BASIC HYDRAULICS n

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Welcome to Basic
Hydraulics Training
IGTR Training - Vijay Bankar Basic - Hydraulics

May 2, 2020 1
Training contents – IGTR
• Introduction
• Basic principles
• Hydraulic system structure
• Hydraulic Pumps
• Pressure control valves
• Direction control valves
• Check valves
• Flow control valves
• Actuators
• Exercises
May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 2

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Introduction:
• During the few decades various automation
techniques has been introduced in the field of
manufacturing in order to enhance the overall
industrial productivity.
• Among the various technologies that are playing
important role in rapid growth of Indian industries, fluid
power is unique.
• During past decade number of applications have been
developed based on Hydraulics.

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• Hydraulics plays an important role in industry because

they have wide application used in various industries
such as
• Automobile
• Marine
• Aircraft
• Machine Tools
• Mining
• Textile
• Water treatment
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• Oil & Petrochemical
• Food & Processing industry
• Control system
• Power transmission industries.
In tool engineering such as
• Tool Design
• Jigs & Fixtures
• Press Tools
• Moulds
• Die Casting Dies

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Choice of working media
• Compressed air (Pneumatics)

• Fluids (Hydraulics)
• Electrical & Electronics
• Combination of above

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Introduction to Hydraulics
“Hydraulics” this word has been derived from Greek word

‘Hydra’ which means water or fluid.
It is the branch of physics which studies about properties,

motion & behaviour of fluid
Hydraulics is of two types
- water hydraulics
- oil hydraulics

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Introduction to Hydraulics
Water hydraulics is used for

- aircraft arrestors during landing & takeoff
- on the ships to stop the aircrafts
- turbines
What we are going to discuss is oil hydraulics

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Reasons for rapid growth
Reliability
Minimal servicing
Flexibility in speed
Low Power consumption (if properly designed)
Choice of control
Smooth operations
Fast response time (compared to mechanical)
Low noise level
Minimal operating cost
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Difference between hydraulics & pneumatics
Hydraulics Pneumatics
It is used for larger forces 4000 to 5000 It is used for smaller forces 4 to 5 tons
tons
Slow speed 0.5 m/s High speed 1.5 to 3 m/s

Cannot be used above 100°C Can be used up to 200°C
More positioning accuracy (0.25 mm) Less positioning accuracy (1 – 2 mm)
Pressures can be more than 500 bar Pressures are 10 – 12 bars
Stroke is proportional to amount of oil Force is proportional to amount air entering

entering the cylinder to the cylinder
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Difference between hydraulics & pneumatics
Pneumatics video Hydraulics video

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Selection criteria for working media :
Force
Stroke
Type of motion (linear, swiveling, rotary)
Speed
Service life
Safety & reliability
Energy cost
Controllability
Storage

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Applications
Machine-tool construction is a
Lathe typical area of application
of hydraulics
.
With modern CNC machine tools,
the
. tools and work pieces are clamped
by hydraulic means.
Feed motion & the spindle drive can
Also be hydraulically powered.

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Press with elevated reservoir This is an application in which

extremely high forces are required.

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On this hydraulic excavator, not only

all working movements but also the
Propulsion of the vehicle are
.
Hydraulically powered.

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Military vehicles
Lifts
Elevating platforms
Aircraft applications
Ship building
Agricultural machineries
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Hydraulics:
Hydraulics is the term used when fluid (oil) is used as working medium
to transmit energy at different required pressures. Generation of
forces or motions by using the hydraulic fluids is possible in this
case.
Types of Hydraulics:
There are two basic types of hydraulics,
- Stationary Hydraulics
- Mobile Hydraulics
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Stationary Hydraulics:
• Stationary hydraulics is fixed at one station where all the activities

are carried out at the same station.
• Stationary hydraulics is used in machine tool applications.
• In modern CNC machines the tool holding & work holding devices
are operated by means of hydraulic systems. Feed and spindle
drives are also operated by hydraulics system.
• In surface grinding machines the reciprocating motion of table is
obtained by the hydraulic system.
• In case of opening & closing of the doors of lifts & elevators.

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Application areas of Stationary Hydraulics:
Production and assembly machines of all types

Transfer lines
Lifting and conveying devices
Power presses
Injection machines
Rolling lines
Lifts & elevators

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Mobile Hydraulics:
• Mobile hydraulics is movable, can be moved from one

place to other by means of wheels or chains.
• Mobile hydraulics is used in the automobiles,
mechanical and construction machinery.
• In different types of automobiles - two & four wheelers.
• In construction machinery – hot mixers, cranes, etc.

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Application areas of Mobile Hydraulics:
Automobiles
Construction Machinery
Mechanical Machinery (Fork Lifts, Cranes)
Tippers
Agriculture Machineries
Aircrafts
Ships

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Basic Principles
Classification of hydraulics
Hydraulics
Hydrostatics Hydrodynamics
F=PxA F=mxa
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Hydrostatics uses pressure energy of fluid (oil)
It is science of liquids under pressure
AT REST – equal pressure acts throughout
IN MOTION – flows from high pressure to low pressure

Point
Pressure only builds up when there is a resistance to flow
No resistance = No pressure

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Hydrodynamics uses kinetic energy of fluid
it is science of moving liquids
F=PxA F=MxA
F = force in Kg or N
P = Pressure
A = area
M = mass
A = acceleration
Our study is about hydrostatics
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Hydrostatic pressure Hydrostatic pressure is the

Pressure created above a
Certain level within a liquid
?As a result of weight of the liquid
Mass. Hydrostatic pressure).

is not
Dependent on the shape of vessel
Concerned but only on the density
& height of the column of liquid.

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Hydrostatic pressure = pressure created by head of liquid
Pressure = weight / area
HEIGHT
WEIGHT
volume x density / area PRESSURE
area x g x height x density / area
Pressure = height x density x g AREA
For mineral oil ΔP = 0.1 bar / meter

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FORCE
FORCE = PRESSURE x AREA
AREA
PRESSURE = FORCE ÷ AREA

PRESSURE
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1 kg 1 kg
1 kg
LOW
PRESSURE HIGH HIGH
PRESSURE PRESSURE

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PASCAL's LAW
It states that “The intensity of pressure at any point in a
liquid at rest, is same in all directions”
Pz
Px
Py Px = Py = Pz
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W
Brahmas intensification principle
100 Kg
1000 Kg

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Brahma's principle
Application of Pascal's law Force transmission

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Force transmission
F1 = 100 Kg, A1 = 10 mm2
A2 = 50 mm2
P1 = F1 / A1 = 10 Kg / mm2
As per PASCAL's law same Pressure is applied at piston 2.
therefore force exerted on piston 2 is
F2 = P2 x A2 = 500 Kg
So the arrangement provides a ratio of 5:1 for any force
applied on piston 1. this increase in power is called as
“hydraulic leverage”.
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Mechanical advantage = load / effort
In above example
Load = F2 = 500 Kg
Effort = F1 = 100 kg
M.A. = 500 / 100
M.A. = 5

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Displacement transmission
As per previous
calculations the amount
of movement of piston 2
is 1/5 the movement of
piston 1. the speed of
piston 2 is also 1/5 the
speed of piston 1.

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Pressure development in a hydraulic system

The pressure in a hydraulic system is developed due to
resistance to flow

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No load
No resistance to
oil flow hence
no pressure
develops in the
system
P

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load is attached on the other

piston or output side now
W
If we apply a force on input side
the load connected on other will
create a resistance to oil flow

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W
Due to resistance offered by
the load we can see that
pressure has been increased

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10 Kg 40 Kg 90 Kg
Cylinder 2 Cylinder 3 Oil flows

through path
of least
Cylinder 1
resistance
20 cm² 30 cm²
10 cm²

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Oil flows through path of least resistance
weight (Kg) area (cm²) pressure (Kg/ cm²)
Cylinder 1 10 10 1
Cylinder 2 40 20 2
Cylinder 3 90 30 3
Cylinder 1 will move first as pressure required to move it is

minimum (least resistance)
Once the cylinder 1 has reached its extreme position then
pressure will start increasing, when it becomes 2 Kg/ cm²
cylinder 2 will start moving & when pressure reaches 3 Kg/ cm²
cylinder 3 moves.

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Viscosity
- Viscosity is tenacity of a hydraulic oil to offer resistance when

opposed to a displacement of adjacent layers.
- It depends on temperature & pressure
- If temp. increases viscosity decreases due to disintegration of

various additives & anti-oxidants.

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Types of flows
- Two types of fluid flows
- Laminar flow & turbulent flow

Basic hydraulic system IGTR
Pump
Cylinder

When the pump is

operated load is lifted

When the pump is

released the load comes
back

To avoid load
coming down non
return valve is used
& to supply more oil
reservoir is used


Basic hydraulic system
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Shut off valve

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BRAMAH PRESS - 1795 IGTR

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To move the weight at a faster rate

pump must continuously work ,
so electrically driven pumps are used.
To complete the hydraulic system two more components are added

-Pressure relief valve
-Direction control valve
BASIC HYDRAULIC SYSTEM
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STRUCTURE OF A HYDRAULIC SYSTEM

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SCHEMATIC DIAGRAM OF A HYDRAULIC SYSTEM
FLOW DIRECTION FLOW HYDRAULIC

CYLINDER CONTROL CONTROL CONTROL MOTOR
VALVE VALVE VALVE
PRESSURE RETURN
CONTROL FILTER
VALVE
ELECTRIC OIL COOLER
MOTOR COUPLER PUMP
TEMP. INDICATOR
INDICATOR
OILLEVEL
SUCTION
FILTER OIL TANK
IGTR Training - Vijay Bankar Basic - Hydraulics 64

May 2, 2020
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Pump
- It is the most important component in power supply unit
Hydraulic pump
overview

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Hydraulic valves
- Valve is a device which is used to control out put of the circuit.

- The main purpose of a valve in hydraulic circuit is to control Final
output.
- Valves are divided into number of groups according to what they
control.
Most commonly used valves are.
1. Direction control valve.
2. Pressure control valve.
3. Flow control valve.

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Fundamentals of valve
Sliding spool principle

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Poppet principle

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Types of poppet valves

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SPOOL PRINCIPLE POPPET PRINCIPLE
Does not provide positive sealing Provides positive sealing
Sensitive to dirt Sensitive to dirt
Pressure compensated Non pressure compensated
Long actuation stroke Short actuation stroke
Simple construction in case of

multi position valves
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Direction control valves

Method of designation of valve:
Control valve symbols –
- The basic symbol for control valve is a square.
- two or more squares are used.
- Each square representing the switching position provided by the valve.
1. Two position valve.
2.Three position valve.

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Lines in the boxes are used to show flow path with arrow indicating
direction of flow.
FLOW
The shut off position is indicated by the line drawn at right angle to the
horizontal line inside the rectangle.
SHUT OFF / NO FLOW

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PIPE CONNECTIONS :-
- The pipe connections i.e. inlet and outlet ports to the valve are
indicated by lines drawn on outside of the box and right angle to
the horizontal line .
- The first position from left indicates the rest, initial or neutral
position when the valve is not actuated.
- The second position or square from left indicates actuated
position.

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PIPE CONNECTIONS :-
1) Single position (initial)
2) Two position valve
3) Three position valve

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PORT TABLE:
- The ports of the valve are show on the outside of the box.
- These are labeled by a number or letter according to its functions.
- For this purpose some standard letters or numbers with symbols are
used which are shown in the following table.
PORT NUMBERING LETTERING SYSTEM
SYSTEM
Pressure supply port 1 P
Tank T
Signal outputs 2,4 A,B
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COMMONLY USED DIRECTION CONTROL VALVE.
D.C. valve is used to control or to change the direction or to start

or stop the fluid flow only on the receipt of any signal which may
be mechanical, electrical or a fluid pressure pilot signal.
D.C. valves are described by number of ports and number of

positions
n / n way valve
( n = 1, 2, 3,……)

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Way Valve Ports Positions
2/2 2 (1 input , 1 output) 2
3/2 3 (1 input, 1 output, 1 tank) 2

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2/2 way valve normally closed
Not actuated

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2/2 way valve normally closed
Actuated Circuit simulation
p3_1_8_6

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3/2 way valve normally closed (poppet principle)
Not actuated

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3/2 way valve normally closed (poppet principle)
Circuit simulation
Actuated
p3_1_8_13

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3/2 way valve normally closed (slide principle)
Not actuated

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3/2 way valve normally closed (slide principle)
Actuated

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4/2 way valve (slide principle) with two pistons
Not actuated

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4/2 way valve (slide principle) with two pistons
Circuit simulation
Actuated

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4/2 way valve (slide principle) with three pistons
Not actuated

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4/2 way valve (slide principle) with three pistons
Actuated

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4/3 way valve types

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4/3 way midposition recirculation /

tandem midposition
Not actuated

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tandem midposition
Left actuated

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tandem midposition
circuit
Right actuated
p3_1_8_28

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4/3 way midposition cutoff / all ports

blocked midposition
Not actuated

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blocked midposition
Left actuated

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blocked midposition
Circuit
Right actuated
simulation

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4/3 way valve overlap positions

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4/3 way valve overlap positions

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Floating center / Y midposition Open center / H midposition

Free movement of piston is possible in neutral position
Note : Circuits after completing non return valves

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Non return valve

B A
B A
Flow can take place only from A to B

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Non return valve

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Delockable non return valve /

pilot operated check valve

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Delockable non return valve /

pilot operated check valve

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Circuit showing application of piloted NRV

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Circuit showing application

of piloted NRV
P3_1_9_11

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Delockable double non return valve

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Delockable double non return valve

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Pressure control valves
- These are single position valves
- In their normal position they can be open or closed
- Two types
- Pressure relief valves

- Pressure reducing valves / Pressure regulator
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Pressure relief valve
Sensing input pressure

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Pressure relief valve When input pressure

becomes more than set
spring force value the valve
opens & excessive pressure
is drained to tank via T port

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Uses of pressure relief valve

- It can be used
- To relive excessive pressure / to protect pump / other parts

- To limit the system pressure
- As a back pressure valve / counterbalancing valve
- As a sequence valve

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PRV used to limit system pressure

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PRV used to limit system pressure

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PRV used as a back pressure valve
Or counterbalancing valve

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PRV used as a sequencing valve
- It can be used for sequencing of two or more operations

(cylinders or between cylinder & motor)
- For ex. Cylinder B has to move when cylinder A has reached its
forward end & a pressure of 30 bar has been reached.
Circuit simulation

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PRV internally controlled, cushioned
Pressure relief valves often incorporate cushioning pistons or flow control valve.
The cushioning device shown provides fast opening & slow closing of valve.
This prevents damage caused by pressure shocks

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PRV externally controlled / remote pilot PRV

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The valve opens

when pressure at X
port is more than
spring force.

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Pressure reducing valve / pressure regulator
2 way pressure regulator
Sensing output pressure

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This valve is combination of 2 way pressure regulator & PRV

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P3_1_7_26

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Flow control valves
Throttle valve (needle restrictor)
Controls the flow in both directions, (load dependent)

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Flow control valves
Throttle valve (Gap restrictor with helix)
Controls the flow in both directions, (load dependent)

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Throttle valve
Circuit simulation

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One way flow control valve
Flow from A to B is controlled,

hence speed gets reduced
Controls the flow in one directions

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Flow from B to A is free, hence no

change in speed
Circuit simulation
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Meter in & meter out control
Circuit simulation

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Two way flow control valve
Controls the flow in both directions independent of load

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Hydraulic cylinders
Single acting cylinder

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Hydraulic cylinders
Plunger cylinder

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Hydraulic cylinders
Double acting cylinder

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Hydraulic cylinders
Double acting cylinder with end position cushioning

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Hydraulic cylinders

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Hydraulic cylinders
P3_1_11_7
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Circuit Symbols
Symbols for energy transfer

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Circuit Symbols
Symbols for energy transfer

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Circuit Symbols
Circuit symbols for energy conversion

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Circuit Symbols
Circuit symbols for hydraulic motors

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Circuit Symbols
Circuit symbols for single acting cylinders

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Circuit Symbols
Circuit symbols for double acting cylinders

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Circuit Symbols
Circuit symbols for direction control valves

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Circuit Symbols

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Circuit Symbols

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Circuit Symbols
Circuit symbols for manual actuation

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Circuit Symbols
Circuit symbols for mechanical actuation

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Circuit Symbols
Circuit symbols for pressure valves

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Circuit Symbols
Circuit symbols for flow control valves

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Basic hydraulics exercises
Exercise 1 Solution 1

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Calculations Ex. 2
Load (force) = pressure x area

Pressure = load / area
A = П x d² / 4 = 3.14 x 1.6² / 4 = 2 cm²
Load pressure = 9 / 2 = 4.5 kg / cm²
Hydraulic resistance or back pressure = Travel pressure - load

pressure
Hydraulic resistance or back pressure = – 4.5 = kg / cm²

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Flow rate = Area x velocity

Velocity = flow rate / Area
Velocity = 2 x 1000 / 2
Velocity = 1000 cm / min
= 1000 / 60
= 16.6 cm / sec
Time = distance travelled / speed

Time = 20 / 16.6
Time = 1.2 sec
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Exercise 8 Solution 8a
Solution 8b
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Filters / strainers
Surface type filters Depth type filters
Single layer porous medium Multi layer porous medium
Micron rating 44 to 238 μ Micron rating 3 to 15 μ
Pressure line 5 to 10 μ
Filler / Suction Return
breather line line
40 μ 125 μ 25 / 40 μ
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Surface type filtering principle
Mesh no. Opening size
60 236 µ
100 149
200 74
325 44

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Depth type filtering principle
Filter media. Max. pressure diff.
paper 10 bar
polyester 200 bar
Stainless fiber 44 bar

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Filter arrangement
Hydraulic filters can be arranged in various different positions within a

system.
A distinction is made between
filtering of the main flow: return, inlet and pressure filtering
filtering of the by-pass flow: only one part of the delivery is filtered.

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Filtering of the main flow

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Filtering of the by-pass flow

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The various possible filter arrangements are listed in the above

diagrams
The most favorable filter arrangement is decided by considering

the sensitivity to dirt of the components to be protected, the
degree of contamination of the hydraulic fluid and the costs
involved

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Power supply section
Provides energy required by hydraulic system
Consists of
- Drive unit
- hydraulic pump
- Pressure relief valve
- Reservoir
- Filter
- Cooler & heater

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Positive head installation
If the pump is below the

tank level it is called
positive head installation
It eliminates cavitation
problem

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cavitation
-P
P=0
+P

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cavitation
-P
P=0
+P

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Flooded suction installation
Pump is inside the reservoir / flooded

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Negative head installation
If the pump is above the

reserviour it is called
negative head installation
It can give rise to cavitation

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Negative head installation

Suction side fitting must be air tight
Oil level must be above minimum

level
The negative head must be lower

than pump suction capacity.
As a rule of thumb pump suction is

max. 125 mm of Hg
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Hydraulic power unit

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Reservoir size, dependent on:
- pump delivery
- the heat resulting from operation
-volume of liquid
- place of application
- circulation time
Minimum reserviour size is 3 to 5 times pump delivery

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Lubrication
WATER
Temp. Range
HYDRAULIC WATER / OIL Corrosion

FLUID
MINERAL OIL Flammability
Ecological
VEGETABLE OIL
Cost
SYNTHETIC
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Hydraulic Calculations
Volume of cylinder (base end) = piston area x stroke length
Volume of cylinder (rod end) = (piston area – rod area) x stroke length
Flow rate = flow velocity x flow area

m³ / sec m / sec m²
Usually flow rate is given in lit / min & area in cm² or mm²

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Example –
Calculate the cross section area required for the suction line of a
pump delivering 40 l/min with a maximum flow velocity of 1.2 m/s

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Flow rate = 40 l/min = 40 x 10 -³ / 60
Flow area = flow rate / flow velocity

Flow area = 40 x 10 -³ / 60 x 1.2
Flow area = 0.555 x 10 - ³ m²
Π x d² / 4 = 0.555 x 10 - ³
d² = 0.555 x 10 -³ x 4
3.142
d = 26.6 mm pipe bore dia.
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Work done = force x distance moved
Force = pressure x area
Work done = pressure x area x distance
Work done = pressure x volume
Power = work done per unit time

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Power = pressure x volume

time
Power = pressure x flow rate
If pressure is in Pascals & flow rate in m³ / sec then power is in Watt
But usually pressure is given in bar & flow rate in lit. / min

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Hydraulic power = pressure (bar) x flow rate (lit./min)

(KW)
600
1 bar = 100000 N / m²
1 lit/min = 1/ 1000 x 60 m / sec
Power (Kw) = 100000 PxQ

60000 x 1000 600

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Exercise 4
Solution 4

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Accumulators
Hydraulic accumulator is an accessory of a hydraulic system
A hydraulic accumulator is a pressure storage reservoir in which a
non-compressible hydraulic fluid is held under pressure by an external
source.
The external source can be a spring, a raised weight, or a compressed
gas. An accumulator enables a hydraulic system to cope with
extremes of demand using a less powerful pump, to respond more
quickly to a temporary demand, and to smooth out pulsations. It is a
type of energy storage device.

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The function of hydraulic accumulator

is to store pressurized oil.
Types
Weighted accumulator
Spring loaded accumulator
Gas-charged accumulator

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The three types of gas-charged accumulators are bladder, piston

and diaphragm.
The most popular of these is the

bladder type. Bladder accumulators
feature fast response (less than 25
milliseconds), a maximum gas
compression ratio of around 4:1 and a
maximum flow rate of 15 liters (4
gallons) per second,

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Piston accumulators, can handle much

higher gas compression ratios (up to
10:1) and flow rates as high as 215
liters (57 gallons) per second. Unlike
bladder accumulators, whose preferred
mounting position is vertical to prevent
the possibility of fluid getting trapped
between the bladder and the shell,
piston accumulators can be mounted in
any position.

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Diaphragm accumulators have most of

the advantages of bladder-type units
but can handle gas compression ratios
up to 8:1. They are limited to smaller
volumes, and their performance can
sometimes be affected by gas
permeation across the diaphragm.
The charging gas pressure is 25% to

30% of operating oil pressure

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Exercise 5
Solution 5

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PRO-ACTIVE
MAINTENANCE

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Titres liés

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May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 2

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• Hydraulics plays an important role in industry because

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Choice of working media

• Compressed air (Pneumatics)

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“Hydraulics” this word has been derived from Greek word

It is the branch of physics which studies about properties,

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Water hydraulics is used for

What we are going to discuss is oil hydraulics

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Slow speed 0.5 m/s High speed 1.5 to 3 m/s

More positioning accuracy (0.25 mm) Less positioning accuracy (1 – 2 mm)

Pressures can be more than 500 bar Pressures are 10 – 12 bars

Stroke is proportional to amount of oil Force is proportional to amount air entering

Pneumatics video Hydraulics video

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May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 12

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 13

Press with elevated reservoir This is an application in which

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 14

On this hydraulic excavator, not only

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 15

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 16

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 17

• Stationary hydraulics is fixed at one station where all the activities

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 20

Application areas of Stationary Hydraulics:

Production and assembly machines of all types

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 21

• Mobile hydraulics is movable, can be moved from one

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 22

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 23

IN MOTION – flows from high pressure to low pressure

Pressure only builds up when there is a resistance to flow

May 2, 2020 IGTR Training - Vijay Bankar Basic - Hydraulics 25

Hydrostatic pressure Hydrostatic pressure is the

Mass. Hydrostatic pressure).

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Pressure = weight / area

area x g x height x density / area

Pressure = height x density x g AREA

For mineral oil ΔP = 0.1 bar / meter

PRESSURE = FORCE ÷ AREA

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M.A. = 500 / 100

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Pressure development in a hydraulic system

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load is attached on the other

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