Lesson 1Typical instrumentation and monitoring points: pressure, flow, temperature, contamination sensors, and vibration/noise sensorsThis part covers tools for checking press hydraulics, like pressure, flow, temperature, dirt, vibration, and noise sensors. It shows where to place sensors, their ranges, signal types, and how data helps in checks and advance 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 part shows central HPU design for 250-bar presses, covering tank design, pump and motor setup, suction and return lines, heat exchangers, and support systems for reliable, quiet, and simple servicing.
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 part discusses heat control in high-pressure press systems, including heat sources, oil-air cooler choice, flow routes, thermostatic bypass setup, and heat load calculation to keep fluid good and parts reliable.
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 part studies proportional directional valves in 250-bar presses, covering types, spool movement, flow control, and electrohydraulic links for exact motion, repeat accuracy, and safe emergency action.
Valve construction and proportional actuation methodsSpool geometry, overlap, and flow metering behaviorDynamic 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 part covers filter plan for high-pressure presses, including types, ratings, and spots on suction, pressure, return lines, plus bypass valves, block indicators, and clean targets for long part 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 part explains hydraulic accumulators for energy saving and pulse reduction, covering bladder, piston, diaphragm types, placement, precharge, sizing for press cycles, and safety as per rules.
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 part builds full fluid circuits for forming presses, teaching diagram symbols, common setups, actuator pipes, bleed/vent routes, and how to read, check, and note hydraulic plans for work.
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 part focuses on variable displacement axial piston pumps in 250-bar presses, explaining work principles, swashplate control, compensator choices, and electronic links for flow, pressure, and energy saving.
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 part checks pressure control parts in press circuits, like relief valves, pressure compensators, sequence valves, unloading valves, explaining settings, stability, links, and role in safety and saving energy.
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
