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BasicHydraulicTraining&Knowledge
SharingModule

ByManishBannore

Purpose:Toenhanceskill&avoidfailureaswellasbreakdown
oftheHydraulicsystem.

Content
1WhatisHydraulicSystem?
HydraulicsSystemistheapplicationoffluidtotransmitthepower
forgettingtheworkdone.Thusitconvertsthefluidenergyinto
mechanicalenergy.

2WhataretheadvantagesofHydraulicsSystems?
Smooth,jerkfreeoperation.
Overloadprotection(bypressurereliefvalve)
EasyreversemotionispossiblebyDirectionControlValve.
OperationspeedcanbecontrolledwithhelpofFlowControl
Valves.
Itiscompactsystemcomparedtomechanicalarrangements.
Suddenstopping&startingofanyoperationispossible,
withoutanyproblemtosystem.
Remoteoperationispossibleanycontroldesksituatedfar
awayfromthesystemcaneasilyoperateit.
Finecontrolofmotionispossible.

3WhatisPascalsLaw?
Pressureappliedonaconfinedfluidistransmittedundiminishedin
alldirections,andactswithequalforceonequalareasandatright
anglestothem.
4WhatisBernoullisTheorem?
In an incompressible & nonviscous fluid flow, the total energy
(pressure+potential+kinetic)perunitvolumeofthefluidremains
constantatanypointoftheflow.i.e.p+v 2+
g
h
Where, p = pressure, = density, v = velocity, h = height, g =
gravitational force. It is also known as the law of energy
conservation.
5WhatisViscosityofFluid?
Viscosityisresistancetoflowoffluid.Iffluidsfloweasilythenits
viscosityislow&fluidisthin.Afluidthatflowswithdifficultyhave
highviscosity&itisthick.


*Dynam ic(absolute)v iscosity:Itisthetangentialforceperunitarea
requiredtomoveonehorizontalplanewithrespecttotheotheratunit
velocitywhenmaintainedaunitdistanceapartbythefluid.
UnitofDynamicViscosityare:gm/cmsec,dynesec/cm2orpoise,
where
1poise=dynesec/cm2=grm/cmsec=1/10Pasec,
Forpracticalusethepoiseistoolargeanditsunitisdividedby100
intothesmallerunitcalledthecentiPoise(cP)i.e.1Poise=100
Centipoise.

*KinematicViscosity:Itistheratioofabsoluteordynamicviscosity
todensity.UnitofKinematicviscosityisStroke.1Stroke=104m2/
sec.sincetheStrokeisunpracticallargeunit,itisusuallydividedby
100togivetheunitcalledCentistroke(cSt).
1Stroke=100cSt
1cSt=106m2/sec

*Force:Forcecanbedefinedasaninfluenceonabodyorsystem,
producingortendingtoproduceachangeinmovementorinshapeor
othereffects.Theforcecanbecalculatedbytheformula:Force=
PressurexArea.UnitofforceisKilogramForce,Newtonetc.
1Kgforce=9.8Newton


*Pressure:Itistheforceperunitarea.Thecommonlyusedunitof
pressureiskg/cm2,foot/inch2(psi),megaPascal,baretc.
1kg/sq.cm=14.22334psi=0.098megaPascal=0.98bar

*Work:W heneveraforceorpushisexertedthroughadistance,work
isdone.
Work=ForcexDistance
Unitsare:NewtonMeter(Joule)

*Power:TherateofdoingworkiscalledPower.
Power=ForcexDistance=Work/Time
Time
Theusualunitofpowerishorsepower(hp).1hp=0.746
InHydraulic,Powerisdefinedaspowertransmittedbycontrolled
circulationoffluidunderpressuretomotorthatconvertsitto
mechanicaloutput,capableofdoingworkorliftingaload.Itcanbe
expressedasFlowxPressure.

6Whatarethefunctionsofahydraulicfluid?
Followingarethefunctionsofhydraulicfluid:
Transmittingthepower
Lubricationofthepumpparts,valvesetc,whichslide
againsteachother.
Sealingthesmallclearanceswithinthevalves.
Transmittingtheheatgeneratedinthesystemtothe
atmosphere.

7Whatshouldbethepropertiesofhydraulicfluid?
Followingarethedesiredpropertiesofhydraulicfluid:
Fluidshouldhavehighviscosity&itshouldbestablewiththe
changeintemperature.
Fluidshouldhaveappropriatepourpoint(pourpointisthe
lowesttemperatureatwhichafluidwillflow)
Fluidshouldhavelubricatingproperty.
Oxidationresistance:.Oxidationcausestheformationoffoam,
gum&sludgeandleadstovalvesstuck.
Rust&corrosionpreventionpropertiesaredesirabletoget
longerlifeofcomponents.
FluidshouldhaveDemulsibility,whichisthepropertyofafluidto
separateoutwater.Themixingofwaterresultsinstickingof
valvesandaccelerateswear.
Fireresistanceisanessentialpropertyoffluidforsafetyofentire
systemaswellaspeople.

8Whatiscontamination?
Contaminationisthepresenceofunwantedelements,whichcreate
negative/adverseeffectsonsystemperformance.Theseare:
AirbubblesinoilAirbubblesreduceoilfilmstrength,reduce
thermalconductivity,causethermaldegradationofoil&pitting.
Moisture/watercontaminationDisintegrateintohydrogenfree
radicalandinitiateoilpolymerization&acidification.Alsoalong
withmetalparticlesactsascatalysttooiloxidation.
SolidcontaminationMetalparticlescausethewearoutofthe
componentsandalsoactsascatalysttooxidation&acidification.
Carbon/sootoxidize&causestickingofthevalves.
Theeffectsofcontaminationdependuponvariousfactorslike
internalclearancesofthecomponents,systempressure,typesof
valvesetc.

Topreventcontamination,oneshould:

Openandremovecomponentscarefully,
 Keepnewpartscovereduntilreadyforinstallation,
Cleandebrisfromoilcoolers,tanksandotherareas,
Keephosescappedandplugged,whenremovedoropened.
Cleanhoses,tubesandpipingbeforeinstallation

*Howtoremovecontaminationfromoil?

Forremovingthecontaminationfromoil,filtersareprovidedat
differentlocationsassuction,pressureline,returnlineand
recirculation.Despitethat,itispossiblethatoilgetscontaminated.To
minimizetheproblem,wecanuseofflinefiltrationsystemsuchas
ElectrostaticLiquidCleaning(ELC)machine.
PrincipleofELC:Contaminationinoilareeitherpositivelyor
negativelychargedduetocontactpotentialdifferencewithoil.When
oilispassedthroughanelectricfield,positivelychargedparticlesare
attractedtothenegativepole&viseversa.
Neutralcontaminantsaredepositedbygradientforcetotheedgeof
thedieelectricmediawheretheintensityofthedeformedelectricfield
isthehighest.
Whencorrugateddieelectricmedia(collectors)areinsertedbetween
electrodes,theelectricfieldisdeformedanddieelectricpolarization
occursatthetipsofthecorrugation.Theelectricfieldisthestrongest
atthetipsandparticlesaredrawnanddepositedonoppositeelectric
polesandremovedfromoil.


*Howtoremovewaterfromoil?

Themoistureinoilcausesreducedservicelifeofcomponents.Soitis
necessarytoremovemoisturefromoil.Themostcommonmethodfor
thisisLowVacuumDehydration(LVDH).Inthissystem,theoilis
indirectlyheatedandfedintoavacuumchamberwhereitisdispersed
intoathinfilmtovaporizewaterandremovedissolvedgases.Theair
andthegasesthatevolvearecondensedandremovedfromoil

*HowtoCheckPressureOnline:

For checking the system pressure online, some arrangements like

minimess coupling to be provided in manifold blocks,nearcylindersor
tothecylinderchambersformeasuringrodend/pistonendpressure.

*Piping&Flushing:

Pipingisveryimportantfactorforahealthyhydraulicsystem.Proper
cleaning,sandblasting,degreasingandpicklingshouldbedonebefore
installation.Thepipesmustberoutedinsuchawaytocreate
minimumpossiblefrictiontominimizeheadloss.Properclampingmust
bedonetominimizevibrations.Thelinesmustbeproperlyflushed
withtheflushingoil.Theflushingoilshouldbeflownthroughthe
pipelines,withhighervelocity&pressurethanitsworkingvelocity&
pressure,toremovecontaminationfrompipeID.


9FluidSymbol:
Referattachedfile

BasicCkt

10WhatispowerPack?Whatareitsfunctions?
Powerpackisthetankwithpumps,valvesetcmountedonit,
thatholdsthesystemfluid.
FunctionsofpowerPack:Thebasicfunctionistoholdthesystem
fluid.Inadditiontothis,ithasfollowingfunctions:
Toactasaplatformformountingthepumps,motorsetc.
Coolsthefluidbyheattransferthroughitswalls.
Alsomountsheatexchangeronittocooltheoil.
Removestheentrappedairthroughbreather,mountedonit.
Facilitatesthefiltrationbyhavingfiltersmountedonit.

11Whatarevarioushydrauliccomponents?
Thehydrauliccomponentsrequiredtoperformvariousoperationsare:
Powerpack
Airbreathertoremovetheentrappedairfromthepowerpack&
maintainatmosphericpressure.
Heatexchangertocooltheoil.
Filterstocleantheoil.
Accumulatorsforcompensationofdamping/jerks.
Pumpstogenerateflow.
Differenttypesofvalvestoregulatepressure,flow&direction.
Cylindersoractuatorstoperformvariousfunctions.

12Whatarevarioustypesofpumps?
Thepumpsareoffollowingtypes:
Pistonpumps:Generallyusedforhighflow&pressure
requirements.
Gearpumps:Generallyusedforhighflow&lowpressure
requirements.
Vanepumps:Generallyusedformoderateflow&pressure
requirements

PistonPump:

The Hydraulic Piston Pump is one of the most versatile, efficient and stronger
pump that it is on the market in these days. Because of thewayitisdesigned,it
canbefixedorvariabledisplacement.

The variable displacement hydraulic piston pump has in general two major
components,therotatinggroupandthecontrol.

Therotatinggroupconsistsof:Pressureplate,P istonBarrel,P istons,Piston

Shoes,S washplateandDriveShaft.Thepistonstravelinsidethebarrelbores
suckingandpumpingoilwhiletherotatinggrouprotates.

TheControl,alsocalledc ompensatorisgenerallyanexternalelementattached
tothecase.Therearemanyvariationsofacompensator,someofthemvery
complex,butwecansaythatingeneralitcontrolsthemaximumpressure,the
flowthatthep umpdeliversandinothercasesthemaximumpower.

Thecompensatoriscapableofthosefeaturesbecauseitcontrolsthepositionof
theswashplate,orinotherwordsitcontrolstheangleoftiltingaccordingtothe
demandsoftheh ydraulicsystem.

Gearpump
A gear pump uses the meshing of gears to pump fluid by displacement.[1].
Gear pumps are also widely used in chemical installations to pump fluidwith
a certain viscosity. There are two main variations external gear pumps
which use two external spur gears, and internal gear pumps which use an
external and an internal spur gear.Gearpumpsarepositivedisplacement(or
fixed displacement), meaning they pump a constant amount of fluidforeach
revolution. Some gear pumps are designed to functionaseitheramotorora
pump.

24 Anexplodedv iewofanexternalgearpump
25 Theoryofoperation
As the gears rotate they separate on the intake sideofthepump,creatinga
void and suction which is filled by fluid. The fluid is carried by the gears to
thedischargesideofthepump,wherethemeshingofthegearsdisplacesthe
fluid. The mechanical clearances are small in the order of 10 m.Thetight
clearances, along with the speed of rotation, effectively prevent the fluid
from leaking backwards.The rigid design of the gears and houses allow for
veryhighpressuresandtheabilitytopumphighlyv
iscousfluids.
Pumpflowrate:inUSgal/min=DisplacementXrpm/231(displacementin
in3/revolution)

VanePump

Vane Pump Overview

Vane pumps can handle moderate viscosity liquids like fuel
oils, gasoline, and refrigerants. Vane pumps are available in a number of vane
configurations including sliding vane ,flexible vane, swinging vane, rolling vane, Vane
pumps are noted for their dry priming, ease of maintenance, and good suction
characteristics over the life of the pump

Despite the dierent

configurations, most
vane pumps operate
under the same general
principle described
below.
1. A slotted rotor is
eccentrically supported
in acycloidalcam.The
rotor is sealed into the cam by two sideplates. Vanes or blades fit within the slots of
the impeller. As the rotor rotates (yellow arrow) and fluid enters the pump and
pushrods push the vanes to the walls of the housing.Thetightsealamongthevanes,
rotor, cam, and sideplate is thekeytothegoodsuctioncharacteristicscommontothe
vane pumping principle.
2. The housing and cam force fluid into the pumping chamber through holes in the
cam (small red arrow on the bottom of the pump). Fluid enters thepocketscreatedby
the vanes, rotor, cam, and sideplate.
3. As the rotor continues around, thevanessweepthefluidtotheoppositesideofthe
crescent where it is squeezed through discharge holes of the cam as the vane
approaches the point of the crescent (small red arrow on the side of the pump). Fluid
then exits the discharge port.

13Whatarevarioustypesofvalves?
Thevalvesarebasicallyclassifiedintofollowing3groups:
Pressurecontrolvalves.
Flowcontrolvalves.
Directioncontrolvalves.

14Whataredifferentpartsofhydrauliccylinders?
Thehydrauliccylinderpartsare:
Barrel
Piston
Pistonrod
Gland
Pistonseal
Rodseal
Orings
Mountingarrangement.

15HowtofillOilintank?
Hydraulicfluidofanykindisanexpensiveitem.Alsochangingtheoil
orcleaningcompletesystemduetocontaminationistimeconsuming.
Soitisbettertopreventthecontaminationduringfillingtheoilinthe
powerpack.Sofollowingpracticeshouldbefollowed:
Oildrumsshouldbestoredproperlyundershedorroof.
Beforeopeningthedrumforfillingtheoil,drumtopshouldbe
cleanedthoroughlysothatdirtoranyothercontaminationmay
notmixwithoil.
Fortransferringtheoilfromdrumtopowerpack,onlyclean
containerorhoseshouldbeused.
Oiltransferpumpwithatleast25micronfiltercanbeused.
Provide200meshscreeninthereservoirfillerpipe.
Besurethatthefilterisintendedforusewiththetypeoffluid
requiredbythesystem.
Whilefillingtheoilinarunningsystem,portablefiltermustbe
usedasthenewoilcanalsohavecontamination.

16Whatcaresshouldbetakenwhileselectinghoses?
Workingpressure:Ratedworkingpressureofthehose
mustbemorethanthesystempressure,forwhichthe
hoseisrequired.
Burstpressure:Theburstpressureofanyhoseisits
destructivetestingpressure.Thismustbeconsidered
accordingtorequiredfactorofsafety.
Temperaturerange:Hosesshouldbeselectedaccordingto
thetemperatureencounteredbythesystem,internallyand
externally.
Fluidcompatibility:Itmustbetakenintoconsideration
thatwhichfluidistobehandledbythehose.Thehoses
 shouldnotgetdamagedduetochemicalpropertiesofthe
fluid.
MinimumBendradius:Whilefittingatthelocation,the
hosesshouldnothavebendtoaradiussmallerthan
recommendationofmanufacturer.Thiswillreducethe
capabilityofthehosetowithstandthepressure.
HoesSize:Therequiredflowshouldbetakeninto
consideration,whileselectinghosesize.IftoosmallI.D.of
thehoseisusedforagivenvolumeofflow,thenitwill
resultinexcessivefluidpressure&heatgenerationthat
canresultintubedamage.
Hoserouting&length:Routingofthehoseshouldbe
propertoavoidrubbingoranyotherchancesofgetting
damaged.Lengthshouldbeselectedconsideringthe
motionoftheequipment.

17Whatprecautionsshouldbetakenwhileworkingon
hydraulicsystems?
Toisolatesystembyclosingshutoffvalves
Isolateaccumulators&releasepressurefromsafety&shutoff
valve
Ifagainstgravityorsingleactingdepressurizefromminimess
WhileremovingcylinderAlwaysdisconnecthoses&allopen
pointswrapwithclothsotoavoidcontamination.
Neverusegascuttingsetonhydraulicpipelinesforcutting.
Theremaybechancesofaccident&fire.
Alwaysuseproperspannerfortightening/looseningofswivel
nut&fastener.
Alwayscleanvalves&actuatorbeforedismantling.
Plidentifyalllines&markedinviewtoavoidblunders.

18Whatarethepreventivemaintenancepractices/check
pointsinhydraulicsystems?

Checkhydraulicoilpressure
Checktempofhydraulicoil
Checkoillevelinthetank
CheckrunningoftheCirculationpump
Checkinlettemp(2930C)ofcoolingwater
Checkoutlettemp(4045C)ofcoolingwater
Check/CleanforUnwanteditemsinthesurrounding
Checkabnormalnoiseinmotor&Pump
Checkvibrationinpump
 Check/cleanpumpstation&valvestand.
Checkleakageinsystem.
Check&Changehydraulicfilterelement
CheckHydraulicactuators
Checkhoses,Pipelines,fittings.
Checkhydraulicsample.
Checkmotorcurrent
CheckCoupling
Checkpipelines&hosesforproperroutine,
Checkmountingofallcylinders
Checkconditionofclevis
CheckconditionofAirbreather.

19Whydohydraulicsystemsoverheat?

Heatingofhydraulicfluidinoperationiscausedbyinefficiencies.
Inefficienciesresultinlossesofinputpower,whichareconvertedto
heat.Ahydraulicsystem'sheatloadisequaltothetotalpowerlost
(PL)throughinefficienciesandcanbeexpressedas:

PLtotal=PLpump+PLvalves+PLplumbing+PLactuators
Ifthetotalinputpowerlosttoheatisgreaterthantheheatdissipated,
thehydraulicsystemwilleventuallyoverheat.

Toachievestablefluidtemperature,ahydraulicsystem'scapacityto
dissipateheatmustexceeditsinherentheatload.Forexample,a
systemwithcontinuousinputpowerof100kWandanefficiencyof
80%needstobecapableofdissipatingaheatloadofatleast20kW.
It'simportanttonotethatanincreaseinheatloadorareductionina
hydraulicsystem'scapacitytodissipateheatwillalterthebalance
betweenheatloadanddissipation.

.20Troubleshooting

S.N
Trouble ActiontobeTaken
.
Anypipingleakage Toreplacepipebytakingshutdownof
1
systemconsequentlyvent/Drainit.
Leakagefrom Tighten/replacefittings.
2
fittings
Pumpisleaking Fitnewpackingring/exchangepump.
3
fromsealondrive
 &drivenside.
DirectionalControl Tightthepipelines.Replacetheoringsif
4
Valveisleaking. leakingfrombase.
Hydraulicfilteris Renewgasketonfilter
5
leaking
Insufficientorno Pump,linesmayhaveleakage.Direction
pressure. ofrotationmaybewrong,Coupling
problem,Checkforsufficientoillevel,
6 pressurereliefsettingshouldbechecked,
ifalltheseareokthenthereischancethat
pumphavinginternaldamage.Then
replacethepump.
ExcessiveNoise Oillevelmaybetoolow,pump/motor
foundationbolts/pipeclampsmayhave
gotloosereliefvalveisnotgetting
7
unloaded,suctionfiltermayhaveclogged.
Ifallotherthingsareokthenthereis
chanceofpumpgettingdamaged.
Frequentloading& Theremaybesomeexternalorinternal
8 unloadingofthe leakageinthesystem.Itshouldbe
reliefvalve. checked.
Excessiveheating Heatexchangermayhavecloggedor
ofoil. water/aircirculationisnotproperthere
9
maybeinternalleakageitshouldbe
checked&rectified.
Contamination& ConnectELCorCentrifugetosystem
10 waterinfluid

Pressurerelief Removepr.Reliefvalve&cleanitIfthis
valveisdirtyor doesnothelpinstallanewvalveorinstalla
11 jammed/valve newspring&measurepressure.after
springisbroken installing.





21 BestMaintenancePractices:

22Thetopfourcausesofcylindersealfailure.

Hydrauliccylindersealscostthemanufacturerpennies.Theyare
usuallypurchasedonalowbidbasis.Butthatsimple,inexpensiveseal
cancostyouthousandsindowntimeandlossofproductionifitfails.If
youhaveaproblemseal,focusonthesefourpointstohelpdetermine
thecauseoffailure.

No.1Improperinstallationisamajorcauseofsealfailure.
Theimportantthingstowatchduringsealinstallationare:
(a) cleanliness,
(b) protectingthesealfromnicksandcuts,and
(c) properlubrication.
(d) Overtighteningofthesealglandwherethereisanadjustable
glandfollowerorfoldingoveraseallipduringinstallation.
No.2Systemcontaminationisaanothermajorfactorin
hydraulic seal failure. It is usually caused by external element suchas
dirt, grit, mud, dust, ice and internal contamination from circulating
metal chips, breakdown products of fluid, hoses or other degradable
system components. As most external contamination enters the
system during rod retraction, the proper installation of a rod
wiper/scraper is the best solution.Internal contamination can be
preventedbyproperfilteringof
systemfluid.Contaminationisindicatedbyscoredrodand
cylinder bore surfaces, excessive seal wear and leakage and
sometimestinypiecesofmetalimbeddedintheseal.

No. 3 Chemical breakdown of the seal material is most often the

result of incorrect material selection in the first place, or a change of
hydraulic system fluid. Misapplication or use of noncompatible
materials can lead to chemical attackbyfluidadditives,hydrolysisand
oxidationreductionofsealelements.Chemicalbreakdowncanresultin
loss of seal lip interface, softening of seal durometer, excessive
swelling or shrinkage. Discolorationofthesealcanalsobeanindicator
ofchemicalattack.

No. 4 Heat degradation is to be suspected when the failed seal

exhibits a hard, brittle appearance and/or shows a breaking away of
parts of the seal lip orbody.Heatdegradationresultsinlossofsealing
lip effectiveness through excessive compression setand/orlossofseal
material. Causes of this condition may be use of incorrect seal
material,highdynamicfriction,
excessiveliploading,noheelclearanceandproximitytooutsideheat
source.Correctionofheatdegradationproblemsmayinvolvereducing
seallipinterference,increasinglubricationorachangeoftheseal
material.Inborderlinesituationsconsideralluppertemperaturelimits
tobeincreasedby50degreesFinhydrauliccylindersealsattheseal
interfaceduetorunningfrictioncausedbytheslidingactionofthe
lips.

Here'sasecretitisnotnecessarytobuyreplacementsealsfromthe
originalhydrauliccylindermanufacturer.Manysealsuppliershavethe
sameexactsealsthatareusedinmosthydrauliccylindersandcan
easilycrossreferenceormatchupareplacement.Inmanycases,if
thereisarecurringproblemwithaseal,yoursealspecialistcan
recommendasolutionandincreasethelifeoftheseal.

23HydraulichosefailureCostsandprevention.

Hydraulichosehasafiniteservicelife,whichcanbereducedbya
numberoffactors.Fromamaintenanceperspective,littleorno
attentionisusuallypaidtothehosesofasystemuntilafailureoccurs.
Hosefailurescostmorethanthereplacementhose.
Additionalcostscaninclude:
*Cleanup,disposalandreplacementoflostfluid.
*Collateraldamagetoothercomponents,e.g.ahosefailureona
hydrostatictransmissioncanresultinlossofchargepressure
*Possibledamagecausedbytheingressionofcontaminants.
*Machinedowntime.
Focusonthefollowingpoints
ExternalDamage
Hosemanufacturersestimatethat80%ofhosefailuresare
attributabletoexternalphysicaldamagethroughpulling,kinking,
crushingorabrasionofthehose.Abrasioncausedbyhosesrubbing
againsteachotherorsurroundingsurfacesisthemostcommontype
ofdamage.Topreventexternaldamage,ensureallclampsarekept
secure,paycarefulattentiontoroutingwheneverareplacementhose
isinstalledandifnecessary,applyinexpensivepolyethylenespiral
wraptoprotecthosesfromabrasion..

MultiPlaneBending
Bendingahoseinmorethanoneplaneresultsintwistingofitswire
reinforcement.Atwistoffivedegreescanreducetheservicelifeofa
highpressurehosebyasmuchas70%andasevendegreetwistcan
resultina90%reductioninservicelife.Multiplanebendingisusually
theresultofpoorhoseassemblyselectionand/orroutingbutcanalso
occurasaresultofinadequateorunsecureclampingwherethehoseis
subjectedtomachineoractuatormovement.

24BasicofServoValves:

Servo valves provideclosedloopfloworpressureresponsetoanelectrical

or electronic control signal. They can be infinitely positioned to control the
pressure and direction of fluid flow. The distinction between servo valves
and proportional valves is servo valves provide a higher degree of
closedloop control. Both typesofvalveareusedforcontrolinpneumatics,
hydraulics, gas, steam, water applications. In a conventional openloop
force control system, servo valves output pressure is applied to the
hydraulic piston that drives the load. The controlled pressure may be the
differential between the two sides of the load actuator or it may be the
pressureinasinglelineconnectedtoonesideoftheloadactuator.
In servo valves, a given electrical signal producesadefinitepositionofthe
mainstage spool, but it does not necessarily produce a fixed flow. Flow is
afunctionofthesquarerootofthedifferencebetweensupplypressureand
load pressure. Thus, as load pressure increases, both flow and effective
pressuredropacrossthevalvedecrease.

Servo valves are available in one, two, or three stage designs. A single
stage is a directly operated (direct drive) valve. Two valve stages are
comprised of a pilot stage and final / main stage. Three stage valves are
similar, except that the pilot itself is a twostage servo valve. Three stage
servovalvesareusedinsituationswhereveryhighflowisanticipated.

Thefirststageofservovalvesisthehydraulicorpneumaticamplifier.This
stagemaybeoneoffourmaindesigns.Flappernozzle,jetpipe,force
motor,orsolenoid.

25Discussion&Visit.