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<strong>Hydraulic</strong> <strong>Training</strong> Prospectus 2009<br />
<strong>Bosch</strong> <strong>Rexroth</strong> <strong>the</strong> Drive and Control Company<br />
PROSPECTUS 02-01-09
Welcome to <strong>Bosch</strong> <strong>Rexroth</strong> Limited – <strong>Training</strong> Services<br />
Production demands placed on our manufacturing industry have never been as high as <strong>the</strong>y are today.<br />
Downtime or stoppages due to lack of basic or specific product knowledge cost industry millions of<br />
pounds per year.<br />
As a major world-wide supplier of automation technology in <strong>the</strong> fields of electronic drives and controls,<br />
hydraulics, pneumatics and assembly products, <strong>Bosch</strong> <strong>Rexroth</strong> are committed to supplying first-class<br />
customer training on our range of products, and to this end our training mission statement is:<br />
"We believe that effective training is a prerequisite for productive work and job satisfaction, and we<br />
will reach out to our customers, end users and education institutions to enhance <strong>the</strong>ir knowledge and<br />
skills required for <strong>the</strong> proper use of our products".<br />
This course prospectus details our range of hydraulic training courses for 2008, offering a wide selection<br />
of basic, advanced and customer specific training courses for students of all abilities and all levels.<br />
The course structures have been specifically formulated to represent <strong>the</strong> ideal training and learning<br />
experience for personnel working within <strong>the</strong> maintenance, repair, field service or technical support fields<br />
of hydraulic systems. All courses are certificated jointly by <strong>Bosch</strong> <strong>Rexroth</strong> and <strong>the</strong> National Fluid Power<br />
Centre. Attendance on <strong>the</strong>se courses is a perfect starting point towards an industry standard qualification<br />
such as <strong>the</strong> British Fluid Power Association Industrial <strong>Hydraulic</strong>s – Level 2 Certificate.<br />
At <strong>Bosch</strong> <strong>Rexroth</strong> we are ready to support all your training needs in <strong>the</strong> fields of hydraulics and we<br />
strongly believe that training and education is key to <strong>the</strong> future.<br />
<strong>Bosch</strong> <strong>Rexroth</strong> Limited<br />
15 Cromwell Road<br />
St Neots<br />
Cambs<br />
PE19 2ES<br />
Tel: +44 (0)1480 223282<br />
Fax: +44 (0)1480 473273<br />
<strong>Training</strong> Room and <strong>Training</strong> Rigs, <strong>Bosch</strong> <strong>Rexroth</strong>, St Neots<br />
2
CONTENTS<br />
DISCIPLINE CODE SUBJECT PAGE<br />
<strong>Hydraulic</strong>s<br />
MH Maintenance <strong>Hydraulic</strong>s 4<br />
MH-s Maintenance <strong>Hydraulic</strong>s (short) 5<br />
Stage 2 <strong>Course</strong>s - Pre-requisites 6<br />
TPS1 <strong>Hydraulic</strong>s - Proportional Systems 7<br />
BHD Basic <strong>Hydraulic</strong> Design 8<br />
PPC Pump and Pump Control 9<br />
Bespoke <strong>Training</strong> 10<br />
<strong>Course</strong> Booking Form 11<br />
3
MH<br />
Aims<br />
• To impart a basic understanding of maintenance<br />
hydraulics<br />
• To increase <strong>the</strong> knowledge of personnel who are<br />
actively engaged on <strong>the</strong> repair and maintenance of<br />
hydraulic systems<br />
• To allow participants to become familiar with fluid<br />
power technologies such as pump flow, cylinder<br />
speed, forces and pipe sizes<br />
• Introduce basic hydraulic <strong>the</strong>ory in a practical way<br />
• To increase <strong>the</strong> knowledge of personnel in<br />
maintenance and fault-finding techniques<br />
associated with hydraulic systems<br />
• To enable participants to understand <strong>the</strong>ir specific<br />
hydraulic installation and circuit diagrams<br />
• To gain hands-on experience of building, faultfinding<br />
and optimising hydraulic circuits using our<br />
range of specially designed training rigs<br />
• To introduce participants to proportional control,<br />
optimising and fault-finding<br />
Maintenance <strong>Hydraulic</strong>s<br />
3.5 Days St Neots<br />
<strong>Course</strong> Content<br />
Day one<br />
• Basic hydraulic principles<br />
• <strong>Hydraulic</strong> symbols and circuit notations<br />
• Pressure control valves and associated circuitry<br />
• Relief valves and pressure reducing valves<br />
• Sequence valves and counter<br />
balance/overcentre valves<br />
• Flow control valves and associated circuitry<br />
• Simple throttle valves<br />
• Pressure/temperature compensated units<br />
• Direction control valves and associated circuitry<br />
• Direct operated spool valves<br />
• Two stage spool valves<br />
• Poppet valves and logic cartridge elements<br />
Day two<br />
• Check valves - type and applications<br />
• Pump and pump control systems<br />
•Pump types and operating principles<br />
•Methods of control/application<br />
•Accumulator types and application<br />
• <strong>Hydraulic</strong> motors and actuators<br />
•Type and operating principles<br />
•Methods of control and application<br />
Pre-requisites<br />
• No previous knowledge required<br />
Participants<br />
• Maintenance Engineers<br />
• Project Engineers<br />
Day three<br />
• Total cleanliness control<br />
• <strong>Hydraulic</strong> fluids, good housekeeping<br />
• Maintenance and trouble shooting techniques<br />
• Practical hands on practice and exercises 1 day<br />
Day four (finish lunch-time)<br />
• Introduction to proportional control<br />
• Factory Tour<br />
Notes<br />
• This course is also run each month on behalf of<br />
<strong>Bosch</strong> <strong>Rexroth</strong> by Sparrows Offshore in Aberdeen -<br />
for dates see course calendar<br />
• <strong>Training</strong> courses can be tailored to <strong>the</strong> systems<br />
and applications currently running at your<br />
premises. In order to undertake this, circuit<br />
diagrams will need to be submitted to <strong>the</strong> course<br />
lecturer in advance<br />
4
MH-s<br />
Maintenance <strong>Hydraulic</strong>s Short <strong>Course</strong><br />
3 Days <strong>Training</strong> Centres & On Site<br />
Aims<br />
• To bring basic hydraulic training to your facility and<br />
<strong>Course</strong> Content<br />
Day One<br />
increase knowledge of your installations<br />
• Basic hydraulic principles<br />
• To impart a basic understanding of maintenance<br />
hydraulics<br />
• To increase <strong>the</strong> knowledge of personnel who are<br />
actively engaged on <strong>the</strong> repair and maintenance of<br />
hydraulic systems<br />
• To allow participants to become familiar with fluid<br />
power technologies such as pump flow, cylinder<br />
speed, forces and pipe sizes<br />
• Introduce basic hydraulic <strong>the</strong>ory<br />
• To increase <strong>the</strong> knowledge of personnel in<br />
maintenance and faultfinding techniques<br />
associated with hydraulic systems<br />
• <strong>Hydraulic</strong> symbols and circuit notations<br />
• Pressure control valves and associated circuitry<br />
• Relief valves and pressure reducing valves<br />
• Sequence valves and counter<br />
balance/overcentre valves<br />
• Flow control valves and associated circuitry<br />
•Simple throttle valves<br />
•Pressure/temperature compensated units<br />
• Direction control valves and associated circuitry<br />
•Direct operated spool valves<br />
•Two stage spool valves<br />
•Poppet valves and logic cartridge elements<br />
• To enable participants to understand <strong>the</strong>ir specific<br />
hydraulic installation and circuit diagrams<br />
Day two<br />
• Check valves - type and applications<br />
• Pump and pump control systems<br />
•Pump types and operating principles<br />
•Methods of control/application<br />
•Accumulator types and application<br />
• <strong>Hydraulic</strong> motors and actuators<br />
•Type and operating principles<br />
•Methods of control and application<br />
• Total cleanliness control<br />
• <strong>Hydraulic</strong> fluids, good house keeping<br />
Pre-requisites<br />
• No previous knowledge required<br />
Day three<br />
• This day is devoted to customers’ circuit diagrams<br />
•Explanation of circuit layout and design<br />
•Type of components installed<br />
• Maintenance and troubleshooting techniques<br />
Participants<br />
• Maintenance Engineers<br />
• Project Engineers<br />
Notes<br />
• No training rigs will be used on this course as it is<br />
designed to bring hydraulic training into your<br />
working environment without <strong>the</strong> need for special<br />
facilities, power supplies or rooms<br />
• As no practical exercises are included in <strong>the</strong><br />
course, day 3 will be devoted to analysing your<br />
circuit diagrams in terms of maintenance<br />
requirement, testing and checkouts and faultfinding<br />
5
TPS-1 / BHD<br />
<strong>Hydraulic</strong>s Stage 2 - Pre-requisites<br />
Pre-requisites for Stage 2 <strong>Course</strong>s<br />
• Knowledge of basic hydraulic principles that<br />
underpin all hydraulic systems (relationship<br />
between, pressure, flow force, torque, speed, pump<br />
size, motor size and cylinder dimensions)<br />
• Be able to read and interpret circuit diagrams using<br />
current symbols<br />
• Know <strong>the</strong> function and operation of relief valves,<br />
sequence valves and pressure reducing valves<br />
• Know <strong>the</strong> principle of pressure compensation<br />
relating to flow control<br />
• Know <strong>the</strong> principle of operation of check valves and<br />
sliding spool valves<br />
• Know <strong>the</strong> principle of operation of gear, vane and<br />
piston pumps<br />
• Know <strong>the</strong> different characteristics of oils and <strong>the</strong><br />
aspects of contamination control<br />
• Know what accumulators are used for<br />
• Have a basic understanding of proportional control<br />
and basic electrical <strong>the</strong>ory<br />
• Have a basic appreciation of pump testing and<br />
component settings up procedures<br />
• Appreciate <strong>the</strong> requirements of risk management<br />
6
TPS-1<br />
<strong>Hydraulic</strong>s -<br />
Proportional Systems<br />
3 Days St. Neots/Treforest/Bradford<br />
Aims<br />
<strong>Course</strong> Content<br />
• To introduce students to <strong>the</strong> principles and<br />
Day One<br />
practices of proportional control<br />
Valve construction and operation:<br />
• Introduction to <strong>the</strong> study of circuit construction and • Types of proportional control devices<br />
circuit components<br />
• Pressure relief<br />
• To introduce basic principles of design of<br />
• Flow control<br />
proportional systems<br />
• Direction control<br />
• Students will gain knowledge of both analogue and • <strong>Hydraulic</strong> symbols<br />
digital proportional systems<br />
• Spool configurations<br />
• Students will gain a knowledge of both open and • Selection & sizing with reference to<br />
closed loop proportional systems<br />
manufacturer’s data<br />
• For student to become familiar with set-up<br />
Electrical operation:<br />
procedures on proportional systems<br />
• Types of proportional control devices<br />
• For students to become familiar with maintenance • Basic electrical circuits and operation<br />
and faultfinding techniques on proportional<br />
• Solenoid design<br />
hydraulic systems<br />
• Comparison between conventional and<br />
proportional valves<br />
• Methods of control<br />
• Comparison between analogue and digital control<br />
Pre-requisites<br />
• Attendance on ei<strong>the</strong>r MH or MH-s<br />
(See Stage 2 prerequisites)<br />
Participants<br />
• Maintenance Engineers<br />
• Project Engineers<br />
Notes<br />
• Practical exercises form an important part of this<br />
course. These are carried out using our range of<br />
specially designed training rigs<br />
• <strong>Course</strong> participants are asked to bring current<br />
circuit diagrams to <strong>the</strong>se sessions w<strong>here</strong> time will<br />
be devoted to <strong>the</strong>ir explanation<br />
Day two<br />
Proportional Attributes:<br />
• Ramp<br />
• Gain<br />
• Deadband<br />
• Di<strong>the</strong>r<br />
• Pulse width modulation<br />
Amplifier cards:<br />
• Principles of operation<br />
• Design and application<br />
• Analogue and digital<br />
Closed Loop:<br />
• Internal and external feedback devices<br />
• Operation and application of closed loop systems<br />
Day three<br />
Integrated Electronics Option Frequency Response:<br />
• Principles of operation<br />
• Bode diagrams and <strong>the</strong>ir use in manufacturer’s<br />
data<br />
• PID control<br />
Practical Exercises:<br />
•Commissioning and set-up procedures<br />
• Open loop circuits<br />
• Closed loop circuits<br />
• Interface to <strong>the</strong> control<br />
• Use of monitoring equipment<br />
7
BHD<br />
Basic <strong>Hydraulic</strong> Design<br />
3 Days St. Neots<br />
Aims<br />
• The BHD course takes a more ma<strong>the</strong>matical<br />
approach to <strong>the</strong> <strong>the</strong>ory covered in <strong>the</strong> MH or MH-s<br />
courses. After covering basic <strong>the</strong>ory and operation<br />
of hydraulic components, <strong>the</strong> emphasis moves to<br />
circuit design and basic project work<br />
• The course is intended for design and technical<br />
personnel who are involved with machine design<br />
and <strong>the</strong> specification of hydraulic components and<br />
systems<br />
• Although this course is not intended to fully instruct<br />
<strong>the</strong> student in proportional technology it is<br />
inevitable that this subject is covered as this<br />
technology forms an integral part of modern<br />
hydraulic systems<br />
• Participants attending this course should have a<br />
basic grounding in ma<strong>the</strong>matics and physics<br />
Pre-requisites<br />
• Attendance on ei<strong>the</strong>r MH or MH-s<br />
(See Stage 2 pre-requisites)<br />
Participants<br />
• Designers and technical personnel<br />
Notes<br />
• Practical exercises form an important part of this<br />
course. These are carried out using our range of<br />
specially designed training rigs<br />
• <strong>Course</strong> participants are asked to bring current<br />
circuit diagrams to <strong>the</strong>se sessions w<strong>here</strong> time will<br />
be devoted to <strong>the</strong>ir explanation<br />
<strong>Course</strong> Content<br />
Day One<br />
Fundamental Principles:<br />
• Cylinders – relationship between valves<br />
• Cylinder size, pressure, area and effective force<br />
• Cylinder size, supply flow rate and velocity<br />
Motors:<br />
• Motor displacement, pressure and shaft torque<br />
• Motor displacement, supply flow rate and shaft<br />
speed<br />
• Motor performance and effects of fluid viscosity<br />
Loads to be moved:<br />
• Application of <strong>the</strong> laws of dynamics, with<br />
reference to Mass and inertia, friction, gravity and<br />
o<strong>the</strong>r external forces; direct and indirect loads<br />
Pumps:<br />
• Displacement, shaft speed and flow rate<br />
• Flow rate, system pressure and fluid viscosity<br />
• Pressure difference, component flow area and<br />
flow rate<br />
• Fluid Viscosity, Renolds number, flow<br />
characteristics, recommended flow velocities<br />
• Pressure difference, flow rates, heat generation<br />
and temperature changes<br />
Day two<br />
• Step by step to follow, relating to system design<br />
• Outline of common design faults<br />
• Preparing outline circuitry<br />
Component selection to meet specification<br />
Actuators:<br />
• Cylinder to meet force, speed and application<br />
needs<br />
• Motors to meet torque, speed and application<br />
needs<br />
• Pressure – Time/flow diagrams and duty cycles<br />
Pumps:<br />
• Sizing, power requirements and Q/P requirements<br />
• Circuitry relating to fixed and variable<br />
displacement pumps<br />
<strong>Hydraulic</strong> valves:<br />
• Size selection, flow rates, pressure and<br />
configurations<br />
Proportional control valves:<br />
• Overview of valve selection, sizing and application<br />
Day three<br />
• Contamination control at <strong>the</strong> design stage<br />
• Health and performance monitoring when<br />
designing<br />
• Reservoir sizing and layout considerations<br />
Design exercises and practical tasks<br />
8
PPC<br />
Pump & Pump Control<br />
2 Days National Fluid Power Centre<br />
Aims<br />
<strong>Course</strong> Content<br />
• To understand <strong>the</strong> function and operation of pumps Day one<br />
and <strong>the</strong>ir controls<br />
• Pump types<br />
• To be able to make <strong>the</strong> correct pump selection for •Function<br />
given applications<br />
•Operation<br />
• To understand <strong>the</strong> causes of pump failure<br />
• Pump selection<br />
• To understand <strong>the</strong> affects of contamination • Pump controls<br />
• To understand <strong>the</strong> setting-up procedures of pump •Fixed displacement<br />
and pump control<br />
•Variable displacement<br />
• To understand safe working practices<br />
•Relief valves<br />
•Flow control valves<br />
•Unloading valves<br />
•Accumulators and pressure switches<br />
•Pressure compensation<br />
•Load sensing<br />
•Constant power<br />
Day two<br />
• Causes of pump failure<br />
• Contamination and target cleanliness<br />
• Manufacturers recommendations / specifications<br />
• Setting up procedures<br />
• Safe working practices - Do’s and Don’ts<br />
Pre-requisites<br />
• Attendance on ei<strong>the</strong>r MH or MH-s<br />
(See Stage 2 prerequisites)<br />
Participants<br />
• Maintenance personnel<br />
• Technical representative<br />
• Service and Repair Technicians<br />
Notes<br />
• This course is run at <strong>the</strong> National Fluid Power<br />
Centre in Worksop due to equipment required<br />
• Due to <strong>the</strong> nature of this course its content is not<br />
limited to <strong>Bosch</strong> <strong>Rexroth</strong> pumps and <strong>the</strong>ir controls.<br />
O<strong>the</strong>r manufacturers’ pumps and controls can also<br />
be covered at request<br />
9
Bespoke<br />
Consultant Services in <strong>Hydraulic</strong> Systems<br />
On site at your facility, or at one of our<br />
Offices throughout <strong>the</strong> UK.<br />
Customer Site or BR <strong>Training</strong> Centres<br />
<strong>Training</strong> programmes to suit your<br />
company specific needs<br />
•Programmes designed to ensure training is<br />
delivered to match customer specific requirements -<br />
providing a cost effective way to guarantee staff<br />
knowledge and skills match workplace tasks.<br />
•Bespoke courses can be carried out at customer<br />
site, or at our training facilities in<br />
- St Neots, Cambridgeshire<br />
- Treforest, Cardiff<br />
- Bradford, Leeds<br />
•<strong>Course</strong> content, delivery times and duration to<br />
customer specification.<br />
How are <strong>the</strong>se courses designed<br />
• A site survey is carried out by one of our hydraulic<br />
engineers / lecturer w<strong>here</strong> <strong>the</strong> following items will<br />
be checked :<br />
Current hydraulic circuit diagrams<br />
Technical data and supplier information<br />
Operating specifications<br />
Current level of knowledge and experience of<br />
staff<br />
Customer expectations of <strong>the</strong>ir staff on<br />
completion of <strong>the</strong> training<br />
• From this survey a complete set of customer<br />
reports are generated covering :-<br />
Full training needs analysis for staff<br />
A full and detailed description of <strong>the</strong> customer’s<br />
staff experience and knowledge in <strong>the</strong> areas<br />
relating to customer plant<br />
A full and detailed course programme detailing<br />
<strong>the</strong> aim, objectives, training outcomes and<br />
course duration<br />
• The course programme will be amended until <strong>the</strong><br />
customer is fully satisfied with its content.<br />
• T<strong>here</strong> is a charge levied for course development<br />
work.<br />
How we proceed after <strong>the</strong> site survey<br />
• Once <strong>the</strong> customer is fully satisfied with our<br />
proposals, an order is placed for <strong>the</strong> training.<br />
• A full and detailed quotation will be forwarded<br />
detailing all costs.<br />
• <strong>Course</strong> dates will be discussed and agreed<br />
• The course or courses will be delivered on site at<br />
your premises, or at a <strong>Bosch</strong> <strong>Rexroth</strong> training site<br />
as required.<br />
• Once <strong>the</strong> training is complete a full evaluation is<br />
produced detailing your staff’s performance during<br />
<strong>the</strong> training session and an evaluation on how we<br />
performed during <strong>the</strong> session.<br />
10
<strong>Training</strong> <strong>Course</strong> Booking Form<br />
If you have already received your quotation you may book a course using this form.<br />
Please fax/e-mail your booking (contact details below).<br />
Note: For information regarding Aberdeen course bookings - please contact Stuart Crawford direct at Aberdeen <strong>Hydraulic</strong>s, 01224 227830,<br />
e-mail stuart.crawford@aberdeenhydraulics.com.<br />
Company Name:<br />
Address:<br />
Contact Name:<br />
Position:<br />
Telephone:<br />
Email:<br />
Signature:<br />
Fax:<br />
Date:<br />
Post Code:<br />
Order Number:<br />
Cheque<br />
Number:<br />
<strong>Course</strong> Code:<br />
<strong>Course</strong> Date:<br />
<strong>Course</strong> Fee:<br />
Location:<br />
Would you like hotel information: (delete as required)<br />
Participants:<br />
Total Fee:<br />
VAT:<br />
Total Payable:<br />
Yes / No<br />
Please return your completed form to:<br />
<strong>Bosch</strong> <strong>Rexroth</strong> Limited,<br />
15 Cromwell Road,<br />
St Neots, Cambridgeshire,<br />
PE19 2ES, United Kingdom<br />
Phone: +44 (0) 1480 223 282<br />
Fax: +44 (0) 1480 473 273<br />
Email: marie.morris@boschrexroth.co.uk<br />
11