Content Chapter 1 Hydraulic energy converters... 10 1.1 List of symbols... 13 1.2 Hydraulic pump types, constant output... 14 1.2.1 External gear pumps... 16 1.2.2 Internal gear pumps... 17 1.2.3 Vane pumps... 18 1.2.4 Radial piston pumps... 19 1.3 Hydraulic pump types, variable output... 20 1.3.1 Swash plate pumps... 20 1.3.2 Proportional flow control... 22 1.3.3 Pressure control... 23 1.3.4 Load sense control... 24 1.4 Summary of pump characteristics... 25 1.5 Formulas... 26 1.5.1 Volumetric efficiency / mechanical efficiency... 27 1.6 Actuators: cylinders... 27 1.6.1 Different types of cylinders... 28 1.6.2 Formulas for a double action cylinder... 29 1.6.3 Permissible speed... 30 1.6.4 Cylinder friction... 30 1.6.5 Application of the cylinder... 31 1.6.6 Buckle calculation for cylinders... 32 1.6.7 Rod layers... 34 1.6.8 Cylinder cushioning... 38 1.6.9 Cavitation... 43 1.7 Actuators: hydraulic motors... 45 1.7.1 Motor with fixed displacement or stroke volume... 46 1.7.2 Motor with variable stroke volume... 48 1.7.3 Formulas for a hydraulic motor... 49 VII Chapter 2 Hydraulic energy control, conductive part... 52 2.1 Pressure control valves... 55 2.1.2 Pressure reducing valve... 56 2.1.3 Pressure sequence valve... 57 2.1.4 Brake (counter balance) valve... 58 2.2 Directional valves... 59 2.3 Flow valves... 61 2.3.1 Non-return (check) valves... 61 2.3.2 Throttle valves... 61 2.4 Proportional and servo valves... 62 2.4.1 General... 62 2.4.2 Proportional controls... 62 2.4.3 Higher pressure drop across the valve ports... 64 2.4.4 Performance curve for the proportional valve... 65 2.4.5 The asymmetrical spool... 66 2.4.6 Slowing down of a load... 67 2.4.7 2-Way and 3-way pressure compensation, loadsensing... 68
Chapter 3 Conductive part, piping and fluids... 72 3.1 List of symbols... 75 3.2 Piping... 76 3.3 Fluid properties... 81 Chapter 4 Fluid conditioners and hydraulic accumulators... 88 4.1 List of symbols... 91 4.2 Reservoir... 92 4.3 Filtration... 95 4.3.1 Different filtration methods:... 96 4.3.2 Design considerations... 97 4.4 Accumulator... 98 4.4.1 Definition... 98 4.4.2 Applications... 98 4.4.3 Types... 99 4.4.4 Working conditions, Law of Boyle-Gay-Lussac... 100 Chapter 5 AC induction machines... 104 5.1 Construction and principle of operation... 109 5.2 Speed and torque control... 116 5.3 Details of the AC-DC-AC... 119 Chapter 6 Control technology... 122 VIII 6.1 List of symbols... 125 6.2 6.3 Block diagram and laplace transformation... 126 1 st order system, step response... 130 6.4 Elasticity of hydraulic fluids... 132 6.5 Stiffness of a cylinder... 134 6.6 Stiffness of a hydraulic motor... 135 6.7 Results of stiffness calculations... 136 6.8 Mass spring system... 138 6.9 Reduced mass and moment of inertia... 140 6.10 Dynamic behaviour... 141 6.11 Complex numbers, polar diagram... 143 6.12 Stability of 2nd and higher order systems... 145 6.13 Control errors... 147 6.14 The integrating controller (i-controller)... 150 6.15 The dynamics of the ac-induction motor... 152 Chapter 7 Linear drives, open-loop... 154 7.1 List of symbols... 157 7.2 Mass loaded cylinder with counterbalance valve... 158 7.3 Mass loaded cylinder with load control valve... 162 7.4 Mass loaded cylinder with flow control valve... 165 7.5 Pressure/force control... 168 7.6 Suspended force... 173
Chapter 8 Linear drives, closed loop systems... 176 8.1 List of symbols... 179 8.2 Proportional control... 181 8.2.1 Static and dynamic parameters... 182 8.2.2 Detailed hydraulic schema... 186 8.3 Servo control, application 1... 188 8.3.1 Functional requirements... 188 8.3.2 Calculation of the drive system... 190 8.3.3 Details of the drive system... 193 8.3.4 Commissioning... 194 8.4 Servo control, application 2... 196 8.4.1 Functional requirements... 196 8.4.2 Calculation of the control system... 197 8.4.3 Back-up accumulator... 200 8.4.4 Design detail... 202 Chapter 9 Heave compensation... 204 9.1 List of symbols... 207 9.2 Passive heave compensation, quasi-static behaviour... 208 9.3 Passive heave compensation dynamics... 212 9.4 Offshore applications... 216 9.5 Type of gas... 218 9.5.1 Combustion of a fluid... 218 9.5.2 Static electricity... 220 9.5.3 Sparks caused by mechanical friction... 220 9.6 Using nitrogen... 221 9.7 Active heave compensation... 224 9.7.1 Method of construction... 224 9.7.2 Deployment/retrieval of the load... 226 9.8 Design of the gas system... 228 9.8.1 Pressure equaliser function... 228 9.8.2 Pressure drop in the pipe work... 232 IX Chapter 10 Rotating drives... 236 10.1 List of symbols... 239 10.2 Primary and secondary hydraulic drives... 240 10.3 Comparison of a hydraulic and an electrical drive... 245 10.3.1 Hydraulic drive... 246 10.3.2 Electrical drive... 249 10.4 Realisation of the drive... 253 10.4.1 The high torque motor solution... 253 10.4.2 The high speed motor solution... 255 10.4.3 The electric motor solution... 257 10.4.4 Design choice... 258 10.5 Hydraulic drive in open loop... 259 10.6 Dynamics of rotational drives... 261 10.7 Secondary drive for sawing mechanism... 265
Chapter 11 Subsea drives... 268 11.1 List of symbols... 271 11.2 Subsea hydraulic drives... 272 11.3 Subsea hammering... 276 11.4 Salvage of the Kursk submarine... 278 11.5 A hydraulic drive for a subsea Grab... 282 11.6 Subsea clamp systems... 286 11.7 Subsea valve control... 287 11.8 Subsea electrical drives... 289 Chapter 12 Safety design rules... 290 X 12.1 Legal requirements... 294 12.1.1 Machinery Directive... 294 12.2 12.2.1 Pressure Equipment Directive... 297 Division into categories... 299 12.2.2 Requirements for the product... 301 12.3 Atmospheres explosive directive... 302 12.3.1 Division into groups and categories... 302 12.3.2 Division into zones and division into gas groups... 303 12.3.3 Methods of protection... 304 12.4 Classifications bureaus... 305 12.5 Risk analysis... 307 12.5.1 Hazard Identification Study... 307 12.5.2 Failure modes analysis... 308 12.6 Examples of real life failures... 310 12.6.1 Free fall of a winch motor (1)... 310 12.6.2 Free fall of a winch motor (2)... 312 Index... 314
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