Hydraulic power systems are widely used in heavy machinery. Safety of such a systems have a major importance due to the fact that any failure may cause environmental contamination or serious injury. One of the component which protects hydraulic drive systems against excessive rising of working pressure is a safety valve which aim is to maintain pressure in the systems below acceptable level. Pressure control valves which plays important role in a hydraulic systems may have very simple or complex structure. Even in case of the simplest structure of such valve modeling is not an easy task. The new quality in designing hydraulic valves bring CFD method and FSI (Fluid Structure Interaction) methods.
This article presents results of numerical modelling, simulation and test bench experiments of a hydraulic direct-acting relief valve was used as a safety valve. The analyzed safety valve was placed in a system consisting of a fixed-speed pump, a control valve, a hydraulic cylinder as an actuator and a second pressure valve in the load line used as a payload generator for the cylinder. In the first step mathematical model of the system was formulated in the form of a system of ordinary differential equations. Next, simulation model was created in Matlab/Simulink. Simulations were carried out for different values of the actuator payload. The obtained results include time series of pressure, flow rate and displacement of the actuator piston. In order to confirm simulation results, a test bench was built and series of experiments were carried out. High compliance of simulation and laboratory results was obtained. It was confirmed that the proposed solution with the relief valve used as a safety valve fulfills its task of protecting the hydraulic system from excessive pressure increase.
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