Hydraulics IOE

•Basics of Hydraulics
•Major applications in Earth Moving Equipment
•Major Components of Hydraulic System
•Hydraulic System Design
Basics of Hydraulics
y
y LIQUIDS HAVE NO SHAPE OF THEIR OWN.
y They acquire the shape of any container. Be cause of this, oil in a hydraulic system
They acquire the shape of any container Be‐cause of this oil in a hydraulic system
will flow in any direction and into a passage of any size or shape.
y LIQUIDS TRANSMIT APPLIED PRESSURE IN ALL
Q
DIRECTIONS.
y LIQUIDS ARE PRACTICALLY INCOMPRESSIBLE.
LIQUIDS ARE PRACTICALLY INCOMPRESSIBLE
y LIQUIDS PROVIDE GREAT INCREASES IN WORK
FORCE
FORCE.
y This principle helps you to stop a large machine by pressing a brake pedal.
1/2/2010 Satya Narayan Shah 2

HOW A HYDRAULIC SYSTEM WORKS
HOW A HYDRAULIC SYSTEM WORKS
1.
1 The PUMP which moves the oil.
which moves the oil
2. The CYLINDER which uses the moving oil to do work.
3. CHECK VALVES to hold the oil the oil flow.
h ld h l h l fl
4.
4 A RESERVOIR ((and its Ancillaries) ) to store the oil.
5. The CONTROL VALVE directs the oil flow.
6
6. The RELIEF VALVE protects the system from high
pressures.
7. G
Gauges show flow and pressure at various points.
h fl d i i
8. Accumulator (if fitted) smoothens the performance.
9. Filters to separate the contamination.
10.
0. Prime mover to drive the pump.
e ove to d ve t e pu p.
Drive unit
Drive unit
y Hydraulic systems are driven by motors (electrical
motors, combustion engines).
y Electrical motors generally provide the
mechanical power for the pump in stationary
hydraulics
y Combustion engines are generally used in mobile
hydraulics

ADVANTAGES
y FLEXIBILITY‐Unlike the mechanical method of power transmission where
the relative positions of the engine and work site must remain relatively
constant with the flexibility of hydraulic lines, power can be moved to almost
t t ith th fl ibilit f h d li li b d t l t
any location.
y MULTIPLICATION OF FORCE‐small forces can be used to move large
f g
loads.
y SIMPLICITY‐The hydraulic system has fewer moving parts, fewer points of
wear And it lubri cates itself
wear. And it lubri‐cates itself.
y COMPACTNESS‐The hydraulic system can handle more horsepower for its
size than either of the other systems.
y ECONOMY‐This is the natural result of the simplicity and compactness
which provide relatively low cost for the power transmitted. Also, power and
frictional losses are comparatively small.
frictional losses are comparatively small
y SAFETY‐fewer moving parts such as gears, chains, belt and electrical
contacts than in other systems. Overloads can be more easily controlled by
using relief valves than is possible with the overload devices on the other
l f l h bl h h l dd h h
systems.

DISADVANTAGES
y EFFICIENCY‐While the efficiency of the hydraulic
system is much better than the electrical system , it is
system is much better than the electrical system it is
lower than for the mechanical trans‐mission of power.
y NEED FOR CLEANLINESS‐Hydraulic systems can be
damaged by rust, corrosion, dirt, heat and breakdown
g y , , ,
of fluids. Cleanliness and proper maintenance are more
critical in the hydraulic system than in the other
methods of transmission.
y FIRE HAZARD‐
FIRE HAZARD Due to neglegence.
D l

APPLICATIONS

Major Components of Hydraulic System
j p y y
y Reservoir
y Tank
y Filters
Filt
y Pumps
y Valves
y Check Valves
y Directional Valves
y Relief Valves
R li f V l
y Hydraulic accumulators
y Cylinders/Motors

Hydraulic reservoir
y
yThe reservoir in a hydraulic system fulfils several
tasks.
y It acts as an intake and storage reservoir for the
hydraulic fluid required for operation of the
system;
y It dissipates heat;
y It separates air, water and solid materials;
y It supports a built‐in or built‐on pump and drive
I b il i b il d d i
motor and other hydraulic components, such as
valves, accumulators, etc.
l l t t

H d li
Hydraulic reservoir
i
y The reservoir consists of
y Reservoir body
y Intake and return lines
y Baffle and separating plate
B ffl d ti l t
y Ventilation and exhaust
y Magnetic plug
y The size of the reservoir depends on
y Pump delivery
p y
y The heat resulting from operation
y The volume of liquid
y The place of application
y The circulation time
y The size of the reservoir is not classified by its physical
Th i f th i i t l ifi d b it h i l
dimensions but its liquid capacity
y Reservoir size (litres) = pump (litres/min) x 3
( ) p p( / ) 3

Reservoir Volume of Reservoir
2 - 3 times delivery of
pump in 1 minute
Breather
Return Filler with filter
Connection
Pump
Return line
Level indicator
Access
panel
Suction line
Strainer
Drain Plug
Baffles

Reservoir Accessories
yHydraulic filter
yThe task of the filter is to reduce the contamination in the system to an
p
acceptable level in order to p
protect the various components
p from
excessive wear.
yFiller cap (breather cap)
yIt should be air tight when closed, but may contain the air vent which
I h ld b i i h h l d b i h i hi h
filters air entering the reservoir to provide a gravity push for proper oil
flow.
yOil level gauge
yIt shows the level of oil in the reservoir without having to open the reservoir.
yIntake filter
yIt is usually a screen that is attached to the suction pipe to filter the hydraulic oil.
yDrain plug
y It allows all oil to be drained from the reservoir.
y Some drain plugs are magnetic to help remove metal chips from the
oil.

y Baffle plate
g g
y It is located lengthwise through the centre of the tank
and is 2/3 the height of the oil level.
y It is used to separate the outlet to pump from the return
li Thi
line. This ensures a circuitous flow instead of the same
i it fl i t d f th
fluid being recirculated.
y The baffle prevents local turbulence in the tank, allows
The baffle prevents local turbulence in the tank allows
foreign material to settle, get rid of entrapped air and
increases heat dissipation.
y Suction and return lines
y They are designed to enter the reservoir at points where
air turbulence are least.
y They can enter the reservoir at the top or at the sides, but
their ends should be near the bottom of the tank
their ends should be near the bottom of the tank.
y If the return line is above the oil level, the returning oil
can foam and draw in air.

S ti
Suction and return lines
d t li
Suction line Return line

y Hydraulic filters
y The task of the filter is to reduce the contamination
in the system to an acceptable level in order to
protect the various components from excessive wear.
y Coolers
y In hydraulic systems, friction causes energy losses
when the hydraulic fluid flows through the lines and
components.
y This causes the hydraulic fluid to heat up.
y To a certain extent, this heat is given off to the
environment via the oil reservoir, lines and other
components
y The following cooling devices are available:
y Air cooler : difference in temperature of up to 25°C
p p 5
possible.
y Water cooler : difference in temperature of up to 35°c
p
possible.
y Oil cooling by means of air fan cooler : when large
quantities of heat must be dissipated.

y Heaters
y Heating elements or flow preheaters are
used for heating and preheating hydraulic
fluid.
fluid
y Heaters are often required to ensure that
optimum operating temperature is quickly
attained.
y This is to ensure that once the system is
Thi i t th t th t i
started up, the hydraulic fluid quickly
reaches the optimum iscosit
reaches the optimum viscosity.
y If the viscosity is too high, the increased
f i i d i i
friction and cavitations lead to greater
l d
wear.

Hydraulic Pumps
Hydraulic Pumps
y The pump basically performs two functions:
y It creates a partial vacuum at the pump inlet port. The
vacuum enables the atmospheric pressure to force fluid from
the reservoir into the pump.
the reservoir into the pump
y The mechanical action of the pump traps this fluid within
the pump cavities, transports it through the pump, and
p p , p g p p,
forces it into the hydraulic system.
y It is often assumed that pumps create pressure, but the
sole purpose of pumps is to create flow.
y Pressure is created by resistance to flow.
y A pump is a mechanism designed to produce the flow
necessary for the development of pressure.
y It cannot itself produce pressure, since it cannot provide
resistance to its own flow.

Hydraulic pumps
y p p
yThree basic types of hydraulic pump can be
yp y p p
distinguished on the basis of the displacement
volume:
yConstant pumps
y Fixed displacement volume
Fi d di l t l
yAdjustable pumps
y Adjustable displacement volume
yVariable capacity pumps
y Regulation of pressure, flow rate.

HYDRAULIC
U C PUMP
U FAMILY
HYDRAULIC
PUMPS
GEAR VANE PISTON
FIXED VARIABLE
EXTERNAL INTERNAL FIXED VARIABLE AXIAL AXIAL
BENT AXIS BENT AXIS
RADIAL
Hydraulic pumps
y p p
y Pump rating
y Rated by the amount of fluid that can be displaced for each
revolution of the pump shaft
y Specified in cubic inches or cubic centimeter per revolution
y Displacement is defined as the volume of oil moved or
displaced during each cycle of a pump.
y There are two forms of displacement :
• Non‐positive displacement
p p
• Positive displacement
y Positive displacement pump
y Delivers to the system a specific amount of fluid per stroke,
revolution or cycle
Hydraulic pumps yThe centrifugal pump
•Besides being positive displacement is an example of the
pumps, they are also categorized as non‐positive aspect, it
either: simply
i l moves theth
•Fixed displacement pumps fluid and allows for
Variable displacement pumps
•Variable
b k flow.
back fl
•Fixed displacement pumps move the
same volume of oil with every cycle.
•This
This volume is only changed when the
speed of the pump is changed.
•Variable displacement pumps can vary

the volume of oil they move with each
cycle - even at the same speed
speed.
•These pumps have an internal

mechanism which varies the output of
oil.
Fixed & Variable displacement pumps
y Fixed
y Fixed displacement pumps move the same
volume of oil with every cycle.
y y
y This volume is only changed when the speed of
the pump is changed.
the pump is changed
y Variable
y Variable displacement pumps can vary the
volume of oil they move with each cycle ‐ even
volume of oil they move with each cycle
at the same speed.
y These pumps have an internal mechanism
which varies the output of oil.
p
Types of hydraulic pumps
Types of hydraulic pumps
y Most pumps used on today’s systems are of three
Most pumps used on today s systems are of three
basic designs:
• Gear pumps
• Vane pumps
• Piston pumps
Pi
y All three designs work on the rotary principle; a
rotating unit inside the pump moves the fluid

Gear pumps
Gear pumps
y They are widely used because they are simple and
y y y p
economical.
y While not capable of a variable displacement,
While not capable of a variable displacement
they can produce the volume needed by most
systems using fixed displacement
systems using fixed displacement.
y Often, they are used as charging pumps for larger
system pumps of other types.
f h

External gear pump
y Gear pumps are fixed
displacement pumps
since the displaced
volume which is
determined by the
tooth gap is not
adjustable.

EXTERNAL GEAR PUMP
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36
EXTERNAL GEAR PUMP CHARACTERISTICS
Typical displacements to 250 cm3/r
Typical pressures to 250 bar
Fixed displacement only
Good speed range, limited indirect
drive capability, simple multiple
assemblies
Generally noisy
Good contamination sensitivity
Poor serviceability
Compact, low weight
Low cost.
Internal gear pumps
y The internal gear pump also uses two gears, but now
a spur gear is mounted inside a larger gear.
a spur gear is mounted inside a larger gear
y The spur gear is in mesh with one side of the larger
gear and both gears are divided on the other side by a
d b th di id d th th id b
crescent shaped separator.
y The drive shaft turns the spur gear, which drives the
larger gear.
g g

INTERNAL GEAR PUMP

INTERNAL GEAR PUMP CHARACTERISTICS
dd l l
Good speed range
Simple multiple assemblies
p p
Low noise
Good contamination sensitivity
Poor serviceability
Good fluid compatibility.
VANE PUMPS
•Vane pumps are fairly versatile pumps and can be
g
designed g double, or even triple
as single, p units.
•All vane pumps move oil using a rotating slotted rotor
with vanes fitted into the slots.
Two types of vane pumps are most often used:
Balanced Vane Pumps-The The rotor is driven by the drive shaft and
turns inside an oval rotor ring. The vanes are fitted into the rotor slots and are free
to move in or out. The pump has two inlet ports, located opposite each other. And it
has two outlet ports, also on opposite sides of the pump. Both sets are connected to
a central inlet and outlet.
Unbalanced Vane Pumps- The unbalanced vane pump uses the
same basic principle of a turning rotor with vanes working inside a fixed rotor ring.
However, the operating cycle only happens once each revolution. So this pump has
only one inlet and one outlet port. Also, the slotted rotor is now set offside in a
circular ring.

VANE PUMP PRINCIPLE

Balanced vane pumps
y The balanced vane pump is strictly a fixed displacement
type pump.
y In the balanced vane pump, the rotor is driven by the drive
shaft and turns inside an oval rotor ring.
y The vanes are fitted into the rotor slots and are free to
move in and out.
y Typical displacements to 200 cm3/r
y Typical pressures to 280 bar
y Fixed displacement only
y P
Provides prime mover soft‐start
id i f
y Simple double assemblies
y Low noise
y Good serviceabilityy

Balanced vane pumps
p p

BALANCED VANE PUMP

Unbalanced vane pump
y The unbalanced vane pump can have a fixed or a
variable displacement.
variable displacement
y It uses the same basic principle of a turning rotor
with vanes working inside a fixed rotor ring.
y However, the operating cycle only happens once
, p g y y pp
each revolution.
y So this pump has only one inlet and one outer
port.
y Al th l tt d t i
Also, the slotted rotor is now set offside in a
t ff id i
circular ring.

p p


Unbalanced variable vane pump
Unbalanced variable vane pump

VARIABLE VANE PUMP PRINCIPLE



VARIABLE VANE PUMP

MULTIPLE VARIABLE VANE PUMP

FIXED VANE PUMP CHARACTERISTICS
Provides prime mover soft‐start
Simple double assemblies
p
Low noise
Good serviceability.

VARIABLE VANE PUMP CHARACTERISTICS
Typical displacements to 10
cm3/r
/
Simple multiple assemblies
Range of pump controls
g p p
Low noise
Low cost.

Piston pumps
y Piston pumps are often favoured on modern hydraulic
Pi f f d d h d li
systems which use high speeds and high pressures.
y However, piston pumps are more complex and more
l d
expensive than the other two types.
y They can be designed for either fixed or variable
displacement.
y Most piston pumps are either:
• Axial piston pumps
p p p
• Radial piston pumps
y Axial piston means that the pistons are mounted in lines
parallel with the pump's axis (a line down the centre).
y R di l i t
Radial piston means that the pistons are set
th t th i t t
perpendicular to the pump's centre like the sun's rays.

Piston pumps ‐
p p introduction

Axial piston pump

Axial piston pump
Axial piston pump

Axial piston pump
Axial piston pump

Axial piston pump
Axial piston pump

Axial piston pump
Axial piston pump

Axial piston pump

Axial piston pump

FIXED AXIAL PISTON PUMP CHARACTERISTICS
Typical displacements to
500 cm3/r
Typical pressures to 350
bar
Multiple assemblies
li l bli
possible
High overall efficiency
Compact package.
FIXED DISPLACEMENT PISTON PUMP
Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)
VARIABLE DISPLACEMENT PUMP - MAX FLOW
STROKE
VARIABLE DISPLACEMENT PUMP - REDUCED FLOW
STROKE
VARIABLE DISPLACEMENT PUMP - REDUCED FLOW
STROKE
VARIABLE DISPLACEMENT PUMP - ZERO FLOW
STROKE
VARIABLE DISPLACEMENT PUMP - ZERO FLOW
STROKE
VARIABLE DISPLACEMENT PUMP - REVERSED FLOW

VARIABLE DISPLACEMENT AXIAL PISTON

FIXED AXIAL PISTON PUMP CHARACTERISTICS
Typical displacements to
500 cm3/r
Typical pressures to 350
bar
Multiple assemblies
li l bli
possible
High overall efficiency
Compact package.
Bent axis axial piston pumps
Bent axis axial piston pumps
y The swash plate does not turn but it can be tilted
back and forth.
y The angle of the swash plate controls the distance
Th l f th h l t t l th di t
that the pistons can move back and forth in their
b
bores.
y The greater the angle, the farther the pistons
travel and the more oil that is displaced by the
p
pump.p

Radial piston pump
y In a radial piston pump, the cylinder block rotates inside a circular
rotor.
y As the block rotates, centrifugal force, charging pressure, or
As the block rotates centrifugal force charging pressure or
mechanical action causes the piston to follow the inner surface of the
ring, which is offset from the centreline of the cylinder block.
g, y
y The pistons takes in fluid as they move outward and discharge it as
they move in.
y Displacements to 750+ cm3/r
y Pressure capabilities to 350/400 bar
y High noise level
y Sensitive to poor inlet conditions & contamination
y High overall efficiency
h ll ff
y Good life expectancy
y L
Large, bulky units
b lk i
y Good fluid compatibility
y Hi h t
High cost.
Piston pumps ‐
Piston pumps ‐ introduction

VARIABLE DISPLACEMENT RADIAL PISTON PUMP

CYLINDERS
y Piston‐Type Cylinders‐give straight move‐ment.
y SINGLE ACTING CYLINDERS give force only one way.
SINGLE‐ACTING CYLINDERS ‐ give force only one way
Pressure oil is admitted to only one end of the cylinder,
raising the load. An out side force such as gravity or a
raising the load. An out‐side force such as gravity or a
spring must return the cylinder to its starting point.
y DOUBLE
DOUBLE‐ACTING CYLINDERS ‐
ACTING CYLINDERS give force in both
directions. Pressure oil is admitted first at one end of the
cylinder, then at the other, giving two way power.
cylinder, then at the other, giving two‐way power.
y Vane‐Type Cylinders‐give rotary movement
y In a round barrel, the shaft and vane rotate as pressure oil
db l h h f d l
enters. Oil is discharged through the outlet hole in the
other side of the cylinder.
h id f h li d

Hydraulic accumulators
y
y Hydraulic accumulators are used for:
y Storing energy
y Absorbing shock
y Building pressure regularly
gp g y
y Maintaining constant pressure
y Types of hydraulic accumulators:
y Gas loaded accumulator
y Weight loaded accumulator
y Spring loaded accumulator

Types Hydraulic Accumulators
yp y
Weight loaded accumulators Gas loaded accumulators Spring loaded accumulators

Characteristics of hydraulic accumulators
y
yWeight loaded accumulator
yConstant pressure is obtained
ySpring loaded accumulator
S i l d d l
yCan be mounted in any position
yGas loaded accumulators
ythe selection and use of this
accumulator depends upon the
pressure and volume needs of the
d l d f h
system
PNEUMATIC ACCUMULATORS
y Uses inert gases like dry Nitrogen
g y g
y Oil and gas chambers are separated by
piston, bladder or diaphragm
bl dd d h
y Gas is compressed while excess oil is taken
during off load period and expands when
supplying oil to the system
y Failure of packing seal causes mixing of gas
and oil

Precautions for Pneumatic Accumulators
y NEVER FILL AN ACCUMULATOR WITH OXYGEN!
p
An explosion could result if oil and oxygenyg mix under ppressure.
y Never fill an accumulator with air. When air is compressed,
water vapor in the air condenses and can cause rust. This in turn
ma damage seals and ruin
may r in the accumulator.
acc m lator Also,
Also once air leaks
into the oil, the oil becomes oxidized and breaks down.
y Always fill an accumulator with an inert gas such as dry
nitrogen. This gas is free of both water vapor and oxygen; this
makes it harmless to parts and safe to use.
y Never charge an accumulator to a pressure more than that
recommended by the manufacturer. Read the label and observe
the "working
working pressure.
pressure "
y Before removing an accumulator from a hydrau-lic system,
y
release all hydraulic pressure.
p
y Before you disassemble an accumulator, release both gas and
hydraulic pressures.
y When
h you di disassemble bl an accumulator,
l make
k sure that
h dirt
di andd
1/2/2010
abrasive material does not enter any of the openings
Satya Narayan Shah 99
SPRING-LOADED
SPRING LOADED ACCUMULATORS
y In operation, pressure oil loads the piston by
compressing the spring .When
When pressure drops,
drops the
spring forces oil into the system.
y The accumulator can be used as a gradual pressure
builder for an automatic transmission. When the
transmission is shifted
shifted, pressure drops and the
accumulator sends a "surge" of oil in to "take up
slack " This fills the chamber behind the clutch
slack."
pistons. Then pressure builds gradually for a smooth
engagement of the clutch.
clutch
y By controlling the flow of oil to the accumulator, the
time needed to charge it can also be controlled

SPRING-LOADED
SPRING LOADED ACCUMULATORS
y The operation of spring‐loaded accumulators can be
varied by changing 1) the strength of the spring, 2) the
i d b h i ) h h f h i ) h
length of the spring, 3) the preload on the spring, 4)
the size of the piston or, 5) the length of the piston
)
stroke.

Hydraulic Valves
y
Hydraulic valves regulate
¾ Pressure
¾ Direction
¾ Volume
T
Types of valve
f l
¾ Pressure control valves
¾ Directional control valves
¾ Volume control valves

Pressure Control Valves (PCV)
( )
PCV are used to limit or reduce
system pressure
Unload a pump
Set the pressure
Examples of PCV are
Relief valves
Pressure reducing valves
d l
Pressure sequence valves etc
P l
Relief Valves
Relief Valves
y Used as safety valves
y Prevents the increase of system pressure
ffrom the specified pressure range
h ifi d
y Cracking pressure is the pressure at which
Cracking pressure is the pressure at hich
the relief valves first begin to open
e e e a es s beg o ope
y Full flow pressure is the pressure at which
the valve passes its full quantity of oil

Pressure Reducing Valves
y To keep the pressure in one branch of
circuit below than that of main circuit
y When not operating this valve is open
Wh t ti thi l i
y The spring tension can be adjusted using
screw
y This valve will limit maximum pressure in
the secondary circuit irrespective of
pressure changes in the main circuit

Pressure sequence Valves
To control the sequence of flow to various
b
branches of circuit
h f i it
Valves allow flow to a second function
only after a first has been fully satisfied
When closed, the valve directs oil freely
to the primary circuit
When opened, the valve diverts oil to a
p ,
secondary circuit
h d li d b i i
The second cylinder begins its stroke k
once first completes its stroke
Directional control valves
Directs the flow of oil in hydraulic
system
Types
¾Check valves
¾Spool valves
Check valves:‐
o One way valve
o Open to allow flow in one direction but close to
p
prevent flow in the opposite direction
o Mostly used to stop reverse flow
Spool Directional valve
p
yDirects oil to start, operate and stop
the actuating units on modern
h d li
hydraulic system
ySpool valve can be categorized by its
S l l b t i d b it
position and way of directing the oil
line
yFor example three position and four
p p
way valve
p


p

Volume control valves
Controls the volume or flow of oil
usually by throttling or diverting
¾Speed of cylinder or motor is
regulated by this valve
l t d b thi l
¾Mostly used in fixed displacement
Mostl used in fi ed displacement
type of valve

Hydraulic filter
¾Filters the contamination from the oil
¾It can be taken from the machine and
cleaned during servicing period. If
l d d i i i i d If
clogged bypass valve comes in action
¾Is generally cartridge type
s ge e a y ca dge ype
¾Hydraulic filter generally is in between
y g y
return line and tank

Hydraulic hoses
Hydraulic hoses
¾Carries hydraulic oil from one
y
component to the another in hydraulic
system
¾Are of high pressure and low as per the
oil flow line
il fl li
¾Flexible in nature
¾ Can be connected with another pipe
through coupling
h h li
¾Sometimes steel pipes can be used for
connecting two components if they are
closed to other
Hydraulic hoses

Hydraulic fluid
yThe hydraulic fluid is the transmitting medium of the
hydraulic system. It performs various tasks:
hydraulic system It performs various tasks:
y Transmission of hydraulic energy
y Prevention of corrosion of moving internal parts
y Removal of dirt, abrasive matter, etc
y Dissipation of heat
y Lubrication
y Sealing

Hydraulic fluid requirements
y Must not boil, vaporize or freeze within the
p y
temperature limits of the system
y Must not corrode the internal parts
y Vi
Viscosity must remain stable
it t i t bl
y Must be chemically stable
y Capable of resisting foaming
y Capable of separating from water
y Compatible with seals and gaskets
y Lubricating ability
y Oxidation resistance
y Load carrying capacity

y Too high a viscosity increases friction, resulting in :
y High resistance to flow.
y Increased power consumption due to frictional loss.
Increased power consumption due to frictional loss
y High temperature caused by friction.
y Increased pressure drop because of the resistance.
y Possibility of sluggish or slow operation.
y Difficulty in separating air from oil in reservoir.
y p g
y Greater vacuum at the pump inlet, causing cavitation.
y Higher system noise level.
g y
y And should the viscosity be too low :
y Internal leakage increases.
I t l l k i
y Excessive wear.
y Pump efficiency may decrease, causing slower operation of the actuator.
Pump efficiency may decrease causing slower operation of the actuator
y Increased temperature result from leakage losses

Types of hydraulic fluids
Types of hydraulic fluids
yPetroleum oil
yFire resistant fluids
• Water glycols
• Water‐oil emulsion
Water oil emulsion
ySynthetic oil

Typical hydraulic circuit
yp y
. Control valve
Pressure Relief R.H. Cylinder

L.H. Cylinder Valve
Main pump
Hydraulic filter
Tank

Design of a simple hydraulic system
Design of a simple hydraulic system
y When designing a simple hydraulic system, we
need to calculate the following:
y Pressure, force and area
Pressure force and area
y Speed of an actuator
y Flow velocity in pipes
y Pipe size requirements
y Work, horsepower and torque
y Reservoir sizing
R i i i

Pressure indicates work load
y Resistance of a load generates pressure.
y Pressure equals to the force of the load divided
by the piston area.
y We can express this relationship by the general
formula:
y P = pressure; f = force and a = area
F
P =
A

Force is proportional to pressure
Force is proportional to pressure
and area
and area
y When a hydraulic cylinder is used to clamp or
press, its output force can be computed as follows:
y F=pxa

Computing piston area
y The area of a piston can be computed by this
formula
π
A=
A= 2
xd
4

Speed of an actuator
y How fast a piston travels or a motor rotates
depends on its size and the rate of oil flow into it.
depends on its size and the rate of oil flow into it
y To relate flow rate to speed, consider the volume
that must be filled in the actuator to cause a given
h b fill d i h i
amount of travel.
Volume = Speed x Area
Time
Volume
Speed = Time
Area

Velocity in pipes
Velocity in pipes
y The velocity at which the hydraulic fluid flows
through the lines is an important design
consideration because of the effect of velocity on
friction.
y Generally the recommended velocity ranges are:
• Pump inlet line = 0.61 – 1.22 metres per second
• Working lines = 2.13 – 6.10 metres per second

Pipe size requirements
y If the LPM and desired velocity are known, use
this relationship to find the cross sectional area:
this relationship to find the cross‐sectional area:
LPMx 16667
Area(mm ) =
2
Velocity(in mmper second)

yWhen the LPM and size of pipe is given, use this
formula to find what the velocity will be:
LPM x 16667
Velocity (mm per second ) = 2
Area (mm )
yAlternatively, the area can be obtained from the
selection chart.
chart

ySelect the proper
conductor internal
diameter if the flow
rate is known.
rate is known
yDetermine exactly what
y
the velocity will be if
the conductor size and
flow rate are known.

Work and power
Work and power
y When a force is exerted through a distance, work
is done.
y Work = force x distance
y Work is usually expressed in joules.
y For example, if a 50n weight is lifted 3m, the work
done is 150nm or j.
done is 150nm or j

Work and power
yThe previous formula does not take into
consideration how fast the work is done.
yThe rate of doing work is called power.
Forcex Distance Work

Power=
Power or
Time Time
yThe usual unit of power is the horsepower
((watt), abbreviated hp (w). (1 hp = 746 watts)
), p ( ) ( p 74 )
yOne watt is equivalent to 1 newton lifted one
metre in one second)

Horsepower in a hydraulic system
yIn the hydraulic system, speed and distance are
indicated by the LPM flow and force is indicated
by pressure.
yThus, we might express hydraulic power this way:
Th i ht h d li thi
Litres Newtons
Power = x
Minutes Square
q Metres

yBy changing the units, we get
LPM x bar
kW =
600

yThese horsepower formulas tell the exact power
being used in the system.
being used in the system
yThe horsepower required to drive the pump will
b
be somewhat higher than this since the system is
h t hi h th thi i th t i
not 100% efficient.
yThe formula is changed when the average
efficiency (η) is taken into account.
y
LPM x bar
kW =
600 x η
Horsepower and torque
Horsepower and torque
y The following are general torque
torque‐power
power formulas
for any rotating equipment:
9550 x kW
q
Torque =
rpm
Torque x rpm
kW =
9550

Margin of error
Margin of error
y When working on the formulas, we must take into
consideration the margin of error if it is given.
y Working pressure, p = operating pressure –
margin of error
i f

Reservoir sizing
Reservoir sizing
y For industrial use, a general sizing rule is used:
y T k i (li
Tank size (litres) = pump lpm x 3
) l

y Given the following:
• Load = 35 000N
• Distance = 0.5m
Distance 0 5m
• Operating pressure = 60 bar
• Margin of error = 10%
• Rate of raising load = 0.15 m/sec
• Flow velocity = 2.5 m/sec
• System efficiency = 90%

A
Area of piston
f it
Load is 35000 N
Pressure is 60 bar
Force 35 000
Area = = 5
= 0.0065 m2
Pressure 54 x 10

Velocity
yRate at which load is to be raised
= 15 cm/sec = 0.15m/sec
15 cm/sec 0.15m/sec
yWhich is equal to 9 m/min
q 9 /

R t f il fl
Rate of oil flow
y Rate of oil flow
R t f il fl = travel rate x area
t l t
y = 9 x 0.0065
y = 0.0585 m3/min
y = 0.0585 x 1000
litres/min
y = 5 5
58.5 litres/min
/

Wattage of motor
LPM x bar
kW =
600 x η
58.5
58 5 x 60
kW = = 6.5kW
600 x 0.9

I id di
Inside diameter of pipe
t f i
y To determine the inside diameter of the pipe if a
flow velocity of 2.5 m/sec is to be maintained.
y Using the nomogram, for 6.5 LPM and 2.5 m/sec,
U i th f 6 LPM d /
we get:
y Area of fluid conductor = 4 cm2

Diameter of hydraulic hose
yWith the area of fluid conductor being 4 cm2
yThe diameter of the hydraulic hose can be obtained:
y
π
x d 2
= 4
4
4 x 4
d =
π
d = 2.26 cm
Reservoir sizing
y Reservoir size
y Reservoir size = 58.5 x 3
y = 175.5 litres

Hydraulics IOE

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•Basics of Hydraulics

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Suction line Return line

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GEAR VANE PISTON

EXTERNAL INTERNAL FIXED VARIABLE AXIAL AXIAL

•Variable displacement pumps can vary

•These pumps have an internal

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1/2/2010 Satya Narayan Shah ANIMATION

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Weight loaded accumulators Gas loaded accumulators Spring loaded accumulators

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