Industrial Hydraulics – Project Manual
Bosch Rexroth AG
Imparting knowledge through project work • Project designation with short description of
the industrial application • Comparison of project exercises Bosch Rexroth AG/BIBB •
Component matrix • Overview of components • Safety aspects
Basic principles of hydraulics
System technologies/energy conversion • Simple hydraulic circuit • Symbols according
to DIN ISO 1219-1 • Circuit systems in the field of hydraulics • Demands placed on drive
elements • Physical basic principles • Hydraulic fluids • Filtration
Fundamental safety notes • 01 Hydraulic power unit • 02 Hydraulic pump/variable displacement pump characteristic curve • 03 Single-rod cylinder/pressure intensification •
04 Single-rod cylinder/flow • 05 Hydraulic motor • 06 4/3 directional valve • 07 Check
valve • 08 Check valve, pilot operated • 09 Throttle valve, adjustable • 10 Throttle check
valve • 11 Flow control valve • 12 Pressure relief valve, direct operated • 13 Pressure relief valve controls • 14 Pressure reducing valve • 15 Pressure switch • 16 Pressure switch/
hysteresis • 17 Hydraulic accumulator • 18 Regenerative circuit • 19 Rapid speed/creep
speed control • 20 Valve circulation control • 21 Commissioning, inspection, maintenance, troubleshooting, repair
RE 07008 General product information about hydraulic products from
Bosch Rexroth AG
The increasing importance of process-oriented working procedures, the growing complexity
and networking of new technologies as well as comprehensive, customer-oriented services
have resulted in the necessity to restructure industrial metalworking professions, which was
laid down in regulations in 1987.
Restructuring of industrial metalworking professions (source: DIHK 06/2004)
The requirements for core qualification are met by solving tasks set in the form of project
steps, which involve informing, planning, decision-making, executing, checking and assessing. Mastering and internalizing the multitude of qualifications finally results in the professional
competence to act.
Time frame – method (source: DIHT 06/2004)
Profession-specific specialized training
Interdisciplinary specialized training
over 21 months, including
specialized task in the
company’s field of
Training period (years)
Analysis of qualification
→ Training pattern
→ Time frame
In the sense of fields of
work/activities within the
context of professionspecific business
- Core qualifications
- Specialist qualifications +
Fields of activities
Core qualificationsIntroduction 2 Bosch Rexroth AG I RE 00845/04.07
Imparting knowledge through project work
The present Project Manual Industrial Hydraulics is intended for imparting the required specialist knowledge in the field of hydraulic control technology in practice-oriented applications.
Through the logically structured project work the trainee:
• is to understand the physical laws and technical interrelationships (area, pressure, force,
work and power),
• is to become able to explain the function, structure, practical operating principle and possible applications of hydraulic equipment,
• is to become able to read and understand symbols and circuit diagrams,
• is to get to know basic controls of hydraulics and assemble units according to prepared
• is to be made familiar with types, properties, requirements and application of hydraulic
The project tasks and project work described in the Project Manual Industrial Hydraulics provide trainers and trainees with information and instruments that will help them comply with the
demands made on the transfer of specialist know-how in the field of hydraulics.
The sub-objectives listed below, which are taken from the framework curriculum for vocational
training of industrial mechanics, are matched with the regulations for vocational training in
industrial metalworking professions dated 09.07.2004 (BGBl. I. S. 1502). The sub-objectives
listed refer to training objectives given for hydraulic control technology.
• plan and organize work sequences, check and assess work results,
• verify mechanical and physical variables,
• assemble and disassemble machines, equipment, fixtures and systems,
• commission systems and plants, including open and closed-loop control equipment, and
• carry out maintenance work and ensure the operability of technical systems,
• prepare technical documentation,
• apply standards and regulations for safeguarding the process and product quality and
contribute to continuing improvements in the work sequences in the company.
Industrial mechanics are mainly assigned to professional activities in the field of production,
assembly, maintenance and automation of technical systems. The fields of activities mentioned
before are dealt with in individual training sections. Within the fields of activities, the training
sections of the individual training years are based on each other.
In training section-oriented lessons the solutions required for project handling are not imparted
like in conventional lessons. The solution of the task set is worked out alternately in systematic,
technical and situation- or case-related training. In the course of the project work it should
be envisaged that the trainee can handle the projects on his/her own and under his/her own
responsibility and, whenever possible, in a team.
This brings the training contents closer to the trainee’s real world of experience, which enables
and simplifies imparting the professional competence to act in the lessons.
To solve a more complex project task, it may be required to impart the basic principles for this
project in systematic technical training.
Fields of activities
Training sectionsIntroduction 3 Bosch Rexroth AG I RE 00845/04.07
Training section 6, which is geared to hydraulic control technology, is described below.
Installing and commissioning
2nd year of training
Recommended time: 60 hours
The trainees are to install and commission control systems. They determine the control
components to be used and the functional sequence for controls on the basis of circuit
diagrams and other documentation for various component technologies. For this, they use
The trainees plan and realize the set-up of the control. They commission the control system
observing rules for safety at work. They develop strategies for troubleshooting and optimization of the control systems and apply them.
They document and present their results utilizing suitable user programs.
• Technology diagram
• Hydraulic power part
• Supply unit
• Flow of material, energy, information
• Electrical circuit diagrams
• Pressure fluids
• Pressures, forces, velocity, flow
• Operating modes
• Plant safety
The starting point of didactic-methodical structuring of the training situation in the individual
training sections is to be the business and work process in the vocational field of activities. This
is reflected in the formulation of objectives in the individual training sections. The objectives of
the training sections are the decisive factors for the structuring of the lessons and represent
the minimum scope together with supplementary contents.
The technical contents of the individual training sections are formulated generally and are not
listed in a differentiated way. The individual contents of the training sections are coordinated
with the training curriculum for in-company training.
According to § 7 of the regulations for vocational training in industrial metalworking professions
deviations from the training curriculum are permitted in terms of technical contents and time
schedule, in particular, where practical requirements necessitate this deviation.
The project tasks described in the Project Manual Hydraulics are structured so that the trainee
achieves the training objectives described in the project definition in 6 project steps:
(Training framework curriculum § 10 section 1 No. 10/Control technology)Introduction 4 Bosch Rexroth AG I RE 00845/04.07
competence to act
The objectives described are geared to the development of competence to act. The trainee will
develop his or her competence to act from the capability and willingness to solve tasks and
problems and evaluate results in a target-oriented manner, skillfully, methodically and independently on the basis of technical knowledge and skills.
The projects described in the project definition are oriented towards practical needs and are
characterized by a high level of conformity with customer orders from industry and trade. Customer orders represent complete activities and develop and promote the trainee’s professional
As mentioned before, the trainee is to work off the project task or the project order in 6
Based on the project definition, the trainee is to get a clear idea of the finished solution, including
any required details. This is achieved through a systematic analysis of the project documentation and, if required, by asking questions.
Possible questions: • What is to be done?
• Have I understood the task completely?
• Which hydraulic component/system is to be dealt with?
Planning means the theoretical preparation and anticipation of the concrete execution. In detail,
planning requires competence to handle the project order and to organize the project handling
Possible questions: • How to proceed?
• What knowledge is required?
• Which aids are available?
• Are there comparable applications in my company?
After the planning stage, the trainee determines the aids to be used, e.g. which data sheets are
required for coping with the project task. He/she decides on the sequence and the interrelationships of the individual project steps. Moreover, a decision should be made as to whether it
would be easier to solve the project task in a team.
Possible questions: • Which hydraulic components will be used?
• How can you know that technical data sheets are up to date?
• Have I utilized all available sources of information?
• Are the prescribed safety instructions at hand?
The order is to be executed according to the work instructions given in the chapter “order execution”, taking all safety notes into account. After a thorough preparatory phase, the trainee is to
carry out the project order largely on his/her own. After the solution was worked out in writing,
it should be verified or questioned, whether the right attempt at a solution was selected.
Depending on the project order, the possibilities of execution may be limited. This is valid, for
example, in the case of costly work in the field of information technology.
Possible questions: • Have I chosen the correct sequence?
The trainee must check intermediate results as early as during the execution stage, and finally
the result of the customer requirement. In some cases, the result can be compared with the
manufacturer’s documents. In the case of measuring exercises, it must be checked, whether the
measured results are realistic. The documentation should also be finally corrected, improved
and completed. This also includes the preparation of a final report. After completion, the trainer
makes a final check.Introduction 5 Bosch Rexroth AG I RE 00845/04.07
Possible questions: • Was the control properly installed?
• Has the project objective been complied with?
• Is the customer satisfied with the project result?
• Which documentation is required?
• Is the result completely documented in the correct order?
In the final evaluation phase, an external or self-evaluation is to be carried out on the basis of
a comparison of project order documents, the installed control and results of measurements
Faults, if any, and their causes must be analyzed and possibilities discussed as to how faults
can be avoided in the future.
The trainee must learn to assess his/her strengths and weaknesses and develop objective quality
standards for his/her acting, which ultimately leads to personal competence. The evaluation can
be finalized in a technical discussion, possibly also in a discussion with the customer.
For didactic reasons, we refer exclusively to trainees and trainers in the present manual. We
expressly point out that these terms include all persons involved in the basic and advanced
training: Instructors, teachers, project managers, etc., whether male or female.
In this manual, we do not give notes on procedural knowledge (explanatory knowledge). It is
the knowledge of how to achieve a certain result with which measures, procedures or processes – in this case, how the learning target can be reached.
The present manual must be understood as a tool for providing the required core and specialist qualification that must be imparted in an integrated form through independent planning,
executing and checking according to the regulations for vocational training in industrial metalworking professions.
The pictograms, which are used as recurrent symbols, are to transfer important information
as quickly as possible in the form of a simplified graphical representation and independently
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