WELCOME

TO

THE PRESENTATION

ON

Fluid Power and Drives (Hydraulics & Pneumatics)

By

N. S. SRIRAM 01.08.07 to 03.08.07

This course is an introduction to the
Fluid Power Systems
which contains two parts
Hydraulics and Pneumatics
 COURSE OBJECTIVES

The objectives of the course are to enable the delegates;

• To understand the basic principles of pneumatics and
hydraulics
• To identify pneumatic and hydraulic components and
their functions
• To learn Integration of Basic Electrical Control in the
Pneumatics/Hydraulics circuits.
• To read and interpret basic Hydraulics/Pneumatics, and
electro-pneumatics/hydraulics circuits using ISO symbols
• To design and draw basic and advanced circuits for
given problem descriptions
• To perform troubleshooting on pneumatic/hydraulics
system
 FLUID POWER BASICS

Fluid power systems are power-transmitting assemblies

employing pressurized liquid or gas to transmit energy from
an energy-generating source to an energy use area.

Fluid power system can be divided into two disciplines, viz.,

HYDRAULICS --------Employing pressurized liquid, and

PNEUMATICS--------Employing a compressed gas.

INDUSTRIAL HYDRAULICS

POWER HYDRAULICS
 Hydraulics (Power hydraulics) is the science of
transmitting force and/or motion through the
medium of a confined liquid.

Hydraulic power is used practically in every branch of

Industry.

Example : Machine Tool, Automobile, Aircrafts, Missiles, boa,

Bread making machines, Jacks for lifting heavy objects,
Hydraulic rams in Presses, elevators etc.,
Reason for this wide spread use is that a fluid is
one of the versatile means of transmitting power
and modifying motion

A FLUID is infinitely flexible, yet as

unyielding as steel.

Fluid can readily change its shape;

It can be divided into parts to do work in different locations;
It can move rapidly in one place and slowly in another; and
It can transmit a force in any one or all the directions.
Most of the Hydraulic machines in use today operate hydrostatically;
that is through pressure. Their study is technically referred to as
PRESSURE HYDRAULICS.

All Hydraulic systems depend on PASCAL’s Law.

PASCAL’S LAW:
It states that,
“Pressurized fluid within a closed container- such as cylinder
or pipe exerts force on all of the surfaces of the container.”
Pressure on a confined fluid is transmitted undiminished in all directions,
and it acts with equal force on equal areas, and at right angles to the
container walls.
The Basic Idea
The basic idea behind any hydraulic system is very simple:
Force that is applied at one point is transmitted to another point using an
incompressible fluid. The fluid is almost always an oil of some sort. The force is almost
always multiplied in the process. The picture below shows the simplest possible hydraulic
system:
A Simple hydraulic system consisting of two pistons and an oil-filled pipe connecting
them. Click on the red arrow to see the animation.
 BASIC CONCEPT OF A HYDRAULIC SYSTEM.

Hydraulics is the engineering science of liquid pressure and

liquid flow. Hydraulic power transmission systems are
concerned with the generation, modulation and control of fluid
pressure and flow.
A Hydraulic system consists of:

A Pump, which converts, available electric or mechanical

power from the prime mover to hydraulic power at the actuator.

The pump moves the liquid in the system. The intake of the
Pump is connected to a liquid source, usually called the Tank
or Reservoir.

Atmospheric pressure, pressing the liquid in the reservoir,

forces the liquid into the pump. (Pumping theory)

When the pump operates, it forces the liquid from the tank into
the discharge pipe at a suitable pressure.
The flow of the pressurized liquid discharged by the pump
is controlled by Valves.

Three control functions are used in most of the hydraulic

systems to control and regulate the fluid flow.

Control of the liquid pressure.

Control of the liquid flow rate, and

Control of the direction of liquid flow.

The fluid/liquid discharged by the pump in Fluid Power System is directed by
valves to:

• A Hydraulic Motor for developing rotary force (torque) and motion

or to

• A Hydraulic Cylinder when linear motion is desired.

• Both, hydraulic motor and hydraulic cylinder uses pressurized liquid as

their energy sources.

• Hydraulic motors operate in a reverse manner to that of a pump.

• Actuators convert hydraulic power to usable mechanical power output

at the point required.
The Direction Control of the piston in hydraulic cylinder or

the direction of rotation of the hydraulic motor depends on,

to which end of the cylinder or motor the liquid enters.

The Direction Control Valves (DCV) carries out this work of

directing the liquid to proper ports of the actuators. As

pressurized liquid enters one end, the existing liquid on the

other end must be drained. The drained liquid is led back to

the reservoir.
Connectors connecting various system components
provide power conductors for the fluid under pressure and
flow return to tank (reservoir). Fluid storage and
conditioning equipment ensure sufficient quality and
quantity as well as cooling of the fluid.

Hydraulic system is not a power source. Power

source is the prime mover such as Electric
motor or as an Engine, which drives the pump.
 HYDRAULIC FLUIDS:
The Oil/Fluid in a hydraulic system serves as the power
transmission medium. It is also the systems lubricant
and coolant.

Selection of the proper Oil is a requirement for

satisfactory system performance and life.

Purpose of hydraulic fluid:

The Hydraulic Fluid has four Primary purposes: viz.,

i) To transmit power,
ii) to lubricate moving parts,
iii)to seal clearances between parts, and
iv)to cool or dissipate heat, in hydraulic system.
 POWER TRANSMISSION
• As a power-transmitting medium, the fluid
must flow easily through lines and
component passages. Too much
resistance to flow creates considerable
power loss. The fluid also must be as
incompressible as possible so that action
is instantaneous when the pump is started
or a valve shifts. Fluid must transmit an
applied force from one part of the system
to another.
 LUBRICATION
• Hydraulic fluid provides internal lubrication in
most hydraulic components. Fluid must provide
adequate lubrication in bearings and sliding
surfaces in pumps, valves and actuators. Pump
elements and other wearing parts slide against
each other on a film of fluid.
• For long component life, the oil must contain the
necessary additives to ensure high anti wear
characteristics. Not all hydraulic fluids contain
these additives.
 SEALING
• In many instances, the fluid is the only
seal against pressure inside a hydraulic
component. Fluid must have adequate film
strength to seal clearances between
moving parts against leakages.

Continued....
 Sliding spool

Body

If this passage is under pressure, the fluid

film seals it from adjacent passages.

• The close mechanical fit and oil viscosity

determines leakage rate.
 COOLING
• Circulation of oil through lines and around the walls of the reservoir
gives up heat that is generated in the system.
• In addition to the above said primary functions, the hydraulic fluid
may have a number of other quality requirements. Some of them
are:
 Prevent rust.
 Prevent formation of sludge, gum and varnish
 Depress foaming
 Maintain its own stability and thereby reduce fluid replacement cost.
 Maintain relatively stable body over a wide temperature range
 Prevent corrosion and pitting.
 Separate out water
 Compatibility with seals and gaskets.
• These quality requirements results due to special compounding and
may not be present in every fluid.
• Properties of hydraulic fluids that enable it to carryout its primary
functions and fulfill some or all of its quality requirements are:
 Advantages / merits of Hydraulic System :

• Freedom of location of input and output power converters such as prime

movers, pumps and actuators. This ensures flexibility.

• Infinitely variable control of output force, output torque, output

speed and actuator position. This provides control of speed & forces over
wide range. Actuators (linear or rotary) of a hydraulic system can be driven
at infinitely variable speed by either varying the pump delivery or by using
a flow control valve. A pressure adjusting / regulating valve can be used to
vary the operating pressure to adjust the output force or output torque.

• Extremely high output forces and force multiplication is possible by means

of the “hydraulic lever”.
• Drive system in hydraulics is reversible.
A hydraulic actuator can be reversed instantly while in
full motion without damage. A 4-way direction control
valve or a reversible pump provides the reversing
control. A pressure relief valve protects the system
components from excess pressure occurring during
instantaneous reversal. Other types of drive like Electric
motor or I.C. Engine etc., have to be slowed down,
stopped completely before reversing)

• Automatic valves, to prevent system breakdown, can

achieve safety and overload protection of the system
components.

• Low inertia and ease of shock absorption during actuator

motion start and stop operation is smooth & quiet.
Vibration is kept to minimum.
• Emergency power can be stored in an
accumulator.

• Greater efficiency and economy due to low

friction losses and high system reliability
(Efficiency is approx. 70% -80%).

• Design of system is simpler.

In most cases few pre-engineered components
will replace complicated mechanical linkages.
• Small packages – The system has high power
to weight ratio, ensuring compactness.

• The hydraulic drive system can be stalled

without damage when overloaded and will
startup immediately when the load is reduced.
During stall, the relief valve simply diverts
pump delivery to tank which results only in loss
of Horsepower.

• Hydraulic systems are self-lubricating and

power can be diverted to alternative actuators.
 Demerits / limitations of a
hydraulic system :
• Precision parts are necessary in fluid power
system.
• Precision parts are exposed to unsympathetic
climates and dirty atmospheres and hence call
for very cautious and regular system
maintenance.
• Initial system cost is high. But high efficiency,
minimum frictional losses keep the cost of power
transmission at minimum. This offsets the
disadvantage of high initial cost.
• Contamination of hydraulic fluid is inevitable & is
the most serious disadvantage of using fluid
power. To prevent clogging of precision
clearances in the fluid actuators and valves
requires extensive filtering systems to maintain
cleanliness in oil.

• Leaking problems, both internal and external, are

sure to occur. Special provisions must be made to
accommodate such leakages. Line ruptures and
bursts can cause hazard due to high velocity oil
jets. Oil might also be flammable posing fire
hazards.

• Controllability of hydraulic systems is not as easy

as electrical systems.