CHAPTER 1

A N IN TR O D U C TIO N TO H Y D R A U LIC S

IS E D
REV ext
d ed T
U p g ra ra p h ic s
and G
PS I
10 00

SI
50 0 P

5
45 G PM
GP M

D R A U L IC S
HY

M
D U S T R IA L

AN
or ce

UAL
re a
re
re s su
IN
 2. A 10 lb. force is applied
to the stopper w ith a surface area of
one square inch.

3. This results in 10 lb of force on

every square inch of surface area
1. The bottle is filled in the container.
w ith liquid, w hich is
not com pressible.

4. If the bottom has an area of 20 sq. in.

and each square inch is pushed on by
10 lb. of force, the entire bottom of the
container receives 200 lb. push.

Figure 1. P ressure (force per unit area) is transm itted throughout a confined fluid

C O P Y R IG H T C (1999) V IC K E R S , IN C O R P O R AT E D
A . S IM P LE H Y D R A U LIC P R E S S

1. A n in put force of 10 lb. on 3. T his pressu re w ill support

a one squa re inch p iston... a 100 lb. w eigh t if th is is a 10 sq . in.
piston.
10 lb.

100 lb.

2. develops a pressure of 10
pounds per square inch (p si)
throug ho ut the container

4. T he force s are proportional to the

pisto n areas.

10 lb. 100 lb.

=
1 in. sq. 10 in. sq.

Fig ure 1.2A P a scal’s p rin ciple ap plied to th e hydraulic press.

C O P Y R IG H T C (1999) V IC K E R S , IN C O R P O R AT E D
1. A n input force of 10 lb. here... 2. W ill balance 100 lb. here...

100 lb.

3. if this arm is 10 tim es 4. this arm .

as long as...

B . S IM P LE M E C H A N IC A L LE V E R

Figure 1.2B S im ilarity betw een sim ple press and m echanical lever

C O P YR IG H T C (19 99) VIC K E R S, IN C O R P O R AT E D

1. M oving the sm all piston 10 in
displaces 10 cu. in. of liquid.
(1 sq. in. X 10 in. = 10 cu. in.)

2. 10 in. cu of liquid w ill m ove

the larger piston only one inch.
10 LB . (10 in. sq. X 1 in. = 10 in. cu.) 100 lb.

1 in.
10 in.

3. The energy transfer here equals 4. The energy transfer here also is 100 in. lb.
10 lb. X 10 in. or 100 in. lb. ( I in. X 100 lb. = 100 in. lb.)

Fig u re 1 .3 En e rg y c a n n e ith e r b e c re a te d n o r d e stro ye d

C O P Y R IG H T C (1 99 9) V IC K E R S , IN C O R P O R AT E D
 2. L ines carry the fluid to a ctuato rs w hich are
pushe d interna lly to p roduce a m ech anical
output w hich m oves the load

1 . The pu m p pushes the hydraulic

fluid into the lin es.
LO A D

P iston & R od

To R eservoir

E lectric M otor

3. S om e actua tors operate in a straight line

(linea r actuators ). the y are ca lled ram s or
PU M P cylinders. They are used to lift w eight, exert force,
cla m p, ect.

A . LIN E A R A C T U ATO R

B . R O TA RY A C T U ATO R M O TO R

E lectric M otor

PUM P
R O TA R Y D R IV E S H A F T

4. R otary actuators or m otors g ive the system rotating

outpu t. T hey can be co nnected to pulleys, gears, rack
and p inions, conveyors, ect.

F ig 1.4 Linear a nd R otary A ctuato r

C O P Y R IG H T C (1999) V IC K E R S , IN C O R PO R AT E D
A . M A X IM U M S P E ED 3. the p iston w ill m ove
2 . and the volum e is 10 g al... this far o n on e m in ute.

1. If the p um p con stan tly delivers

10 gallons per m inute...
LO A D

E lectric M otor

PUMP

6 . the actuator receives on ly 5 ga l. a nd

A. REDUCED SPEED o nly trave ls ha lf as fa r in one m in ute.

5 . b ut a valve restricts the flow...

FLO W C O N TR O L LO AD
VA LV E

R E L IE F VA LV E

4. If the pum p
delivers 1 0 gpm ...

5 g al.

E le ctric M otor

PUMP 7 . E xcess 5 gp m . is d ive rted ove r th e

relief valve.

Figure 1.5 H ydraulic D rive S peed is Va riable

C O P Y R IG H T C (1999 ) VIC K E R S , IN C O R P O R ATE D
 2. pum p d elivery is directed to the 3. T he p isto n rod extends.
cap end o f the cylinder.

1. In this position of the

directional valve... LO A D

4. E xhaust oil is pushed out of

the rod end and back to tank

E lectric M otor

D IR E C T IO N A L VALV E
PUMP

6. T he p isto n rod retracts.

5. In anoth er position , oil
is directed to the rod end of the cylinde r.

LO A D

7. Exhaust oil from the cap end is

E lectric M otor
dire cted to tank.

PUM P
8. T he relief valve p rotects the system by
m om entarily diverting flow to tank during
reve rsing, and w hen the piston is stalled or
stops at the end of stroke.

Figure 1.6 H ydraulic D rives are R eversible

C O PY R IG HT C (1999) V IC K ER S , IN C O R P O R ATE D
 0.4 psi
1. If this w eigh t is divided eq ually ove r the 144 sq. in.
the fo rce o n the bottom of each square inch is .4 lb.
T hus the p ressure a t the bottom is .4 psi.

1 cub ic foot of oil w eig hs ap pro x. 58 lbs

12 in.

12 in.
2 psi 10 ft.

12 in.

2
4 psi
A rea = 14 4 in
F orce 58 lbs
P ressure =
A rea = 144 in
2
= 0.4 psi

2. If the flu id colum n height is 10 ft then the pressu re

at the base of the colum n w ill be 4 psi. It is the
height of the colum n, not its volum e that determ ines
th e pressure.

F igure 1.7 W eight of O il C reate s P ressure

C O P Y R IG H T C (1999) V IC K E R S , IN C O R P O R AT E D
A . FLU ID AB O V E PU M P C H A R G E S T H E IN LE T.

1. If the fluid level is 10 ft. above

the inlet of the pum p a charge
or “ head pressure” o f 4 psi.
w ill be presen t at the pu m p inle t.

10 ft.

B . O IL LE V E L B E LO W

2. If the pum p is 10 ft. above the fluid level, then the pum p
m ust create a vacuum equal to 4 psi just to push the fluid
into the pum p inlet.

10 ft.

F igure 1.8 P um p Inlet Loca tions

C O P YR IG H T C (1999) V IC K ER S, IN C O R P O R ATED
1. O n the intake stroke, the pum p 2. A partial vacuum or void is
piston m oves out expanding the created here.
pum ping cham ber

O utlet

Inlet
A tm ospheric
P ressure 3. A tm ospheric pressure
pushes the fluid into the
pum p to fill the void. Fluid
is pushed not pulled into
a pum p.

Figure 1.9 P ressure D ifferences P ush O il Into P um p

C O P Y R IG H T C (1999) V IC K E R S , IN C O R P O R ATE D
 1. T he load is 8000#
A
2. T he area is 10 sq. in.

LO A D
500
1000
750 1 250
1500
8000#
250 17 50
0 2 000
psi

E lectric M otor

PUMP 3. The pressure equals the force area

equals 8000 lb. 10 in. sq. = 800psi.

F igure 1.10A P ressure Loss R equires Full Loss of P um p O utlet

C O P YR IG H T C (19 99) V IC K E R S , IN C O R P O R ATE D

 1. T he load is 8000#
2. T he area is 10 sq. in.

LO A D
7 50
500
1000
1250
1500
8000#
250 1 75 0
0 200 0
psi

E lectric M o tor

PUM P 3. The pressure equals the force area

equals 8000 lb. 10 in. sq. = 800psi.

4 . If 9.5 g pm . is lost through a

B leak...

5. the oil m u st still m ove the

piston.

LO A D
750
500
1000
1250
1500
8000#
250 1750
0 2000
psi

E lectric M otor

PUM P 6. T here is still a 8000# load on the piston, the

cylinder still m oves, bu t at a low er rate of
speed. T he pressure is still 800 psi.

F igu re 1.10 P ressure Loss R equires F ull Loss of P um p O utlet

C O P Y R IG H T C (1 99 9 ) V IC K E R S, IN C O R P O R ATE D
 1. W h en the fa ucet is w ide op en,
2. T he re is virtua lly n o p ressure in 7 50
50 0
10 00
1 250
15 00
R E LIE F VALV E all th e pum p flow p asse s
the system a t th is tim e . 250 17 50
20 00 10 00 psi unre stricted .
0
ps i

1 0 g pm
E lectric M otor 10 gp m

PUMP

4. P ressu re in the system increase s as 10 00

the re sistan ce to flow increa se s. 7 50
50 0
1 250
15 00
R E LIE F VALV E 3 . Th e restrictio n is no t sufficie nt
250
0
17 50
20 00 10 00 psi to lim it the qu antity of flow out
ps i of th e fa ucet

1 0 g pm
E lectric M otor 10 gp m

PUMP

6. P ressu re in the system increase s 10 00

un til the re lie f va lve pre ve nts a ny 7 50
50 0
1 250
15 00
R E LIE F VALV E 5 . If the restrictio n is incre ased
furthe r rise in p re ssu re . 250
0
17 50
20 00 10 00 psi furthe r, the ra te of flo w w ill
ps i de cre ase un til th e fa ucet is fully
clo sed stopp in g a ll flow.

1 0 g pm
E lectric M otor 5 g pm
5 gp m

PUMP 7. Th e u nu se d flo w is diverted o ver the

relief valve.

C O P Y R IG H T C (199 9) V IC K ER S , IN C O R P O R AT E D

Figure 1.11 Pre ssu re C a used by R e strictio n and L im ite d b y P ressure C o ntrol Valve
 A
A

100 psi

1. T he fluid can follow one of three paths, it w ill

alw ays take the path of least resistance. B

200 300 400

100 500
50 600
700
200 psi
0
psig

300 psi

2. T he fluid follow s the path of least resistance

( T hrough valve A ) because the spring in the
valve offers the low est resistance to flow.

B
100 psi
X
B

200 300 400

100 500
50 600
700
200 psi
0
psig

300 psi

3. W ith the path through valve A blocked,

the path through valve B becom es the
path of least resistance, the pressure in
the system becom es 200 psi.

CO PY RIG H T C (1999) VIC KE R S , INC O R PO R ATE D

5. 150 psi. of back pressure added to 3. It takes 50 psi of hydraulic pressure
here to overcom e the spring 2. T he pressure at this
the 150 psi. spring value of the
point is virtually zero
valve force the pressure to rise to
300 psi
200 30 0 400 2 00 300 40 0 200 30 0 4 00 200 30 0 4 00
1 00 500 10 0 5 00 100 50 0 100 50 0
50 600 50 6 00 50 60 0 50 600

0 700 0 700 0 70 0 0 70 0

psig psig psig psig

150 psi 100 psi 50 psi

1. R esistances in series add. 4. 50 psi. of back pressure added to

the 100 psi. spring value of the
valve force the pressure to rise to
150 psi

Figure 1.13 S eries R esistances A dd P ressure

C O P YR IG H T C (1 99 9) V IC K E R S , IN C O RP O R ATE D
 A 1. If the flow path is blocked
60 0
800 thro ugh the orifice, the 600
800
1000 10 00
400 1 200 pressures w ill equalize and 400 12 00
200 1400 there w ill be no flow. 20 0 1400

0 1 600 0 1 600

psig N ote: D etla P is the difference in psig

pressure betw een the gauges up
and dow n strea m o f the restriction.
It m ay also be expressed as P.

D elta P = 0 psi.
P

800 800
60 0 1000 600 10 00
B 400 1 200 400 12 00
200 1400 2. If there is a flow path through 20 0 1400

0 1 600 the orifice, then a pressure 0 1 600

psig d rop w ill exist. T his p ressu re psig

d rop or delta P is the force
that pushes the fluid through
the orifice.

D elta P = 500 psi.

P

C
800 800
60 0 1000 600 10 00
1 200
3. If the d elta P is reduced then 12 00
400 400
200 1400 the rate o f flow w ill also be 20 0 1400

0 1 600 reduced. 0 1 600

psig psig

D elta P = 200 psi.

P

F igure 1.14 P ressure D rop and F low T hrough an O rifice

C O PY R IG H T C (1 999) VICK E RS , IN C O R P O R ATE D
 1. T his valve lim its the 2. The force is 2000 psi. X 20 sq. in.= 40,000#
m axim um pressure in or 20 tons of pressing force.
the system to 2000
psi. T his controls the 7 50
500
1 00 0
12 50
1 50 0

m axim um force of the

25 0 17 5 0
0 20 0 0
psi

press.
20 sq. in.
R elief Valve
S et A t 2000 psi.
10 0 0
750 12 50
500 15 0 0
25 0 1 75 0
0 2 00 0
ps i

M oving P laten

Fixed P laten

F igure 1.15 F orce E quals P ressure M ultiplied by A rea

C O P Y R IG H T C (1999) V IC K E R S, IN C O R P O R AT E D
A 1. The one gpm pum p w ill cause the
cylinder piston to m ove 2 ft. in one
m inute
T he cylinder has a 2 ft. stroke.

1 gpm pum p
1 00 0
75 0 1 25 0
50 0 1 5 00
25 0 17 5 0
0 20 00
psi

LO A D

60

10
50
60 S econds

40

20
30

B 2. A tw o gpm 3. The rate of fluid delivery

pum p w ill cause the and its area determ ine the
cylinder piston to spee d of the cylinder.
m ove 2 ft. in 30
seconds.
T he cylinder has a 2 ft. stroke.

2 gpm pum p
1 00 0
75 0 1 25 0
50 0 1 5 00
25 0 17 5 0
0 20 00
psi

LO A D

60
10
50

30 S econds
40

20

30

Figure 1.16 S peed D epends on C ylinder S ize and R ate of O il Flow to it.
C O P Y R IG H T C (1 999) V IC K E R S , IN C O R P O R AT E D
 1. T he diam eter of the large pipe is tw ice that of the 2. It w ould take four of the sm aller pipes to
sm aller one. equal the flow area of the larger one.

1 in dia

2 in dia

3. If the velocity through this pipe is 20 4. The sam e gpm w ill have to go
fps and the flow is lam inar (sm ooth). through an opening w ith ¼ the
area, the velocity w ill have to be
80 fps to allow the fluid to pass.

2 in dia 1 in dia

Lam inar flow Transitional flow Turbulent F low

5. A t this high velocity the flow w ill be turbulent, (rough) this

increases the frictio nal losses in the pipe and is highly
unde sirable.

F igure 1.17 Fluid Velocity is Inversely Proportional to P ipe C ross-S ectional A rea

C O P Y R IG H T C (1999 ) VIC K E R S , IN C O R P O R AT E D
 W all T hickness

1. Tubing size is quoted

as outside diam eter

Internal D iam eter ? 2 in dia

2. To find the internal

diam eter, subtract tw o
tim es the w all thickness
from the quoted size.

F igure 1.18 Tubing Inside D iam eter

C O P Y R IG H T C (199 9) V IC K E R S , IN C O R P O R ATE D
 1. To raise an 8000# load 30 inches, a cylinder w ith at
least a 30 inch stroke is require d.

30 in.
30 in.

LO A D
8000#

Figure 1.19 U se a C ylinder to R aise a Load

C O P Y R IG H T C (199 9) V IC K E R S , IN C O R P O R AT E D
 LO A D
8000#

2. T he pressure required to lift

the load equals the load
divided by the piston area.

8000#
= 800 psi
10 sq. in.
1. If the piston area is 10 sq. in.

F igure 1.20 C hoosing C ylinder S ize

C O P Y R IG H T C (1999) V IC K E R S , IN C O R P O R ATE D
 3. pum p delivery is directed to the 4. T he piston rod extends.
cap end of the cylinder.

2. In this position of the

directional valve... LO A D

1. T he relief valve protects the

system from over pressure by
diverting the pum p flow to tank
w hen the m axim um pressure
setting is reached

5. E xhaust oil is pushed out of

the rod end and back to tank

E lectric M otor

D IR E C TIO N A L VA LV E
PUMP

F igure 1.21 Valving to P rotect and C ontrol the S ystem

C O PYR IG H T C (1999) VICK E RS , INC O R PO RATED