This electronic brochure highlights our capabilities and activities in the area of Hydraulic Systems Design and Development. Please sign our guestbook. For additional information, e-mail Glenn R. Wendel, Southwest Research Institute.

Hydraulic Systems Design and Development 

Hydraulic fluid power systems produce unparalleled levels of power with tremendous flexibility and minimal size and weight requirements. As a multidisciplinary research and development organization, Southwest Research Institute (SwRI) is uniquely qualified to aid clients in developing specialty hydraulic systems, while identifying and resolving pneumatic and hydraulic fluid power problems.

SwRI’s Engine and Vehicle Research Division has achieved certification to ISO 9001, ensuring compliance with stringent quality control procedures in design, development, and testing.

SwRI engineers routinely conduct tests that verify the operation of an Institute-developed hydraulic-related component.

During the initial development or improvement of hydraulic systems, SwRI engineers refine existing designs and develop innovative solutions to problems. Using commercial and SwRI-developed software, Institute engineers perform three-dimensional solid modeling, structural analysis, and performance simulation for hydraulic components and systems, including:

  • Pumps and motors
  • Valves
  • Accumulators
  • Actuators
  • Integrated systems

Design

In designing a new hydraulic system, engineers and designers perform a wide spectrum of services, ranging from generating innovative concepts to preparing final machining and assembly drawings. SwRI provides products such as:

  • Requirement and specifications development
  • Concept formulation and brainstorming
  • Three-dimensional solid modeling of components and assemblies
  • Design for manufacture and assembly (DFMA)
  • Realistic design illustration for enhanced concept review and product promotion
  • Concept evaluation and trade studies
  • Detailed component machining drawings
  • Assembly drawings, including exploded assembly views

Using computational fluid dynamics analysis, engineers improve fluid flow in a manifold.

Analysis

Institute engineers analyze the operating characteristics of hydraulic components and systems to improve existing designs or develop and optimize new ones. Analytical techniques include:

  • Linear and nonlinear finite element analysis
  • Structural optimization
  • Thermodynamic evaluation
  • Computational fluid dynamics
  • Kinematic analysis
  • Modal evaluation
  • Torsional analysis
  • Tribological analysis
  • System Dynamics

Institute engineers use finite element analyses to evaluate the stresses and deflections in a pump cylinder barrel, enabling the component’s power density to be increased substantially.

Optimization

SwRI engineers optimize hydraulic system designs to meet performance requirements, minimize wear, and increase service life. In improving a hydraulic system, engineers consider numerous criteria, including:

  • Production cost
  • Weight
  • Flow capacity
  • Torque and pressure “ripple” Safety
  • Noise
  • Size
  • Efficiency
  • Durability

Institute engineers evaluate a number of factors to determine their impact on system performance. These factors include:

  • Cavitation
  • Fluid compressibility
  • Leakage
  • Aeration
  • Permeation
  • Stability
  • Heat generation
  • Stiction
  • Windage
  • Noise, vibration, and  harshness (NVH)

SwRI engineers optimize the valve plate interface of a motor and pump to meet industry or client requirements for noise, stability, leakage, and durability.

Fabrication

SwRI provides exensive fabrication services, using state-of-the-art equipment and facilities, rapid functional and conceptual prototyping capabilities, and proven suppliers. Institute staff routinely fabricate hydraulic component prototypes, including:

  • Pumping elements
  • Bladders
  • Spool and poppet valves
  • Pistons
  • Housings
  • Seals
  • Hoses and lines
  • Control systems
  • Electrical and electronic interfaces

Testing

Using flexible and well-equipped test facilities, SwRI staff test hydraulic components and systems to verify and validate new designs and to measure existing design characteristics. SwRI evaluates a wide range of hydraulic-related characteristics, such as:

  • Efficiency
  • Flow loss
  • Burst and proof pressure
  • Durability
  • Noise
  • Pressure transients
  • Environmental

This brochure was published in February 2002. For more information about hydraulic systems design and development, contact Glenn R. Wendel, Phone (210) 522-2622, Fax (210) 522-4673, Engine, Emissions and Vehicle Research Division, Southwest Research Institute, P.O. Drawer 28510, San Antonio, Texas 78228-0510.

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