LECTURE 1- INTRODUCTION TO HYDRAULICS AND PNEUMATICS

FREQUENTLY ASKED QUESTIONS

1. Define the term fluid power.

Fluid power is the technology that deals with the generation, control and transmission of forces
and movement with the use of pressurized fluids in a confined system.

2. Differentiate between fluid transport and fluid power systems

Fluid transport systems have their sole objective the delivery of a fluid from one location to
another to accomplish some useful purpose. Examples include pumping stations for pumping
water to homes, cross country gas lines.

Fluid power systems are designed to perform work. In fluid power systems, Work is obtained
by pressurized fluid acting directly on fluid cylinder or fluid motor. A cylinder produces a force
resulting in linear motion, whereas a fluid motor produces a torque resulting in rotary motion

3. Differentiate between hydraulics and pneumatics

Oil hydraulics employs pressurized liquid petroleum oils and synthetic oils, and pneumatics
employs compressed air which is exhausted to the atmosphere after performing the work.

3. List the six basic components used in a hydraulic systems

i) Reservoir ii) Pump iii) Prime mover iv) Valves v) actuators vi) Piping

4. List the six basic components used in a pneumatic systems

i) Compressed air tank ii) compressor iii) Prime mover iv) Valves v) actuators vi) piping
5. List ten applications of fluid power in the automotive industry

1. Power brakes, 2. Power steering, 3.Shock absorbers 4.Air conditioning 5.Automobile

transmission. 6. Agriculture 7. Aviation, 8.Fabrication industry 9.Machine tools 10. Oil industry
and Pharmaceuticals

6. Name five hydraulic applications and five pneumatic applications

Hydraulic applications Pneumatic applications

Automobile power steering, brakes, aircraft Packaging machinery, Bottle filling
landing gear, lift trucks, front end loaders Industry, artificial heart, logic control
systems and robotic materials handling
devices.

7. List five advantages and five disadvantages of hydraulics

Advantages of Hydraulic system

1. Large load capacity with almost high accuracy and precision.

2. Smooth movement.
3. Automatic lubricating provision to reduce to wear.
4. Division and distribution of hydraulic force are easily performed.
5. Limiting and balancing of hydraulic forces are easily performed.
Disadvantages of Hydraulic system

1. A hydraulic element needs to be machined to a high degree of precision.

2. Leakage of hydraulic oil poses a problem to hydraulic operators.
3. Special treatment is needed to protect them from rust, corrosion, dirt etc.,
4. Hydraulic oil may pose problems if it disintegrates due to aging and chemical
deterioration.
5. Hydraulic oils are messy and almost highly flammable.
8. List five advantages and five disadvantages of pneumatics

Advantages of Pneumatic system

1. Low inertia effect of pneumatic components due to light density of air.

2. System is light in weight.
3. Comparatively easy operations of valves.
4. Power losses and leakages are less in pneumatic systems.
5. Low cost.
6. Cylinder cushioning is not required
7. Leakage does not influence the systems and is not harmful

Disadvantages of Pneumatic systems

1. Suitable only for low pressure and hence low force applications
2. Availability of the assembly components is doubtful.
3. Generation of the compressed air is expensive compared to electricity
4. Exhaust air noise is unpleasant and silence has to be used.
5. Rigidity of the system is poor
6. Weight to pressure ratio is large
7. Less precise

9.List the main components of Fluid power system and their function

Pump To convert mechanical power to fluid power

Cylinder/motor To convert fluid power to linear or rotary mechanical power
Valves To control direction , pressure and flow
Filters and regulators To condition the fluid
Hose tube and couplings To conduct fluid
Seals To contain the fluid
Accumulators To store the fluid
Measuring instruments To monitor the performance of fluid power system and
such as Pressure switch, maintain it
Flow meter, Temperature
transducers
10. Compare different Power Systems used in industry

Property Mechanical Electrical Pneumatic Hydraulic

Input Energy I C Engines I C Engines I C Engines I C Engines
source Electric motor Water/Gas Pressure Tank Electric Motor
Turbines Air Turbine

Energy Levers, Gears, Electrical Pipes and Pipes and

Transfer Shafts Cables and hoses hoses
Element Magnetic field
Energy Carrier Rigid and Flow of Air Hydraulic
elastic Objects electrons liquids
Power to Poor Fair Best Best
weight ratio
Torque/Inertia Poor Fair Good Best
Stiffness Good Poor Fair Best
Response Fair Best Fair Good
speed
Dirt Sensitivity Best Best Fair Fair
Relative cost Best Best Good Fair
Control Fair Best Good Good
Motion Type Mainly Rotary Mainly Rotary Linear or Linear or
Rotary Rotary

11. What is the main difference between a open loop and closed loop fluid power system

i) Open loop system: there is no feedback in the open system and performance is based on
characteristics of individual components of system, Open loop system is not accurate and error
can be reduced by proper calibration and control.

ii) Closed loop system: This system uses feedback. The output of the system is fed back by a
measuring element to a comparator. The comparator compares the actual output to the desired
and gives a error signal to the control element. The error is used to change the actual output and
bring it closer to the desired value. Simple closed loop system uses servo valves and advanced
system uses digital electronics
12. List five major manufactures of fluid power equipments and systems in India.

1. Hycom Engineering (India) Pvt Ltd;

2. Hannover Milano Fairs India Pvt Ltd

3. Yuken India Limited.

3. Bosch Rexroth (India) Ltd;

4. Pall Corporation India limited

13. List five major manufactures of fluid power equipments and systems in world.

Rexroth, Vickers, Ingersoll-Rand, Eaton corporation, Brown and Sharp Manufacturing

Company, DeLaval IMP pump Division, Sheffer corporation.

14. Visit any Industry nearby and list the hydraulic/pneumatic parts or systems used and
its purpose.

Students should visit and make note of the following

1. Size of hydraulic power pack used

2. Oil used and its designation
3. Piping used – whether rigid, or flexible and their material and capacity
4. Valves used for control device
5. Type of controller used – like Siemens, Yamasaki etc
6. Valve mountings
7. Coolant recirculation system used
8. Lubricant unit and oil used and grade
9. Rating of pumps and motor
10. Safety devices used in machine
 LECTURE 7 TO 9
HYDRAULIC PUMPS

FREQUENTLY ASKED QUESTIONS

1. What is the purpose of a hydraulic pump in a fluid power system ?

Purpose of hydraulic pump is to generate flow so that energy conversion from mechanical to
fluid energy is possible. Mechanical energy is provided to pump by electric motor.

2 Differentiate between positive displacement and non-positive displacement pump

Positive displacement pump is a pump in which
there is a physical displacement of boundary of
fluid mass
In positive displacement pump, outlet flow is
(almost) independent of system pressure.
Flow
Centrifugal pump is a non positive displacement
pump. In this there is a relative motion between
the fluid and motor
In centrifugal pump, the outlet flow is dependent
on system pressure, so when pressure increases ,
the flow reduces

Flow

Pressure Pressure

3. What is the principle of operation of a pump?

Pumps operate on the principle whereby a partial vacuum is created at the pump inlet due to the
internal operation of a pump. This allows atmospheric pressure to push the fluid out of the oil
tank (reservoir) and into the pump intake. The pump then mechanically pushes fluid out of the
discharge line.

4. What are the three pumps classifications?

1. Classification based on displacement

 Non positive displacement pumps (hydrodynamic pumps)
 Positive displacement pumps (hydrostatic pumps)
2. Classification based on delivery
 Constant delivery pumps
 Variable delivery pumps

3. Classification based on motion

 Rotary pump
 Reciprocating pump.

5. Classify the positive displacement pumps

Based on the construction, Hydrostatic pumps are classified
1. Gear Pumps ( fixed displacement pumps)
(a) External gear pump
(b) Internal gear pump
a. Lobe pump
b. Gerotor pump
(c) Screw pump
2. Vane Pumps ( fixed or variable displacement pumps)
(a) Balanced Vane pump
(b) Unbalanced Vane pump

3. Piston Pumps ( fixed or variable displacement pumps)

(a) Axial piston pump b)Radial piston pump

6. Why must positive displacement pumps are protected by relief valves ?

Pumps are expensive items and if pressure shoots up do to some reason, then relief valve will
allow the fluid to go back to the tank, if not pressure will rise to due to blockage of fluid and
parts of pumps may fail. Relief valve thus limits the maximum pressure to which pump
components can be subjected with.

9. Why are centrifugal pumps used so little in fluid power system?

Flow output of a centrifugal pump is not constant. Therefore it cannot be used for fluid power
application. It is useful in fluid transport systems.

10. Why gear pumps cannot be used as a variable displacement pump

In the gear pump, once the design parameters are finalized all the dimensions of gear pair is fixed
and there is no way to vary the displacement.
11. What are the reasons for the popularity of external gear pumps?
o Simple to design
o Because gear pumps have only two moving parts, they are reliable, simple to operate, and
easy to maintain.
o Low cost compared to other pumps

12. What is the most important application for internal gear pumps?

o The speed of the internal gear pumps is considered relatively slow compared to
centrifugal types. Speeds up to 1,150 rpm are considered common. Because of their
ability to operate at low speeds, internal gear pumps are well suited for high – viscosity
applications and where suction conditions call for a pump with minimal inlet pressure
requirements
o They're also bi-rotational, meaning that the same pump can be used to load and unload
applications

13. How does the lobe pump differ from the other gear type pump

Lobe pumps are frequently used in food applications because they handle solids without
damaging the product. Particle size pumped can be much larger in lobe pumps than in other PD
types. Since the lobes do not make contact, and clearances are not as close as in other PD
pumps, this design handles low viscosity liquids with diminished performance. Loading
characteristics are not as good as other designs, and suction ability is low. High-viscosity liquids
require reduced speeds to achieve satisfactory performance. Reductions of 25% of rated speed
and lower are common with high-viscosity liquids

14. What is the most significant characteristic of the screw pump

o They are quiet pumps

o Screws are continuous , most reliable
o No pressure pulsation will occur
o High speed operation is possible
o No pump turbulence and oil churning

15. List four parameters that affect noise level of hydrostatic pump
o Pressure
o Size of the pump
o Speed of the pump
o Entrained air bubbles
16. How is the output of an unbalanced vane pump varied?

Output of the unbalance vane pump is varied by mechanically varying eccentricity between the
cam ring and rotor.

17. How can the displacement of an axial piston pump be varied

In axial piston pumps, by varying the stroke length the displacement can be varied . In bent axis
type, by varying the angle between the cylinder block and drive shaft centerline, the stroke
length is varied. In swash plate type by varying the swash plate angle the stroke length can be
varied.

18. What is cavitation?. Name four popular methods to reduce cavitation

During the working of positive displacement pump a vacuum is created at the inlet of the pump.
This allows atmospheric pressure to push the fluid in. In some situations the vacuum may
become excessive, and a phenomenon known as Cavitation occurs.

1) Keep the suction line velocities below 1.5 m/s

2) Keep the pump inlet as short as possible
3) Minimize the number of fittings in the inlet line
4) Mount the pump as close as possible to the reservoir.

19. What is pressure compensated vane pump and how does it work

In the unbalanced vane pump, the displacement can be varied by varying eccentricity. By a
compensator piston arrangement, the eccentricity is varied depending on the system pressure
there by pump delivery is varied.

20. Why is the operation of screw pump quiet

In the screw pump, the fluid moves linearly and do not rotate. Therefore even at high speed there
is no pulsations and operates quietly.

21. Define: Volumetric efficiency, Mechanical efficiency and overall efficiency

Volumetric efficiency ( )

Mechanical efficiency ( )
Overall efficiency (

22. Draw the characteristics curves of different types of pumps used in Industry

See Figure 7.19

23. List the important considerations in the selection of a pump for any given application

1) Flow rate requirement

2) Operating speed of pump
3) Pressure rating
4) Performance/application
5) Reliability
6) Maintenance
7) Cost
8) Noise level of the pump
9) Oil compatibility
10) Type of pump control
11) Pump contamination tolerance
12) Availability of pump and spars

24. Name the three ways by which noise of pump can be reduced
o By proper design of pump
o By proper clamping of hydraulic distribution like pipes , fittings etc.
o By using sound absorption material in the design of fluid power systems.

25 Why should the suction head of pump not exceed 35 kPa.

This is to avoid the cavitation. When the suction head pressure is too low and if the below the
vaporization pressure of the oil, then the bubbles will form and these bubbles produce very large
impact forces on the metallic components of pump and erodes them.
 LECTURE 12 TO 14

HYDRAULIC ACTUATORS

FREQUENTLY ASKED QUESTIONS

1. What is the function of a hydraulic cylinder in a hydraulic system

Function of hydraulic cylinder is to provide linear motion. It converts the fluid energy into
mechanical energy ( linear movement).

2. When is a telescoping cylinder used?

A telescoping cylinder is a cylinder employing several pistons which telescope into each other.
This cylinder is used when a relatively long working stroke is needed for a short cylinder
length.Telescopic configuration cylinders are used in a variety of applications that require the use
of a long cylinder in a space-constrained environment.

3. Explain the operation of Tandem type cylinder and mention its application

Tandem Cylinders

Figure 8.8: Tandem Cylinder

A tandem cylinder is used in applications where a large amount of force is required from a small-
diameter cylinder. Pressure is applied to both pistons, resulting in increased force because of the
larger area. The drawback is that these cylinders must be longer than a standard cylinder of
larger flow rate than a standard cylinder to achieve an equal speed because flow must go to both
pistons.

4. Explain the function of cushioning in cylinders

Due to inertial forces of the moving parts at the end of piston travel, the piston will hit the
cylinder head at full speed, To overcome this , the designers provide an arrangement by which
hydraulic cylinder can be slowly retarded or cushioned during the last portion of the cylinder
stroke.

5. Why are wiper rings used on cylinder rods ?

Wiper rings are used to prevent foreign abrasive or corrosive particles from entering a cylinder.
These particles cause scratches and thus the leakage. Their purpose is not seal against pressure.

6. Mention two applications of single acting cylinders.

o Single acting cylinder are extensively used in jigs and fixtures, for clamping a work piece
o Used in transfer lines to eject a heavy component like knuckle of automobile

7. How does a welded type of cylinder differ from tie rod type?. Mention the major parts of
tie rod cylinder

A tie-rod cylinder is a hydraulic cylinder that uses one or more tie-rods to provide additional
stability. Tie-rods are typically installed on the outside diameter of the cylinder housing. In
many applications, the cylinder tie-rod bears the majority of the applied load. A welded cylinder
is a smooth hydraulic cylinder that uses a heavy-duty welded cylinder housing to provide
stability.

8. What are the technical specification of a hydraulic cylinder ?,

Important operating specifications for hydraulic cylinders include the cylinder type, stroke,
maximum operating pressure, bore diameter, and rod diameter. Choices for cylinder type
include tie-rod, welded, and ram.Stroke is the distance that the piston travels through the
cylinder. Hydraulic cylinders can have a variety of stroke lengths, from fractions of an inch to
many feet. The maximum operating pressure is the maximum working pressure the cylinder can
sustain. The bore diameter refers to the diameter at the cylinder bore. The rod diameter refers to
the diameter of the rod or piston used in the cylinder.

9. Name the material that are commonly used to manufacture i) cylinder covers ii) Piston
rods iii) pistons iv) Tie rods

Cylinder High Precision Seamless Steel

tube,ST42,ST44,ST5216Mn 27SiMn
25Mn St52 SAE1026, plasma nitrited
Piston rod Forged steels, C45ground- hardened and hard
chrome plated.
Tie rods (inside) 4140HT steels, 1045 steel with heat treatment
subsequent to thread rolling to give sufficient
strength

10. What is hydraulic ram

A hydraulic ram is a device in which the cross-sectional area of the piston rod is more than one-
half the cross-sectional area of the moving component. Hydraulic rams are primarily used to
push rather than pull, and are most commonly used in high pressure applications.

11. Mention the different types of mountings used in fixing the hydraulic cylinders

Pivoted center line mounts
- Rod end trunnion
- Blind end trunnion
- Clevis mounted
- Center truunion
Fixed centerline mounts
- Tie rod
- Rod end flange
- Blind end flange
- Centre line lugs
Fixed non-centerline mounts
- End lug mounts
- Side lug mounts
- Integral key mounts
- Flush mounts
 LECTURE 15 TO 17

DIRECTIONAL CONTROL VALVES

FREQUENTLY ASKED QUESTIONS

1. Explain briefly the function of directional control valves

o To start, stop, accelerate , decelerate and change the direction of motion of hydraulic
actuator
o To permit the free flow from the pump to the reservoir at low pressure, when the pump’s
deliver is not needed into the system
o To vent the relief valve by either electrical or mechanical control
o To isolate certain branch of circuit

2. Draw a schematic of 4/3 DCV that is direct operated electrically and briefly explain its
Function
A B

A B

A
Spool
P T

P T

A B A B

P T
Spool

P T

Four way DCV are capable of controlling double acting cylinders and bi-directional motors.
Figure shows the operation of a typical 4/2 DCV. A four way has four ports labeled P,T A & B.
Pis the pressure inlet and T is the return to the tank. A & B are outlets to the system. In the
normal position, pump flow is sent to outlet B. Outlet A is connected to the tank. In the actuated
position, the pump flow is sent to port A and port B connected to the tank T. In four way DCV’s
two flows of the fluids are controlled at the same time, while 2 way and 3way DCV’s control
only one flow at a time. Figure (c) shows the complete graphic symbol for a four way two piston
DCV.
3. Draw a schematic of 3/2 DCV that is manually operated and briefly explain its function

3/2 way DCV (normally closed)

Three way valves either block or allow flow from an inlet to an outlet. They also allows the
outlet to flow back to the tank, when the pump is blocked, while a two way valve does not. A
three way valve has three ports namely a pressure inlet (P),an outlet to the system(A),and a
return to the tank(T). The above figure shows the operation of a 3/2 way 0valve normally closed.
In it’s normal position the valve is held in position by a spring as shown in figure(A). In the
normal position the pressure port P is blocked and the outlet A is connected with the tank. In the
actuated position shown in figure(B) the pressure port is connected with the tank and the tank
port is blocked.

P T
P T

Port A and T are connected when force is not

applied (Valve unactuated)

A
A

Spool P T

P T

Port A and P are connected when force is applied

(Valve actuated)

4. State the different ways of control of Directional control valves

i) Manually operated:
ii) Mechanically operated
iii) Solenoid operated:
iv) Pilot operated:
5. How are Directional control valves classified

Classification of Direction control valves based on fluid path

i) Check valves
ii) Shuttle valves
iii) 2 way valves
iv) 3 way valves
v) 4 way valves

Classification of Direction control valves based on design characteristics

i) Internal valve mechanism which directs flow of fluid of fluid. Such mechanism can
either be a poppet, a ball, a sliding spool, a rotary plug, a rotary disc.
ii) Number of switching positions (usually 2 or 3)
iii) Number of connecting ports or ways.
iv) Method of valve actuation; which causes the valve mechanism to move into alternate
position.

6. Explain the construction and operation of electric solenoids and compare the DC and AC
solenoids

1. When coil 2. Armature is pulled against

is energized push pin Coil
Pushpin

3. Push pin moves spool Spool Armature

Like mechanical or pilot actuators, solenoids work against a push pin, which in turn actuates a
spool. There are two types of solenoid design used to dissipate the heat developed in electric
current flowing in the coil. The first type dissipates the heat into surrounding air and is referred
to an “air gap solenoid”. In the second type “wet pin solenoid”, the push pin contains an internal
passage way that allows the tank port oil to communicate between the housing of the valve and
the housing of the solenoid. Wet pin solenoids do a better job in dissipating heat because the cool
oil represent a good heat sink to absorb heat from the solenoid. As the oil circulates, the heat is
carried in to the hydraulic system where it can be easily dealt with.
7. Cite the classification of check valves, and explain the function of pilot operated check
valve, giving the necessary drawing.

o Ball valve
o Poppet valve
o Pilot operated
o Shuttle valve

11.1.2 Pilot operated check valve

Pilot operated valve along with it's symbol is shown in figure 4 This type of check valve always
permits free flow in one direction but permits flow in the normally blocked opposite direction,
only if pilot pressure is applied at the pilot pressure point of the valve. The check valve poppet
has the pilot piston attached to the threaded poppet stem by a nut.
The light spring holds the poppet seated in a no flow condition by pushing against the pilot
piston. The purpose of the separate drain port is to prevent oil from creating a pressure build up
on the bottom of the piston The dashed line in the graphical symbol represents the pilot pressure
line connected to the pilot pressure port of the valve. Pilot check valves are used for locking
hydraulic cylinders in piston.

NO
PIL
OT
SIG
NA
L
Free flow

NO
PIL
OT
SIG
NA
L
No flow

PIL
OT
SIG
NA
L

Return
flow

Figure 4 : Pilot operated check valve

8. What is the difference between an open-center and closed-center type of directional
control valve?
The open center type connects all ports together when the valve is unacutated . The closed –
center design has all ports blocked when the valve is unactuated.

9. What is a shuttle valve? Name one application

A shuttle valve is another type of directional control valve. It permits a system to operate from
either of two fluid power sources. One application is for safety in the event that the main pump
can no longer provide hydraulic power to operate emergency devices.
 LECTURE 18 AND 19

PRESSURE CONTROL VALVES

FREQUENTLY ASKED QUESTIONS

1. Deal with the function of the pressure control valves in hydraulic power systems

o Restricting maximum pressure in a system thereby ensuring safety using relief valve etc
o Reducing /regulating pressure in certain section of the circuit like pressure reducing valve
o Unloading system pressure using unloader valve
o Providing pressure control for sequential operation of actuators in a circuit e.g sequence
valve
o Any other function accomplished by pressure control

2. Discuss in detail the static characteristics of a direct operated relief valve, and explain
how to reduce the override pressure.

Flow pump flow

pressure

Cracking
Pressur

pressure
e

Full Pump
flow
Flow through relief
valve
If the hydraulic system does not accept any flow, then all the pump flow must return to the tank
via the relief valve. The pressure relief valve provides protection against any overloads
experienced by the actuators in the hydraulic system. Of course, a relief valve is not needed if a
pressure compensated vane pump is used. Obviously one important function of a pressure relief
valve is to limit the force or torque produced by hydraulic cylinders or motors.
The main advantage of direct-acting relief valves over pilot operated relief valves is that they
respond very rapidly to pressure buildup. Any relief valve does not know there is a problem until
pressure is very near or at its setting. Then it must open to relieve excess flow as quickly as
possible to keep pressure overshoot low. Because there is only one moving part in a direct-acting
relief valve, it can open rapidly, thus minimizing pressure spikes.

3. Draw schematically a pilot operated relief valve and explain its function

The pilot operated pressure relief valve has a pressure port that is connected to the pump line and
the tank port is connected to tank. The pilot relief valve is a poppet type. The main relief valve
consists of a piston and stem. The main relief piston has a orifice drilled through it. The piston
has equal areas exposed to pressure on top and bottom and is in balanced condition due to equal
force acting on the both sides. It will remain stationary in the closed position. The piston has a
light bias spring to ensure that it will stay closed. When the pressure is less than that of relief
valve setting, the pump flow goes to the system. If the pressure in the system become high
enough , it will move the pilot poppet off its seat. A small amount of flow begins to go through
the pilot line back to tank. Once flow begins through the piston orifice and pilot line, a pressure
drop is induced across the piston due to restriction of the piston orifice. This pressure drop then
causes the piston and stem to lift off its seat and the flow goes directly from the pressure port to
tank.

4. Discuss the application of pilot operated relief valve

 o It is used in counter balance application
o It is used in locked cylinder circuits

5. Discuss the principle of pressure reduction in fluid power systems

A second type of pressure reducing valve is pressure reducing valve. This type of valve (which is
normally open) is used to maintain reduced pressures in specified locations of hydraulic systems.
It is actuated by downstream pressure and tends to close as this pressure reaches the valve
setting. See also question 6

6. Discuss briefly the operation of pilot operated pressure reducer

The pressure reducing valve uses a spring loaded spool to control the downstream pressure. If
downstream pressure is below the valve setting, fluid will flow freely from the inlet to the outlet.
Note that there is an internal passageway from the outlet, which transmits outlet pressure to the
spool end opposite the spring. When the outlet (downstream) pressure increases to the valve
setting, the spool moves to the right to partially block the outlet port. Just enough flow is passed
to the outlet to maintain its preset pressure level. If the valve closes completely, leakage past the
spool could cause downstream pressure to build up above the valve setting. This is prevented
from occurring because a continuous bleed to the tank is permitted via a separate drain line to the
tank.

Adjustable
screw

Drain
line
Sprin
g
Main
Press
ure
line
Redu
ced
press
ure
line

No pilot pilot
signal signal

Reverse free flow through the valve is only possible if the pressure exceeds the valve setting, the
valve will close, thus making reverse flow impossible. Therefore, pressure reducing valves are
often equipped with a check valve for reverse free flow.
External forces acting onto a linear actuator will increase the pressure between the pressure
reducing valve and the actuator. In some systems, it is therefore desirable to relieve excess fluid
from the secondary system to the tank in order to maintain a constant downstream pressure,
regardless of such external forces.

7. Explain the function of the direct operated sequence valve

A sequence valve is a pressure control valve that is used to force two actuators to be operated in
sequence. They are similar to pressure relief valves. The symbol for sequence valve is as shown
below.

Instead of sending flow back to tank, a sequence valve allows flow to a branch circuit, when a
preset pressure is reached. The check valve allows the sequence valve to be bypassed in the
reverse direction. The component enclosure line indicates that the check valve is an integral part
of the component. The sequence valve has an external drain line; therefore a line must be
connected from the sequence valve’s drain port to the tank.

Dr
ain
Secon
dary
I
port
Ou
n
t
Dire
ct
pilo
t
Remote pilot

8. What are the difference between the relief valve and the sequence valve

A sequence valve is a pressure control valve that is used to force two actuators to be operated in
sequence. They are similar to pressure relief valves. Instead of sending flow back to tank, a
sequence valve allows flow to a branch circuit, when a preset pressure is reached.

9. Discuss the application of sequence valve used in hydraulic systems

Application of Sequence Valve

The following hydraulic circuit is an example of an application of a sequence valve in which a

clamp cylinder extends first to hold a work piece, and then a second cylinder extends to bend the
work piece in the desired shape.

Sequence
Valve 1
Bending
Cylinder
(B)

Clamp
Cylinder (A) Sequence W
Valve 2

Figure 17 Application of sequence valve

In this circuit, two cylinders are connected in parallel. Without the sequence valve, these
cylinders would extend together as they are both unloaded. In order for this circuit to function
properly, the clamp cylinder must extend completely before the bending cylinder begins to
extend. But by the application of sequence valve which does not allow flow into the bending
cylinder branch of the circuit until the clamp cylinder extends completely. When the clamp
cylinder extends completely, the pressure will rise and open the sequence valve. Thus, allowing
the bending cylinder to extend. The sequence valve must be set enough so that it opens only after
the clamp cylinder has extended completely.

During the retraction of cylinders, check valve allows sequence valve to be bypassed. The
sequence valve has no effect on the circuit in this situation. Both cylinders will retract together
because both are unloaded and will split the pump flow.

10. Name two applications of counter balance valve

 o Used on counter balance application to prevent the load to run away like in
counterbalance of vertical broaching machine
o Used in hydraulic press to prevent the load from running away

11. What is the function of a sequence valve?

When the operation of two cylinders is required to be performed in sequence the sequence valve
is made use of.

12. What is the function of an unloading valve?

The unloading valve is useful to control the amount of flow at any given time in systems having
more than one fixed delivery pump

13. How the unloading valve different from a pressure relief valve

Unloading valves are pressure-control devices that are used to dump excess fluid to tank at little
or no pressure. Remote pilot signal is used to control. Where as in pressure relief valve pilot
from system pressure controls the valve.

14. What is the function of pressure relief valve in fluid power systems?

Function of the pressure relief valve is to unload the pump in the event of extreme pressure in the
circuit. When the set pressure is reached relief valve will send all the fluid back to the tank.

15. What is the advantage of using an unloading circuit, when feed and speed of a machine
need to be varied?

o When high speed is required during air cutting, high flow pump can be used to get the
rapid extension and cutting time is saved.
o When cutting is taking place ( torque requirement is high), low flow pump can be used
o This circuit eliminates the necessity of having a very expensive high pressure, high flow
pump.
 LECTURE 20

FLOW CONTROL VALVES

FREQUENTLY ASKED QUESTIONS

1. What is the function of a flow control valve

Flow control valves are used to regulate the speed of hydraulic cylinders and motors by
controlling the flow rate to these actuators.

2. What are the three ways of applying flow control valves

Meter in, meter out and bleed off are ways of applying flow control valves.

3. What is meant when a flow control valve is said to be pressure compensated

A pressure compensated flow control valve is one which provides the desired flow rate
regardless of changes in system pressure.

4. What is the meter in ciruit and where it is used

In meter in circuit flow control is placed in in the pressure line. Pump delivery in excess of
metered amount is divered to tank through pressure relief valve. This is used wehre load
characteristics are constant and positve

5. What is the meter out circuit and where it is used

In meter in circuit flow control is placed in in return lineThis is used in machine tools like
drilling in which tools is dragged suddenly at the end of drilling.

6. What are the advantage of meter in circuit

o Finer speed control is possible

o Suitable for high pressure applications
o Low level of friction – longer service life of components
7. What are the disadvantage of meter in circuit

o Cannot be used for hydromotor

o Pressure drops across due to throtlle and hence the pressure of the fluid fed into the
actuator will be less than required
o Inefficent because excess flow goes to tank
o Cannot prevent the load from running away as in the case of drilling machine
o Heat generated due to throttling is fed to the actuator.

8. What are the advantage of meter out circuit

o No loss of pressure of the oil at the head end of the cylinder

o The actuator movement is more stable
o Suitable for controlling the speed of both cylinder and motor
o Heat generated during throttling goes to the tank
o Provide positve speed control of cylinder
o Pump works against the maximum pressure
o Positive speed control and stable

9. What are the disadvantage of meter out circuit

o Even at no load the cylinder is subjected to maximum pressure

o Piston rod side is subjeted to counter pressure which increases as area ratio increases
o The friction is higher
o If the flow control is installed after the DCV, leakage in DCV will affect the accuracy

10. What are the advantage of By pass or bleed off circuit

o Efficiency is better
o Heat generated due to throttling is fed into the tank

11. What are the disadvantage of By pass or bleed off circuit

o Positive speed control is not possible

o Not suitable for accumulator circuit
o Fluctuation of flow rate in pump affects the speed of the actuator
 o Pump works against the load
o Can be used for fixed displacement pump and motor
o The motor continues to rotate even when the pump delivery is cut off from the fluid
motor
o Not efficient with variable displacement pump.

12. What is a modular valve and what are its benefits

Modular valve is a stack of control valve one on the other to perfomr a complete valve pack.This
arrangemetn forms a compact system, thereby reducing assembly cost and eliminates much of
the complex interconnection of pipe work. Modular valve saves space and easy to troubleshoot.

13. What is hydraulic fuse

A hydraulic fuse prevents hydraulic pressure from exceeding an allowable valve in order to
protect circuit components from damage. It is analogous to an electric fuse.

Drain to
tank
Hydraulic fuse

Electric Motor

Thin metal disk Inlet Pressure

Figure E8 : Hydraulic fuse

14. What is the need for temperature compenstaion in flow control valve
As the viscoisty of oil varies with temperature, the oil becomes less viscous when temperature
increases. As the less viscous fluid flow more rapidly through an orifice, the increase in
temperature causes increase in flow for a valve setting, so temperature compensation is needed to
offset the effect of such temperature variations.

15. What is the differnece between hydraulic fuse and Pressure relief valve

Hydraulic fuse Pressure relief valve

Hydraulic fuse is a safety device. When the line
pressure exceeds the design capacity of thin
metal sheet, it ruptures and connects it to
drain
It protects the hydraulic system.
It is analogous to electrical fuse. which need to
be replaced once thin metal plate ruptures
Rupture is due to plastic deformation of the
thin metal sheet.
Pressure relief valve is also safety valve. which
crack opens when the fluid line pressure
exceeds the set pressure. Once the pressure
drops below set pressure, Valve resets
It is used to regulate the pressure and protects
the expensive parts of pump against the over
pressure which may be due to stopage, or
blocking.
It is analgous to cirucit breaker, which can be
reset. like cirtuit breaker, relief valves are
available with different maximum set
capacities.
Opening of the valve is due to set pressure
which can be adjusted by spring force.
 LECTURE 24 TO 26 - HYDRAULIC CIRCUIT DESIGN

FREQUENTLY ASKED QUESTIONS

1. List three important considerations to be taken into account while designing a hydraulic
circuit

There are 3 important considerations in designing a hydraulic circuit.

 Safety of machine and personal in the event of power failures

 Performance of given operation with minimum losses
 Cost of the component used in the circuit.

2. What are advantages of regenerative circuit?

The speed of the extension can be made greater than that of regular double acting cylinder. The
extending speed can be made greater than the retracting speed if the rod size is made small
enough.

3 Explain the Regenerative circuit for Drilling Machine:

C F LOAD

A B C – Double acting cylinder

D – 3 Position, 4 Way,
1 0 2 Regenerative center,
D P T solenoid actuated,
spring centered DCV
R – Relief Valve
E R F - Filter
P E – Electric Motor
F T T- Tank
T P - Pump
Figure shows an application of regenerative circuit in a drilling machine. Here a 3-position, 4-
way , regenerative center directional control valve is used. When the DCV is in the spring-
centered position, port P is connected to A and B and tank port T is blocked. In this position
pump flow goes to A and flow from rod end of the cylinder also joins the pump flow to gives
rapid spindle advance ( no work is done during this period )
Why does the spring-centered position give rapid extension of the cylinder (drill spindle)? The
reason is simple. Oil from the rod end regenerates with the pump flow going to the blank end.
This effectively increases pump flow to the blank end of the cylinder during the spring-centered
mode of operation. Once again we have a regenerative cylinder. It should be noted that the
cylinder used in a regenerative circuit is actually a regular double-acting cylinder. What makes it
a regenerative cylinder is the way it is hooked up in the circuit. The blank and rod ends are
connected in parallel during the extending stroke of a regenerative center.
When the DCV shifts to 1st position, P is connected to A and B to T gives slow feed
(extension) when the drill starts to cut into the work piece. Similarly when the DCV shifts to 2nd
position, P is connected to B and A is connected to T, since the ring area is less the cylinder will
have fast return motion.

4 With the help of neat sketch explain the pump unloading circuit

F LOAD
C

A B

1 0
2
D P T

CV

P
U
F T
T
. Pump unloading circuit.
C = Double acting cylinder
P = Pump
T = Tank
F = Filter
U = unloadingValve
D =3-position, 4 way ,closed center, Manually operated and Spring Centered DCV

Refer to the above figure, we see a circuit using an unloading valve to unload a pump. The
unloading valve opens when the cylinder reaches the end of its extension stroke because the
check valve keeps high-pressure oil in the pilot line of the unloading valve. When the DCV is
shifted to retract the cylinder, the motion of the piston reduces the pressure in the pilot line of the
unloading valve. This resets the unloading valve until the cylinder is fully retracted, at which
point the unloading valve unloads the pump. Thus, the unloading valve unloads the pump at the
ends of the extending and retraction strokes as well as in the spring-centered position of the
DCV.

5 With the help of circuit diagram explain Double Pump Hydraulic system ( Hi – Lo circuit

C F LOAD

A B

0
1 2
D P T

CV

R P1 P2 U
T T
F F

Double pump Hydraulic system

P1 -- Low discharge, High pressure pump CV – Check valve
P2 -- High discharge, Low pressure pump D – 3 Position, 4 Way, closed
R -- Relief valve center, manual actuated DCV
U – Unloading valve C- Double acting cylinder
T - Tank F - Filter

Figure shows a circuit that uses two pumps, one high-pressure, low-flow pump and the other
low-pressure, high-flow pump. One can find application in a punch press in which the hydraulic
ram must extend rapidly over a large distance with very low pressure but high flow requirements.
However, during the short motion portion when the punching operation occurs, the pressure
requirements are high due to the punching load. Since the cylinder travel is small during the
punching operation, the flow-rate requirements are also low.
The circuit shown eliminates the necessity of having a very expensive high-pressure,
high-flow pump. When the punching operation begins, the increased pressure opens the
unloading valve to unload the low-pressure pump. The purpose of the relief valve is to protect
the high-pressure pump from overpressure at the end of the cylinder stroke. The check valve
protects the low-pressure pump from high pressure, which occurs during the punching operation,
at the ends of the cylinder stroke, and when the DCV is in its spring-centered mode.

6 Explain the application of Counter Balance Valve

Figure illustrates the use of a counterbalance or back-pressure valve to keep a vertically mounted
cylinder in the upward position while the pump is idling i.e when the DCV is in its center
position. During the downward movement of the cylinder the counterbalance valve is set to open
at slightly above the pressure required to hold the piston up ( check valve does not permit flow in
this direction ). The control signal for the counterbalance valve can be obtained from the blank
end or rod end of the cylinder. If derived from the rod end, the pressure setting of the counter
balance valve equals FL/ (AP-Ar ). If derived from blank end the pressure setting equals FL / AP.
This pressure is less and hence usually it has to be derived from blank end. This permits the
cylinder to be forced downward when pressure is applied on the top. The check valve is used to
lift the cylinder up as the counterbalance valve is closed in this direction. The Tandem -center
directional control valve unloads the pump. The DCV is a manually -actuated, spring-centered
valve with tandem-center flow path configuration
 CB

F LOAD
CV
A B

1 0 2
D P T

P R
T
F
T

Counter balance application

C = Double acting cylinder mounted vertically
P = Pump
CB = Counter Balance Valve
CV = Check Valve
T = Tank
F = Filter
R = Relief Valve
D =3-position, 4 way , Tandem center, Manually operated and
Spring return DCV
7 Explain the application of pilot check valve for locking double acting cylinder

In many cylinder applications, it is necessary to lock the cylinder so that its piston cannot be
moved due to an external force acting on the piston rod. One method for locking a cylinder in
this fashion is by using pilot check valves, as shown in Fig 5.13. The cylinder can be extended
and retracted as normally done by the action of the directional control valve. If regular check
valves were used, the cylinder could not be extended or retracted by the action of the DCV. An
external force, acting on the piston rod, will not move the piston in either direction because
reverse flow through either pilot check valve is not permitted under these conditions

F LOAD
C

PCV1 PCV2

A B

1 0
2
D P T

P R
T
F
T

. Locked Cylinder using Pilot Check Valve.

 C= Double acting cylinder
P = Pump
PCV1 & PCV2 = Pilot Check Valve
R = Relief Valve
T = Tank ; F = Filter
D =3-position, 4 way , closed center, manually operated DCV

8 Explain the speed control circuit for hydraulic motor

Figure shows a circuit where speed control of a hydraulic motor ( Bi -directional motor) is
accomplished using a flow control valve to control the fluid flow to the motor.
In the spring-centered position of the tandem four-way valve, the motor is hydraulically locked.
When the four-way valve is actuated into the 1st position, the motor rotates in one direction. Its
speed can be varied by adjusting the setting of the throttle of the flow control valve. In this way
the speed can be infinitely varied as the excess oil goes to the tank through the pressure relief
valve. When the four-way valve is deactivated, the motor stops suddenly and becomes locked.
When the 2nd position of the four-way valve is in operation, the motor turns in the opposite
direction. The pressure relief valve provides overload protection if, for example, the motor
experiences an excessive torque load.
M

D 1 0
2

F R

Speed control of Hydraulic motor using Flow control valve.

 M = Bi-directional Hydraulic motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
D =3-position, 4 way ,Tandem center, Manually operated and Spring Centered DCV

9 Explain the speed control circuit for hydraulic motor using meter in and meter out
circuit. Write the equations for volumetric efficiency and comment
The speed of hydraulic motor can be controlled either by meter-in control or meter- out control.
Figure shows a unidirectional hydraulic motor speed is controlled by a meter- in circuit. Here
the flow control valve is placed between the pump and motor.
FCV Q1

P M
R QL
( Q1-QL)
F

Fig 5.20. Meter- in Speed control of Hydraulic motor

M = Uni-directional Hydraulic Motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve

Figure 5.21 shows a unidirectional hydraulic motor speed is controlled by a meter- out
circuit. Here the flow control valve is placed between the motor and tank.
Q1

P M
QL
FCV
F R
( Q1- QL)
. Meter- out Speed control of Hydraulic motor
M = Uni-directional Hydraulic Motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
We know that the volumetric efficiency of the motor is given by
Vol=Theoretical flow rate the motor should consume
Actual flow rate consumed by motor
Vol=QT /QA
Due to leakage, a hydraulic motor consumes more flow rate than it should theoretically
consume. The theoretical flow rate is the flow rate a hydraulic motor would consume if there
were no leakage. If Q1(=QA ) is the flow of fluid to the motor, and QL the leakage , Then QT is
equal to Q1 – QL

ThenVol= (Q1 – QL )/Q1

In meter- in control Q1 is maintained constant despite varying load , QL varies with load ,
therefore volumetric efficiency varies with load. Hence meter-in system will not give precise
control of speed. Whereas in meter – out control Q1 varies with load hence precise control of
speed regardless of flow.

10. Differentiate between open loop and closed loop Hydrostatic Transmission systems

Hydrostatic Transmission ( HST ): These are special cases of energy transmission system. It
consists of a drive with hydraulic energy as input. Hydraulic motor convert hydraulic energy to
mechanical energy. Hydrostatic transmission is a whole unit in which pumps and motors are
designed to match ( the speed torque characteristics ) to get optimum transmission. The HST
can be open or closed circuit.
P. E
M .E M.E
PUMP Hydrostatic transmission
MOTO
Open circuit HST : Figure shows open typeRcircuit. They are called open circuit drives because
the pump draws its fluid from a tank. Its output is then directed to a hydraulic motor and
discharged from the motor back to the tank. In the closed circuit drive, exhaust oil from the
motor is returned directly to the pump inlet.

Variable displacement pump

M

Open circuit (open loop ) HST

 Figure shows a closed circuit that allows either direction of motor rotation. The feed pump is
provided for replenishing the fluid in the circuit. The check valves prevent the oil flow from the
main pump to the feed pump. Here two relief valve R 1 and R2 are used to protect the main
pump in both the direction of rotation.
The motor speed is varied by changing the pump displacement. The torque capacity of
the motor can be adjusted by the pressure setting of the relief valve.
Closed circuit drives are available as completely integrated units with all the controls and
valving enclosed in a single, compact housing.

Variable displacement
Pump ( Main )

M
R1 R2

Feed Pump

Closed circuit (open loop ) HST

Performance:
1. Hydraulic power input ,Phyd = p QP ( Watts )
where p = pressure setting of relief valve in N / m2
QP = pump theoretical flow rate = pump displacement (m3/ rev) * Speed (rps)
2. Q1 = Qp* VP where VP = volumetric efficiency of the pump;
Q1 = Actual flow rate to motor
3. Motor theoretical flow rate ,QM = Q1*VM
Where VM = volumetric efficiency of the motor
1. Motor capacity , CM = QM/ speed of motor ( m3/ rev )

2. Power delivered to motor, Phyd = System pressure * Q1 ( Watts )

3. Mechanical power generated, PMech = Phyd* V M*MM

whereMM = mechanical efficiency of hydraulic motor
4. Actual Torque developed by motor, Ta = PMech / 2 N
Where N = speed of motor in rps
8. Ideal torque , Ti = CM * P / 2

9. Actual torque, Ta = Ti *MM

11. What are the conditions for the two cylinders to be synchronized?
For the two cylinders to be synchronized, the piston area of cylinder 2 must beequal to the
difference between areas of the piston and piston rod for cylinder 1.
i.e. Ap2 =Ap1 –AR1
Also, the pump should be capable of delivering a pressure force P1ApI in cylinder 1 to overcome
the loads F I and F 2 acting on both cylinders. .
i.e.P1Apl =FI +F2

12. What is the use of bleed-off circuit?

Bleed off circuit is used to .control the flow of fluid in both directions of flow (or) on a
specific line and limits speed in only one direction of the cylinder travel.
 LECTURE 30 to 31– ACCESSORIES USED IN FLUID POWER SYSTEMS

FREQUENTLY ASKED QUESTIONS

1. Explain the two types of the leakages in hydraulic system. In what way do they affect the
performance of a fluid system?

Leakage in hydraulic system can be classified as

1. Internal Leakage
2. External leakage

Internal leakage increases the clearances between mating parts due to wear. If the entire system
leakage becomes large enough, the actuators will not operate properly.

External leakage represents a loss of fluid from the system. It is unsightly and represents a safety
hazard. Improper assembly of pipe fittings is the most common cause of external leakage.

2. What is a seal and what are their functions

Seals are used in hydraulic systems to prevent excessive internal and external leakage and to
keep out contamination. Functions are
 Prevent leakage – both internal and external
 Prevent the dust & other particles entering into the system
 Maintain pressure
 Enhance the service life & reliability of the hydraulic system.

3.How are hydraulic seals classified? What is meant by positive sealing and non
positivesealing?
Classification of hydraulic seals
1. Hydraulic seals can be classified according to the method of sealing as
a. Positive Sealing
b. Non-positive sealing
 2. Hydraulic seals can be classified according to the relative motion exist between the seals
and other pars as
a. Static seal
b. Dynamic seal
3. Hydraulic seals may be classified according to geometrical cross section as
a. O-Ring seal
b. V-Ring & U-ring seal
c. T-ring seal
d. Piston cup packings
e.Piston rings
f.Wiper rings

A positive seal prevents even a minute amount of oil from getting past. Positive seals do not
allow any leakage whatsoever (external or internal). A non-positive seal allows a small amount
of internal leakage, such as the clearance of the piston to provide a lubrication film.

4. Distinguish between static seal and dynamics seal

Static Seal: Static seals are used between mating parts that do not move relative to one another.
Typical examples are flange gaskets and seals, o-rings, etc. These are relatively simple. They are
essentially non-wearing and usually trouble free if assembled properly.
Dynamic Seals: There are assembled between mating parts that move relative to each other.
Hence dynamic seals are subject to wear because one of the mating parts rub against the seal.

5. How are seals classified based on geometrical cross section?

Hydraulic seals may be classified according to geometrical cross section as

a. O-Ring seal
b. V-Ring & U-ring seal
c. T-ring seal
d. Piston cup packings
e.Piston rings
 f.Wiper rings
6. Explain the different types of sealing materials commonly used
Natural rubber is rarely used as a seal material because it swells and deteriorates with time in the
presence of oil. In contrast, synthetic rubber materials are compatible with most oils. The most
common types of materials used for seals are leather, Buna-N, silicone, neoprene,
tetrafluoroethylene, viton and of course, metals.
 Leather. This material is rugged and inexpensive. However, it tends to squeal when dry
and cannot operate above 90 , which is inadequate for many hydraulic systems.
Leather does not operate well at cold temperatures to about -50 .
 Buna-N. This material is rugged and inexpensive and wears well. It has a rather wide
operating temperature range (-45 to 110 ) during which it maintains its good sealing
characteristics.
 Silicone. This elastomer has an extremely wide temperature range (-65 to
232 )Hence, it is widely used for rotating shaft seals and static seals where a wide
operating temperature is expected. Silicone is not used for reciprocating seal
applications because it has low tear resistance.
 Neoprene. This material has a temperature range of 50 to 120 F. It is unsuitable
above 120 because it has a tendency to vulcanize.
 Tetrafluoroethylene. This material is the most widely used plastic for seals of hydraulic
systems. It is a tough, chemically inert, waxy solid, which can be processed only by
compacting and sintering. It has excellent resistance to chemical breakdown up to
temperatures of 370 . It also has an extremely low coefficient of friction. One major
drawback is its tendency to flow under pressure, forming thin, feathery films. This
tendency to flow can be greatly reduced by the use of filler materials such as graphite,
metal wires, glass fibers and asbestos.
 Viton. This material contains about 65% fluorine. It has become almost a standard
material for elastomer-type seals for use at elevated temperatures up to 240 Its
minimum operating temperature is 28 .
7.What are the primary and secondary functions of a reservoirsystem
The function of a fluid reservoir in a power hydraulic system are the following
 To provide a chamber in which any change in volume of fluid in the hydraulic circuit can
be accommodated. When the cylinder extend there is an increased volume of fluid in the
circuit and consequently there is a decrease in the reservoir level.
 It provide a filling point for the system.
 The reservoir serves as a storage space for the hydraulic fluid used in the system.
 The reservoir also uses as the location where the fluid is conditioned.
 To provide a volume of fluid which is relatively stationery to allow entrained air to
separate out and heavy contaminants to settle. The reservoir is where sludge, water and
metal slips settle
 The reservoir is a place where the entrained air picked up by the oil is allowed to escape.
 The dissipation of heat is accomplished by a properly designed reservoir. It provides a
radiating and convective surface to allow the fluid to cool.

8. Explain the important elements of a reservoir system and explain the function of each
Elements of a reservoir are as follows
Filler Cap (Breather Cap)
It should be air tight when closed, but may contain the air vent which filters air entering the
reservoir to provide a gravity push for proper oil flow.
Oil Level Gauge
It shows the level of oil in the reservoir without having to open the reservoir
 Motor and
Filler Return pump
with flow
filter

Filling level
Indicator Intake
(Max) pipe

Servicing
aperture

Filling level
Indicator
(Min) OIL RETURN SUCTION
CHAMBER CHAMBER
Drain
screw

Baffle
plate

Hydraulic Reservoir

Baffle Plate
It is located lengthwise through the centre of the tank and is 2/3 the height of the oil leve. It is
used to separate the outlet to pump from the return line. This ensures a circuitous flow instead of
the same fluid being recirculated. The baffle prevents local turbulence in the tank, allows foreign
material to settle, get rid of entrapped air and increase heat dissipation.

Suction and Return Lines

They are designed to enter the reservoir at points where air turbulence are least. They can enter
the reservoir at the top or at the sides, but their ends should be near the bottom of the tank. If the
return line is above the oil level, the returning oil can foam and draw in air.

Intake Filter
It is usually a screen that is attached to the suction pipe to filter the hydraulic oil.

Drain Plug
It allows all oil to be drained from the reservoir. Some drain plugs are magnetic to help remove
metal chips from the oil.
Strainers and Filters
Strainers and filters are designed to remove foreign particles from the hydraulic fluid. Strainers
and filters are discussed later in detail.

9. What is a filter and How are filters classified?

Filter is a device whose primary function is the retention, by some fine porous medium, of
insoluble contaminants from the fluid. Fluid flow has to follow a winding path and through the
element.Filters are used to pick up smaller contaminant particles because they are able to
accumulate them better than a strainer.
Types of Filters
A). Filters may be classified according to the filtering methods as
i. Mechanical Filters
ii. Absorption Filters
iii. Adsorbent Filters

i) Mechanical filters: This type normally contains a metal or cloth screen or a series of metal
disks separated by thin spacers. Mechanical filters are capable of removing only relatively coarse
particles from the fluid.
ii) Absorption filters: These filters are porous & permeable materials such as paper, wood pulp,
diatomaceous earth, cloth, cellulose and asbestos. Paper filters are impregnated with a resin to
provide added strength. In this type of filter, the particles are actually absorbed as the fluid
permeates the material. Hence these filters are used for extremely small particle filtration.
iii) Adsorbent filters: Adsorption is a surface phenomenon and refers to the tendency of
particles to cling to the surface of the filters. Thus the capacity of such a filter depends on the
amount of surface area available. Adsorbent materials used include activated clay and chemically
treated paper.
B).Filters may be classified according to the size of pores in the material as
i. Surface filters
ii. In depth filters

i) Surface filters: These are nothing but simple screens used to clean oil passing through their
pores. The screen thickness is very thin and dirty unwanted particles are collected at the top
surface of the screen when the oil passes. e.g. Strainer
ii) Depth filters: These contain thick walled filter medium through which the oil is made to flow
& the undesirable foreign particles are retained. Much finer particles are arrested and the
capacity is much higher than surface filters.
C).Filters are classified according to the location of filters as
i. Intake or inline filter
ii. Pressure line filter
iii. Return line filter

10. What are surface and depth filters

i) Surface filters: These are nothing but simple screens used to clean oil passing through their
pores. The screen thickness is very thin and dirty unwanted particles are collected at the top
surface of the screen when the oil passes. e.g. Strainer
ii) Depth filters: These contain thick walled filter medium through which the oil is made to flow
& the undesirable foreign particles are retained. Much finer particles are arrested and the
capacity is much higher than surface filters.

11. What are the important locations of filters? Explain the advantages and disadvantages
of each locationC).Filters are classified according to the location of filters as
i. Intake or inline filter
ii. Pressure line filter
iii. Return line filter

i) Inline filter (suction strainer): These are provided first before the pump to protect the pump
against contaminations in the oil. These filters are designed to give a low pressure drop.
Otherwise the pump will not be able to draw the fluid from the tank. To achieve low pressure
drop across the filters, a coarse mesh is used. These filters cannot filter out small particles.

Figure 20.8 Suction filter

Advantages
1.A suction filter protects the pump from dirt in the reservoir. Since the suction filter is outside
the reservoir, an indicator telling when the filter element is dirty can be used.
2. The filter element can be serviced without dismantling the suction line or reservoir. (Easy to
maintain)

Disadvantages
A suction filter may starve the pump if not sized properly

ii) Pressure line filters (High pressure filter): These are placed immediately after the pump to
protect valves and actuators and can be finer & smaller mesh. They should be able to withstand
the full system pressure. Most filters are pressure line filters.

Figure 20.9 Pressure filter

Advantages
1.A pressure filter can filter very fine contaminant since the system pressure is available to push
the fluid through the element
2. A pressure filter can protect a specific component from the harm of deteriorating particles
generated from an upstream component

Disadvantages
1.The housing of a pressure filter must be designed for high pressure because it is operating at
full system pressure. This makes the filter expensive.
2. If pressure differential and fluid velocity are high enough, dirt can be pushed through the
element or the element may tear or collapse.

Return line filters (Low pressure filters): These filters filter the oil returning from the pressure
relief valve or form the system i.e. actuator to tank. It is generally placed just before the tank.
They may have a relatively high pressure drop & hence can be fine mesh. These filters have to
withstand low pressure only and also protect the tank & pump from contamination.

Figure 20.10 Return line filter

Advantages
1.A return line filter catches the dirt in the system before it enters the reservoir
2.The filter housing does not operate under full system pressure and is therefore less expensive
than a pressure filter

Disadvantages
1. There is no direct protection for circuit components.
2. In return line full flow filters, flow surges from discharging cylinders, actuators and
accumulators must be considered when sizing.

12. Why the temperature of the working fluid should be properly maintained
Heat is generated in hydraulic systems because no component can operate at 100% efficiency.
Significant sources of heat include the pump, pressure relief valves and flow control valves. Heat
can cause the hydraulic fluid temperature to exceed its normal operating range of 35 to 70 .
Excessive temperature hastens oxidation of the hydraulic oil and causes it to become too thin.
This promotes deterioration of seals and packing and accelerates wear between closely fitting
parts of hydraulic components of valves, pumps and actuators.