CHAPTER 1

INTRODUCTION

1.1. Introduction

Hydraulics has proven to be the most efficient and economical system

adaptable to aviation. First used by the ancient Greeks as a means of elevating the
stages of their amphitheaters, the principles of hydraulics were explained
scientifically by the seventeenth century scholars Pascal and Boyle. The laws
discovered by these two men regarding the effects of pressure and temperature on
fluids and gases in confined areas form the basis of the principle of mechanical
advantage; in other words, the "why and how" of hydraulics. This chapter explains to
you the basic applications of hydraulics in Army aviation and the characteristics of
these systems. The explanations include detailed definitions of the terminology
peculiar to hydraulics with which you must be familiar to fully understand this
subject. In aviation, hydraulics is the use of fluids under pressure to transmit force
developed in one location on an aircraft or other related equipment to some other
point on the same aircraft or equipment. Hydraulics also includes the principles
underlying hydraulic action and the methods, fluids, and equipment used in
implementing those principles.

The word "hydraulic" is derived from two Greek words: "hydro" meaning
liquid or water and "aulos" meaning pipe or tubing. "Hydraulic," therefore, is an
adjective implying that the word it modifies is in some major way concerned with
liquids. Examples can be found in the everyday usage of "hydraulic" in connection
with familiar items such as automobile jacks and brakes. As a further example, the
phrase "hydraulic freight elevator" refers to an elevator ascending and descending on
a column of liquid instead of using cables and a drum. On the other hand, the word
"hydraulics" is the generic name of a subject. According to the dictionary "hydraulics"
is defined as a branch of science that deals with practical applications (such as the
transmission of energy or the effects of flow) of a liquid in motion.
 “Hydraulics” is one of drive systems to control machinery and equipment,
comparable with pneumatics and electricity. It was in the early 1900’s that practical
hydraulic applications were first seen in the marketplace. A hundred years before that,
“water hydraulics,” the origin of the fluid power systems, emerged. Figure 1.1 traces
the development history of some typical water and oil hydraulics. Recently,
production machinery and their drive systems have been required to be
environmentally friendly; “water hydraulics” is attracting attention again because of
its cleanliness and safety.

Figure 1.1 Hydraulic Application Trends and Milestone

Hydraulics, which owes much to the high lubricity of mineral oils being used as
working fluids, offer compact, high power, and easy-to-control system components in
various industrial fields. In 2004, total shipments exceeded 270 billion yen, excluding
hydraulic products manufactured in-house by construction machinery suppliers and
power steering pumps for automobiles.
According to the statistics, the global market scale for hydraulic products is estimated
at approximately two trillion yen. The market is shared equally among North
America, the EU countries, and Asian countries including Japan.

The advantages of hydraulics are as follows.

(1) Allows easy speed and position control;

(2) Facilitates stepless power control;

(3) Easily changes directions of movement;

(4) Capable of accumulating energy;

(5) Smoothly provides safety mechanisms, and;

(6) Allows for combination with electric controls.

Compared to pneumatics and water hydraulics, oil hydraulics is:

(1) Superior in respect to lubricity and rust resistance and easy to maintain;

(2) Able to provide compact systems that operate under high pressures, and;

(3) Superior to pneumatics in respect to the rigidity of control and response speed.

Basic components to be used in hydraulic systems are categorized as follows.

(1) Energy converters (hydraulic pumps, motors, and cylinders)

(2) Energy controllers (directional, pressure, and flow control valves)

(3) Accessories (reservoirs, filters, accumulators, sensors, etc.)

1.2 Aim and Objectives

The main aim of the thesis is to design hydraulic system for dump truck. The
main objectives of the thesis are;

1. To study the operation of hydraulic system in dump truck,

2. To study hydraulic actuator

3. To study hydraulic pump

 4. To calculate the design of hydraulic actuator for dump truck.

1.3 Scope of the Thesis

The scope of the thesis is to design calculation of hydraulic cylinder for dump
truck. And to study the working principle of hydraulic system of dump truck and
efficient, the advantages and goodness for society.

1.4 Implementation Program

The implementation program for this thesis is carried out by the following
procedures.

1. Studying the theory of hydraulic system for dump truck

2. Studying the type of pump and hydraulic actuator

3. Calculating the design of hydraulic actuator

1.5 Outline of the thesis

There are five chapters in this thesis. Chapter one includes introduction, aim
and objectives, scope of thesis, implementation program and outline of the thesis.
Then, history and components of hydraulic system are expressed in Chapter two.
Hydraulic system of dump truck and theories are mentioned in Chapter three. Design
consideration and calculation of hydraulic actuator are expressed in Chapter four.
Finally, discussions, conclusions, and recommendations of this thesis are described in
Chapter five.
 CHAPTER 2
2.1 History of Dump Truck
Check out this throwback1920 dump truck tipper! The first dump trucks with
motors were invented in 1910 by small equipment companies like Galion Buggy
Company, Lauth-Juergens, and Fruehauf Trailer Corporation. Shortly afterward,
hydraulic dump beds came about, thanks to Wood Hoist Company.
Old-fashioned versions of dump trucks have been around even longer, well
before diesel or gasoline engines graced the earth. Horse-drawn two-wheel carts were
commonly employed around the railroad and in coal mines to haul and dump material.
The first farm dump truck dates back to 1896 when Thornycroft developed a steam
dust cart in Europe.
Dump Trucks became very popular during World War 1 because they were in
huge demand. When Fruehaul introduced hydraulics into the picture in the early
1920s, the “Bathtub Dump” became a big seller for mining companies, heavy hauling
companies, and road construction outfits.
Today, Dump trucks are designed for a myriad of purposes like hauling rocks
and gravel, dirt, refuse, and most anything else that can be loaded. Landscapers,
construction companies, and gravel pit crews are among those who use them.
Available in diesel and gas versions, Dump Trucks can be found with both
standard and automatic transmissions. Isuzu, International, Cat, and Hino are some of
the best and most popular brands on the market.
Dump Trucks are well-known for specifically accommodating the needs of a
wide range of work. For that reason, they come in tons of shapes, sizes, and types
including Standard Dump Trucks, Semi-Trailer Dump Trucks, Transfer Dump
Trucks, Truck and Pups, Super Dumps, Semi-Trailer Bottom Dump Trucks, Side
Dump Trucks, Double and Triple Trailer Bottom Dump Trucks, Winter Service
Dump Trucks, Roll-Off Dump Trucks, Off-Highway Dump Trucks, and more. For
those who have highly specialized needs, Dump Trucks can be customized.
In the past, Dump Trucks were considered dangerous to operate and to be
around in general. New technology has stepped in to help by better balancing that
prevents the trucks from tipping over and also sound an alarm the vehicle is backing
up.
Dump Trucks have come a long, long way since the first one was invented. If
you are embarking on a new company or are perfecting your existing one, a new
Dump Truck is sure to help you maximize your business.

Figure 2.1 Dump Truck

2.2 Components of Hydraulic System

Hydraulic systems are incredibly complex and all vary slightly depending on
their intended use. Every system must contain 7 different basic components in order
to function correctly. These are
1. a reservoir oil tank,
2. pipes,
3. a hydraulic pump,
4. an actuator,
5. valves,
6. filters,
7. power supplies

Figure 2.2 Basic Hydraulic System

2.3 Reservoir of Hydraulic System
The hydraulic reservoir can be thought of as a container that is capable of
holding the fluid required by the system. It also includes a reserve to cover any kind
of losses from minor leakage and evaporation. The reservoir can be made mainly to
provide space for the expansion of the fluid, permit air entrained in the fluid to escape
and help in cooling the fluid.

2.3.1 Why Is Hydraulic Reservoir Required?

Hydraulic systems always require a finite quantity of fluid usually liquid, that
should be stored and reused continually as the systems keep on working. Thus, part of
a hydraulic reservoir or tank is a very important part of hydraulic systems. This
reservoir or tank may be a part of the framework of the main machine or maybe a
separate stand-alone unit. In both cases, the design of the reservoir and
implementation play an important role.
Poor tank design can greatly reduce the efficiency of a well-designed
hydraulic system. A hydraulic reservoir does not only provide a place to put fluid, but
it also does much more than that. A well-designed reservoir is also used to dissipate
excess heat energy, allow time for contamination to drop out of the fluid, and allow
air bubbles to come to the surface and dissipate out of the fluid. It might give a
positive pressure to the inlet of the pump and makes a convenient mounting place for
the pump and its motor, and valves.

2.3.2 Standard Layouts of Hydraulic Reservoirs:

1. Pump on top: This layout is a really common reservoir/pump layout and is used by
many suppliers. The top surface, which is flat, of a standard reservoir, is a perfect
place to mount the pump and motor.
The main condition for this configuration is that the pump must create a
vacuum which is enough to increase as well as accelerate the fluid into the inlet of the
pump. For most reservoirs or pumps, this is not a big problem, however, it is not the
best situation for any reservoir. The piping done in this layout should be sealed, must
be as short as it can be made, and have very few or no bends.
2. Pump alongside tank: This design can be considered satisfactory for any type of
reservoir. A lot of suppliers prefer this configuration. This layout is sometimes known
as a flooded suction, mainly because the pump inlet is always filled with fluid.
 Although the inlet of the pump always has fluid in it, this creates some
vacuum in the line of the inlet when the reservoir is running. A reservoir or pump
with its inlet below the level of the fluid no longer has to raise the fluid, but it does
have to accelerate and move it. But, this design is considered far better than the pump
on top layout and can extend the service life of any type of configuration of the tank.
3. Pump under tank: This design places the pump below the reservoir to take the
benefit of static head pressure. There is always some pressure at the bottom of any
fluid column. With the tank placed above, the pump not only consists of fluid at its
inlet all the time, but this fluid also can be at 2- to 4-psi positive pressure.
This configuration can prove to be difficult to work on without enough
headroom for the mechanic.

Figure 2.3 Hydraulic Reservoir

2.3.3 Accessories of The Hydraulic Reservoir:

No matter what is the size or style of the reservoir being used, it is always
suggested that some or all of these commonly used accessories are included in the
construction of the reservoir:
• Visual fluid level/temperature gauge
• Air breather/filler cap assembly
• Clean-out cover (bolt-down top)
• Fluid level switch
• Fluid temperature switch
• Magnet rod assembly
• Fluid drain/sampling valve
• Corrosion-resistant interior coating

2.3.4 Maintenance of The Hydraulic Reservoir:

All industrial hydraulic systems must include the need for pressure line filters,
return line filters and reservoir air breathers to decrease the number of contaminants
of fluid entering the tank. Some systems must also incorporate suction strainers or
some filters. Filter indicators or switches and a maintenance schedule must be
included to make sure that the dirty filter elements are replaced timely. Lastly, it is
always suggested that the reservoir be drained and the inside portion is cleaned at
least once a year.

2.4 Pipes
Hydraulic piping is a very important part of the hydraulic system. Hose pipe
flexibility enables components to be positioned inside the most efficient places,
because the hose is able to bend all-around corners, through tight places or across
long distances. Here is a few things you might want to know when it comes to
hydraulic piping.

2.4.1 What is Hydraulic Piping?

Hydraulic piping provides transportation for fluid from one component to
another. It can provide an inherent versatility to designers at times.

2.4.2 SAE Standards

The SAE answers questions regarding its J517 hydraulic hose standard. This
standard is the most common point of reference in industrial hydraulics. The J517 are
guideline that apply to the SAE 100R series of hoses.

2.4.3 Hydraulic Hose Construction

Hydraulic hose usually consists of an inner tube that carries the fluid, a
reinforcement layer and a protective outer layer.
 The inner tube must be compatible with the fluid it is carrying. It must also be
flexible. Compounds that are most commonly used are synthetic rubber,
thermoplastics, and PTFE (sometimes called Teflon).
The reinforcement layer consists of sheaths of braided wired, spiral-wound
wire or textile yarn. Depend on the environment, the outer layer is resistant to
weather, oil or abrasion.
Hydraulic hoses have limited life. In order to better extend the life of a hose is
to size it properly and use the appropriate type of hose needed. Although these will
help, there are many different factors that affect how long a hose will last. According
to SAE, some factors that play the biggest role of a hose lifespan include flexing a
hose less than the minimum specification, twisting or pulling of the hose, operating
the system at the incorrect temperature and not following the instructions properly.

2.4.4 Selecting the Proper Hose

There are many factors to consider when selecting a hose.
Size is always an important factor to consider. Having a hose that is too short
may cause the hose to contract and stretch, leading to a reduced lifespan. Measuring
the diameters of the hose, inside and out, using an exact precision-engineered caliper,
will aid choosing the proper hose size. When hose-support clamps or when hoses are
being routed through bulkheads, check individual hose specification tables for ODs in
the catalogs from the suppliers. Be sure to cut the new hose the same length as the one
you are replacing.
Temperature is also important to consider. All hoses are based on the fluid
temperature, ranging from 200° to 300°F. High temperature exposure can cause hoses
to lose flexibility. Not using hydraulic oil with proper viscosity can make this problem
worse. To prevent this from happening always follow the manufacturer’s
recommendations.
Exceeding the temperature recommendations can reduce the life of the hose
considerably. Acceptable temperatures depend on the materials being used. External
temperatures only become a factor if the hoses are exposed some sort of heat source.
You can reduce this risk of the by using insulating sleeves to protect the hoses.
Another factor that is important to consider is the application. It is important
for the hose to meet the bend requirements. If the bend radius is too small it can injure
the hose reinforcement and reduce its lifespan.
 By routing high-pressure hydraulic lines parallel to machine contours, it can
reduce the line lengths and minimize the number of hard-angle, flow-restricting
bends. Not only does this practice save money, it also protects lines from external
damage.
The materials are also an important factor to take into consideration. Checking
the compatibility is required to make sure the tube compound is compatible with the
fluid. Some factors that will affect the chemical compatibility of the tube include
elevated temperature, fluid contamination and concentration. Petroleum-based oils are
compatible with most hydraulic hoses.
Pressure Capabilities is another factor to consider. The pressure of the hose
must always be greater than or equal to the maximum system pressure, including
spikes in pressure. Pressure spikes will shorten the lifespan of the hose.
Another important factor to consider is the hose ends. The hose must be
compatible with the coupling-to-hose mechanical interface. This is so that the
connection of the components mating will result in leak-free sealing.
The last factor is delivery. Consider the availability of the product and how
soon it can be delivered to the distributor or end user. These will maximize flexibility
and avoid any delays.

Figure 2.4 Pipes

2.5 Hydraulic Pumps

A hydraulic pump is a mechanical device used in hydraulic systems for
converting mechanical power to hydraulic energy. They work by pushing large
amounts of hydraulic fluid through a cylinder or motor. Different types of hydraulic
pumps are capable of generating different types of liquid pressure.
Hydraulics is a flexible and efficient form of energy transfer. Many modern
machines and devices make use of innovative hydraulic pump technology as their
source of power.
There are several types of hydraulic pumps that are used in various kinds of
equipment and machinery. The three most common types of hydraulic pumps are gear
pumps, piston pumps, and vane pumps. However, there are other kinds of pumps as
well. They are hydraulic pumps with a clutch, hydraulic pumps with a dump valve,
and hydraulic pumps used for refuse vehicles such as dry valve pumps.
In this article, we’ll look into the different types of hydraulic pumps their
features, and their applications.

2.5.1 Working principle of hydraulic pumps

The principle of operation of the hydraulic pump is based on the method of
displacement which involves the use of mechanically sealed chambers to transport
fluid from the inlet or suction port to the outlet or pressure port.

2.5.2 Types of Hydraulic Pumps

There are generally 2 categories of hydraulic pumps – fixed displacement
pumps and variable displacement pumps. The following are the most used type of
hydraulic pumps:
1. Vane Pump
2. Gear Pump
3. Piston Pump
4. Screw Pump

2.5.3 Vane pumps

A vane pump has a cartridge that is located inside a housing. The input shaft
of the pump is attached to the back of the cartridge. The output shaft of the pump is
connected to the front of the cartridge. The rotating of the input shaft of the pump
causes oil to be pumped. The more that the input shaft rotates, the more that oil will
be pumped out of the pump. In a vane pump, the vanes are on the cartridge. When the
input shaft rotates, the vanes change the area of the cartridge.
 These are hydraulic pump that operates with low flow pulsation. Vane pumps
produce less noise. They have low-pressure capability. The Vane pump produces a
relatively high speed of up to 3,600rpm at a hydraulic pressure of 300ba. They have
usually used injection molding and die casting machines applied by several industries
as well as land and road construction companies.
Vane pumps come in different types:
 Variable displacement
 Fixed displacement
 Single dension vane pump
 Double dension vane pump and
 Triple dension vane pump.

Figure 2.5 Hydraulic Vane Pump

Advantages of Vane pumps
 Operationally quiet
 They have a moderate efficiency
 They come with many control options
Disadvantages
 Gives off much heat waste
2.5.4 Gear pumps
Gear pumps are hydraulic pumps with a simple design and widespread
availability. They are employed in many hydraulic systems due to their design and
working operation. Gear pumps have only a few moving parts and operate at a
pressure of up to 210 bar. They are fixed displacement, also called positive
displacement pumps. The same volume of flow with each rotation of the pump’s shaft
is produced. The displacement chambers in a gear pump are formed between the
rotating gear wheel and the housing of the hydraulic pump.
Different types of gear pump available include:
 External gear pumps
 Internal gear pump
 Screw spindle jump
 Gear ring pump.

Figure2.6 Hydraulic Gear Pump

Applications: The gear pumps most commonly used in open center hydraulic systems
are the gear pump, the vane pump, and the lobe pump. Gear pumps come in a wide
range of sizes. The smaller ones will be used in engine systems with low pressures
and low horsepower needs. The larger sizes are used in high-pressure applications.
Advantages of Gear pumps
 They are easy to install
 Economical
 Reliable when in use
Disadvantages
 Relatively lower efficiency
 They give off noise during operation

2.5.5 Piston pumps

Hydraulic piston pumps are used when high operating pressures are required,
these types of hydraulic pumps deal with higher pressure than gear pumps in the same
displacement. Reciprocating pistons are used to alternately generate suction and flow
discharge. However, its limitation is the higher cost of acquisition and it is usually
susceptible to contamination. Some designs of vane pumps are capable of 95%
efficiency. Piston pumps are designed to withstand higher pressure than gear or vane
pumps.
There are two types of piston pumps:
 Axial piston pump and
  Radial piston pump.

Figure 2.7 Hydraulic piston pump

Advantages of Piston pump

 They are highly efficient
 Used to generate suction and flow discharge
 Can withstand higher pressure
Disadvantage
 They are expensive
 Susceptible to contamination

2.5.6 Screw pump

This type of pump is a fixed displacement pump that is widely used in
hydraulic systems. It features two screws that are interconnected and are enclosed
inside a single chamber. Screw pumps are used in onboard ships with a hydraulic
pressure system. They are used for high flows with relatively low pressure. They are
used in controlling ball valves and also to help drive the steering and other parts. They
give a low sound level but have a low-efficiency level. The hydraulic transition is also
usually transmitted in an opposing direction to the flow.
Advantages of Screw pump
 Quiet operation
Disadvantages
 Low efficiency
 Figure 2.8 hydraulic Screw pump

2.6 An Actuator
Hydraulic systems are used to control and transmit power. A pump driven by a
prime mover such as an electric motor creates a flow of fluid, in which the pressure,
direction and rate of flow are controlled by valves. An actuator is used to convert the
energy of fluid back into the mechanical power. The amount of output power
developed depends upon the flow rate, the pressure drop across the actuator and its
overall efficiency. Thus, hydraulic actuators are devices used to convert pressure
energy of the fluid into mechanical energy.
Depending on the type of actuation, hydraulic actuators are classified as
follows:

1. Linear actuator: For linear actuation (hydraulic cylinders).

2. Rotary actuator: For rotary actuation (hydraulic motor).
3. Semi-rotary actuator: For limited angle of actuation (semi-rotary actuator).
Hydraulic linear actuators, as their name implies, provide motion in a straight
line. The total movement is a finite amount determined by the construction of the unit.
They are usually referred to as cylinders, rams and jacks. All these items are
synonymous in general use, although ram is sometimes intended to mean a single-
acting cylinder and jack often refers to a cylinder used for lifting. The function of
hydraulic cylinder is to convert hydraulic power into linear mechanical force or
motion. Hydraulic cylinders extend and retract a piston rod to provide a push or pull
force to drive the external load along a straight-line path.
Continuous angular movement is achieved by rotary actuators, more generally
known as a hydraulic motor. Semi-rotary actuators are capable of limited angular
movements that can be several complete revolutions but 360 degree or less is more
usual.

Figure 2.9 hydraulic actuator

2.6.1 Types of Hydraulic Cylinders
Hydraulic cylinders are of the following types:
1. Single-acting cylinders.
2. Double-acting cylinders.
3. Telescopic cylinders.
4. Tandem cylinders.

2.6.2 SINGLE ACTING CYLINDER

• It consist of piston inside a cylindrical housing called as barrel.
• On one end is attached a rod, which can reciprocate.
• At the opposite end, there is a port for the entrance and exit of the oil.
• They produce force only in one direction by hydraulic pressure acting on the
piston.
• The return of the spring is not done hydraulically, it is either done by gravity
or spring.

2.6.3 DOUBLE ACTING CYLINDER

• A double acting cylinder with piston on both sides is a cylinder with a rod
extending from both the ends .
• The application involves in a process where work can be done by both the
ends of the cylinder, thereby making the cylinder more productive .
 • Double rod cylinder can withstand higher side loads because they have an
extra bearing on each rod to withstand the loading.

2.6.4 TELESCOPIC CYLINDER

Construction:
• They generally consist a nest of tubes and operate on the displacement
principle.
• The tubes are supported by bearing rings, the innermost set of which have
grooves or channels to allow the fluid flow.
• The front bearing assembly on each section includes seals and wiper rings.
• Stop rings limit the movement of each section, thus preventing the
separation.
• For a given input flow rate, the speed of operation increases in steps as each
successive section reaches the end of its stroke. Similarly, for a specific pressure, the
load shifting capacity decreases for each of the successive section.

2.6.5 TANDEM CYLINDER

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

2.7 Valves
There are many types of hydraulic valves available in the industry. Hydraulic
valves are mechanical equipment for controlling the flow of fluid in hydraulic pipes
or systems. They can be utilized to thoroughly check the flow level to a specific
domain, redirect pressurized fluid or close a line.
Hydraulic valves can be used to control the flow of fluid in a circuit as well as the
quantity of fluid power. As a result, the pressure and flow rate in various portions of
the circuit would be controlled by these valves. Hydraulic valves can regulate system
pressure. The hydraulic valve relieves the pressure on the pump or lowers the
temperature of the oil before it enters the hydraulic circuit.

Figure 2.10 Hydraulic four-way valve

2.8 Filters
Many fluid power systems fail simply because there is too much
contamination in the medium. In fact, some estimate that 75% of all fluid power
failures can be attributed to contamination issues.
There are multiple reasons why fluid can become contaminated. Use and wear
of the components, poor plumbing, and contamination brought in with new fluid (or
new components) are just a few of the possibilities. This is why no fluid power system
can be complete without the use of a filter. Hydraulic filters keep the hydraulic fluid
contaminant free.

Figure 2.11 Filters

2.9 TRUCK MOUNTED HYDRAULIC PARTS

Truck mounted, or mobile, hydraulic systems are required to operate under
more rigorous conditions than stationary hydraulic systems. Regardless of their
application, the basic components include a power source, reservoir, pump,
directional control valve, and a cylinder.
Gear pumps - Hydraulic pumps are capable of generating a considerable amount of
fluid power in a very compact space. Gear pumps are the most common design used
for dump trucks and dump trailers. The typical gear pump has a pair of intermeshing
gears, one of which is connected to a drive shaft. As the shaft turns, the two gears are
put into motion to pressurize the hydraulic fluid.
Telescopic cylinders - Hydraulic cylinders convert fluid energy to mechanical energy.
They also multiply force, making it possible to raise a dump body, for example. They
may be single acting or double acting; single stage or multiple (telescopic) stage.
Most telescopic cylinders are single acting, which means they are extended by
hydraulic force but rely on gravity or an opposing force or weight to retract. This is
the most common type of cylinder found on dump truck bodies.