HYDRAULIC

WELCOME
TO
BASIC HYDRAULIC
TRAINING
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 Hydraulic?????.
What do we mean by hydraulic?
Hydraulic systems are used in modern production and
manufacturing installation.

By hydraulic, we means the generation of forces and

motion using hydraulic fluid.

The hydraulic fluids represent the medium for power

transmission.

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 HISTORY OF HYDRAULIC

In 1795,Joseph Bramah,an engineer,invented the first

hydraulic press.This demonstrated that a low
force,acting over a long stroke,on a small
diameter piston could develop a pressure in a
fluid on contact with the piston.

If this fluid under pressure was allowed to act on the

face of a large diameter,short stroke piston,
a very large force would be exerted by this piston.

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 DEFINATION
• From Greek word -Hydro means FLUID
• Hydraulics is the science that studies the
behavior of fluids that stand still or move
(hydrostatics and dynamics)

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Typical application fields for
hydraulics :
• Construction machinery
• Excavator
• Elevating platforms
• Lifting & conveying devices
• Agricultural machinery
• Injection moulding
• Presses machine
 Advantages of hydraulics
• Transmission of large forces using small
component
• Precise position
• Start-up under heavy load
• Smooth operation
Disadvantages of hydraulics
• Pollution of environment
• Sensitivity to dirt
• Danger result from excessive pressures
• Temperature dependence (change in
viscosity)
Design Of A Simple Hydraulic Circuit (i)

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Design Of A Simple Hydraulic Circuit (ii)

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Design Of A Simple Hydraulic Circuit (iii)

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Go to HT- Other Application
Basic Principle
of Hydraulic
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Pressure due to external forces
F
If a force acts
on an enclosed liquid,
a pressure P is produced
which extends throughout
P the whole of the liquid.
The same pressure applies
at every point of the closed
system.

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 PASCAL’S LAW
The property of a liquid to transmit pressure equally throughout
itself is known as “Pascal’s Law ”,in honor of Blaise Pascal who
discovered it.
The mathematical expression which describes Pascal’s Law is
the same as that used to describe any pressure:

F
P (PSI) =
orce(lbs)

Area(in. ) 2

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COMPONENT
SYMBOL OF HYDRAULICS SYSTEM’S
COMPONENTS
ACTUATOR

• Tank FLOW CONTROL VALVE

• Filter DIRECTIONAL CONTROL VALVE

• Pump ACCUMULATOR
RELIEF VALVE

• Accumulator
• Valve
•
CHECK VALVE

Actuator
• Motor. Pam Motor
FILTER

TANK
 Hydraulic Reservoir

Mounting plate Filter/Breather Cap Function of a hydraulic reservoir

is to contain or store a system’s
hydraulic fluid.

Hydraulic reservoir consist of four

Oil Level Gage
walls (usually steel); dished
bottom;flat top with mounting
line;four legs;suction;return;and
Dished drain lines;drain plug;oil level
Bottom Clean out Cover gage;filler/breather cap;cleanout
cover;and baffle plate.

Drain Line Drain Plug

Return Line
Baffle Plate

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 TANK
Drain line 3 Micron Air Breather
with Water Removal Element
Pump Inlet line
Return line

Clean Out
Access Plate

Baffle Plate
Temperature / Sight Gauge Drain Plug
Inlet Filter

Figure 5-1 Typical industrial reservoir

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Filtered Breather Cap
Capacity of 2-3
Times Pump Flow Return Line
Sight Gauge Filter

Large Surface Area

for Cooling
Fluid Level Above
Pump Inlet
Clean-out
Plate

Pump Inlet Line

Baffles to Separate Magnetic Drain Plugs

Return Line from Outlet Line at Low Point(s)

Figure 5.2 Baffle plate controls direction of flow in tank

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 TANGKI
Kegunaan takungan
1. tempat menyimpan bendalir hidraulik
2. membebaskan udara terperangkap
3. sebarang bahan enap cemar boleh
dimendakkan.
4. Menampung sebarang kebocoran yang
berlaku di dalam sistem .
5. Menyediakan permukaan untuk
menyejukkan bendalir.
 PUMP
to circuit to circuit

Outlet Outlet

Inlet Inlet
Atmospheric Atmospheric
Pressure Pressure

Inlet Phase Output Phase

Figure 15-3 Positive displacement pump

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 PUMP
• Type’s of pumps:-
1.Gear
2.vane type
3.Piston
4.Screw
 Hydraulic Pumps
GEAR PUMPS
Gear pump generate a
pumping action
by causing gear to mesh
and unmesh.
Internal Gear Pump
Consists of one external gear which
meshes with the teeth on the inside
circumference of a larger gear.This pump
sometimes referred to as a gear-within-
External Gear Pump gear pump.
Both meshing gears have teeth on their
outer circumferences.These pumps are
sometimes referred to as gear-on-gear
pumps 24
 The most important feature of internal gear pumps is the very Important parameters
low noise level.Hence they are primarily used in industrial
hydraulic(presses,machines for plastic and tools, etc .)and in Displacement volume 3 to 250cm2
vehicles which operate in an enclosed space(electric fork-lift, etc .)
FUNCTION Operating pressure up to 300bar(dependent on
The gear rotor is connected to the drive.When the gear rotor and size
internal gear rotate,the space between the gear increases.The pump
“sucks” Range of speed 500 to 3000rpm
(dependent on size)
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External Gear Pump
Outlet

Volume on this side Driven Gear

decreases as gear
teeth mesh

Idler Gear Volume on this side

increases as gear
teeth unmesh

Inlet

Figure 15-9 External gear pump

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External Gear Pump
Vane pump

Vane pumps generate a pumping action by Ring

causing vanes to track along a ring.
Rotor

What a vane pump consists of?

Vane
1) Rotor

2)Vanes
Shaft
3) Ring

4) Port plate with kidney-shaped

inlet and outlet port.

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Vane pump
The stroke movement of the vanes
pump is limited by a ring with a
circular internal form.
Due to the off-center position of the
ring with respect to the rotor,the
volume is changed within the
displacement chambers.
The process of filling the
chamber(suction)and
emptying is in principle the same as
for double chamber vane pump.
Vane pumps generate a pumping
action by causing vanes to track
along a ring.

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PAM JENIS RAM@ MOTOR BILAH
(VANE TYPE)
Increasing Decreasing
Volume Volume
Inlet side Outlet side

Figure 15-13 Eccentricity between rotor and cam ring

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 Vane

Cam Ring

Rotor

Figure 15-12 Basic pumping elements of a vane pump

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 PISTON PUMPS

Stroke Stroke Stroke

Inlet Inlet Inlet

Outlet Outlet Outlet

Figure 15-41 Pump displacement is based on swash plate angle

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 Full Stroke

Yoke Actuating Piston

Yoke
Swashplate
Pressure
Compensator

Figure 15-40 Cross section of an in-line piston pump

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 Cylinder Block
Case Drain
Swash Plate

Outlet

Rotation

Spherical Washer
Inlet
Shoe Retractor Plate
Piston
Pre-Load Spring

Figure 15-32 An in-line piston pump

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SCREW PUMP
Directional Valve:Symbol
Development

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Draw valve symbol
Directional Valve:Symbol Development
Valve switching position
are represented as squared

The number of squares shows how

many switching position the valve has.
Lines indicate flow paths,arrows show
the direction of flow.

Shut off position are identified in the boxes

by lines drawn at the right angle.
The connection (inlet and outlet ports)are shown
be lines on the outside of the box and are drawn
in the initial position. 40
 Directional Control Valves are classified
as follow according to the number of port
Number of ports
A Number of switching position
2 / 2 Way Directional Valve
P
A 3 / 2 Way Directional Control Valve
Normally closed
P T
A
3/2 Way Directional Control Valve
P T
Normally open

A B
4/2 Way Directional Control Valve
P T
A B
4/3 Way Directional Control Valve
P T 41
 Port Designation
A
2/2 - way valve
P P pressure port
A
T return port
3/2 - way valve
P T
A
A B
4/2 - way valve
working port
P T B
A B
4/3 - way valve
P T
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How this valves can be actuated??

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 Methods Of actuation

Manual operation

General symbol with spring

return and bleed port

By manual push button and

spring return

By hand lever

By hand lever with detent setting

By pedal and spring return

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 Methods Of actuation
Mechanical Actuation

By stem or push button

By spring

By roller stem

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Pressure Relief Valve

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 Pressure valve
The position of the valve within the square indicates whether
the valve is normally open or normally closed.

A A P P

or or

B B T T
open closed

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Flow Control
Valves

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 Flow control valve

Throttle Orifice

A B A B

set
set

A B A B

adjustable adjustable

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Non Return Valves

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Non Return Valves

FUNCTION

Non return valves are used in hydraulic

system to stop flow in one direction

and to allow free flow in the opposite

direction.They are known as check valve.

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 Check Valve
Symbol

Outlet Inlet
Port Port

Spring Poppet

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 Check Valve
Symbol

Outlet Inlet
Port Port

Free Flow
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 Check Valve
Symbol

Outlet Inlet
Port Port

No Flow
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 Basic
Check Valve
Ball Type

No Flow

Free Flow

Figure 8-2 A check valve is a one-way valve. Ball type is shown

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(ACCUMULATOR)
1. Holds system under pressure (w/out
contin. pump)
2. Provides hydraulics when pump
off/lost
3. Compensates for leakage/makeup
volume
 Gas Valve

Nitrogen Gas
Bladder

Anti-Extrusion
Valve Shell

Port

Figure 17-6 Bladder-type accumulator

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 1000 1000 1000
500 1500 500 1500 500 1500

0 2000 0 2000 0 2000

psig psig psig

System Pressure System Pressure System Pressure

Less Than pprecharge at pmax at pmin

Figure 17-7 Bladder accumulator operation

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Method of valve actuation (move)
HYDRAULIC
CIRCUIT
The advantages and disadvantages
of hydraulic system’s basic circuit:

• a. Opened center system

• b. Closed center system
 a. Opened center system
1. Pump-inlet and motor-return (via the directional ISO DIAGRAM
valve) are connected to the hydraulic tank.
2. Open center circuits use pumps which supply a
continuous flow.
3. The flow is returned to tank through the control
valve's open center; that is, when the control
valve is centered, it provides an open return
path to tank and the fluid is not pumped to a
high pressure.
4. Otherwise, if the control valve is actuated it
routes fluid to and from an actuator and tank.
The fluid's pressure will rise to meet any
resistance, since the pump has a constant
output.
5. If the pressure rises too high, fluid returns to
tank through a pressure relief valve.
 b. Closed center system
ISO DIAGRAM
1. Motor-return is connected directly to the pump-inlet. To keep
up pressure on the low pressure side, the circuits have a
charge pump (a small gear pump) that supplies cooled and
filtered oil to the low pressure side.
2. Closed-loop circuits are generally used for hydrostatic
transmissions in mobile applications.
3. Advantages: No directional valve and better response, the
circuit can work with higher pressure.
4. Disadvantages: Large charge pumps is thus very important
if the transmission is designed for high pressures and high
motor speeds. High oil temperatures is usually a major
problem when using hydrostatic transmissions at high
vehicle speeds for longer periods, for instance when
transporting the machine from one work place to the other.
High oil temperatures for long periods will drastically reduce
the lifetime for the transmission.
5. Closed loop systems in mobile equipment are generally
used for the transmission as an alternative to mechanical
and hydrodynamic (converter) transmissions.
 Kebaikan Sistem Pusat Terbuka
• Didapati sistem ini adalah lebih ringkas dalam
binaan dan mempunyai pelbagai kebaikan iaitu
tekanannya lebih rendah pada masa
pergerakan.
• Ini mengurangkan getaran dan hausan serta
mengurangkan tenaga disebabkan oleh
kebocoran apabila sistem berkeadaan neutral.
• Disamping itu ia mempunyai litar yang mudah
dan senang dibina.
• Ianya juga mengurangkan penyenggaraan.
 Litar Sistem Tertutup
• Dalam litar sistem tertutup, pam akan berhenti semasa injap kawalan
arah berada dalam keadaan neutral.
• Injap kawalan arah akan menghalang aliran minyak dari pam.
• Ini akan menyebabkan pam hidraul berhenti dari mengepam minyak.
• Pam akan dimatikan dengan memutuskan bekalan arus ke motor
yang memusingkan pam.
• Suis tersebut dikawal oleh tekanan minyak. Contoh litar sistem
tertutup adalah seperti ditunjukkan dalam rajah.
Litar sistem tertutup semasa
neutral
 KEBAIKAN SISTEM PUSAT
TERTUTUP
• Pam hanya bergerak apabila sistem memerlukan
minyak. Cara ini menjimatkan kuasa enjin apabila alat
hidraul digunakan.
• Minyak disimpan dengan tekanan yang tinggi untuk
tindakan cepat. Cara ini menjimatkan masa kendalian
(operating time).
• Kelambatan tindakan sistem hidraul dapat dikurangkan
dengan menyediakan minyak bertekanan tinggi untuk
tindakan segera berbanding dengan sistem pusat
terbuka di mana minyak hendaklah dirangkap sebelum
tekanan minyak boleh dinaikkan atau ditinggikan untuk
operasi .
• Jika sistem hidraul digunakan untuk membuat pelbagai
kerja dalam satu masa yang sama memanglah gerakan
sistem akan mengambil masa yang panjang untuk
meningkatkan tekanan ke tekanan sistem.
Steering Hydraulic’s System
• For sequence A+ B+ B- A-
movement.
1. Cylinder’s A extent, then
2. Cylinder’s B extent, then
3. Cylinder’s B retract, then
4. Cylinder’s A retract.
 Steering Circuit
Drilling work Gripper

B A

2
1
3 4
 Flow control at
hydraulic system’s actuators

• To control the speed of actuator

• Prevent sudden movement.
• Divided to THREE types:-
• Meter - Out
• Meter - In
• Bleed – Off
 Litar Meter – Out

• Figure shows a schematic drawing

of a meter-out flow control circuit
that restricts fluid as it leaves an
actuator port.
• Meter-out circuits work well with
both hydraulic and pneumatic
actuators.
• Cylinder-mounting attitude is not
important because outlet flow is
restricted and an actuator cannot
run away.
• Meter-out flow controls work on
resistive loads or running away
loads because the actuator can
never move faster than the fluid
leaving it allows.

Litar Meter – Out

pulling
 Litar Meter – In

• Figure provides a schematic

drawing of a meter-In flow control
circuit restricting fluid as it enters
an actuator port.
• Meter-in circuits work well with
hydraulic fluids.
• Note that the cylinder is
horizontally mounted, which
makes it a resistive load.
• Meter-in flow controls only work
on resistive loads because a
running-away load can move the
actuator faster than the circuit
can fill it with fluid.

Litar Meter – In
pushing
 Litar Bleed – Off
• Bleed-off flow control circuits are
found only in hydraulic systems.
• There is little or no advantage to
using this type flow control with
pressure-compensated pumps.
• Figure shows a bleed-off circuit
at rest with the pump running.
• A needle valve’s inlet is teed into
a line going to the cylinder and
its outlet is connected to tank.
• The circuit only works with one
actuator moving at a time
because all pump flow goes to
the presently operating function.
• Like a meter-in circuit, it only
works with resistive loads
because it controls fluid into the
actuator. Litar Bleed -Off