Cyclone Hydraulic Reservoir

Fluid Power Conference and Exposition

Milwaukee School of Engineering June 11, 2013

Terry Glidden V.P. Mobile Markets Price Engineering Co., Inc. Bob Doll Sr. Engineer Price Engineering Co., Inc.

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What is A Cyclone Reservoir

It is a reservoir which removes entrained air by spinning the fluid.

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Recent Articles

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Patented in 1999

Also covered by the following patents: EP0831238 European Union 69705474.8 Germany 510629 - Sweden

Price Engineering licensed in 2005

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Original Application

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Original Application

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Why is the limited volume of the Cyclone important?

Removal of entrained air Reduces the size of the reservoir Reduces the space claim of the reservoir Reduces the weight of the hydraulic system Faster Recovery from a large air ingestion Reduced G force sensitivity Faster Warm Up Lower Installed Cost

Benefits of Cyclone Reservoir

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Technical Discussion The 4 States of Air in Hydraulic Oil

Entrained Air Bubbles less than 1 mm, appears as milky color. Remains suspended in the fluid.

Free Air Air trapped in corners, high spots and reservoir freeboard space. Feeds Dissolved Air.

Dissolved Air Typically runs 6% -12%. Resides dissolved in oil between molecules without ion exchange. Similar to oxygen in water. Source for Entrained Air.

Foam Large bubbles surrounded by oil film float on oil surface.

Is air a Contaminant?

Oxidation Compressibility/Reduced Bulk Modulus Reduced Density Thermal Degradation/Reduced Heat Transfer Cavitation

Affects of Air in Oil

Jan 2009 10

Jet generates local surface pressures in excess of 100,000 psi

http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=ShtQq0BqnHjHoM&tbnid=i4y_sQ8LSeBz1M:&ved=0CAgQjRwwAA&url=http://en.wikipedia.org/wiki/Cavitation&ei=iaeoUaD1Mqj7igKzwYHwBQ&psig=AFQjCNGN-j7DqrRxTDsvER7m9yat1v5EBQ&ust=1370093833877432http://www.google.com/imgres?imgurl=http://181555167.r.cdn77.net/cms/wp-content/uploads/cavi.jpg&imgrefurl=http://www.lgsonic.com/lg-sonic-vs-cavitation/&docid=pOEYCDv7zKJKsM&tbnid=aVz5_kWA8P0k3M&w=325&h=196&ei=iaeoUaD1Mqj7igKzwYHwBQ&ved=0CAcQxiAwBQ&iact=ricl

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Theory of Operation Cyclone Hydraulic Reservoir

Air is removed near suction at the wall

To Pump suction with positive head

Return from system drives spinning action

The lighter Microscopic air is concentrated towards the middle

Macroscopic bubbles form which float up

Conventional Cyclone Separator Cyclone Hydraulic Reservoir Dirty Fluid enters here

Heavy particles collect at wall and drop to the bottom

Clean fluid leaves here

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Analysis Computational Fluid Dynamics

De-aeration Geometry observed in testing

High Velocities near wall. Resists G Forces.

Idle upper chamber allows larger bubbles to escape more easily.

Rule of thumb => 25% to 30% of the system power must be removed as waste heat.

Heat Rejection Rate => 200 W/m2 to 300 W/m2(steel reservoirs and free convection).

Example: 40 GPM system at 3000 psi (70 HP) Conventional Reservoir (40 Gallons) Cyclone Reservoir (4.4 Gallons) At 100% Duty Cycle Rejection Requirement => 25% (17.5 HP) 25% (17.5 HP)

Reservoir Heat Rejection => 10% ( 1.75 HP) of the 25% (17.5 HP) 6% (1.00 HP) of the 25% (17.5 HP)

Heat X Heat Rejection => 90% (15.75 HP) of the 25% (17.5 HP) 94% (16.5 HP) of the 25% (17.5 HP)

At 50% Duty Cycle

Rejection Requirement => 25% (8.75 HP) 25% (8.75 HP)

Reservoir Heat Rejection => 20% ( 1.75 HP) of the 25% (8.75 HP) 11.4% (1.00 HP) of the 25% (8.75 HP)

Heat X Heat Rejection => 80% (7 HP) of the 25% (8.75 HP) 88.6% (6.75) of the 25% (8.75 HP)

As the duty cycle becomes more intermittent the need for a larger Heat

Exchanger becomes more likely.

Heat Rejection Conventional Versus Cyclone

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System Warm up Conventional Versus Cyclone

Example: 40 GPM system at 3000 psi (70 HP@2400 RPM)

Assume => 20% of the system power is injected for warm up (14 HP, 1000 RPM @ 1500 psi).

Heat Exchanger is being bypassed. Heat Capacity of Oil => 13.37 HP-s/Gal-R Conventional Reservoir (40 Gallons) Cyclone Reservoir (4.4 Gallons) Total Oil including System => 50 Gallons 14.4 Gallons

Initial to final Warm up => 40 F to 120 F 40 F to 120 F

Warm up Time => 19.65 minutes 5.66 Minutes

Warm up occurs 3.5 time faster.

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System Generated Entrained Air - Cavitation

Automation Studio Simulation

Cavitation Studies Cyclone Performance

Verification Heat Rejection Analysis Efficiency Assessment

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Circuit Design

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Test Verification Data Acquisition

Verify Analysis Collect Performance Data Study Design Advances Develop Applications Information Qualify for Hydraulic Cylinder Operation

Other Patents Pending

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The Cyclone in Operation

Video Here

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Size Range

Capacity of the only Cyclone tank configuration offered by Eaton is approximately 75 lpm.

To date, Price Engineering has implemented 5 larger capacities or other materials encompassing the following:

75 lpm Aluminum 150 lpm Steel 180 lpm Steel 190 lpm Steel 340 lpm Steel

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Customization

Fluid Conditioning Pod

Reservoir Accessories

Filler Breather

Proportional Level Sensor

Top Mounted Cleanout

Magnetic Drain Plug

Visual Level/Temp Gauge

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20 GPM Cyclone Reservoir Conventional Reservoir

20 gallons of fluid 1.3 gallons of fluid Savings of 18.7 gallons

Fluid weight = 146 lbs. Fluid weight = 9.5 lbs. Savings of 136.5 lbs

Cost of oil = $250.00 Cost of oil = $16.25 Savings of $233.75

Space claim = 3.5cu. Ft. Space claim = 0.5 cu. Ft. Savings of 3 cu. Ft.

20 GPM System Comparison

11 gallons of fluid savings of 79-169 gallons

Weight = 80 lbs savings of 1,234 lbs.

Cost of oil = $137.50 savings of $2,112.50

Space claim = 2 cu. ft. savings of 28 cu. ft.

180 gallons of fluid Weight = 1,314 lbs. Cost of oil = $2,250.00

Space claim = 30 cu. ft.

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90 GPM Cyclone Reservoir Conventional Reservoir

90 GPM System Comparison

Cyclone Hydraulic ReservoirFluid Power Conference and ExpositionMilwaukee School of EngineeringJune 11, 2013What is A Cyclone Reservoir Recent ArticlesPatented in 1999Original ApplicationOriginal ApplicationWhy is the limited volume of the Cyclone important?Benefits of Cyclone ReservoirTechnical DiscussionThe 4 States of Air in Hydraulic OilAffects of Air in OilTheory of Operation Cyclone Hydraulic ReservoirAnalysis Computational Fluid DynamicsHeat Rejection Conventional Versus CycloneSystem Warm up Conventional Versus CycloneSystem Generated Entrained Air - CavitationCircuit DesignTest Verification Data AcquisitionThe Cyclone in OperationSize RangeCustomization20 GPM Cyclone Reservoir90 GPM Cyclone Reservoir