hydraulic power pack structure design calculation

ChatGPT said:

Hydraulic Power Pack Structure Design Calculation

Designing the structure of a hydraulic power pack involves calculating the frame strength,
vibration resistance, oil tank capacity, material selection, and load distribution to ensure
durability and efficiency. Below are the key calculations involved:

1. Load Calculation (Structural Frame Strength)

The power pack frame should support:

 Hydraulic components (Pump, motor, reservoir, valve manifold, etc.)

 Operational forces (Vibrations, impact loads)

 External loads (Weight of hydraulic fluid, accessories)

Frame Load Calculation

Total Load on Frame:

Wtotal=Wmotor+Wpump+Wtank+Woil+WaccessoriesW_{\text{total}} = W_{\text{motor}} +
W_{\text{pump}} + W_{\text{tank}} + W_{\text{oil}} + W_{\text{accessories}}Wtotal=Wmotor
+Wpump+Wtank+Woil+Waccessories

Factor of Safety (FOS):

Frame Deflection Check (Beam Calculation)

Use beam deflection formula if it's a simple supported frame:

δ=5WL4384EI\delta = \frac{5W L^4}{384 E I}δ=384EI5WL4

Where:

 δ\deltaδ = Deflection (mm)

 WWW = Load on frame (N)

 LLL = Span of the beam (mm)

 EEE = Young’s Modulus of the material (N/mm²)

 III = Moment of Inertia (mm⁴)

 MS Square/Rectangular Tube (Mild Steel)

 SS or Aluminum (For corrosion resistance and lightweight design)

2. Oil Tank Design Calculation

The oil reservoir should have sufficient capacity for cooling and operational efficiency.

Oil Tank Capacity Calculation

General rule:

Voil=Q×TV_{\text{oil}} = Q \times TVoil=Q×T

Where:

 VoilV_{\text{oil}}Voil = Required oil volume (liters)

 QQQ = Pump flow rate (LPM)

 TTT = Retention time (3 to 5 minutes for cooling)

For example, if the pump flow is 30 LPM and retention time is 4 min,

Voil=30×4=120 LitersV_{\text{oil}} = 30 \times 4 = 120 \text{ Liters}Voil=30×4=120 Liters

Oil Tank Thickness Calculation

Using pressure vessel thickness formula:

t=PRSE−0.6Pt = \frac{PR}{SE - 0.6P}t=SE−0.6PPR

Where:

 ttt = Tank wall thickness (mm)

 PPP = Internal pressure (assumed ~1 bar for open tanks)

 RRR = Tank radius (mm)

 SSS = Material strength (N/mm²)

 EEE = Weld efficiency (Typically 0.7 to 1)

For a mild steel tank with low pressure, a thickness of 3mm to 5mm is sufficient.
3. Motor and Pump Mounting Vibration Calculation

Vibration isolation is essential to prevent structural fatigue.

Natural Frequency Calculation

fn=12πkmf_n = \frac{1}{2\pi} \sqrt{\frac{k}{m}}fn=2π1mk

Where:

 fnf_nfn = Natural frequency (Hz)

 kkk = Stiffness of mounting (N/m)

 mmm = Mass of pump + motor assembly (kg)

To avoid resonance, ensure:

foperating≠fnf_{\text{operating}} \neq f_nfoperating=fn

Use rubber mounts or anti-vibration pads for isolation.

4. Fastener and Bolt Selection

Bolts should withstand operational forces.

F=TKdF = \frac{T}{K d}F=KdT

Where:

 FFF = Bolt tension force (N)

 TTT = Torque applied (Nm)

 KKK = Friction coefficient (typically 0.2 for lubricated bolts)

 ddd = Bolt diameter (mm)

For a 5 kW motor, typically M12 or M16 bolts with Grade 8.8 or 10.9 are used.

Conclusion

 Frame Design: Use MS rectangular tube (50x50x4mm or 75x50x5mm)

 Oil Tank Size: 3-5x Pump Flow Rate for proper cooling
  Vibration Isolation: Use anti-vibration mounts

 Bolt Selection: M12 or M16 Grade 8.8

Would you like a detailed SolidWorks model or drawing for the structure? 😊

4o

You said:

if 700 liters tank, tell me structural design calculations

ChatGPT said:

Structural Design Calculations for a 700-Liter Hydraulic Power Pack Tank

A 700-liter hydraulic tank must be designed considering material strength, thickness, weight,
deflection, and support structure to ensure durability and stability.

1. Tank Dimensions

Assumptions:

 Tank Shape: Rectangular

 Material: Mild Steel (MS) or Stainless Steel (SS)

 Wall Thickness: To be calculated

Tank Volume Calculation

V=L×W×HV = L \times W \times HV=L×W×H

For a 700 L (0.7 m³) tank, we assume practical dimensions:

 Length (L) = 1200 mm

 Width (W) = 600 mm

 Height (H) = 1000 mm

V=(1.2×0.6×1.0)=0.72 m3=720 litersV = (1.2 \times 0.6 \times 1.0) = 0.72 \, m³ = 720 \,
litersV=(1.2×0.6×1.0)=0.72m3=720liters

This is slightly above 700L to accommodate oil expansion.

2. Tank Wall Thickness Calculation

Since the tank is not pressurized, only static oil pressure is considered.

t=PRSE−0.6Pt = \frac{PR}{SE - 0.6P}t=SE−0.6PPR

Where:

 ttt = Minimum thickness (mm)

 PPP = Static oil pressure (Pa) = ρgh\rho g hρgh

 RRR = Tank wall radius (For rectangular, use plate width)

 SSS = Material strength (N/mm²)

 EEE = Weld efficiency (assumed 0.7 to 1 for welded joints)

Oil Pressure Calculation:

P=ρgh=(850×9.81×1.0)=8.34 kPaP = \rho g h = (850 \times 9.81 \times 1.0) = 8.34 \,

(Considering 850 kg/m³ as hydraulic oil density)

For Mild Steel (MS) (Yield strength 250 MPa) and E = 0.85,

t=(8.34×600)(250×0.85−0.6×8.34)t = \frac{(8.34 \times 600)}{(250 \times 0.85 - 0.6 \times

Approximating:

t≈3 mmt \approx 3 \text{ mm}t≈3 mm

Recommended: 5 mm MS Plate for durability and welding strength.

3. Tank Structural Frame Design

The tank requires stiffeners and a support frame to handle oil weight and external loads.

Total Tank Load Calculation

Woil=ρVgW_{\text{oil}} = \rho V gWoil=ρVg Woil=(850×0.7×9.81)=5830 N≈590 kgW_{\text{oil}}

Considering Tank + Components Weight ≈ 800 kg, the frame must support at least 1000 kg with
a safety factor of 2 → 2000 kg capacity.
Frame Material Selection

 MS Square Tube (50x50x5 mm)

 Angle Frame (75x75x6 mm) for bottom support

4. Deflection and Stiffener Calculation

Tank side walls experience bending due to fluid pressure.

Deflection Calculation for Side Walls

δ=5PL4384EI\delta = \frac{5 P L^4}{384 E I}δ=384EI5PL4

Where:

 EEE = Young’s modulus of steel (2 × 10⁵ MPa)

 III = Moment of inertia for 5mm plate (using I=bt312I = \frac{b t^3}{12}I=12bt3)

 LLL = Panel width (600 mm)

 PPP = Hydraulic pressure (8.34 kPa)

For a 5mm steel plate, δ≈2.5\delta \approx 2.5δ≈2.5 mm (Acceptable for a stiffened tank).

Add Vertical Stiffeners Every 400-500 mm:

 Flat bars (50x5 mm) or Square Tubes (50x50x5 mm)

5. Fastener & Support Leg Selection

 Bolt Size: M12 Grade 8.8

 Leg Height: 150-300 mm for space below the tank

 Base Plate: 10 mm thick for mounting stability

Final Design Recommendations

 Tank Wall Thickness: 5 mm MS

 Top Cover: 6 mm MS with gasket

 Stiffeners: 50x5 mm flat bars every 400 mm

 Legs: 75x75x6 mm MS angle

Would you like a detailed CAD model or fabrication drawing for this design? 😊