Hydraulic power control systems are a common and important part of mechanical systems. In hydraulic power system design, power, pressure flow rates, and mechanism of circuitry are all important factors when analyzing any hydraulic system. Pumps, electric motors, reservoirs, working fluid propertied, hydraulic circuitry, and a large variety of valves make up a functional hydraulic system. Applications for hydraulic systems vary widely from automotive, mechanical etc. It is engineers’ job to design a hydraulic system that will be functional, efficient, and safe.
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A test bench could prove to be a useful tool in illustrating the functionality of pressure reducing, and directional control valves. The effect of different system pressures and resulting operational pressures for various circuits. By analyzing the fluid mechanics by the hydraulic system, we can apply hydraulic power and fluid analysis theoretically and validate experimentally with the test bench.
A test bench can shorten troubleshooting time, take guesswork out of the diagnoses, and let your company thoroughly test new or rebuilt components and sub-assemblies prior to installation in a working system. Listed are some more specific uses for a test bench system.
· Test incoming hydraulic components to identify problems.
· Test all rebuilt parts for proper operation to ensure customer satisfaction.
· Carefully “break in” components with rotating parts (pumps and motors) using clean, filtered hydraulic fluids to give rebuilt pumps and motors a long service life.
· Prevent warranty claims and help customers solve hydraulic system problems.
· Conduct performance test on rebuilt hydraulic components for proper operation before they are reinstalled on equipment, preventing additional expensive production equipment downtime.
· Check used components removed from production equipment. Parts can be tested for proper operation and unnecessary repair work can be eliminated.
· Test used hydraulic components before they are sent out, preventing unnecessary expensive repair work. In many instances, we may find that only on inexpensive shaft seal or housing O-ring is necessary to put a component back in operation.
· Ensure your company is receiving quality components and prevent expensive additional production equipment downtime by performance testing components.
· System equipment could allow for complete testing of new equipment, from pumps to end components like compressors, transfer pumps pneumatic and hydraulic, even cranes with remote mounting, without ever using a truck chassis.
· The system can be configured to remotely store different drums of various fluids outdoors to simulate different viscosities, at different temperatures.
Basic Fundamentals of Component Testing
PUMPS
Pumps are driven by the variable speed bi-directional hydraulic motor on the test bench. Pumps are mounted on the universal mounting bracket supplied with bench. The physical connection between test pump and bench motor is accomplished with a universal driveshaft and adapters between the drive shaft and test pump shaft. The test pump receives oil from the bench reservoir. Discharge flow from the test pump is measured by a flow meter and restricted by a load valve before discharge flow is returned to the bench reservoir. Pumps are checked for efficiency at a rated working pressure and for external leaks. The standard test bench tests only one pressure port at a time, we are adding a second pressure port for the use of a tandem pump arrangement.
MOTORS
Motors are driven by the variable volume hydraulic pump on the test bench. The test motor drives the hydraulic motor on the bench (therefore, we are using the test bench motor as a pump). Mounting the test motor and the physical connection between the test motor and the bench motor is the same as described the “pump test” above. The discharge flow of the bench motor is restricted with a load valve thereby putting the test motor under a work load. Motors are checked for efficiency at rated working pressure and for external leaks.
CYLINDERS
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Cylinders are pressurized and operated by the variable volume hydraulic pump on the test bench. Flow is directed to and from the cylinder by a manual operated four way valve. Cylinders are checked for scored cylinder bores, worn piston packing and external leaks.
RELIEF VALVES
Relief valves are pressurized and operated by the variable volume hydraulic pump on the test bench. Flow returning from the valve to the bench can be measured by the bench. Relief valves are checked for internal leakage, external leakage, “cracking” pressure, pressure setting and resetting pressure.
FOUR-WAY VALVES and VALVE BANKS
Four-way valves and valve banks are pressurized by the variable volume hydraulic pump on the test bench. Generally, the valve spool is shifted to a direct oil to a blocked valve port and leakage past the spool is visually checked at the non-pressurized adjoining port. Valves are checked for external leaks.
EXPLANATION OF CONTROLS
· 5000 psi pressure gauge that indicates the operating pressure of the main test bench pump. This gauge also indicates the test pressure applied to motors, valves and cylinders being tested on the test bench. The pressure is controlled by the main pump pressure control valve or by the horse power demand to drive the test pumps.
· 5000 psi pressure gauge that indicates the working pressure being applied to a pump being tested on the test bench. Pressure on this gauge is controlled by pump test pressure control valve.
· 5000 psi pressure gauge that indicates the amount of load being applied to the discharge port of the test bench hydraulic motor when being used as a load pump when testing hydraulic motors. Pressure on this gauge is controlled by the test pressure control valve.
· Temperature gauge which indicates the test bench reservoir oil temperature. The test bench should not be run if this gauge exceeds 160° F.
· Digital flow meter (0-100 gpm) measuring the amount of oil flow in gallons per minute being returned to quick disconnect ports on the test bench. Pressure control valve and pressure gauge are located in series with port.
· Main pump pressure control regulates the operating pressure on the main test bench pump between 200 and 5000 psi.
· Circuit selector valve is a two position (either open or closed) valve located between the main test bench pump and the test bench hydraulic drive motor. In the open position it allows main pump flow to turn the hydraulic drive motor which I turn drives the test pump. In the closed position, it blocks off oil flow to the hydraulic drive motor for valve, cylinder and hydraulic motor test.
I could continue with about a dozen more gauges, valves and meters, but this is a standard piece of equipment of a tried a true test bench, used across the industries for hydraulic component testing and relief valve setting process. It comes with a full operating and maintenance manual and factory replacement parts and support.
In a force range of 500 N up to 2.5 kN, we offer the following preowned table-top testing machines:
Used zwickiLine table-top testing machines are available with test speeds ranging from 0.0005 to 3,000 mm/min (2,000) and test area heights of 565 to 1,365 mm (1,373).
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