Design of Hydraulic Cylinder Test Apparatus
Banwait, Kawaljeet Singh
This report outlines the design of the hydraulic cylinder test apparatus requested by the client. This report first features an introduction section that showcases the project background, problem statement, and project objectives to ensure that the team understands the client's requirements. The report then outlines a summary of client needs and specifications along with engineering calculations required to select the concepts for measurement equipment, hydraulic system design, hydraulic cylinder mounting frame, and hydraulic cylinder shielding. The report then goes over the concept selection methodology for each component of the test apparatus, followed by a detailed design section where details of design components are provided. Next, the report showcases recommendations that will allow the test apparatus to become more productive during the testing of the hydraulic cylinders, followed by the conclusion which includes the final design specifications of the test apparatus. The client utilizes hydraulic cylinders in their agricultural equipment, such as headers and windrowers, for position control. The client purchases hydraulic cylinders from external vendors, and as per their purchasing agreement, requires the vendors to perform quality assurance tests on the hydraulic cylinders in order to ensure that the cylinder meets required specifications. The client sees value in developing an in-house hydraulic cylinder test apparatus to evaluate old cylinders and build relationships with new vendors. Therefore, the critical objective of the project is to develop a test apparatus that can be used to perform tests specified by the client. The test apparatus is to have measurement devices that are within ±2% measurement tolerance. As per the deliverables, requested CAD (Computer-Aided Design) models, CAD drawings, BOM (Bill of Materials), and Hydraulic System Schematics of the test apparatus. The test apparatus includes hydraulic cylinder mounting design which features the cap end bracket and rod end bracket. The cap end bracket is designed to mount different configurations of cylinders while sustaining the load exerted by the hydraulic pressure during the performance tests. The rod end bracket is designed to support the weight of various cylinders while providing clearance between the cylinder and testing table. The test apparatus includes hydraulic cylinder shielding design which provides protection for the operators during performance tests. The design consists of L-shaped railings, handle, hinges, and acrylic glasses. The test apparatus also includes hydraulic system design which features hydraulic system schematics and hydraulic components. The components are sourced out from vendors. The components and vendor information is as follows: hydraulic hoses (GreenLine Hose and Fittings), hydraulic adapters (GreenLine Hose and Fittings), hydraulic reservoirs (Grainger), hydraulic filters (Grainger), hydraulic directional control valves (Rexroth), ball valve (Parker), check valve (Tu-Lok), pressure relief valve (Hyvair), hydraulic oil coolers (Grainger), and hydraulic pumps (Parker). The test apparatus also includes electrical system design which includes selecting an input layer in the existing data acquisition system and selecting corresponding sensors that would interface with that layer and are hence compatible with the data acquisition system. The sensors were chosen based on the test requirements and are all sourced out from a single vendor, Omega. The sensors included pressure sensor (for hose pressure measurement), LVIT (for rod displacement measurement), and thermocouple (for fluid temperature measurement). Each sensor required mounting adapters and electrical schematic to collect and output data. Mounting adapters were sourced out for pressure sensor and thermocouple, and a custom design was developed for LVIT to mount to collect rod displacement data.