with pressure and temperature gauges, electrical components like motors, anti-vibration dampening parts, and casters for easy transportation.
Preparation
Fill the reservoir with the specified hydraulic fluid using a funnel and medium. Then, inspect all the hoses, couplings, and connections for tightness and wear. Ensure everything is secure and any damaged or worn-out parts are replaced before use.
Startup
If the hydraulic system is electric, switch it on. But if the system is powered by air, ensure the compressor is connected and powerfully set. After that, run the pump.
Adjust pressure
Use the pressure valve to set the desired pressure level. Ensure it fits the demands of the connected tools or machinery.
Check hydraulic fluid level
Open the reservoir and visually check the fluid level. Alternatively, use a dipstick to check it. Add more fluid if it is low using the manufacturer-recommended fluid type.
Flush
Turn off the motor and unplug the hydraulic power unit. Loosen the hose clamps and remove the hoses from the hydraulic tool. Then, use a wrench to open the quick-release couplers and detach the couplers from the hydraulic power unit.
Inspect hoses
After flushing the system, check the hoses for cracks, abrasions, and bulges. Replace any damaged ones with new ones using a pipe cutter to cut the old hose to the desired length. Use a wrench to open the quick couplers and pull out the plug.
Repairs
Run a visual inspection on the hydraulic power unit and check the pump, hose, couplings, and other components for possible damage. Consult with the repair manual for troubleshooting tips. Use gauges to check the pressure and other operating parameters.
A. The fluid colour says a lot about its quality. If it looks dirty, cloudy, or dark, the fluid needs to be changed. Also, pay attention to any unusual odour. If it has an overheating smell, it will be time to change it.
A. The most common problems are system leaks, noises, overloading, overheating, and component failure. However, occasional contamination can also damage the system.
A. The key to a longer life for any hydraulic unit is routine maintenance like checking the fluid levels, replacing worn-out parts, and cleaning the system.
A. The major difference between pneumatic and hydraulic systems is the medium used for fluid transmission. Pneumatic systems use air or gas, while hydraulic systems use liquid, usually water or mineral-based fluid. Air is easier and cheaper to get than gas, which makes pneumatic systems more environmentally friendly than hydraulic systems.
A. Hydraulic fluid transmission force, lubricates internal components, dissipates heat, and serves as a barrier for contaminants. It is also used to generate and transfer mechanical power from one point to another.
