Hydraulic Actuator Test Rig

Abstract

Hydraulic actuator is the main component in hydraulic power steering system of tractors and other hydraulic machinery. These actuators must be inspected to an acceptable level through an efficient inspection machine in order to prevent mechanical failure. Previous studies have shown that actuators with end of line quality testing perform well and enhance reliability and durability. Previous studies on analyzing industrial products through automated inspection machines make a significant contribution in the development of these products. In this research project , we have develop a fully automated hydraulic actuator test rig for hydraulic cylinder manufacturers for end of line quality testing. A series of advanced control valves combined with intelligent algorithm have been employed to measure the key performance parameters. Two external actuators have been connected with the central work piece actuator to enable the cylinder to cycle against an external load sufficient to maintain a constant operating pressure of 140 bar for 90,000 cycles. This will enable actuator to perform accordingly as per standard requirement in which total leakage shall not exceed 50ml/90,000 cycles. Hydraulic gear pump is used for fluid flow in the circuit. Hydraulic Pump is connected with eclectic 3-phase motor through couplings to transfer the hydraulic oil in hoses. Solenoid directional control valves, pressure distributor valve and pressure relief valves were used for maintaining the hydraulic oil pressure at 140 bar during endurance testing. Another test namely performance test has been performed on the hydraulic actuator in which piston keeps in between 25 mm and pressure on one side of the piston keeps at 240 bar for 1 minute and then pressure reduces to zero and than again pressure increases to 20 bar for 5 minutes. Same procedure was repeated on the other side of piston. Standard for this test requires no external leakage and internal leakage is set to be not exceeded than 5ml/minute during pressure test. Results of endurance test shows that leakage was not exceeded than 50ml/90,000 cycles. Results of performance test shows no external vi leakage and internal leakage was not exceeded than 5ml/minute. The project research present an effective procedure to quality check hydraulic actuators with proof of the concept to actuators manufacturers. The new procedure is a significant improvement towards manufacturing more reliable actuators.