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Hydraulic Power Pack and Actuator System

About

The Hydraulic Power Pack and Actuator System is a skid-mounted, modular electro-hydraulic unit delivering up to 300 kW at 250 bar through a stepless variable-displacement pump paired with auxiliary fixed-displacement stages and optional redundancy. Its 2,000 L stainless-steel reservoir features internal baffling, rapid air/oil separation, and multi-stage filtration—including 10 μm and 3μm absolute filters, coalescers, and electrostatic cleaning—to maintain ISO-class cleanliness. Thermal management is handled by a 300 kW shell-and-tube heat exchanger and a VFD-driven 95-ton cooling tower, while integrated dehydration and degasification units ensure <50 ppm water content. An Allen-Bradley or Siemens HMI/PLC suite provides local/remote control, Ethernet/IP and ProfiBus connectivity, 30-day data logging, and predictive-maintenance analytics, with comprehensive SIL-rated safety interlocks and hot-swap serviceability. Designed for applications from railway fuel-tank filling and industrial test benches to offshore and aerospace ground support, the system offers extensive customization—reservoir sizes (1,000–5,000 L), fluid compatibility packages, explosion-proof motors, and environmental enclosures—ensuring reliable, precise hydraulic power in the most demanding environments.
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Technical Details

Parameter Specification
Max. Power 300kW
Max. Pressure 250 bar
Flow Rates 0–220 L/min variable; two 100 L/min fixed pumps (optional third)
Reservoir Capacity 2,000 L (1,000–5,000 L optional)
Filtration 10 μm primary, 3 μm secondary; coalescer; electrostatic cleaner
Heat Exchanger 300 kW @ 700 L/min, ΔP 10 bar; upgradable to 500 kW
Cooling Circuit 95 ton tower; 3.7 kW VFD fan; glycol-water loop optional
Data Logging Allen-Bradley ControlLogix or Siemens S7; OPC UA, Profinet
Control Platform 1 Hz historian, 1 year local storage; OPC HDA support
Accuracy (Mass) ±0.1 % setpoint; ±0.02 % dynamic control
Operating Temp. –20 °C to +60 °C (cold-start to –40 °C)
Noise Level <75 dBA at 1 m (with sound-attenuating enclosure)
Safety Ratings SIL 3 (optional), ATEX Zone 1, CE, UL
  • Railway Fuel-Tank Filling: Provides automated, mass-based fueling with ±0.1 % accuracy via integrated load cells and interlocked valve sequences, preventing overfills and ensuring regulatory compliance for environmental emissions control.
  • Industrial Actuation & Test Benches: Supplies precise pressure and flow for dynamic load simulation up to 1 MN, servo-valve characterization, and endurance fatigue testing of valves and cylinders in R&D and production environments.
  • Mobile Offshore & Defense: Delivers ruggedized hydraulic power on vibration-isolated mounts, with marine-grade paint and corrosion-resistant fiƫngs, for subsea winches, deck machinery, and turret stabilization systems.
  • Aerospace Ground-Support: Powers test stands for flight-control actuators and engine accessory drives, featuring rapid thermal cycling through a glycol-water heat-exchanger circuit to validate components under extreme temperature profiles hydraulic-power-pack.

Key Features

  • Precision Flow Control via digital swashplate actuation and load-sense logic
  • Superior Cleanliness to ISO 4406 ≤ 16/14/11 with electrostatic and coalescer stages
  • Energy Efficiency from VFD-driven pumps, fans, and insulation jackets
  • Advanced Diagnostics including vibration-based predictive-maintenance alerts
  • Safety-Certified to SIL 3 (optional) and ATEX Zone 1 standards
  • Rapid Serviceability with hot-swap filters and plug-and-play modules

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Details

Introduction
The Hydraulic Power Pack and Actuator System is engineered as a fully modular, skid-mounted electro-hydraulic solution delivering up to 300 kW of continuous power at pressures up to 250 bar.
Built around a compact footprint, the skid incorporates vibration-isolated mounts, removable access panels, and integrated cable trays to simplify installation in constrained plant environments. Its core manifold block is CNC-machined from high-grade aluminum alloy, minimizing internal leakage paths and ensuring consistent flow distribution. The reservoir features internal baffling for rapid air/oil separation, sight-glass level indicators, and a 50 mm inspection port to facilitate visual checks and fluid sampling without system depressurization.

Applications
• Railway Fuel-Tank Filling: Provides automated, mass-based fueling with ±0.1 % accuracy via integrated load cells and interlocked valve sequences, preventing overfills and ensuring regulatory compliance for environmental emissions control.
• Industrial Actuation & Test Benches: Supplies precise pressure and flow for dynamic load simulation up to 1 MN, servo-valve characterization, and endurance fatigue testing of valves and cylinders in R&D and production environments.
• Mobile Offshore & Defense: Delivers ruggedized hydraulic power on vibration-isolated mounts, with marine-grade paint and corrosion-resistant fiƫngs, for subsea winches, deck machinery, and turret stabilization systems.
• Aerospace Ground-Support: Powers test stands for flight-control actuators and engine accessory drives, featuring rapid thermal cycling through a glycol-water heat-exchanger circuit to validate components under extreme temperature profiles.

Core Components
Pumping Assembly
• Variable-Displacement Axial Piston Pump: Up to 220 L/min at 250 bar, stepless control via a swashplate actuator driven by a digital servomotor for precise flow modulation.
• Fixed-Displacement Auxiliaries: Two 100 L/min pumps engage through a pressure-sensing load-sense valve as demand increases; optional third pump provides N+1 redundancy.
• Priority and Sequence Valves: Ensure uninterrupted minimum flow to critical servos; sequence valve manifold orchestrates fill, drain, and bypass operations during startup and shutdown.

Reservoir & Filtration
2,000 L SS 304 Reservoir: Features internal cones to direct return oil toward the suction port, minimizing aeration; includes 5 kW immersion heater for low-temperature startups. Filtration Train: 10 μm ABS-rated primary filter with pressure-differential bypass, followed by a 3 μm
secondary filter; a fine-coalescer module removes water and entrained air, and an optional electrostatic cleaner strips sub-micron contaminants to ISO 4406 classes 16/14/11 or better.

Thermal Management
• Shell-and-Tube Heat Exchanger: Rated 300 kW at 700 L/min with adjustable flow-control valves; provides ±1 °C temperature stability via RTD-feedback loop.
• Cooling Tower Circuit: 95-ton nominal capacity with VFD-controlled fan and auto-purge drain; glycol-water loop option for glycol-based fluids or potable-water restrictions.
• Dehydration & Degasification: Vacuum-degas module draws moisture-laden vapors, routed through a molecular-sieve dryer to maintain <50 ppm water content.

Control & Monitoring
• HMI/PLC Suite: Allen-Bradley ControlLogix or Siemens S7 plaƞorm with 10o color touchscreen, OPC UA and Profinet gateways, and built-in cybersecurity features (firewall, user-role access).
• Data Logging & Analytics: Embedded Historian stores 1 year of 1 Hz data for pressure, temperature, flow, and mass; supports OPC HDA for remote trending and integration with digital-twin plaƞorms.
• Alarms & Notifications: Configurable SLAs for high/low pressure, temperature excursions, filter differential, and mass thresholds; automatic SMS/email alerts and SCADA-level OPC DA tags for plant DCS integration.

Maintenance & Serviceability
• Quick-Change Filters: Spin-on housings with captive bolts; integrated differential gauges and bypass indicators enable “hot-swap” without system shutdown.
• Modular Sub-Assemblies: Pump, heat-exchanger, and controller modules can be unplugged via multi-pin quick connectors, reducing mean time to repair (MTTR) to under 2 hours.
• Predictive Diagnostics: Vibration sensors on pump bearings and motor shafts feed into the PLC’s predictive-maintenance block, issuing maintenance alerts based on MTTF algorithms.

Customization & Options
• Reservoir Variants: 1,000 L–5,000 L capacities; carbon-steel, SS 316, or polyurethane-lined for abrasive or corrosive fluids.
• Fluid Compatibility: Supports mineral, fire-resistant (HFDU, HFC), and biodegradable hydraulic fluids with tailored elastomer seals.
• Environmental & Safety Packages: ATEX/IECEx explosion-proof motors, SIL 3 rated safety PLC add-ons, cold-start packages with heat-trace lines, and sound-attenuating enclosures achieving <75 dBA at 1 m.

Operating Highlights
• Pre-Start: Automatic self-test of sensors and valve actuators; reservoir pre-heat to 40 °C in <15 min.
• Filling Sequence: Load-cell feedback holds mass setpoint within ±0.02 %; valve manifold executes multi-stage fill profile to reduce surge.
• Continuous Operation: Active filter regeneration cycle every 72 h, based on differential pressure; chiller compressor modulation maintains ±1 °C thermal band.
• Shutdown & Safeguards: Controlled ramp-down of pump swashplate, followed by automatic purging of return lines to prevent residual pressure traps.

Key Features
• Precision Flow Control via digital swashplate actuation and load-sense logic
• Superior Cleanliness to ISO 4406 ≤ 16/14/11 with electrostatic and coalescer stages
• Energy Efficiency from VFD-driven pumps, fans, and insulation jackets
• Advanced Diagnostics including vibration-based predictive-maintenance alerts
• Safety-Certified to SIL 3 (optional) and ATEX Zone 1 standards
• Rapid Serviceability with hot-swap filters and plug-and-play modules

Technical Specifications
Parameter Specification
Max. Power 300kW
Max. Pressure 250 bar
Flow Rates 0–220 L/min variable; two 100 L/min fixed pumps (optional third)
Reservoir Capacity 2,000 L (1,000–5,000 L optional)
Filtration 10 μm primary, 3 μm secondary; coalescer; electrostatic cleaner
Heat Exchanger 300 kW @ 700 L/min, ΔP 10 bar; upgradable to 500 kW
Cooling Circuit 95 ton tower; 3.7 kW VFD fan; glycol-water loop optional
Data Logging Allen-Bradley ControlLogix or Siemens S7; OPC UA, Profinet
Control Platform 1 Hz historian, 1 year local storage; OPC HDA support
Accuracy (Mass) ±0.1 % setpoint; ±0.02 % dynamic control
Operating Temp. –20 °C to +60 °C (cold-start to –40 °C)
Noise Level <75 dBA at 1 m (with sound-attenuating enclosure)
Safety Ratings SIL 3 (optional), ATEX Zone 1, CE, UL

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