Hydraulics DS4
Hydraulics DS4
The DS4 Hydraulic Training System by Bosch Rexroth AG is designed for comprehensive training in industrial and mobile hydraulics, as well as pneumatic systems. It is part of the Drive & Control Academy's offerings, aimed at transferring technical knowledge to provide a competitive advantage in the global market.
The DS4 system is modular and configurable to meet specific training needs. It includes a hydraulic power unit, TÜV-tested safety valves, industry-standard valving, control blocks, and various components for practical exercises. The system is adaptable and expandable, allowing for additional study topics such as on/off hydraulics, proportional valve technology, and mobile hydraulics.
The DS4 system can be configured with two independent workstations for hydraulics or pneumatics, or a combination of both. Key components include a hydraulic power unit, electrical device racks, measuring glass, hose rack, load simulator, and oil drip pans. The system is delivered fully assembled and can be tailored to specific training requirements.
The DS4 system complies with the Machinery Directive 2006/42/EC and includes a CE certificate. Safety features such as pressure limitations and protective covers for cylinders ensure a safe training environment.
The system is supported by educational materials, including project manuals, specialist books, and teaching media, designed to help trainees gain technical knowledge and prepare for professional tasks in the industry.
The DS4 Hydraulic Training System is a versatile and comprehensive solution for training in hydraulic and pneumatic systems, designed to meet the evolving needs of industry and education, providing a practical and effective learning experience.
The document lists several power units with different voltage and frequency specifications, including 230 V/50 Hz, 400 V/50 Hz, and 230 V/60 Hz. These units are equipped with either single or double pumps and are designed to supply two workstations. Key specifications include dimensions, weight, coating, pressure limits, oil tank capacity, flow rate, and protective motor switch ratings.
Various mounting kits are described for attaching power units, oil trays, and fixed storage units to the DS4 system. The document specifies dimensions, weight, and material for each kit, emphasizing their compatibility with the DS4 configuration.
The document details different oil trays designed for the DS4 substructure, highlighting their dimensions, weight, and material. These trays are essential for managing oil spills and maintaining system cleanliness.
Hose lines of varying lengths are provided for hydraulic connections, along with installation kits for LS pumps. These components are crucial for ensuring efficient hydraulic flow and connectivity within the system.
The document outlines the specifications for electrical power supplies, control boxes, and connection cables. These components are designed to provide safe and reliable power to the DS4 system, with features like short-circuit protection and emergency stop buttons.
Other components such as measuring glasses, hose racks, and load simulators are described, each with specific dimensions, weight, and material details. These components enhance the functionality and versatility of the DS4 system.
The document lists different models of hydraulic power units with specifications such as voltage, frequency, power, and pump configurations. Key models include single and double pump units with variable displacement control, suitable for DS4 training systems. Operating pressures, safety limitations, and displacement rates are specified for each unit.
Various components like racks, control boxes, measuring glasses, hose racks, and load simulators are detailed. Each component is described with its material, dimensions, weight, and mounting type. Accessories such as portable storage units, drawer organization sets, and monitor support arms are also included, highlighting their design and functionality.
The DS4 Hydraulic Training System is designed for practical training in hydraulics, covering topics like on/off hydraulics, proportional valve technology, and mobile hydraulics. The system includes training manuals for trainers and trainees, with exercises on hydraulic power units, valves, and circuit applications.
The document outlines study topics for the DS4 system, including hydraulic basics, project exercises, troubleshooting, proportional control, position control, throttle control, load sensing control, and LUDV control. Each topic is structured to enhance understanding and practical application.
The manuals are available in multiple languages (German, English, Spanish) and are divided into sections for trainers and trainees. They cover hydraulic basics, project exercises, and troubleshooting techniques. Each manual is designed to facilitate learning through practical exercises and project tasks.
The document lists various hydraulic components used in training, such as hose lines, pressure gauges, valves, and motors. These components are standard industrial size 6 and are intended for use with the DS4 training system.
The exercises are based on topics proposed by BiBB and are designed to teach students independent project planning, execution, and analysis. Topics include hydraulic power units, pressure control, flow control, and troubleshooting.
The document includes a section on troubleshooting hydraulic systems, with device sets containing integrated faults for practical learning. It emphasizes systematic troubleshooting and maintenance.
This section focuses on proportional control, with exercises designed to teach trainees about electrohydraulic control technology. It includes project tasks that require independent planning and implementation.
The document provides detailed lists of necessary hydraulic and electric components, measuring devices, and accessories required for the exercises.
- Components: Standard size 6 hydraulic components are used, including proportional directional valves, control valves, and pressure relief valves. Electric components include pressure switches, gauges, and various operating modules.
- Training System Requirements: The DS4 training system requires specific equipment such as measuring glasses, electronic module racks, and hydraulic power units.
- Training Focus: Exercises are designed for hands-on learning, emphasizing the understanding of open and closed loop control systems.
- Components: Includes horizontal loading units, control valves, and pressure gauges. Electric components feature operating modules for command value generation and display.
- Project Exercises: Cover controlling positions using directional and proportional valves, and closed loop position control.
- Training Focus: Practical examples from mobile control technology are used, assuming prior basic hydraulic knowledge.
- Components: Utilizes control blocks, pressure relief valves, and gear motors. The DS4 system is equipped with load sensing functions.
- Project Exercises: Include flow and velocity control, pressure and force control, and load holding valve operations.
- Training Focus: Emphasizes independent learning through practical tasks related to load sensing technology.
- Scope of Delivery: Includes project manuals for trainers and trainees, with lists of necessary components and measuring devices.
The document serves as a detailed manual for trainers and trainees in hydraulic systems, providing structured exercises and necessary equipment lists to facilitate effective learning and understanding of hydraulic control technologies.
The manual begins with an overview of the historical development of mobile hydraulics, which is essential for understanding the classification and application of load sensing control in various machines.
Detailed explanations are provided on load sensing control, including its operation and the special symbols used in this technology. The manual covers components such as the 2M4-12 LS control block, spool stroke limitation, pressure compensators, and hydraulic pilot control.
The manual outlines a series of project exercises, starting with primary pressure limitation and progressing through topics like actuator flows, load pressure compensation, and parallel operations. Each exercise is designed to build on the previous one, enhancing the learner's understanding of mobile hydraulics.
Basic safety guidelines are included to ensure safe execution of the exercises.
The manual lists necessary hydraulic components and measuring devices, all optimized for the DS4 training system. Components include load sensing control blocks, pressure relief valves, throttle valves, and various hose lines.
The manual also covers LUDV (anti-saturation) control, explaining its operation and components like the LUDV 2SX-12 control block and pressure compensators. Exercises related to LUDV control focus on pressure settings, actuator speeds, and the effects of loads.
Separate manuals are available for trainers and trainees, providing detailed project instructions and necessary background information. These manuals are available in both German and English.
The manual includes detailed specifications for various components, such as directional control valves, pressure control valves, and hydraulic motors, along with their material numbers and operational parameters.
1. 4WE6G6X/ 4/3 Directional Valve: Modified for aging and wear simulation. Features a 4-port, 3-spool position, lever-operated, spring-centered design. Operating pressure max is 120 bar with a voltage of 24V DC and power consumption of 30W.
2. 4WE6J6X/ 4/3 Directional Valve: Lever-operated with a spring-centered spool. Dimensions are L206 x W125 x H98 mm, weight 2.9 kg, and operating pressure max is 120 bar.
3. 4WE6E6X/ 4/3 Directional Valve: Solenoid-operated with a concealed manual override. Similar dimensions and specifications as the 4WE6J6X model.
1. 4WREE6E08-2X/ 4/3 Proportional Directional Valve: Features integrated electronics and load simulation. Dimensions are L350 x W125 x H210 mm, weight 5.9 kg, and operating pressure max is 120 bar.
2. 4WRPEH6 4/4 Directional High-Response Valve: Includes electric position feedback and integrated electronics. Dimensions are L199 x W125 x H150 mm, weight 4 kg.
1. DBDH6G1X/100 Pressure Relief Valve: Manual operation with a max operating pressure of 120 bar and set pressure up to 100 bar.
2. DR6DP1-5X/75 Pressure Reducing Valve: Direct operated with a max secondary pressure of 75 bar.
3. DBEE6-1X/50 Proportional Pressure Relief Valve: Pilot operated with integrated control electronics. Max operating pressure is 120 bar.
1. DV06-1-1X/V Throttle Valve: Manual operation with a max flow of 15 l/min.
2. DRV06-1-1X/V Throttle Check Valve: Features a color scale and manual operation.
1. S6A1.X Check Valve: Hydraulic operation with a max flow of 18 l/min.
2. S6A3.X Check Valve: Similar to S6A1.X but with a higher cracking pressure.
1. CD70F25/16-200 Single-Rod Cylinder: Features a protective housing and a piston ratio of 1.6:1.
2. Vertical Loading Unit: Simulates dynamic features of hydraulic systems with a load weight of 80 kg.
The document describes different types of hydraulic cylinders, including their dimensions, weight, mounting type, operating pressure, and specific features like zero leak quick disconnects and position feedback systems. Key specifications include cylinder stroke, load weight, and loading force.
Details are provided for bi-directional gear motors and axial piston units, including dimensions, weight, mounting type, operating pressure, speed, displacement, and oil flow capacity.
The document outlines the specifications for line-mounted filters and diaphragm-type accumulators, including material numbers, dimensions, weight, nominal pressure, and filter ratings.
Information on hydraulic distributors for grid and line mounting is provided, along with pressure gauges with various pressure ranges and measuring hoses.
Specifications for hose lines with quick disconnect couplings are detailed, including dimensions, weight, operating pressure, and minimess connections.
The document describes operating modules for installation in 19-inch racks, including distribution terminals, switch-buttons, and signal display modules, with details on dimensions, weight, operating voltage, and protection class.
The components are designed for high-pressure operations with zero leak quick disconnects, standardized connections, and safety features like bypass valves and visual clogging indicators. The system is suitable for simulating open and closed-loop positioning systems.
Various modules such as BPS8.1, BRS1.2, BRS2.1, BPS5.2, BPS6.1, BPS20, BPS21.0, BPS30.0, BPS3.1, and VRPA1 are described with their dimensions, weight, mounting type, division grid, operating voltage, and protection class (IEC 60529 IP50).
Include BRS1.2 and BRS2.1 with specifications like operating voltage (24V DC), response voltage, dropout voltage, continuous current, and protection class.
BPS5.2 and BPS20 provide command value generation with output voltage of +/-10V and are equipped with rotary switches and potentiometers.
BPS3.1 and VRPA1 facilitate connections to valves and signal values, with features like potentiometer settings, ramp time adjustments, and protection against reverse polarity.
- All modules are designed for installation into a 19-inch frame rack using screwed mounting type.
- Modules are equipped with contact-safe 4 mm laboratory sockets for secure connections.
- All modules conform to protection class IEC 60529 IP50, ensuring protection against dust and limited ingress of water.
- Some modules include features like short-circuit protection, cable break detection, and fault monitoring for enhanced safety and reliability.
- These modules are primarily used in hydraulic training systems, facilitating the control and monitoring of hydraulic components through electrical signals.
- They are suitable for educational and industrial applications where precise control and feedback are required.
These are used to close unused installation areas in a 19" frame. They are made of anodized aluminum, 2.5 mm thick, and come with captive screws. Various sizes are available, with dimensions ranging from L107 x W14 x H129 mm to L21 x W14 x H129 mm, and weights from 0.05 kg to 0.025 kg.
The document lists several types of solenoid cables, pressure switch cables, and connection cable sets. These cables vary in length, color, and presence of LED indicators. They are designed for specific electrical connections and have different didactic designations.
The document describes various measuring devices, including multi-meters, data acquisition sets, and tachometers. These devices are used for measuring electrical and hydraulic parameters, with features like LED displays, solar power, and data memory capabilities.
Includes pressure transducers, speed sensors, and temperature sensors. These sensors have specific measuring ranges and output signals, and are used for monitoring various parameters in hydraulic systems.
The document details control units and blocks used in mobile hydraulics. These components are designed to control hydraulic pressures and flows, with specifications on dimensions, weight, and operating pressures.
- Materials: Anodized aluminum, various cable materials. - Dimensions: Vary by component, detailed in the document. - Weight: Ranges from 0.025 kg to 19 kg depending on the component. - Operating Pressure: Up to 120 bar for hydraulic components. - Electrical Connections: Various standards including DIN 43650 and M12.
The document serves as a comprehensive guide to the components of the DS4 Hydraulic Training System, providing essential specifications and descriptions for each part, aiding in the understanding and assembly of the system.
Catalog excerpts
Bosch Group Drive & Control Academy
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Bosch Rexroth AG | DS4 Hydraulic Training System The data specified above only serves to describe the product. No statements concerning the suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of use of their own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging. © This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to...
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Introduction DS4 Hydraulic Training System | Bosch Rexroth AG 3 Drive & Control Academy 4 Hydraulic Training System DS4 6 Hydraulic power unit 36 Proportional valve technology 60 Mobile hydraulics 69 Measurement technology 135 Mobile hydraulics 139
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4 Bosch Rexroth AG > OS4 Hyd'a* - the decis\ve competitlve advantage Training Training Systems Knowledgi Portal & Control Technologies
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DS4 Hydraulic Training System | Bosch Rexroth AG Bosch Rexroth is one of the leading global specialists in drive and control technology and has unique technology know-how. This knowledge is passed on by the Drive & Control Academy and supports customized training and further development as well as the qualification of technical experts. Knowledge is everything Training systems a company with a decisive advantage in global competition. with practice-oriented knowledge in the areas hydraulics, pneu- Technical knowledge and competence of its employees provides Under the umbrella of the Drive & Control...
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Bosch Rexroth AG | DS4 Hydraulic Training System Rexroth’s technical know-how and solution competence in the area of industrial applications are smoothly integrated into the modularly structured training systems - in this way, they perfectly satisfy the quality levels demanded by industry. Rexroth training systems Bosch Rexroth training systems are based on standard components from the various Bosch Rexroth product areas. A complete training system consists of the hardware and the training and project manuals for trainers and trainees. By means of the training systems, both newcomers and advanced...
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DS4 Hydraulic Training System | Bosch Rexroth AG ► Hydraulics: Two independent work stations are possible by mounting a grid on each side ► Pneumatics: Two independent work stations are possible via a central grooved plate or one grooved plate on each side ► Hydraulics / pneumatics combined: Two independent work stations are possible by mounting a central grooved plate and one grid or via grooved plate on one side and a grid on one side. Expandable for additional study topics In order to achieve your training targets, you can tailor your training system to your requirements. ► On/off hydraulics ►...
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Bosch Rexroth AG | DS4 Hydraulic Training System
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DS4 Hydraulic Training System | Bosch Rexroth AG 9/158 Work stations
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10/158 Bosch Rexroth AG | DS4 Hydraulic Training System Table of Contents: Work stations Contents Page DS4 configuration - Examples ► DS4 training system for hydraulics, double-sided 12 ► DS4 training system for hydraulic and pneumatic systems 13 DS4 configuration - Description of the individual components (type key field) ► Product range - Product group + Series code (field1+2) 14 ► Connection block hydraulics (field 6) 24 ► Electrical device rack (field 7) 25 ► Electrical supply (field 8) 26-29 ► Measuring glass (field 9) 30 ► Hose storage (field 10) 31 ► Load...
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DS4 Hydraulic Training System Bosch Rexroth AG Work stations / DS4 configuration We configure your work station according to your requirements Assemblies of the DS4 work station according to the type key fields Type key field 1 + 2 Product: Range, Group, Series code 3 Frame 4 Grid 5 Substructure kit - Fixed storage unit - Power unit - Oil tray 6 Connection block hydraulics 7 Electrical device racks 8 Electrical supply 12 Oil drip pan / writing surface
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12/158 Bosch Rexroth AG | DS4 Hydraulic Training System This example configuration is suitable for training on industrial and mobile hydraulics. Both working sides are prepared for mounting hydraulic components. The power unit used has two pumps with variable displacement pressure compensated (load sensing) controllers, for completing independent exercises. The system includes: TS-DS4-1X/ Movable component support DS4 ProLine R Mounting frame for DS4 with mounting kit G2 Two grids with reinforcement for mounting to the DS4 U14 Load sensing power unit, 400 V/50 Hz; 2.2 kW; with double...
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DS4 Hydraulic Training System | Bosch Rexroth AG 13/158 DS4 training system for hydraulics and pneumatics Type: TS-DS4-1X/NG1U06V3A1E11M1S3L3T5-W Material no. R961006445 This example configuration is suitable for training on hydraulics and pneumatics. One working side is prepared for mounting hydraulic components and the other is prepared for mounting pneumatic components. The power unit used has one variable displacement pressure compensated pump. The system includes: TS-DS4-1X/ Movable component support DS4 ProLine N Central grooved plate for DS4 with mounting kit G1 Grid with reinforcement...
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14/158 Bosch Rexroth AG | DS4 Hydraulic Training System R961000160 Basis for all DS4 Work stations. Frame with two oil drip trays attached.
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DS4 Hydraulic Training System | Bosch Rexroth AG 15/158 Central grooved plate for DS4 with mounting kit Can be used to allow pneumatic training with the DS4. The grids can still be mounted for hydraulic training.
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16/158 Bosch Rexroth AG DS4 Hydraulic Training System Work stations / DS4 configuration - Description of the individual components Assembly of the DS4: "Grid" (type key field 4) Reinforced grid for mounting onto the DS4 Material no. With reinforcement for hydraulic components with 50 mm grid sections Dimensions Grid sections Steel, aluminum profile Grooved plate for mounting onto the DS4 Material no. With mounting bolts Dimensions Groove distance
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