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 them, their ranges, signal types, and how the data helps with checks and upkeep.
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 the main HPU setup for 250-bar presses, covering tank design, pump and motor setup, suction and return lines, coolers, and extra systems for steady, 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, auto-bypass valves, and heat load checks to keep oil 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 looks at proportional valves for 250-bar presses, covering types, spool movement, flow control, and electric-hydraulic links for accurate movement, consistency, and safe stops.
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 cleaning plans for high-pressure presses, with filter types, sizes, and spots on suction, pressure, and return lines, plus bypasses, clog alerts, 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 accumulators for storing energy and smoothing pulses, covering bladder, piston, and diaphragm types, placement, gas charge, sizing for press cycles, and safety gear 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 systems for forming presses, teaching diagram signs, common setups, actuator pipes, bleed and vent routes, and how to read, check, and record hydraulic plans.
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 adjustable axial piston pumps for 250-bar presses, explaining how they work, swashplate control, compensators, and electronic links for flow, pressure, and 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 part checks pressure controls in press systems, like relief valves, compensators, sequence, and unloading valves, covering settings, steadiness, links, and roles 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
