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Hydraulic System Design for Service Assurance - Table of Contents & Preface

Preface | Table of Contents | Sample Pages | Pricing

Hydraulic System Design for Service Assurance

by Dr. E.C. Fitch and Dr. I. T. Hong


The assurance of service reliability and longevity of hydraulic components and systems has been the subject of over 35 years of research by the authors. During this period of time they conducted millions of dollars worth of research for both the government and industrial sponsors. They pursued and obtained critical answers to problems that were critically needed to improved hydraulic systems. This book is the first comprehensive document written and published for general use that discloses many of the once proprietary teachings and technologies gained from this research. The material presented in this book has been bolstered and verified by many successful field studies involving all types of hydraulic machinery. A great number of companies and service organizations worldwide have participated in the overall program.

It is interesting to note that much of the theory and "proof of concepts" originally developed and presented became cloaked in controversy due to the importance of the subject matter and the impact the results could have on many of the participants (particularly component and system manufacturers). Those companies which continued to guide and direct the researchers, tried the concepts, and eventually implemented the results in their systems became the true industrial leaders of today. The authors feel that since the confidentiality time period has elapsed on all of this sponsored research, that the technology should be made available to the public in general, therefore they are revealing all aspects of their research in this Computerized Fluid Power Series.

The authors are indebted to the armed services of the United States and over 125 companies located worldwide for their sponsorship (financial support and technical guidance) of the BFPR (Basic Fluid Power Research), FRH (Fire Resistant Hydraulics), and TSF (Tribological System Fluids) programs at the Fluid Power Research Center, Oklahoma State University and hundreds of individual contract projects. In addition, the authors wish to recognize the efforts of several hundred researchers who conducted both library and experimental studies on the subjects contained in this book while pursuing the requirements for their advanced degrees in fluid power.

This book was written in response to many research sponsors who requested that the more than fifty volumes of research reports be organized and condensed into manageable volumes that engineers throughout industry and the government could use as the basis for their technical training, hydraulic design, and application programs in order that they can gain an upper hand on the service reliability and longevity assurance of their systems.

The topics presented in this book required many years of study and testing to reach valid conclusions. The subjects of some of these long term studies were: contamination control, hydraulic fluids, hydraulic reservoirs, fluid conditioners, heat in hydraulic systems, leakage control, tribological wear, condition monitoring, and system reliability. This book contains critical material on each of the subject areas at varying levels of complexity. This means that the readers regardless of their level of knowledge and degree of experience can use this book to achieve higher and higher levels of sophistication as his or her knowledge and experience grows. We believe that even the most inexperienced reader should be able to apply many of the concepts contained in the book and avoid the problems that invariably confront designers and cause them to sacrifice the reliability and longevity of their systems.

The information that is presented provides a theoretical foundation for the algorithms contained in the computer software package, called HyPneu, which is commercially available from Bardyne, Inc. Examples and exercises contained in the book, use HyPneu to provide and store the algorithms. HyPneu also produces analytical results associated with a variety of applications. Such results will guarantee system service reliability and enhance the longevity of hydraulic systems under various operating conditions.

For those readers possessing some background in computerized system design techniques, this book provides a complete mathematical reference for calculating nearly all the critical design aspects needed for system application to achieve a high degree of service reliability. The reader should gain sufficient insight from the analytical examples and exercises in the book to make proper decisions and component selections. It is, however, difficult to develop practical machines without having substantial experience with real mechanical systems. It is therefore recommended that HyPneu be used as the basis for a virtual laboratory in conjunction with this book, to create and use component and system models to achieved the desired service performance, reliability and longevity of hydraulic systems. In this way, the reader will gain experience in the actual application, design and analysis of hydraulic systems.

As work continues in the task of condensing the results of over thirty-five years of fluid power research directed by the authors, several additional books are in various stages of completion that will further expand and clarify some of the issues advanced in this book.

E. C. Fitch
I. T. Hong
Stillwater, Oklahoma, USA

Table of Contents: Hydraulic System Design for Service Assurance

Chapter 1 Introduction

1.1 Service Reliability Perspective
1.2 An Approach to the Failure Dilemma
1.3 The General Contents
1.4 Why Computerize Service Assurance Aspects
1.5 Computerized Service Assurance Examples

Chapter 2 Hydraulic Fluids

2.1 Status of Hydraulic Fluids
2.2 Composition of Hydraulic Fluids
2.3 Stability of Hydraulic Fluids
2.4 Physical Properties of Fluids
2.5 Viscosity
2.6 Bulk Modulus
2.7 Vapor Pressure (Volatility) and Aeration
2.8 Aeration and Foam
2.9 Specific Gravity/Density
2.10 Surface Tension
2.11 Hygroscopicity
2.12 Obliteration Stability
2.13 Flammability Characteristics
2.14 Chemical Properties of Fluids
2.15 Oxidation Stability
2.16 Thermal Stability
2.17 Hydrolytic Stability
2.18 Material Compatibility
2.19 Anti-Rust and Corrosion Stability
2.20 Antiwear Stability
2.21 Antiwear Assessment
2.22 Hydraulic Fluid Selection

Chapter 3 Contamination Control and Filtration

3.1 Contamination Control Overview
3.2 Scope of Contamination
3.3 Particulate Contaminants
3.4 Water Contaminant
3.5 Contaminant Analysis
3.6 Cleanliness Level Descriptions
3.7 Wear Debris Analysis
3.8 Contaminant Ingression Control
3.9 Contamination Level Reference State
3.10 Component Contaminant Sensitivity
3.11 Fluid Filtration
3.12 Filtration Mechanics
3.13 Filtration Structural Integrity
3.14 Particle Capture Assessment
3.15 Filtration Models
3.16 Interpreting Filter Performance
3.17 Filter Performance Irregularities
3.18 Filter Location Options
3.19 Omega Rating Rationale

Chapter 4 Hydraulic Reservoir and Fluid Conditioners

4.1 Scope of Fluid Conditioning
4.2 Reservoir Function and Design
4.3 The Conventional or JIC Hydraulic Reservoir
4.4 The Bootstrap Reservoir System
4.5 The Mobile Reservoir
4.6 The Critical Volume Reservoir (CVR)
4.7 CVR Design Considerations
4.8 Selecting and Assessing Hydraulic Reservoirs
4.9 Suction Line Hydraulics
4.10 Pump Filling Characteristics
4.11 Reservoir Pump Outlet Port Pressure
4.12 Pump Supercharging Options
4.13 Dehydration System
4.14 Deaeration or Degassing System

Chapter 5 Heat in Hydraulic Systems

5.1 Heat Control
5.2 Heat Generation
5.3 Modes of Heat Transfer
5.4 The Overall Heat Transfer Coefficient
5.5 Thermal Steady State Analysis
5.6 Thermal Transient Analysis
5.7 Sizing of Heat Exchangers
5.8 Air Coolers
5.9 Pre-Heating Hydraulic Fluid

Chapter 6 Leakage in Hydraulic Systems

6.1 Leakage
6.2 Leakage Causality
6.3 Effects of Leakage
6.4 Leakage Classification
6.5 External Leakage Assessment
6.6 Internal Leakage Assessment
6.7 Leakage Sources
6.8 External Leakage Sites
6.9 Static Seal Leakage Sites
6.10 Dynamic Seal Leakage Sites
6.11 Internal Leakage Sites
6.12 Leakage Summary

Chapter 7 Tribological Wear

7.1 Scope of Tribological Wear
7.2 Abrasion Wear
7.3 Adhesion Wear
7.4 Surface Fatigue Wear
7.5 Delamination Wear
7.6 Fretting Wear
7.7 Erosion Wear
7.8 Cavitation Wear
7.9 Corrosion Wear
7.10 Hydrogen-Induced Wear
7.11 Electrokinetic Wear
7.12 Radiation Wear

Chapter 8 Motion Impediment

8.1 Overview of Motion Failures
8.2 Mechanical Lock
8.3 Mechanical Overload
8.4 Surface Lubrication
8.5 Thermal Lock
8.6 Thermal Shock
8.7 Hydraulic Lock
8.8 Adhesive Lock
8.9 Contaminant Lock
8.10 Static or Bridgement Jam
8.11 Shear or Coincidence Jam
8.12 Dynamic Jam or Silt Lock Seizure
8.13 Obliterant Choke
8.14 Viscous Lock
8.15 Flow Lock
8.16 Magnetic Lock
8.17 Bernoulli Spring Force
8.18 Port/Orifice Obstruction
8.19 Interstitial Closure By Obliteration

Chapter 9 Structural Deficiencies and Design Mechanics

9.1 Introduction
9.2 Material Strength Considerations
9.3 Mechanical Static Loads
9.4 Material Fracture Loads
9.5 Stress Concentrations
9.6 Mechanical Dynamic Loads
9.7 Synergistic Effects of Loading Conditions
9.8 Material Damage Modes
9.9 Material Failure Factors
9.10 Failure of Basic Component Elements
9.11 Failure of System Interconnecting Elements

Chapter 10 Condition Monitoring of Hydraulic Systems

10.1 Onset and Progression of Failure
10.2 Role of Condition Monitoring
10.3 Features of Condition Monitoring Systems
10.4 The Diagnostic System
10.5 Measurement Methods
10.6 Internal State Diagnostics
10.7 System Prognosis
10.8 Prescriptive Action
10.9 Weak Points of Systems
10.10 Fuzzy Logic Approach to Condition Monitoring

Chapter 11 Hydraulic System Reliability

11.1 Reliability Concepts
11.2 Characterizing Reliability
11.3 Reliability Functions
11.4 Product Life Curve
11.5 Distribution Functions
11.6 The Mortality Model
11.7 Weibull Plot and Failure Analysis
11.8 Plotting on Weibull Probability Paper
11.9 Non-linear Weibull Plot
11.10 Reliability Quantification
11.11 Reliability Predictions
11.12 System Reliability Models
11.13 Component Hazard Data
11.14 A Deterministic Reliability Approach
11.15 Maintaining System Reliability
11.16 Designing for Reliability
11.17 Specific Reliability Design Factors

Chapter 12 System Design Methodology

12.1 System Design Process
12.2 System Analysis Process
12.3 The Complete Design Process Steps
12.4 System Design Details
12.5 Virtual Laboratory Design Analysis

The above may change as deemed necessary by the authors. All of the above information is copyrighted by BarDyne, Inc. and is protected by the US copyright laws.

Sample Pages


$995 USD includes the book and all Hydraulic System Design for Service Assurance course material including a coupon for a free course in the future.

$250 USD for the book only.  If bringing this book to the Hydraulic System Design for Service Assurance course, you may deduct the price of the book from the course registration fee.

Copyright 2008 BarDyne, Inc. All rights reserved.

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