1. Basic Parameter Determination
– Clarify the working pressure, flow rate, and driving power required by the system to avoid insufficient power or energy waste.
– Determine the working medium (hydraulic oil type, viscosity grade) according to ambient temperature, load characteristics, and service life.
– Define the cycle mode: continuous operation, intermittent operation, or high-frequency start-stop, to match the heat dissipation and component durability design.
2. Oil Tank
– Reasonably calculate the effective volume of the oil tank, generally 3 to 5 times the system flow rate to ensure oil heat dissipation and bubble separation.
– Set up oil suction and return partitions, liquid level gauges, oil temperature gauges, air breathers, and drain valves.
– Use anti-rust and anti-corrosion materials, with smooth inner walls to reduce oil residue and pollution.
3. Pump
– Select the appropriate hydraulic pump: gear pump (low pressure, low cost), vane pump (medium pressure, low noise), piston pump (high pressure, high efficiency).
– Match the driving motor with rated power, speed, insulation grade, and protection level (IP54/IP65) based on working conditions.
– Reserve installation space for shock absorbers to reduce vibration and noise transmission.
4. Valve & Circuit Design
– Configure control valves (directional, pressure, flow control valves) reasonably to meet speed, pressure, and direction regulation requirements.
– Optimize the pipeline layout to reduce bending, avoid eddy current and pressure loss, and use high-pressure hoses and hard pipes matching the pressure level.
– Add overload protection, pressure relief circuits, and check valves to prevent hydraulic shock and oil backflow.
5. Cooling & Heating System
– Design an air cooler or water cooler according to the calorific value to control the oil temperature within 30–55°C.
– Equip an electric heater for low-temperature environments to ensure the viscosity of hydraulic oil is within the usable range.
– Install temperature sensors and automatic temperature control switches.
6. Filtration & Pollution Control
– Install oil suction filters, pressure filters, and return filters to control oil contamination level (generally NAS 8–10).
– Set up filter clogging alarm devices to remind maintenance and replacement.
– Ensure the sealing performance of the entire system to prevent dust and moisture intrusion.
7. Noise & Vibration Control
– Adopt low-noise hydraulic pumps and motors, and install shock-absorbing pads and mufflers.
– Optimize pipeline fixation to avoid resonance and reduce fluid noise caused by throttling and impact.
8. Safety & Reliability Design
– Set up emergency stop buttons, pressure relief valves, and explosion-proof devices for high-risk working conditions.
– Adopt redundant design for key components to improve system stability.
– Reserve test ports for pressure, flow, and oil quality detection to facilitate maintenance.
9. Installation & Maintenance Convenience
– Arrange components in a compact and reasonable layout for easy observation, disassembly, and replacement.
– Reserve enough space for pipeline connection, filter replacement, and oil filling/draining.
– Match the installation size with the equipment base to ensure stability.
10. Environmental & Application Adaptability
– Strengthen protection for outdoor, high-temperature, low-temperature, humid, or corrosive environments.
– Comply with industry standards and safety regulations for special applications such as marine, mining, and mechanical equipment.
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