International Journal of Trend in Research and Development, Volume 2(5), ISSN 2394-9333

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Design of Hydraulic System - A Review

1
Mr.S.R.Jadhav, 2Mr.Y.P.Ballal and 3Mr. A.R. Mane
1
UG student, 2Asst.Professor, 3Asst.Professor,
Department of Mechanical Engineering,
Annasaheb Dange College of Engineering & Technology, Ashta, Maharashtra, India.

Abstract - Hydraulic components are manufactured to
provide the control function required for the operation of a
wide range of system and application. This review on
hydraulic system design gives an understanding of basic
types of hydraulic components, their operational principle
and estimation of their performance in various
applications. The analytical methods that are used helps to
designing the hydraulic components like reservoir, pump,
motor, cylinder (actuator), control valves.
Keywords- Fluid, Reservoir, Filters, Pumps, Motor,
Cylinder, Control Valve.
I. INTRODUCTION
In the industry we use three methods for
transmitting power from one point to another. Mechanical
transmission is through shafts, gears, chains, belts, etc.
Electrical transmission is through wires, transformers, etc.
Hydraulic transmission is through liquids or gas in a
confined space.
Hydraulics is a type of science and engineering
that deals with mechanical properties of liquids and gases.
Hydraulics is part of the more general discipline of fluid
power. Fluid mechanics provides the foundation for
hydraulics, which focuses on engineering uses of fluid and
gas properties.
Hydraulics means study of water or other fluids at
rest or in motion, especially with respect to engineering
application. Hydraulics and hydraulic systems can be
found almost everywhere. Hydraulics can be found at any
construction site. Some machines that use hydraulics are
bulldozers, fork lift, and cranes. Hydraulics are used to lift
cars so mechanics can work underneath them. Many
elevators use the same operating technique.
Hydraulics is the science of transmitting force
and/or motion through the medium of a confined liquid. In
a hydraulic device, power is transmitted by pushing on a
confined liquid. The transfer of energy takes place
because a quantity of liquid is subject to pressure. To
operate liquid-powered systems, the operator should
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have a knowledge of the basic nature of liquids. This
chapter covers the properties of liquids and how they act
under different conditions.
II. HYDRAULIC PRINCIPLE
The basic idea behind any hydraulic system is
very simple: force applied at one point is transmitted to
another point using and incompressible fluid, which is
almost always going to be a type of oil. In some systems,
such as brake systems in a car, multiply the process. A
major part of hydraulics is Pascal’s principle: Pascal’s
principle - the change in pressure on one part of a
confined fluid is equal to the change in pressure on any
other part of the confined fluid. Following fig. shows the
principle of hydraulic.
Fig 1: Pascal’s Principle
III. COMPONENTS IN HYDRAULIC SYSTEM
A hydraulic system consists of a many
components for operating the system. Hydraulic systems
are power-transmitting assemblies employing pressurized
liquid as a fluid for transmitting energy from an energy-
generating source to an energy-using point to accomplish
useful work. Figure 2 shows a simple circuit of a
hydraulic system with basic components.
A hydraulic system consist of fluid for system
reservoir, filter, pump, motor, pressure regulator, direction
control valve, cylinder (actuator), gripper these main
parameters. [1]
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 International Journal of Trend in Research and Development, Volume 2(5), ISSN 2394-9333
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Fig 2 Components in Hydraulic System
A .Fluid-
Hydraulic fluid is the medium of power transfer in
hydraulic equipment, it is important to know the
properties of hydraulic fluids and its influence on system
performance. There are different types of fluids based on
their availability, working purpose etc.
A hydraulic the fluid is transmitting medium of a
hydraulic system. It is, therefore, an essential part of the
system and we must know enough about it to ensure that
the hydraulic system works efficiently. The most common
liquid that is used as a medium in fluid power systems is
petroleum-based mineral oil. [7]
 Factors Influencing the Selection of a Fluid
The selection of a hydraulic fluid for a given
system is governed by the following factors:
1. Operating pressure of the system.
2. Operating temperature of the system and its
variation.
3. Material of the system and its compatibility with oil
used
4. Speed of operation.
5. Availability of replacement fluid.
6. Cost of transmission lines.
7. Contamination possibilities.
8. Environmental condition (fire proneness, extreme
atmosphere like in mining, etc.).
9. Lubricity.
10. Safety to operator.
11. Expected service life. [7]
B. RESERVIOR-
The hydraulic reservoir is a container for holding
the fluid required to supply the system, including areserve
to cover any losses from minor leakage and evaporation.
The reservoir can be designed to provide space for fluid
expansion, permit air entrained in the fluid to escape, and
to help cool the fluid. Fig. No. 3 shows two typical
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reservoirs. Compare the two reservoirs item by item and,
except for the filters and bypass valve, notice the
similarities.
Fig 3. Cut Section of Reservoir
In order to the suitable for the demand of heat
dissipation and air separation, the oil reservoir must be
designed be as large as possible. Primarily size of
reservoir is decided by the pump delivery flow. By an
imperial rule these are taken as
V=3.5 for stationery installation
V=1*Q………….For mobile installation
Where V=Reservoir size in liter.
Q=Pump delivery flow in liter per minute.
C. FILTERS-
Contamination of hydraulic fluid is one of the
common causes of hydraulic system troubles. Installing
filter units in the pressure and return lines of a hydraulic
system allows contamination to be removed from the fluid
before it reaches the various operating components. Filters
of this type are referred to as line filters.
 Filtering Material and Elements:
The general classes of filter materials are
mechanical absorbent, inactive and absorbent active.
1. Mechanical filters contain closely woven metal
screens or discs. They generally remove only fairly coarse
particles.
2. Absorbent inactive filters, such as cotton, wood
pulp, yarn, cloth, or resin, remove much smaller particles;
some remove water and water-soluble contaminants. The
elements often are treated to make them sticky to attract
the contaminants found
in hydraulic oil.
3. Absorbent active materials, such as charcoal
and Fuller's Earth (a claylike material of very fine
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particles used in the purification of mineral or vegetable- Let, D= Outside diameter of gear teeth in mm.
base oils), are not recommended for hydraulic systems. [1]
d= Inside diameter of gear teeth in mm.
D. PUMP- L= Width of gear teeth in mm.
A hydraulic pump is a heart of hydraulic system.
Its function is to convert mechanical energy into hydraulic N= Speed of pump in rpm.
energy by pushing the hydraulic fluid into the system.
Hydraulic pumps convert mechanical energy from V= Displacement of pump in m/rev
a prime mover (engine or electric motor) into hydraulic
(pressure) energy. The pressure energy is used then to M= Module of gear.
operate an actuator .Pumps push on a hydraulic fluid and
z= Number of teeth.
create flow.
Volume Displacement,
 Gear pump-
A fixed positive displacement external gear pump V=π/4(𝐷 2 − 𝑑2 )L
has been selected in this system with maximum flow rate
of 36 lit./min and volume displacement of24 cm3/rev. Theoretical discharge,
Technical data of this pump is summarized in Table No. 1
Q= V*N
Table No.1Technical Data of Hydraulic Pump
If the gear is specified by it’s module and number of teeth,
Sr. No. Name of Specification then the theoretical discharge can be found by
Component
1 Maximum flow 36 lit/min Q= 2 πL𝑚2 N[z+(1+(π2 𝑐𝑜𝑠 2 α/12 ) )]
rate at speed 1500
rpm  Selection of pump can be based on following points:
2 Displacement 24 cm3/rev
3 Continuous 220 bar a) Safe and maximum system working
maximum pressure
pressure b) Allowable pump speeds
4 Maximum Speed 3000 rpm c) System flow requirement
d) Leakage loss
e) Drive type and mounting
f) Hydraulic oil characteristics
g) Heat, noise and vibration generation
h) Power-to-weight ratio
i) Initial and running cost

Following steps can be adopted while selecting hydraulic

pump:

a) Select the actuator and its size

b) Select the system operating pressure
c) Determine the pump speed
Fig. No. 4 External Gear Pump d) Select the pump type [4]

 Design of External Gear Pump:

The flow rate of an external gear pump is depends
on the volume displacement and theoretical discharge.
The flow rate of an external gear pump can be
calculated as follows:
E. MOTOR-
Hydraulic motors are installed in hydraulic
systems to use hydraulic pressure in obtaining powered
rotation. A hydraulic motor does just the opposite of what
a power-driven pump does. A pump receives relative
force from an engine or other driving unit and converts it

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 International Journal of Trend in Research and Development, Volume 2(5), ISSN 2394-9333
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into hydraulic pressure. A hydraulic motor receives
hydraulic fluid pressure and converts it into relative force.

Fig No. 6 Hydraulic Cylinder

 DESIGN OF CYLINDER-

Fig. No.5 Hydraulic Motor For designing the hydraulic cylinder following
parameters are to be consider
1. Force
 Selection of motor depends on following factor-
2. Piston rod velocity
Theoretical Torque, Power, and Flow rate 3. Power developed during extension and
retraction stroke
 Theoretical Torque-
The torque generated by a frictional Force and velocity during extension
hydraulic motor is known as theoretical torque. Velocity v = Q/A
Q= Flow rate of fluid
Theoretical Torque (T) A= Circular piston area
Force F = p * A
T= (p*V)/2π p = Pressure in N/m^2
Force and velocity during extension
P = Pressure in N/m^2
Velocity v = Q/(A-a)
V = Volumetric displacement in m^3/rev Q= Flow rate of fluid
A= Circular piston area
 Power- a = Area of piston rod
The power generated by a frictional Force F = p * (A - a)
hydraulic motor is known as theoretical power. Power developed during extension and retraction
P=p*Q
Power P =T*ω p = pressure in N/m^2
Q= Flow rate in [7]
ω = Seed of motor in rad/sec
G. CONTROL VALVES-
 Flow Rate-
The flow rate hydraulic motor would
Valves are used in hydraulic systems to control
consume if there were no leakage is known as the operation of the actuators. Valves regulate pressure by
theoretical flow rate. creating special pressure conditions and by controlling
Flow Rate Q= V * n how much oil will flow in portions of a circuit and where
it will go. The three categories of hydraulic valves are
n = speed of motor in rev/s [7] pressure-control, flow- (volume-) control, and directional-
control valves have multiple functions, placing them into
F. CYLINDER (ACTUATOR)- more than one category. Valves are rated by their size,
pressure capabilities, and pressure drop per flow.
A basic actuating cylinder consists of cylinder
housing, one or more pistons and piston rods, and one or  Pressure Control Valve-
more seals. The cylinder housing contains a polished bore A pressure-control valve may limit or regulate
in which the piston operates and one or more ports pressure, create a particular pressure condition required
through which fluid enters and leaves the bore.

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 International Journal of Trend in Research and Development, Volume 2(5), ISSN 2394-9333
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for control, or cause actuators to operate in a specific
order. All pure pressure-control valves operate in a
condition approaching hydraulic balance. Usually the
balance is very simple: pressure is effective on one side or
end of a ball, poppet, or spool and is opposed by a spring.
In operation, a valve takes a position where hydraulic
pressure balances a spring force.
 Directional Control Valve-
A DCV is mainly required for the following
purposes:
[3] En Li, Zize Liang; “Design of hydraulic cylinder
pressure based”; March 2011
[4] X. S. Li; “Research on variable pump based system” ;
June 2012
[5]. N. Harris, McClaroch; “A end effector of an electro
hydraulically controlled robot; Oct 1984
[6]. S. A. Ahmed, A. J. Ishak; “Design of Gripper” ; Dec
2012.

1.To start, stop, accelerate, decelerate and change the [7]. “Fluid Power Generation Transmission and Control”;
direction of motion of a hydraulic actuator. Jagadeesha T., Thammaiah Gowda; 2013; page no. 42 to
2, To permit the free flow from the pump to the reservoir 287.
at low pressure when the pump’s delivery is not needed
into the system.
3. To vent the relief valve by either electrical or
mechanical control.
4. To isolate certain branch of a circuit. [7]

 Flow Control Valve-

Flow control valve achieve their primary
function of regulating the fluid flow by varying the
area of an orifice. Flow through control orifice is usually
considered to be turbulent and the quantity of the fluid
flowing given by,

q =KA ∆𝑝
Where q =Flow rate through the valve
A=Orifice area
∆𝑝 =Pressure drop across the orifice

CONCLUSION

Studying the various components used in

hydraulic system it helps to know the selection of proper
component used for any hydraulic system. In this study a
co-relation and co-ordination of different types of
hydraulic fluid, filter, reservoir, pump, motor, cylinders,
valves, power pack, end effectors is help to design of
hydraulic system.

References

[1] D. J. Dunn; “Basic hydraulic system and component”;

September 1994

[2] Chen Huanming; “Research on features of hydraulic

oil for hydraulic pump”: June 2012
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