HYDRAULIC CONTROL

By Hydraulics, we mean generation of forces and motion using hydraulic fluids.The hydraulic fluids
represent the medium for power transmission.

CLASSIFICATION OF HYDRAULIC SYSTEMS

Generally Hydraulic control can be broadly classified in to Hand lever (Manual control) Hydraulics
and Electro Hydraulics ( Solenoid control)

A basic distinction is made between stationary hydraulics and mobile hydraulics

• Mobile hydraulic systems move on wheels or tracks, for example Earth Moving Equipments

• Stationary hydraulic systems which remain firmly fixed in one position.

• A characteristic feature of mobile hydraulics is that the valves are frequently manually
operated. In the case of stationary hydraulics, however, mainly solenoid valves are used.
Other areas include marine, mining and aircraft hydraulics

ADVANTAGES OF HYDRAULIC CONTROLS

This comparison reveals some important advantages of hydraulics:

• Transmission of large forces using small components, i.e. great power intensity

• Precise positioning

• Start-up under heavy load

• Even movements independent of load, since liquids

are scarcely compressible and flow control valves can be used

• Smooth operation and reversal

• Good control and step less regulation

• Favourable heat dissipation

•  Simple overload protection

DISADVANTAGES

• Pollution of the environment by waste oil (danger of fire or accidents)

• Sensitivity to dirt

• Danger resulting from excessive pressures (severed lines)

• Temperature dependence (change in viscosity)

• Unfavourable efficiency factor

Applications: Example- Excavators (JCB), Cranes, Lifts, Aircraft wings control,

STRUCTURE OF HYDRAULIC CONTROL
PASCALS LAW
• The pressure applied to a confined fluid is transmitted undiminished in all directions

Pascal’s Law

It acts on all surfaces in a direction at right angle to those surfaces.

The amount of pressure in the fluid is equal to the weight force with respect to the area being acted
upon. Mathematically, it is defined as

Pressure = Force / Area i.e, p = F / A

Hydraulic force transmission

As pressure distributes equally in all directions, the shape of the container is irrelevant. If we now
pressurize surface A1 with force F1, we create pressure, p = F1 / A1 Pressure acts on all sides
equally and simultaneously. Therefore it acts also on surface A 2

The force which can be achieved is

F2 = p A2 ,

Thus F1 / A1 = F2 / A2

Or F2 / F1 = A2 / A1

The relationship of the paths S1 and S2 of the two pistons is then opposite to that of the surface.

i.e., S1 / S2 = A2 / A1

Hydraulic power transmission uses the principle of Pascal’s law. By applying small force F1 on a
smaller area a large load can be lifted with a large area, the pressure of the fluid being the same in
both the cylinders
Hydraulic power transmission uses the principle of Pascal’s law. By applying small force F1 on a
smaller area a large load can be lifted with a large area, the pressure of the fluid being the same in
both the cylinders

In hydraulic system mechanical energy is converted to hydraulic energy.

There are 6 basic components required in a hydraulic system

1. A tank or reservoir to hold the liquid, which is usually a hydraulic fluid.

2. Energy conversion : Hydraulic pumps

3. An electric motor or other power sources to drive the pump.

4.  An Actuator

5. Control of energy

a) Directional control valves

b) Pressure control valves

c) Flow control valves

d) Non return Valves

6. Piping
 SUMMARY OF POSITIVE DISPLACEMENT PUMPS

HYDRAULIC PUMPS
1. Hydraulic Pumps are positive displacement pumps. During every revolution of the rotor of
the pump there is specific amount of volumetric displacement of the oil.

2. Pump only generates flow

3. Pump does not develop pressure

4. It is only the system resistance which is responsible for the pressure to build up. If there is no
resistance ahead of the pump the pump discharge pressure will be atmospheric

Positive displacement Pumps used hydraulic systems can be classified as follows:

 Geared Pumps

 External Geared Pump

 Internal Geared pump
 Screw Pump

 Vane Pumps
Vane pump with eccentric rotor
[ fixed or variable flow]
Balanced Vane pump

 Piston Pumps: a. Axial Piston Pump

b. Radial Piston Pump
PUMPS: DISPLACEMENT VOLUME

EXTERNAL GEAR PUMP

One of the gear wheel (driven gear) is driven by motor, other just engages with the driven gear. And
rotates in the opposite direction. During rotation of the gear wheels, certain amount of oil is
trapped ( from the bottom) and volumetrically displaced around the space between the tooth space
and pump casing, transferring the oil to the downstream side ( upper portion). Any resistance
offered to the flow on the down stream side will result in pressure rise of oil.
INTERNAL GEAR PUMP

Cresent shaped partition

External Gear Internal Gear

 The two gears one internal and one external teth mesh together are not identical
 They are separated by a cresent shaped partition located between the two gears
 Entrapped Oil is displaced over the tooth spaces and cresent shaped partition from
suction side to discharge side ports.
 More compact and occupies less space
 More silent in operation
 Can be designed for higher operating pressure
 Relatively costlier

VANE TYPE PUMPS

Can be classified as a) Fixed Displacement Pump and

b) Variable Displacement Pump
Also as c) Balanced vane Pump
And d) Un balanced Vane Pump

In a fixed displacement vane pump, there is an outer pump housing which is called the Cam ring.
Inside the Cam ring an eccentrically located rotor is driven by a motor. The rotor is provided with
number of radial vanes (rectangular shaped blades) are provided which is radially moves. These
blades are vanes are spring at the center and seaos off the passages between adjacent partitions
Drive Elements are Actuators where final command is executed to produce thrust or motion.
Actuators can be classified as
• Linear Actuators –Cylinders
• Rotary Actuators- For Angular motion [0-360]
• Hydraulic Motors- For continueous rotation

LINEAR ACTUATORS

Hydraulic cylinders are available in different diameters, Lengths and designs.

Force developed by the cylinder depends upon on the diameter and Oil pressure and the length of
the cylinder decides the required displacement

CLASSIFICATION OF ACTUATORS
Hydraulic Cylinders can be mainly classified as
• Single Acting Cylinders
Plunger /Ram type cylinder
Cylinder with built-in spring
• Double Acting Cylinders
Conventional cylinder –single ended Piston rod
with or without end cushioning
Double ended Piston Rod cylinder
Differential cylinder
Telescopic Cylinder
Tandem cylinder
 Tandem cylinder

RECIPROCATING MOTION OF THE PISTON IS TRANSLATED INTO ROCKING

MOTION OF THE PINION. THE PINION ROTATES BY 360 EITHER CLOCK WISE OR
ANTI CLOCK WISE AS THE PISTON EXTENDS OR RETRACTS
There are 3 basic types of control devices in Hydraulic systems:
1. Directional control valves
2. Pressure control valves
3. Flow control valves.

Directional Control Valves are used to control the start, stop and change in
direction of flow of pressurized fluid.
They are used to extend, retract, position or reciprocate hydraulic cylinder
and other components for linear motion

Directional control valves are designated as per the following functions:

• Number of ports on the valves
• Number of switching positions
• Method of actuation
• Method of reset
• Design and constructional features
DOUBLE ACTING TYPE: ALSO AVAILABLE WITH SINGLE ACTING CONSTRUCTION
APPLICATION ; SUITABLE FOR LONG STROKE LENGTHS.
METER IN AND METER OUT CONTROL

• Pressure drop of oil occurs in oil fed to the cylinder due to throttling
effect of the flow control valve. Hence for low pressure system one
should be careful to select meter in control
• Finer speed control is possible.
• Heat generated due to throttling is transferred to the actuator
• Suits well for resisting load actuated by cylinder. Should not be used
with Hydraulic motor

• No loss in pressure to the actuator as the full oil is fed to the cylinder.
Even at no load the actuator is subjected to full pressure.
• The actuator movement is more stable
• The heat generated due to throttling is transferred to the reservoir.
• Suits both over running loads as well as speed control of hydraulic
motors as the cylinder is fed with entire pump pressure there is
possibility of friction loss (higher) .Pump works against ma pressure.
Provides positive speed control