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Introduction
This article contains everything you need to know about hydraulic lifts and their use.
You will learn
What is a Hydraulic Lift?
How a Hydraulic Lift Works
Hydraulic Lift Applications
Types of Hydraulic Lifts
Safety and Compliance Standards
And much more …
Chapter 1: What is a Hydraulic Lift?
A hydraulic lift is a lifting tool that uses the force of an incompressible fluid to move a piston to raise and lower a load. The design of hydraulic lifts is based on Pascal’s law for the generation of force that states that a change in the pressure of an incompressible liquid in a confined space is passed equally through the liquid. The force of a hydraulic lift requires a small amount of force being applied to the incompressible liquid to produce a great amount of force in the lifting mechanism.
To raise a hydraulic lift, oil is pumped into a cylinder that pushes a piston to raise the load. When the lift is to go down, a valve opens that releases the oil holding the piston that is pushed back into the lift’s reservoir by the force of gravity and the load lowers. Once the oil has been removed and contained in the reservoir, a valve closes keeping the oil from entering the cylinder.
The use of hydraulic lifts covers a why array of applications from lifting cars for repair to forklifts for moving loads in a warehouse. All of the different hydraulic systems follow the same principles with the main components being a piston in a cylinder, an oil reservoir, a pump, a motor to drive the pump, and the valve connected to the reservoir.
Chapter 2: How Do Hydraulic Lifts Work?
A hydraulic system is based on Pascal’s principle of fluid pressure, which hypothesizes that a change in pressure in a fluid is transmitted to all points of the fluid in all directions. With a hydraulic lift, an electrically powered pump pushes fluid into a cylinder at the base of a lifting jack system that lifts the platform up and down.
Hydraulic systems consist of a ram that slides inside a fixed cylinder with openings at the bottom for hydraulic fluid to enter and is designed to allow the ram to slide up and down. A cage is attached at the top of the ram and acts as a platform to carry people or goods. The pressure of hydraulic fluid, beneath the ram, pushes the platform upward.
When the hydraulic fluid is drained from the cylinder into a reservoir, the platform moves downward.
Hydraulic lifts are less expensive and take up less room than other systems. They can lift heavy loads effectively and efficiently without the need for overhead controlling mechanisms.
Chapter 3: Hydraulic Lift Applications
Hydraulic lifts are preferred over other types of lifting equipment for their reliability, safety factors, and ease of maintenance. The wide use of hydraulic lifts has been a major factor in the improvement of the performance of the supply chain regarding its speed, efficiency, and reliability. In every instance, in industry and warehousing, hydraulic lifts provide the force and power to complete jobs quickly and safely.
Loading and Unloading
In industrial operations, hydraulic lifts are used to raise heavy loads that cannot be lifted by any other means. Table lifts are used to position work materials to an ergonomic height for easy access. They provide support that otherwise would be handled manually. Forklifts, pallet jacks, and dock lifts are used to load trucks and position the dock for easy access to the truck bed.
Hydraulic lifts are capable of placing items wherever they are needed and can repeatedly load and unloaded materials as many times as required. They replace the need for manual lifting and moving and make the positioning and movement of heavy equipment and machinery safe and efficient.
Load Positioning
Several industries rely on hydraulic lifts to position loads for further use. In industrial settings, hydraulic lifts lift equipment for inspection, shipping, repair, and assembly. The construction industry relies on hydraulic lifts for a wide assortment of applications from carrying supplies from trucks to lifting workers to the various levels of a project.
In the mining industry, much like construction, hydraulic lifts are widely used for lift loads in open and closed pit mines as well as transporting minerals for shipping. A major factor regarding the use of hydraulic lifts in mining is safety since, in the past, miners have been seriously injured when lifting minerals manually. The safety factor is also the reason for the use of hydraulic lifts in aerospace where many of the components are oversized but need exact and accurate positioning.
Heavy Machinery
The movement of heavy cumbersome machinery is difficult, dangerous, and time consuming. It requires a great deal of planning and forethought. The size and weights of these types of loads make their handling a unique job that requires the greatest amount of force and power. In automotive factories, it is necessary to reposition hydraulic presses to accommodate changes in assembly operations. Large hydraulic lifts are used to support presses as hydraulic hoists move the presses.
Warehousing
At the center of all warehousing operations is a wide assortment and collection of lifting equipment that include gantries, AGVs, forklifts, pallet jacks, scissor lifts, and an array of other pieces of equipment. A common part of warehousing is the movement of materials, which may be light individually but are heavy when in a batch or load. In the past, warehouse tasks were performed manually and at the risk of injury. The implementation and use of hydraulic lifts has drastically improved efficiency and reduced the number of back, leg, and arm injuries.
Due to the introduction of hydraulic lifts, the number of warehouse personnel has decreased while efficiency and on time deliveries has increased. Although it can be said that automation is part of the reason for the change, included in the many robotic and automated pieces of equipment are hydraulic lifting devices capable of moving heavy loads, easily and effortlessly.
Manufacturing
There are several aspects of manufacturing that depend on the resilience and strength of hydraulic lifts. The most obvious and common application is providing parts and supplies for assembly operations using AGVs. Additionally, hydraulic lifts help position worktables, lift workers when working on large assemblies, move products from station to station on assembly lines, and assist welders rotate and tilt workpieces for processing. The key in all instances is the smooth and careful way that hydraulic lifts can change the nature of a load from a big hassle to an easy to maneuver workpiece.
The few applications for hydraulic lifts that are listed here are just a sampling of the many ways that hydraulic lifts benefit industrial, construction, and manufacturing operations by providing a safe alternative to manual labor. In addition to the standard types of hydraulic lifts, manufacturers work with their clients to custom design lifts that meet the needs of special applications that are outside the realm of normal hydraulic lift operations.
The 21st century has seen the rapid growth of the hydraulic lift industry due to the many innovations that manufacturers are discovering as well as the growing need to meet ergonomic standards and requirements. In all cases, hydraulic lifts are the key to safe, efficient completion of an application by providing the power and strength to complete otherwise hazardous or dangerous lifting processes.
Chapter 4: Types of Hydraulic Lifts
There are several types of hydraulic lifts, each of which is designed for a special function. They are lifting solutions that are designed to safely and ergonomically lift heavy loads efficiently and protect workers from serious injury. The operation of hydraulic lifts is dependent on choosing one that fits the specific needs of an application. Aside from the long list of available hydraulic lifts, manufacturers are able to adjust and customize their products to fit the requirements of special applications, such as hydraulic lifts making access to buses and vans easier or ones for lifting armored vehicles for the military.
Aerial Lift
Aerial Lifts, also known as aerial work platforms, are used to lift workers and equipment and include boom platforms, aerial ladders, articulating boom platforms, and combinations of each type. A common use for aerial lifts is at construction sites as a safety measure for lifting workers to a particular area or level. The term “aerial lift” is used in reference to elevated work platforms that are raised and lowered to position workers closer to a work area that is out of reach by normal means.
The wide use of aerial lifts has replaced the use of ladders and scaffolding due to their flexibility and mobility. The sturdiness of aerial lifts is due to their construction, which includes various metals and fiberglass reinforced plastics. Although pneumatic and electrical lifts are less expensive than hydraulic lifts, hydraulic lifts are the most resilient and long lasting of the three power types. They provide power, force, and exceptional durability in any conditions. Three common types of hydraulic lifts are scissor lifts, boom lifts, and manlifts.
As with so many types of heavy equipment, aerial hydraulic lifts are required by OSHA to be regularly inspected for personal safety and equipment maintenance to ensure the mechanism is operating up to acceptable standards. The main reason for the concerns and the need for inspections is the heavy loads that aerial lifts handle, which can cause several issues and potential failures.
Industrial Turntable
Hydraulic industrial turntables are a rotating platform with items stationed on the turntable at various intervals. As each item passes a production station, it is worked on before moving on to the next station. Hydraulic turntables come in different sizes and configurations and may be powered by a manual hydraulic system or motor powered hydraulic system. They are known for their low maintenance and their ability to rotate heavy, cumbersome, and oversized loads with efficiency and accuracy.
The capacity of hydraulic industrial turntables enables them to be used for rotating transformers and generators during handling and installation. The reversible hydraulic powered control rotates a hydraulic industrial turntable for precise positioning of its loads. Although the load capacity of hydraulic industrial turntables varies, high capacity models can manage loads as large as 1000 tons (907 metric tons). They have a graphite grease slide surface for low maintenance with cylinders that reset automatically during operation and a durable rubber top for better load contact and friction.
The drive piston for a hydraulic industrial turntable is connected to its rotating platform by a rod, which rests on its pivot point. In order for the turntable platform to rotate smoothly, it is mounted on a rotating carrier plate at the center of which is the pivot point. The rotating carrier plate is where the graphite grease is used on its slide surface.
Lift Table
One the most popular and widely used of hydraulic lifts is hydraulic lift tables, which are designed to perform a wide array of functions from raising forklift loads to positioning items that need assembly or repair. The surfaces of lift tables raise and lower loads to make changes to items easy by raising the items to a height that is optimally accessible.
They are ergonomically designed to eliminate the need to lift materials from the floor and provide a safe work space.
Hydraulic lift tables are a simple, portable, convenient, and effective method for handling loads, especially in conditions that can involve repetitive bending and lifting. Recessed lift tables that are placed in a pit in the floor make it possible for forklifts and pallet jacks to maneuver and place loads directly on the lift table surface for easy lifting and access.
As with other types of lifts, hydraulic lift tables are the most reliable and cost effective type of lift table. In most cases, they have scissor legs upon which a flat rectangular or square platform rests. The reason for the wide use of hydraulic lift tables, especially in industrial applications, is their ability to lift extreme or heavy loads and hold the loads for extended periods of time.
A hydraulic table is powered by hydraulic pressure that raises and lowers a rectangular or square table surface. They are scissor type lift that easily extends and retract. Hydraulic pressure moves a piston in a cylinder beneath the table connected to the scissor lifts that causes the table to go up or down as the pressure is increased or decreased in the cylinder. Hydraulic tables can be made to extend a few inches, a few feet, or more based on the requirements of an application. For less demanding applications, the lift mechanism is powered by pumping a foot pedal to generate hydraulic pressure.
Mobile Lift
Mobile lifts are used on construction sites to raise and lower workers or building materials. Some types of mobile lifts have four wheels and a motor that allow them to be steered and driven by an operator such that they can be moved and positioned conveniently. Other forms of mobile lifts have four supports and are positioned using a forklift or tractor. Mobile lifts are manufactured in a variety of styles with varying weight capacities and height abilities.
The key factor in the use of mobile lifts is their safety, which is unlike ladders and scaffolds. The weight capacity of mobile lifts varies from several hundred pounds up to thousands of tons, depending on the materials used to produce the lift and its lifting mechanism. The types of mobile lifts vary from ones that are used to raise automobiles for repair to ones on an articulating boom. The two basic types of mobile hydraulic lifts include scissor lifts that can reach several feet to articulated lifts that can reach and lift. The main characteristic of mobile lifts is their strength, durability, and versatility. They can be placed anywhere and are capable of withstanding the harshest conditions.
Scissor Lift
The various types of scissor lifts are constructed of very sturdy material with the majority being made of steel. They have a platform with railings and struts that support the platform. The name scissor lift comes from the shape of the struts that have the appearance of scissors opening and closing. The struts have an X pattern that increases the height of the scissor lift as more struts are added. The technical name for the X pattern is pantograph, which refers to a jointed framework with hinged and jointed rods. Scissor lifts are powered by a hydraulic system that can consist of one or more hydraulic cylinders depending on the highest point that the scissor lift can reach.
The typical lift height of a scissor lift is between 10 to 60 feet (3 to 18 meters) with the working height being between 20 to 40 feet (6 to 12 meters). Although these heights are the standard heights, specially designed scissor lifts are capable of reaching even higher. Depending on the type of scissor lift and its controls, mobile scissor lifts can be moved when extended, an action that is undertaken with great caution. The load level of scissor lifts varies from approximately 800 to 1000 pounds (363 kg up to 454 kg) with platforms that are 2 ft by 5 ft up to platforms of 5.5 ft by 10 ft (61 cm by 152 cm up to 168 cm by 304 cm).
Types of Hydraulic Scissor Lifts:
Scissor Lift Tables - Scissor lift tables have the same type of structure as larger scissor lifts but have one, two, three, or four sets of scissors depending on the weight of the loads they are required to handle, which can vary from motors and heavy machinery to boxes being unpacked for storage. They are designed to assist workers with repetitive tasks that may require bending and lifting. Their ergonomic design prevents back injuries and makes it possible to lift the work space to the best height for workers.
Mobile Scissor Lift - An additional type of scissor lift is a mobile scissor lift that can have wheels on the four corners of its supports or be sufficiently compact to be moved using a forklift. The versatility of mobile scissor lifts makes them a valuable tool in a wide range of applications from construction sites to large warehouses. Mobile scissor lifts have power controls that make it possible to move the scissor lift when it is in the raised position, which is ideal for use in warehouses during a picking process.
Dock lift
Dock hydraulic lifts are a part of shipping and receiving that position the loading and unloading platform to the level of the truck being unloaded. They line up the loading dock to the height of the bed of a truck. As with many hydraulic lifts, they are labor saving safety devices that protect dock workers from having to move loaded materials by hand. Dock lifts assist shipping and receiving by making loading and unloading efficient and help avoid damage to products and injuries to workers.
Hydraulic dock loading lifts can be permanently installed as a part of the dock or be portable for greater versatility and flexibility. They have vertical travel height of up to 60 inches (152 cm) to accommodate truck beds with the highest height. Made of hardened steel, dock hydraulic lifts are a strong, dependable, and convenient method for quickly receiving or shipping goods and materials.
The mounting of dock hydraulic lifts varies depending on the structure of the dock and the material it is made of. Most newly constructed docks have dock hydraulic lifts that are built into the dock in a pit that is below the level of the floor. Other versions and mobile dock hydraulic lifts sit on the floor requiring loads to be moved up and out and over the dock lift. Regardless of how they are installed, dock hydraulic lifts provide the same exceptional assistance.
Vehicle Lift
As with all hydraulic lifts, vehicle lifts move upward as the piston in the cylinder is forced upward. Hydraulic lifts are chosen over chain lifts because they are more compact, streamlined, and have fewer moving parts. The various designs of vehicle lifts include two post, four post, scissor lifts, and pit or in ground lifts.
Mechanics prefer hydraulic lifts due to their reliability, power, strength, and durability. Hydraulic vehicle lifts make equal contact with four points on a vehicle to ensure that the vehicle will not tip forward or backward while in vertical motion. Additionally, hydraulic lifts are a safe solution for raising a vehicle for repair since they seldom fail and provide a strong sound foundation.
Two post hydraulic vehicle lifts are the simplest version of vehicle lifts and are the most common. They consist of two posts with arms that extend from the posts that have four contact points to support a vehicle. They are very compact and can fit into any repair shop.
Four post hydraulic vehicle lifts are the most stable of the vehicle lifts. They are similar to two posts lifts in that they use posts but have two sets of posts instead of one set. Each of the posts has an arm that extends out to support a vehicle. With four post hydraulic vehicle lifts, it is very unlikely that a vehicle will be able to tip forward or backward. Unlike two post vehicle lifts, four post vehicle lifts take up more room and are used in large repair shops.
The final two hydraulic vehicle lifts are scissor lifts and in ground lifts. Scissor hydraulic vehicle lifts have a similar design to that of work platforms and mobile lifts with cross rods that open and close to raise and lower a vehicle. They are used due to their ability to lift vehicles higher. In ground lifts have been used for many years and rest in a pit that makes them level to the ground when not in use. In most cases, their platform has an H pattern with one or two hydraulic systems to lift a vehicle.
Small Hydraulic Lifts
Small hydraulic lifts are smaller than average industrial sized hydraulic lifts and are used for small scale applications and include pallet jacks, small lift tables, and car jacks. They are smaller than industrial hydraulic lifts but not as small as microhydraulics or mini hydraulics, which are used for very small applications that require extra power.
The typical small hydraulic lift can be a mobile hydraulic table that does not have a motor to power the hydraulic mechanism to lift its load but is powered by a manual pump. These tables are similar to a shopping cart with a flat surface in place of a shopping cart's basket.
Another form of small hydraulic lift is a compact hydraulic lift table that is designed for lighter loads up to 1000 pounds (454 kg). In most cases, they have a scissor lift design as an ergonomic solution for lifting lighter loads. Compact hydraulic lift tables can be on wheels or have a flat platform base depending on their design and use. The hydraulic system is operated by a pedal pump that raises the table’s one or two hydraulic cylinders.
In certain warehousing conditions and storage facilities, the distance between the rows of racks is limited making it difficult to squeeze a forklift or scissor lift down the aisle to pick items from the shelves. Small or mini scissor lifts that have a very small footprint are used in such cases that have a slim base and enough room for one worker. Due to the size of their base, such lifts are unable to rise very high but can get into tight spaces.
Pallet Lift
Pallet hydraulic lifts, known as pallet jacks and pallet trucks, are one of the best inventions in the history of warehousing. They are an efficient and easy method for moving pallets without necessitating the use of a forklift or manpower. The first pallet jack was patented in the 1930s. They consist of a long handle that serves as a means to move the pallet jack and a handle to pump the hydraulic cylinder that raises the two legs that support the pallet.
Made of various types of heavy material, pallet hydraulic lifts have sufficient power to lift pallets a few inches off a surface. They are an ergonomic tool that eliminates the need for workers to lift heavy materials by hand and make loading and unloading trucks faster and more efficient.
Although the traditional form of pallet jack can lift pallets a few inches off the floor for ease of transport, modern pallet jacks are more versatile, have larger hydraulic cylinders, can raise higher, and make it possible to position parts and materials for easy handling or repair. The flexibility of modern pallet jacks has made them an essential tool for warehousing, product movement, and the positioning of tools and equipment.
Portable Lifts
Portable hydraulic lifts take several forms with each type having some type of wheels and one or more hydraulic cylinders. They perform as portable workstations that make it safe to move products and materials at an ergonomically appropriate height for the user. Portable hydraulic lifts include lift tables, workstations, transporters, and workbenches.
Facilities with heavy machinery require maintenance and repair personnel to move to a piece of equipment. In the past, workers would carry a bag of tools with them to make the repairs, which may have required several trips in order to have the proper tools for the job. Portable hydraulic lift work tables and workbenches make it possible for personnel to bring their repair bench with them such that they can have on hand all of the tools required to finish a repair or adjustment quickly and efficiently as well as a surface to place any components.
Lift tables, workstations, and small forklifts are common forms of portable hydraulic lifts. Lift tables can be capable of lifting up to 500 lbs. (227 kg) to heights ranging between 28 in and 44 in (71 cm and 112 cm) and provide workers with a mobile adjustable workstation. Portable workstations can serve as worktables and assembly tables and provide a clean, sanitary surface to complete precision, delicate work. A unique form of portable hydraulic lifts are small, forklift like transporters capable of carrying 250 lb loads with a cantilever design for access to racks and machinery with a lift height of 48 in (122 cm) and a very small footprint.
The description of portable lifts above are a small sampling of the many portable hydraulic lifts that are designed for a wide variety of applications. Portable lifts include aerial hydraulic lifts, scissor lifts, and other forms of mobile hydraulic lifts.
Scissor Lift Tables
Scissor Lift Tables use scissor shaped arms that expand and contract when the table is raised or lowered and can have a motor powered hydraulic system or hand or foot pump system. They are widely used in industrial settings due to their lifting capacity, lifting speed, and exceptional strength and durability. Scissor lift tables have the same type of structure as their larger brothers with a cylinder, rods for the scissors, a firm base, and flat stable work surface.
The flexibility of positioning and ergonomic design make hydraulic scissor lift tables a valuable asset for improving worker performance and efficiency. Hydraulic scissor lift tables are heavy duty pieces of equipment that are designed to be used under tough challenging working conditions. They are capable of handling heavy vehicle parts and components of industrial machinery and are used on docks, factory floors, shipping ports, and machine shops.
The strength of hydraulic scissor tables is in their ability to be raised, lowered, adjusted, and manipulated repetitively during their use. Large batches of products can be loaded onto a hydraulic scissor lift table to be assembled or categorized. The various types of scissor lift tables include conveyor roller tables and rotating platform scissor lift tables.
Welding Positioner
While normal flat workpieces can be welded in the conventional way, round or tube shaped workpieces have to be constantly repositioned to reach the spots to be welded. Hydraulic welding positioners make it possible to easily weld round or tubular workpieces by rotating and tilting them for proper placement and positioning, which allows the welder to sit or stand while working on a level surface. Using a welding positioner increases efficiency, productivity and consistency while reducing worker fatigue, since welders do not have to move to reach the workpiece. Welding positioners increase the consistency and quality of welds.
The components of hydraulic positioners include a rotating table and tilting system with electronic remote controls. Hydraulic welding positioners can be free standing or welded to the floor for extra stability. The controller makes it possible to rotate the table of the positioner remotely for precise positioning and accuracy. Rotations can be clockwise or counterclockwise at adjustable speeds depending on the requirements of the workpiece with tilting available to achieve the positioning at any angle.
Hydraulic welding positioners are an ergonomic method for positioning heavy weight workpieces for welding. They are used for assembly work, machining, and welding. Their ability to be continuously adjusted for height, inclination, and rotation using remote controls minimizes workpiece handling and increases worker productivity. If a workpiece needs to be rotated during welding, a foot pedal control facilitates the procedure.
The workpiece is clamped to the rotating table of a hydraulic welding positioner using T grooves evenly placed in the table. While held secure, the rotating table is rotated and tilted by a spur gear transmission system that accurately positions the workpiece.
Personnel Lifts
Personnel lifts take several forms with each type having the basic function of lifting a person or persons to complete a task, place an item, or serve as an elevator to reach a level of a project. For power line repair, hydraulic lifts raise personnel to the height of the power line such that they can easily repair the line or perform regular maintenance. In the past, work that required an employee to reach a higher level was performed on a ladder or scaffold, which was dangerous, unstable, and time consuming. Modern efficiency has seen the advent of hydraulic lifts of multiple sizes capable of reaching any height depending on the design of the lift.
The purpose of personnel lifts is to give workers access to hard to reach places using a safe and secure lifting mechanism capable of handling heavy loads. There is some confusion regarding personnel hydraulic lifts since some versions are used in conjunction with a forklift. The misunderstanding relates to the structure of a forklift, which has two forks to lift pallets. When a forklift is used as a personnel lift, a special attachment is used that has safety rails, a firm base, and safety access gates. They are lifted by a forklift like a pallet. The drawback to forklift personnel lifts is the restrictions as to how high they can go.
Other forms of personnel lifts include scissor lifts, drivable platform lifts, and counterbalanced lifts, which are designed for a variety of applications. The typical personnel hydraulic lift is a scissor lift that has a rectangular or square platform with an entrance gate, solid platform, and safety rails. There are several types of scissor platform lifts that vary in size, heights, hydraulic power, and mobility.
Forklifts
Forklifts are material and supply chain tools that have been used for many years as a means for quickly lifting and transporting loads for assembly lines, loading and unloading trucks, warehouse organization, and the movement of heavy machinery. The term forklift is a generic term that applies to a wide assortment of forklifts that vary from small compact forklifts that can maneuver between warehouse racks to massive forklifts that are used to load ships and place boilers and generators.
The idea for forklifts originated in 1913 when material handlers were considering the idea of having a truck that could lift loads aside from transporting them. The original forklifts did not have the power and force of modern forklifts due to the absence of hydraulic power, which was added in 1920 followed by the addition of cantilever lifting. Over the years, electronics, tilting masts, different wheelbases, and solid joints were added that made the original forklifts look like modern forklifts.
Modern forklifts have taken a rather radical turn with the advent of AGV driven forklifts that do not require a driver and are able to be programmed to pick up and deliver loads. Regardless of this innovation, most present day forklifts are driven by a driver that uses various means to steer and position the forklift. Loads are lifted along the mast of a forklift using hydraulics and pulleys, regardless of the size and type of forklift.
One of the problems of forklifts in the middle of the 20th century was the fumes they emitted, especially for forklifts that were used in factories and were fueled by gasoline or propane. The use of batteries for forklifts began with pallet jackets and was added to forklifts to improve air quality.
Hand and Pedal Pump Lifts
The appearance of pedal and hand pump hydraulic lifts is similar to motorized lifts but with a smaller profile, such as small forks, smaller body, shorter mast, and powered by manual force. The lifting mechanism is powered by a hand pump with a release lever that lowers the load. Hand and pedal pump lifts are sturdy and maintenance free with the ability to lift one ton over six feet. Manually operated hydraulic lifts are operated by a long handle, level, pedal, or toggle as a means to activate the fluid in the hydraulic cylinder.
Although hand pump hydraulic lifts have a small footprint, they are available in several configurations and can perform some of the same tasks as motor powered hydraulic lifts but on a smaller scale. Personnel hydraulic lifts that can rise to 20 feet (6 m) can be powered by a hand pump. An old form of hand pump hydraulic lift is pallet jacks that have a long handle that is pumped to lift a load a few inches and drop a load by squeezing a handle on the pumping handle.
Hydraulic Upender
Hydraulic upenders tilt, position, and ergonomically move materials to the correct orientation for workers to use the materials. They can be tilted and rotated in both directions with limit switches and stops to precisely orient materials for use. Hydraulic upenders are another form of labor saving safety device specifically designed to prevent injuries and protect workers from unnecessary manual labor. The type of load an upender is required to move determines the number of hydraulic cylinders it will require with two hydraulic cylinders being very common.
Sometimes referred to as tilting tables or tippers, hydraulic upenders are capable of lifting heavy loads to a specified height and rotate or tilt the load for precise positioning. In the majority of cases, hydraulic upenders work in tandem with hydraulic forklifts that load the materials for use. One form of upender functions like a welding positioner without straps for holding the workpiece.
The work use of hydraulic upenders is for handling heavy loads and streamlining manufacturing processes especially in cases involving coils, which can be positioned faster using an upender than using an overhead crane. The types of hydraulic upenders include mold, coil, and die splitters. Hydraulic upenders are used by the auto industry, various types of manufacturing, die splitting, coil handling, injection molding, forging, and any industry that works with steel or aluminum.
Boom Lifts
Boom hydraulic lifts are a form of aerial lift with an articulated arm that can reach any height, depending on the design of the lift. They have a platform, bucket, cage, or some form of container for workers to stand to perform a repair, reach a level for construction, or make adjustments. A common use for boom hydraulic lifts is for the repair, positioning, maintaining, and installation of power lines. Over the years, boom hydraulic lifts have been found to be the safest and most efficient method for making power line repairs.
Although boom hydraulic lifts have been widely used with powerline crews, they have found use in other industries such as construction, particularly in large projects that involve great heights that cannot be reached by ladders or scaffolding. In warehousing, boom hydraulic lifts are used to maintain racking, load and unload shelves, and repair ceilings and rafters.
The many advantages of boom hydraulic lifts includes the heights that they can reach, which can be up to 210 feet (64 m), which is the height of a 17 story building and far higher than a scissor lift can reach. A key advantage of boom hydraulic lifts is their ability to reach inaccessible spaces at work sites. Although not necessarily an advantage, boom lifts are available in a wide range of platform sizes to fit the needs of any industry.
Vertical Mast Lift
Vertical mast hydraulic lifts, also known as one man lifts, vertical platforms, and personnel lifts, are a compact, lightweight piece of equipment that can compress into a small footprint but expand to several feet or meters high. They are used in a wide assortment of applications from manufacturing and industrial applications to construction sites and warehousing for placing inventory, delivering supplies, performing maintenance, and checking roofing.
One of the features of vertical mast hydraulic lifts is their compact structure made of sturdy lightweight aluminum that keeps the structure stable and safe. When they are retracted, they take up little floor space to be easily stored. Regardless of their size, vertical mast hydraulic lifts are the most versatile of hydraulic lifts. Their size and weight makes it possible to deliver a vertical mast lift at one location, perform a process, and return it to storage or to another location.
Part of the versatility of vertical mast hydraulic lifts is their many shapes and sizes, which makes it possible to find a vertical mast hydraulic lift for any application. The operation of a vertical mast hydraulic lift is similar to that of a scissor lift. The cross rods of a scissor lift are replaced on a vertical mast hydraulic lift by a multi-stage perscoping mast that holds a platform with guardrails at one end of the mast or periscope.
The types of vertical mast hydraulic lifts include many configurations and structures with some having forks for lifting heavy machinery while others have articulating arms to be able to reach into an enclosure of the floor of a building. Aside from their use to place workers in hard to reach spaces, vertical mast hydraulic lifts are used to deliver inventory, assist in cleaning buildings, and as a help for firefighters during high rise fires. The secure and safe platform that vertical mast hydraulic lifts provide makes them an ideal tool for work in high spaces.
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Chapter 5: Hydraulic Systems
Although the use of hydraulic systems varies by application, function, and design, the basic elements of a hydraulic system and how they operate are all the same for all types. In simple terms, hydraulic systems perform functions or tasks using a fluid under pressure, where pressurized fluid does the work and carries the load. The wide use of hydraulic systems is due to the amount of power that is produced by the pressurized fluid.
In a hydraulic system, pressure is applied to the contained fluid at any point in the system, which is transmitted undiminished throughout the system. The pressurized fluid acts on a piston in a contained vessel to create force and power. It is the force of a hydraulic system that makes it possible for workers to move and lift heavy loads with minimal effort and be able to easily complete repetitive tasks.
Blaise Pascal is credited with achievements in the fields of hydrostatics and hydrodynamics and the invention of the first hydraulic press that used hydraulic pressure to multiply force. He postulated Pascal’s Law or the Pascal principle of hydrostatics that states that fluid at rest in a closed container can incur high pressure change without loss to any portion of the fluid and to the walls of the container.
The key to hydraulic systems is its incompressible fluids, oils, and liquids that don’t squeeze when pressure is applied. In one form of a hydraulic system, there is a piston at one end of the system that compresses a liquid that is forced out through a narrow pipe from which it leaves at high speed. When the process is done in reverse where the incompressible liquid is pushed through a wide pipe, the result is force and power at a slower rate, which is a factor in lifting heavy loads. When a large piston on the wide end is six times larger than the smaller end of the pipe, the force at the smaller end will be six times as powerful. A 100 pound force at the wider end will produce 600 pounds of force at the narrow end, which is the principle upon which hydraulics work.
The essential parts of a hydraulic system include:
Reservoir - The reservoir is designed to hold excess incompressible fluid for powering the mechanism. It cools the fluid through its metal walls and allows trapped air to leave the fluid since air compresses and can interfere with the movement of the piston.
Incompressible Fluids - Hydraulic fluids take several forms but are typically petroleum and mineral or vegetable oils and have different properties based on their applications. Some of the properties of incompressible fluids include a high boiling point, lubrication, resistance to radiation, and viscosity.
Motor - The size of the motors hydraulic systems varies by the size of the machine being powered by the system. The motor is an essential part of the system since it allows the system to work.
Pump - The pump supplies oil to the hydraulic cylinder by sending a flow of oil through the valve into the cylinder. Its efficiency is measured in gallons per minute and pounds per square inch (psi).
Cylinder - Hydraulic cylinders, also known as actuators, generate the mechanical force in linear motion. The cylinder receives the high pressure fluid from the valves to create the movement of the piston.
Valve - Aside from transporting hydraulic fluid throughout the system, valves control pressure, direction, and flow.
Filter - Filters in a hydraulic system remove impurities and particulate matter from the fluid that can be damaging to the system. The fluid in the system is forced through a porous filter that is able to capture contaminants and removes them from the system.
Hoses - The hoses of a hydraulic system are tubes or channels that move hydraulic fluid to the vital parts of the system and are designed in compliance with the Society of Automotive Engineers (SAE) and EN Standards. They include hoses that are braided, multi-spiral, braided stainless steel, and thermoplastic hoses. Hydraulic hoses are chosen in accordance with the type of hydraulic fluid, the conditions, hose length and diameter, durability and flexibility, and their ends and couplings.
Directional Control Valve - The directional control valve directs the flow of the hydraulic fluid through the system by controlling when and where the fluid in the system flows. They control the pressure in the system by opening and closing, which happens instantly and causes the fluid to accelerate or decelerate and are selected in accordance with the working pressure of the system.
Hydraulic Cylinders
Hydraulic cylinders are built in a wide variety of sizes from micro cylinders that weigh a few ounces up to huge, massive cylinders capable of powering excavators and hoists. All forms of hydraulic cylinders have the same basic parts.
Piston - The rod of the piston extends through the head of the cylinder and retracts or extends by the force of the hydraulic fluid. It is tightly sealed to maintain pressure in the barrel of the cylinder.
Barrel - In order to maintain the pressure, prevent leaks, and contain the fluid for a hydraulic system, the barrel is made of a tube of seamless steel.
Cylinder Head - The head of the cylinder has bearings and seals that align the piston and keep the cylinder sealed.
The Base - Equipment that uses the power of a hydraulic cylinder are connected to the cylinder at the base. As with other aspects of a cylinder and an important part of their use, the base is tightly sealed.
Sealing Elements - The gaskets and seals of a hydraulic cylinder are dynamic and capable of withstanding the extreme pressure and high temperatures generated by a hydraulic system. They are made of an assortment of materials including Teflon, polyurethane, fluorocarbons, various pressure resistant metals, and nitrile rubber.
A hydraulic cylinder is 25 times more powerful than a pneumatic cylinder of the same size and can have a pump that produces 4000 psi. Since a hydraulic system is sealed and does not require additional fluids or liquids, it is capable of supplying constant force and torque with little need for maintenance.
Chapter 6: Safety and Compliance Standards
All manufacturing equipment have safety as their first consideration, which is an important factor in the operation, maintenance, and use of hydraulic lifts. Although they provide many benefits, they are still heavy duty equipment that require training, guidance, and maintenance to operate and have operators that must be trained and certified. During the installation and initial use of hydraulic lifts, manufacturers provide training, guidance, literature, and specifications regarding the safe use of the equipment. They are also available during the use of hydraulic lifts as a partner and support.
Since hydraulic lifts are designed to supply force and power, the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI) provide standards, requirements,and instructions regarding the safe operation of hydraulic lifts. Although neither organization is supported by legislation, they are highly respected by manufacturers who call upon them to offer help to their employees and certification.
OSHA
The focus of OSHA is on the dangers and hazards that involve employees. The work of the organization has drastically improved working conditions and guaranteed the safety of workers. In the case of hydraulic lifts, the critical standards are Standard 1926.451, Standard 1926.451, and Standard 1910.29
Standard 1326.451 - This standard is in regard to safety and health regulations for construction sites. It covers requirements for guardrails and protection from falls. The standard was originally written in regard to scaffolding but has been expanded and edited to include hydraulic lifts.
Standard 1910.29 - This standard is also in reference to guardrails and railings but includes standards for walking and working surfaces and covers fall system protection and protection from falling objects. Part of the specifications for standard 1910.29 includes references to the amount of weight a guardrail or railing must be able to withstand and their diameter.
Standard 1926.451 (g) - A portion of this standard makes reference to the types of guardrails that are required for scissor lifts and specifies the acceptable materials for guardrails and railings.
ANSI
Since scissor lifts are a popular form of personnel hydraulic lift, ANSI has published MH26.1-2020 in regard to scissor lifts that are raised and lowered by hydraulics. The standards include language in regard to personal injuries and accidents, criteria for design, manufacture, operation, and performance of scissor lifts. It further identifies who is responsible for the performance of scissor lifts and includes designers, manufacturers, owners, and operators.
ANSI B56.1-2020 - ANSI B56 1-2020 stipulates the standards in regard to forklifts and other lifting equipment. As with scissor lifts, B56 1-2020 has established standards regarding design, manufacturing, applications, operation, and maintenance of forklifts or low lift and high lift powered equipment. The essence of the standard is to promote safety and can serve as a guide for government inspectors regarding safety regulations.
ANSI A92 - ANSI A92 defines what an aerial lift is and specifies that an aerial lift must have two types of sensors with one to sound an alarm and another that triggers an alarm when the slope level is too steep. Chains may not be used as gates, and toe guards are required. Hydraulic lifts used outdoors must have a wind speed sensor and specially designed tires.
ANSI MH29.1-2012 - MH29.1-2020 has been revised as to how personnel can operate a hydraulic lift and be raised or lowered. As with other standards, it has details regarding the responsibilities of manufacturers, users, owners, and operators.
Certification
The standards for hydraulic lift certification have been published by OSHA and are available for a wide range of hydraulic lift equipment. OSHA certification is required for workers who operate lift platforms, such as aerial lifts, boom lifts, and scissor lifts. As with all aspects of OSHA programs, the purpose of the certification program is to protect workers and prevent injuries. To receive full certification, operators have to complete an OSHA approved course or can complete a course provided by an employer or owner of a hydraulic lift.
Chapter 7: Uses for Hydraulic Lifts
After reading about the types of hydraulic lifts and their regulations, it may be assumed that hydraulic lifts are specialized pieces of equipment that are used for complex operations such as construction, manufacturing, warehousing, and other industrial operations. Many hydraulic lifts are used in everyday applications from theme park rides to chairs and tables at the doctor’s office.
Theme Parks
Every theme park in the world relies on hydraulic lifts to lift customers and guests. They are the central tool for lifting customers on rides that look like Dumbo the elephant and whirl around like a dragon. Spectacular presentations that have performers lifted from ground level to several feet in the air are powered by hydraulic lifts. The world of entertainment relies on hydraulic lifts to present their illusions.
Aside from the pleasure they provide, hydraulics on theme park rides ensure the safety of guests and are able to provide the necessary force to enable them to handle the constant repetitive motion, which they do with precision and accuracy. Hydraulics ensure that every spin, push, pull, and lift is performed with a high level of control.
Elevators
Elevators have become so commonplace that their safety and operation are unquestioned. Although many elevators operate using metal ropes and counterweights, many modern elevators rely on the power of hydraulic systems, which are powered by a piston, cylinder, and electric motor that pumps fluid into the cylinder. The smooth ride of a hydraulic elevator is controlled by valves that release oil. The fluids used by a hydraulic elevator are the same as those used for other applications. The use of hydraulic elevators is limited by the heights they can reach, which prevents them from being used in high rise buildings.
Chairs
Dentist chairs, operating tables, and examination tables are raised and lowered using hydraulic systems due to their accuracy, safety, and stability. With hydraulic chairs used for medical procedures, the tables and chairs are powered by a hydraulic system that has a quietly operating motor. Other forms of lift chairs, such as barber shop chairs and beauty salon chairs, have a hydraulic system powered by a pump pedal that moves the hydraulic fluid into the lifting cylinder.
Film Production
Hydraulic lifts are a necessary and common part of film production and are used for positioning lights, cameras, lifting directors and personnel, and may be included in a production to create various illusions and dynamics. They are relied upon due to their safe method of operation and for the protection of film crews and performers.
Conclusion
A hydraulic lift is a lifting tool that uses the force of an incompressible fluid to move a piston to raise and lower a load. The design of hydraulic lifts is based on Pascal’s law for the generation of force that states that a change in the pressure of an incompressible liquid in a confined space is passed equally throughout the liquid.
Hydraulic lifts are less expensive and take up less room than other systems. They can lift heavy loads effectively and efficiently without the need for overhead controlling mechanisms.
Although hydraulic lifts provide many safety benefits, they are heavy duty pieces of equipment that require training, guidance, and maintenance to operate
Hydraulic systems vary by application, function, and design, but the basic elements of all hydraulic systems and how they operate are all the same.
There are several types of hydraulic lifts, each of which is designed for a special function. They are lifting solutions that are designed to safely and ergonomically lift heavy loads efficiently and protect workers from serious injury.
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