Lesson 1Typical instrumentation and monitoring points: pressure, flow, temperature, contamination sensors, and vibration/noise sensorsThis section defines instrumentation for monitoring press hydraulics, including pressure, flow, temperature, contamination, vibration, and noise. It explains sensor placement, ranges, signal types, and how data supports diagnostics and predictive maintenance.
Pressure transducer ranges and mounting locationsFlow measurement for pumps and actuator branchesOil temperature sensing in tank and critical linesParticle counters and cleanliness monitoring pointsVibration and noise sensors on pumps and motorsLesson 2Central hydraulic power unit (HPU) layout: reservoir, pump(s), prime mover, heat exchanger, auxiliary systemsThis section presents central HPU layout for 250-bar presses, detailing reservoir design, pump and motor arrangement, suction and return routing, heat exchangers, and auxiliary systems that ensure reliable, low-noise, and easily serviced operation.
Reservoir sizing, baffling, and deaeration featuresPump mounting, alignment, and suction line designPrime mover selection and coupling arrangementsReturn line routing and de-foaming strategiesIntegration of coolers, filters, and manifoldsLesson 3Thermal management: oil-air coolers, flow paths, thermostatic bypass valves, and heat load estimationThis section covers thermal behaviour of high-pressure press circuits, including heat generation sources, oil-air cooler selection, flow paths, thermostatic bypass design, and heat load estimation to maintain fluid properties and component reliability.
Sources of heat generation in press hydraulicsHeat load estimation and duty cycle assessmentOil-air cooler sizing and performance curvesCooler placement, flow paths, and piping layoutThermostatic bypass valve selection and tuningLesson 4Directional control: proportional directional valve types, spool dynamics, flow control and electrohydraulic interfacesThis section examines proportional directional valves used in 250-bar presses, covering valve types, spool dynamics, flow metering, and electrohydraulic interfaces needed for precise motion control, repeatability, and safe emergency behaviour.
Valve construction and proportional actuation methodsSpool geometry, overlap, and flow metering behaviourDynamic response, hysteresis, and dither techniquesOnboard electronics, drivers, and signal standardsFail-safe positions and emergency stop strategiesLesson 5Filtration and contamination control: filter types, locations (suction, pressure, return), bypass and monitoringThis section addresses filtration strategy for high-pressure presses, covering filter types, ratings, and locations on suction, pressure, and return lines, as well as bypass valves, clogging indicators, and cleanliness targets for long component life.
Target cleanliness classes for press componentsSuction strainers versus low-pressure filtersHigh-pressure filter selection and sizingReturn line filters and offline kidney-loop unitsBypass valves and differential pressure indicatorsLesson 6Energy storage and smoothing: accumulator types, placement, sizing and safety devicesThis section explains hydraulic accumulators for energy storage and pulsation damping, covering bladder, piston, and diaphragm types, placement, precharge, sizing for press cycles, and safety devices required by standards and regulations.
Accumulator types and construction detailsEnergy storage calculations for press cyclesPrecharge pressure selection and verificationPlacement for pulsation damping and responseSafety blocks, shutoff valves, and standardsLesson 7Fluid circuits and schematic interpretation: common arrangements for forming presses, actuator piping, and bleed/vent pathsThis section develops complete fluid circuits for forming presses, teaching schematic symbols, common press arrangements, actuator piping, bleed and vent paths, and how to read, verify, and document hydraulic diagrams for projects.
ISO hydraulic symbols and line conventionsTypical single- and double-acting press circuitsClamping, forming, and return stroke arrangementsBleed, vent, and air removal provisionsReading and checking complete press schematicsLesson 8Power transmission elements: variable displacement axial piston pump principles and control interfacesThis section focuses on variable displacement axial piston pumps used in 250-bar presses, describing operating principles, swashplate control, compensator options, and electronic interfaces that coordinate flow, pressure, and energy efficiency.
Axial piston pump operating principlesSwashplate mechanisms and stroke controlPressure and load-sensing control optionsElectrohydraulic pump control interfacesStartup, commissioning, and troubleshootingLesson 9Pressure control components: relief valves, pressure compensators, sequence and unloading valvesThis section analyzes pressure control components in press circuits, including relief valves, pressure compensators, sequence valves, and unloading valves, explaining settings, stability, interaction, and their role in safety and energy efficiency.
Main system relief valve sizing and settingPump pressure compensator functions and tuningSequence valves for staged cylinder operationsUnloading valves for low-loss idle operationInteraction of multiple pressure control devices
