Water Hydraulic Conversion Water Hydraulic Conversion byby

Dan Pitstick Dan Pitstick Dan Sellers Dan Sellers

Nathan Schoonover Nathan Schoonover

IntroductionIntroduction

The purpose of this project is to convert an The purpose of this project is to convert an oil hydraulic turf mower into a water oil hydraulic turf mower into a water

hydraulic turf mower. The key systems are hydraulic turf mower. The key systems are drive train, steering, and mower drive. drive train, steering, and mower drive.

Hydrostat Design CalculationsHydrostat Design Calculations

Tractive Effort (TE)Tractive Effort (TE)

TE = (RR + GR + Fa + DP) * 1.1TE = (RR + GR + Fa + DP) * 1.1RR = Rolling Resistance = Gross Vehicle Weight(GVW) * RR = Rolling Resistance = Gross Vehicle Weight(GVW) *

Rolling RadiusRolling RadiusGR= Grade Resistance = 0.01 * GVW * Grade %GR= Grade Resistance = 0.01 * GVW * Grade %Fa = Acceleration Force = (Velocity * GVW) / (time * Fa = Acceleration Force = (Velocity * GVW) / (time *

32.16)32.16)DP = Drawbar Pull) = 0 since no drawbar pullDP = Drawbar Pull) = 0 since no drawbar pull

TE = 390 lbsTE = 390 lbs

Hydrostat Design CalculationsHydrostat Design Calculations

Required TorqueRequired TorqueTreq = (TE * r) / (G*N)Treq = (TE * r) / (G*N)

G = Gear Ratio = 4G = Gear Ratio = 4N = Number of Motors = 2N = Number of Motors = 2

Treq = 487 in-lbsTreq = 487 in-lbs

Maximum Required Motor SpeedMaximum Required Motor Speed

S = (168 * V * G)/ r = 500 rpmS = (168 * V * G)/ r = 500 rpm

Motor SelectionMotor Selection

Old MotorOld MotorParker TJ 0165 Low Speed High Torque MotorParker TJ 0165 Low Speed High Torque Motor

Displacement = 163 cc/revDisplacement = 163 cc/rev

New MotorNew MotorNessie MVM 160 Water Hydraulic MotorNessie MVM 160 Water Hydraulic Motor

Displacement = 160 cc/revDisplacement = 160 cc/rev

Max Torque = 100 N-m = 885 in-lbsMax Torque = 100 N-m = 885 in-lbs

Design ProblemsDesign Problems

Maximum Motor SpeedMaximum Motor Speed– Max Speed of Nessie Motor is 200 rpmMax Speed of Nessie Motor is 200 rpm

– Required Motor Speed of 511 rpm to reach 7.6 mphRequired Motor Speed of 511 rpm to reach 7.6 mph

– Max ground speed using Nessie Motor 3 mphMax ground speed using Nessie Motor 3 mph

Axial LoadingAxial Loading– Motor cannot handle any axial loadingMotor cannot handle any axial loading

– Fairfield planetary final drive solves this problemFairfield planetary final drive solves this problem

– S07AS07A» Reduction Ratio of 4:1Reduction Ratio of 4:1

List of Fittings and HosesList of Fittings and Hoses

Quantity Parker Part # Description4 7/8" Adapters for Danfoss Motors2 7/16" Drain Line Adapter for Danfoss Motor4 0603-14-12SS 7/8" to 3/4" Reducers4 0603-12-10SS 3/4" to 5/8" Reducers4 10643-10-10C 5/8" Female Swivel to fit 5/8" ID hose2 063T-12-12SS 3/4" Swivel Nut Run Tee8 10643-12-12C 3/4" Female Swivel2 0303-12-12SS 3/4" Union4 Female Swivel for Drain Line1 Drain Line Tee

15 ft 301-10 5/8" Hydraulic Hose15 ft 301-12 3/4" Hydraulic Hose15 ft Hydraulic Hose for Drain Line

Lift HydraulicsLift Hydraulics

Hydraulic LiftHydraulic Lift

Hydraulic CylindersHydraulic Cylinders– Volume DisplacedVolume Displaced

» Rod EndRod End V = A * L V = A * L

– A = Outside – InsideA = Outside – Inside

– L = Length of RodL = Length of Rod V = .994 * 5.870 = 5.835 inV = .994 * 5.870 = 5.835 in33

» Cylinder EndCylinder End V = A * LV = A * L

– A = Cyl. AreaA = Cyl. Area

– L = Length of CylL = Length of Cyl V = 2.76 * 5.87 = 16.2 inV = 2.76 * 5.87 = 16.2 in22

Hydraulic LiftHydraulic Lift Hydraulic CylindersHydraulic Cylinders

– Flow requiredFlow required» Q = V / sQ = V / s

V = Volume DisplacedV = Volume Displaced S = time displacedS = time displaced

» For Rod EndFor Rod End Q = 5.835 inQ = 5.835 in33 / 2s = 2.92 in / 2s = 2.92 in33/s/s Q = .758 gpm = 2.87 L/minQ = .758 gpm = 2.87 L/min

» For Cylinder EndFor Cylinder End Q = 16.2 inQ = 16.2 in33 / 2s = 8.1 in / 2s = 8.1 in33/s/s Q = 2.1 gpm = 7.96 L/minQ = 2.1 gpm = 7.96 L/min

– Total FlowTotal Flow» For CylindersFor Cylinders

2 Cylinders * Max Flow = 2 * 2.1 gpm = 4.2 gpm2 Cylinders * Max Flow = 2 * 2.1 gpm = 4.2 gpm

Reel HydraulicsReel Hydraulics

Reel MotorsReel Motors Reel DescriptionReel Description

– 11 Blade Reels with Cutting Frequency of 11 Blade Reels with Cutting Frequency of .047 in / mph.047 in / mph– Maximum Mowing Speed of 3.7 mphMaximum Mowing Speed of 3.7 mph– Reel Diameter = 5 inchesReel Diameter = 5 inches

Reel Motor Speed CalculationReel Motor Speed Calculation– Reel Circumference = Pi * D = 3.14 * 5Reel Circumference = Pi * D = 3.14 * 5

= 1.309 ft = 2.44792 E= 1.309 ft = 2.44792 E-4-4 miles miles

– 3.7 mph * (1rev / 2.44792 E3.7 mph * (1rev / 2.44792 E-4-4 miles) = 250 rpm miles) = 250 rpm Required FlowRequired Flow

– Q = N * DQ = N * D = 250 rpm * 10cc/rev= 250 rpm * 10cc/rev

= 2.5 L/min= 2.5 L/min– Total Flow = 3 * 2.5 = 7.5 L/min = 1.98 gpmTotal Flow = 3 * 2.5 = 7.5 L/min = 1.98 gpm

Reel Mounting ProblemsReel Mounting Problems

Oil Hydraulic MotorOil Hydraulic Motor– Smaller ShaftSmaller Shaft– Splined ShaftSplined Shaft

Water Hydraulic MotorWater Hydraulic Motor– Larger ShaftLarger Shaft– Smooth Shaft with KeywaySmooth Shaft with Keyway

SolutionSolution– Design adapter incorporating Splined shaft with Design adapter incorporating Splined shaft with

smooth shaft of water hydraulic motorsmooth shaft of water hydraulic motor

Front Reel HydraulicsFront Reel Hydraulics

Description Dash Size Thread Size QTYMAH 10 CCW 2Elbow 90 deg 6-8 11/16-16;3/4-16 4

Elbow 90 deg Bulkhead 6-6 11/16-16 4Tee, Bulkhead 4-4-4 9/16-18 1

Union, Bulkhead 6-6 11/16-16 1Connector Straight 4-4 9/16-18;7/16-20 2Connector Straight 6-8 11/16-16;3/4-16 1Locknut, Bulkhead 5Locknut, Bulkhead 2

Elbow, 45 deg Bulkhead 4-4 9/16-18 1

Parts List

Rear Reel and Return HydraulicsRear Reel and Return Hydraulics

Description Dash Size Thread Size QTYMAH 10 CCW

Adapter, Straight 8-8 13/16-16;3/4-16 1Adapter, Straight 8-10 13/16-16;7/8-14 1Adapter, 45 deg 6-8 11/16-16;3/4-16 1Adapter, 90 deg 6\8 11/16-16;3/4-16 4

Tee, Straight Thread Run 8-8-8 13/16-16;3/4-16;13/16-16 1

Cross Connector 1Fitting, Beaded, 90 deg 2

Adapter, Straight 4-4 9/16-18;7/16-20 1O-Ring #6 2

Locknut, Bulkhead 2Elbow, 90 deg 8-8 13/16-16;3/4-16 1

Parts List

Lift HydraulicsLift Hydraulics

Description Dash Size Thread Size QTYTube, U 1

Tube, Soft Drop 1Needle Valve 1Check Valve 1

O-Ring, SAE #^ 2Locknut, 11/16 -16 Bulk 7

Adapter, Straight 6-6 11/16-16;9/16-18 3Adapter, .06 Orifice Strt 6-6 11/16-16;9/16-18 1Adpater, .04 Orificet Strt 6-6 11/16-16;9/16-18 1

Adapter, 90 deg 6-6 11/16-16;9/16-18 5Adapter, .087Orifice 90 deg 6-6 11/16-16;9/16-18 1

Adapter Swivel RunTree 6-6-6 11/16-16;11/16-16 1Adapter, 90 deg Bulk 6-6 11/16-16;11/16-16 2Adapter, Straight Bulk 6-6 11/16-16;11/16-16 3

Adapter, Straight Thread Run Tree 6-6-6 11/16-16;9/16-18;11/16-16 1Lift Cyl 2

Lift Valve 1

Parts List

Goals of steering Goals of steering

To develop a steering valve design for To develop a steering valve design for water usewater use

Be able to steer effectively with small user Be able to steer effectively with small user input.input.

Be able to produce the valve for use in Be able to produce the valve for use in Jacobsen turf mower.Jacobsen turf mower.

4 design possibilities 4 design possibilities

Chrome plate existing design Chrome plate existing design Convert to electric steeringConvert to electric steering Design completely new valveDesign completely new valve Use 3 position 4-way valve at cylinder with Use 3 position 4-way valve at cylinder with

toggle switch to control.toggle switch to control.

Chrome platingChrome plating

Use of electroless nickel plating provided Use of electroless nickel plating provided by Millcreek metal finishing of Erie, PAby Millcreek metal finishing of Erie, PA

May be free of charge depending on size of May be free of charge depending on size of parts and other specifications.parts and other specifications.

Good resistance to corrosion.Good resistance to corrosion.

May have tolerance problem.May have tolerance problem.

Electric steeringElectric steering

Use electric solenoid with screw type gear Use electric solenoid with screw type gear to produce force.to produce force.

Not much information on parts and Not much information on parts and components.components.

No knowledge of how system works.No knowledge of how system works. Costs?Costs?

New designNew design

Simple so shop can manufacture it.Simple so shop can manufacture it. Will be able to build prototype for sure.Will be able to build prototype for sure. Will not have functionality of original. (It Will not have functionality of original. (It

will be a jerk steer design).will be a jerk steer design).

Final design: use two ideas so if Final design: use two ideas so if one doesn’t work, have the other.one doesn’t work, have the other. Chrome plate existing Chrome plate existing

design…maybedesign…maybe Find out more on Find out more on

electric steering.electric steering.

Make new design out Make new design out of plastic. Maybe test of plastic. Maybe test if Dan Pitstick finishes if Dan Pitstick finishes Hydro-drive.Hydro-drive.

If other possibilities If other possibilities fail implement new fail implement new valve design. valve design.

Most critical equation: Most critical equation: P=(T/R)/AP=(T/R)/A

P=Pressure required to turn P=Pressure required to turn T=experimental torqueT=experimental torque R=radius of turn from cylinder to kingpin.R=radius of turn from cylinder to kingpin. A= functional cross-sectional area of A= functional cross-sectional area of

cylinder.cylinder. In this case: P=(612lb-in/3in)/1.63inIn this case: P=(612lb-in/3in)/1.63in22

Pressure required =125 psi.Pressure required =125 psi.

Other important calculationsOther important calculations

Swept volume (SV) = stroke*ASwept volume (SV) = stroke*A Valve disp. (HD) = SV/n. Note: n is Valve disp. (HD) = SV/n. Note: n is

number of turns.number of turns. Minimum pump flow (Q) = Minimum pump flow (Q) =

HD*SS*60/231. Q=1.9 approximately.HD*SS*60/231. Q=1.9 approximately.

Pump FlowPump Flow

Hydrostatic Drive Max = 17 gpmHydrostatic Drive Max = 17 gpm Steering Max = 2 gpmSteering Max = 2 gpm Reel Drive Max = 2 gpmReel Drive Max = 2 gpm Lift Cylinder Max = 5 gpmLift Cylinder Max = 5 gpm Total Flow = 26 gpmTotal Flow = 26 gpm

ContactsContacts

Motors, Valves, and PumpMotors, Valves, and Pump– Danfoss – NessieDanfoss – Nessie– FennerFenner

FittingsFittings– ParkerParker– SwagelokSwagelok– FasterFaster

HosesHoses– ParkerParker– SwagelokSwagelok

Time LineTime Line March 9March 9

– Have all Motors, Valves, and Cylinders orderedHave all Motors, Valves, and Cylinders ordered– Contact fitting suppliers to see what is available and place Contact fitting suppliers to see what is available and place

ordersorders– Make list of hose length and size needed and contact Make list of hose length and size needed and contact

supplierssuppliers March 23 – April 6March 23 – April 6

– Upon arrival of parts, begin assemblyUpon arrival of parts, begin assembly April 20April 20

– Finalize posterFinalize poster April 27April 27

– Turn in project reportTurn in project report