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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

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