Fluid Power

Systems

FLUID POWER SYSTEMS

UNIT 1
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UNIT 1
Introduction to Hydraulic Power: Review of Pascals law and
its applications in Fluid Power Systems, Structure of Hydraulic
control system, Advantages and disadvantages of fluid power &
its applications.

The Source of Hydraulic Power: Hydraulic Pumps, pumping

theory, pump classification, Gear pumps, Vane pumps, piston
pumps, variable displacement pumps, pump performance and
pump selection.
8 Hrs

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Hydraulics and Pneumatics is the technology that deals

with the generation, control and transmission of power using
pressurized fluid. This subject is designated as FLUID POWER,
and is world wide accepted.
The word Hydraulics is derived from the Greek word
HYDRO and means Water. This comprised all things in
affiliation with Water.
The word Pneumatics is derived from Latin Word
PNEUMO means Breathing.
It can be said that Fluid Power (meaning Hydraulics and
Pneumatics) is the muscle that moves Industry.

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Applications in Industry

It jacks up an automobile( Hydraulic jack)

Drills out teeth
Launches space ship
Control submarines
Coal mines
Moves earth ( earth moving equipment like
excavators, bull dozers, borewell drills etc.,
Harvest crops
Presses
Machine tools
Material handling equipment
Transportation
Construction

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Why Fluid Power ?

Fluid power provides flexible and easy control of variable force,

distance and speed. Fluid power can be varied from a delicate touch of a
few grams to a gigantic force of 36,000 tons or more. It provides
constant torque at speed of nearly 100 km/hr within a few centimeter or
give a creeping speed of a fraction of a cm per minute.
Hydraulic system uses liquids such as petroleum oils, water,
synthetic oils etc. The first hydraulic fluid to be used was water because
it is readily available but it has been replaced by oils.
Pneumatic systems use air as the gas medium because air is
very abundant and can be readily exhausted into the atmosphere.

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Fluid flow fundamentals

The knowledge of the fundamental laws and equations

which govern the flow of fluid is essential for the design of
hydraulic control components and systems.
The field of fluid mechanics is broken down as follows:
1. Hydrostatics : Mechanics of still fluid. It is the pressure
which acts on the base of container filled with fluid and is
dependent on the height of head of fluid inside the
container.
2. Hydrodynamics: It is related to mechanics of moving fluid.
It is concerned with the fluid flow laws and their effective
forces.

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Hydrostatics

Mathematically , p=gh
Where = mass density, Kg/m 3
h= height of fluid level ( head) in m
p = pressure intensity in bar,
(1 bar = 105 Pascal = 105 N/ m2)
g = acceleration due to gravity, m/ s2
The Hydrostatic Paradox: The pressure intensity at all points
along a horizontal plane remains the same i.e., p1= p2 = p3

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Hydrodynamics

Continuity equation : Matter such as hydraulic oil cannot

be created nor destroyed and since it is incompressible, the
mass rate of flow of fluid into any fixed space is equal to the
mass flow rate of flow out of the fixed space. Thus the mass
flow rate of fluid past all cross section of a tube is equal.

i.e, 1A1v1 = 2A2v2

Since 1 = 2 , A1v1 = A2v2 = Constant

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Hydrodynamics
Bernoullis equation :
It states that the total energy of a flow of fluid does not change as
long as energy is not supplied from the outside or transferred to the
outside.

Total energy is made up of :

-- Potential energy
-- Pressure energy, which is dependent on the column of fluid and
on static pressure.
-- Kinetic energy, which is dependent on the velocity of flow and
on back pressure.

Hence, Ptotal = Z + p / g + v2/ 2g

Where Z =elevation
p= Pressure of fluid
v= Velocity of flow
= Density of fluid

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Hydrodynamics

Friction and Pressure losses :

If the fluid is still ( no fluid movement) , then pressure is
same at all the point.

If fluid is flowing through the system, heat is created by

friction. Thus part of energy is lost as heat energy, which
means loss of pressure.

The amount of friction loss is related to

Length of pipe
Surface roughness of the pipe
Cross sectional area of pipe
Number of pipe bends
Velocity of fluid flow
Viscosity of fluid flow.

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Hydrodynamics

Types of flow

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Hydrodynamics

Types of flow

Laminar flow : Up to a certain velocity fluid moves along

pipes in layers (Laminar). The inner most fluid layer travels at
the highest speed. The outer most fluid layer at the pipe wall
does not move.

Turbulent flow: It the velocity of flow is increased, the type

of flow changes at the critical velocity and becomes turbulent.
This results in an increase of flow resistance and thus the
hydraulic losses increases. Therefore turbulent flow is not
usually desirable. The critical velocity is not a fixed quantity, it
is dependent on the viscosity of the fluid and on the cross
sectional area through which flow passes.

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Hydrodynamics

Reynoldss number (Re)

The type of flow may be roughly determined Using Reynoldss number

Re = v* dh /, where v = Velocity of flow m/s, dh = Hydraulic diameter
in m, with circular cross- sections equal to the pipe internal diameter,
and otherwise calculated as d h = 4 * A / U
A = Cross- sectional area, U = Circumference
= Kinematic viscosity in m2 / s and Re crit = 2300

At Re crit the type of flow changes from laminar to turbulent and vice
versa.

Laminar flow occurs for Re < Recrit , and

Turbulent flow occurs for Re> Recrit

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Pascals Law

Fluid power technology actually began in 1650 with the

discovery of Pascals Law. Simply this law says that:
Pressure in a fluid at rest is transmitted equally in all
directions

It acts on all surfaces in a direction at right angle to those

surfaces. The amount of pressure in the fluid is equal to the
weight force with respect to the area being acted upon.

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Hydraulic force transmission

As pressure distributes equally in all directions, the shape of the

container is irrelevant. If we now pressurise surface A1 with force F1, we
create pressure, P = F1 / A1
Pressure acts on all sides equally and simultaneously. It is therefore
equal at all points. Therefore it acts also on surface A2 The force which
can be achieved is
F2 = P A2
Thus F1 / A1 = F2 / A2
Or F2 / F1 = A2 / A1

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Hydraulic force transmission

If it is possible to achieve the pressure necessary to

overcome the load F2 (Via surface A2 ) by means of force F1
and surface A1, Then load F2 can be raised . ( Friction losses
need not be taken into consideration here).

The relationship of the displacement S1 and S2- of the two

pistons is then opposite to that of the surface. i.e., S1 / S2
= A2 / A1

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Numerical Example 1

For a hydraulic press, following data are available:

A1 = 100 mm2, A2 = 2000 mm2
S1 = 25 mm, F1 = 100N

Determine the following:

F2, S2, energy input and energy output

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Numerical Example 1

Solution:

F2/F1 = A2/A1

F2 = 2000x100/100 = 2000N

S2/S1 = A1/A2

S2 = 100x25/2000 = 1.25 mm

Energy input = F1XS1 = 100X25 = 2500 N.mm

Energy output = F2XS2 = 2000X1.25 = 2500 N.mm

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Numerical Example 2

For the pipe shown in figure, following data are given:

D1 = 100 mm, D2 = 50 mm, v1 = 1.20 m/sec

Find the volume flow rate Q and v2

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Numerical Example 2

Solution:

Q = Q1 = A1v1

A1 = D12/4 = (0.1)2/4 = 0.0314 m2

Q = 0.0314(1.2) = 0.03768 m3 / sec

v2 = v1(D1/D2)2 = 1.2(0.1/0.05)2 = 4.8 m/sec

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Advantages of using Fluid Power

Fluid power provides flexibility in the control of machines

Fluid power provides high forces (torque) with compact size
i.e, high power density.
Stepless regulation of speed
Simple overload protection
Suitable for controlling fast movement and for extremely
slow precision movement.
Fluid power is simple and provides ease of installation and
maintenance.
Fluid power is readily available.
It provides predictable performance.

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Components of a Hydraulic System

1. A tank or reservoir to hold the liquid, which is usually a

hydraulic fluid.
2. Energy conversion : Hydraulic pumps are primarily used to
convert mechanical energy to hydraulic energy.
3. An electric motor or other power sources to drive the pump.
4. An Actuator to convert the energy of the liquid into
mechanical force or torque to do useful work. Actuator can
either be cylinders to provide linear motion, or hydraulic
motor to provide rotary motion.
5. Control of energy: Hydraulic energy has to be controlled by
controlling elements. These are nothing but valves. Valves
control liquid direction, pressure and flow rate.
1. Directional control valves control direction of fluid flow.
2. Pressure control valves control and regulates the pressure
in the system.
3. Flow control valves are used to regulate the flow rate of
fluid into the actuators.

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Components of a Hydraulic System

6. Piping, which carries the liquid from one location to

another.

Apart from these 6 basic components the complete

hydraulic system should also include several accessories.
These are
1. Pressure gauges
2. Various types of filters
3. Heat exchanger(cooler) : To cool the fluid to the
desired operating temperature.
4. Heater : These are used to heat the pressure fluid to
operating temperature.
5. Accumulators : It is a device to store the potential
energy of an incompressible fluid held under
pressure by an external source against some
dynamic force. These elements are called as an
auxiliary power source.

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Conversion of Units

Quantity SI Unit Conversion to other

acceptable units

Flow rate, Q M3/sec = 60,000 lts/min

Force, F Newton, N

Pressure, P N/m2 = 1 Pa= 10-5 bar

Power Watt, W = 1 J/sec

= 1 Nm/sec

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Hydraulic fluids

In a hydraulic system, the fluid assumes the task of

force transmission. This means that certain
demands must be placed on the fluid.

The fluid should:

be incompressible for the transmission of forces
dissipate heat that is generated
not change its viscosity at different temperatures
carry away abrasion from hydraulic components
be easy to filter
be neutral against metal guides, seals and paints
feature good lubrication properties
be resistant to aging
not be detrimental to health
be easy to dispose of after use

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Hydraulic fluids

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Hydraulic fluids
Classification of Hydraulic oils

Hydraulic Oils

Hydro-dynamic
Hydro-static application
application

Mineral Oils Flame-retardant oils

Oils compatible with

Bio-degradable Oils
Food stuffs

Oil for Mobile

Hydraulics

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Hydraulic fluids
Mineral oils

Sl. Composition Field of application

No. Typical properties
1 Mineral oils without active Hydraulic
additives
(base oils)
2 Mineral oils with active additives
to increase the resistance to
aging and to improve corrosion
protection
3 Mineral oils of type HL with
active additives to improve wear
protection in the mixed friction
area
Operating temperature
systems without
specific requirements (only in
rare applications today)
-10 to 90 C
Hydrostatic drives with high
thermal stress, good water
separation capacity
-10 to 90 C
Hydrostatic drives with high
thermal stress, which require
additives for the reduction of
wear, good water separation
capacity -20 to 90 C

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Hydraulic fluids
Mineral oils

Sl. Composition Field of application

No. Typical properties
4 Mineral oils of type HL with
active additives to improve
viscosity /temperature
characteristics
5 Mineral oils of type HM with
active additives to improve
viscosity /temperature
characteristics
6 Synthetic fluids without specific
flame-retardant properties
Operating temperature
Extended operating temperature
range when compared with HL
Oils -35 to 120 C
Among others, hydrostatic drives
in mobile hydraulics
-35 to 120 C
Special applications in
hydrostatic systems
-35 to 120 C

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Hydraulic fluids
Flame-retardant oils

Sl. Composition Field of application

No. Typical properties Operating temperature
1 Oil-in-water emulsions, mineral Power hydraulics of about 300
oil / synth. Esters Concentrate bar, for example in shield
share < 20 % tunneling in the field of mining
2 Mineral oil-free watery solutions Hydrostatic drives - working
of chemicals Concentrate share pressures < 160 bar, 5 to < 55
< 20 % C
3 Synthetic fluids based on Lubrication and control of steam
phosphate esters, water-free turbines, industrial hydraulics
-20 to 150 C in hydrostatic
systems often 10 to 70 C
4 Synthetic fluids of other Hydrostatic drives, industrial
composition (mostly carboxylic hydraulics -35 to 90 C
acid, polyesters) water-free

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Hydraulic fluids
Additives

No hydraulic fluid can meet all requirements.

Thanks to additives, certain properties of the
hydraulic fluid can be optimized to suit the
requirements of specific applications.

For example:
for improving:
corrosion protection
pressure resistance
resistance to aging
viscosity/temperature behavior

for reducing:
the pour-point
foaming
wear

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Hydraulic Pumps

The pumps are the heart of the hydraulic system. They

transform the mechanical energy which they receive from
the prime mover (Electric motor) into hydraulic energy.
Due to mechanical action, the pump creates a partial
vacuum at its inlet. This permits atmospheric pressure to
force the fluid through the inlet line and into the pump.
The pump then pushes the fluid into the hydraulic system

Types of pumps:
1. Non-positive (dynamic) displacement pumps
2. Positive displacement pumps

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Hydraulic Pumps
Non-positive Displacement or Hydrodynamic Pumps

These are low pressure, high volume flow pumps.

They are used only for fluid transport and are not used in fluid
power industry because they cannot withstand high pressures.

They have relatively small volumetric efficiency compared to

positive pumps and low pressure discharge output.

Max pressure limited to 15 to 20 bars

Examples of these pumps are:

Centrifugal pumps (Impeller Type)
Axial Pumps (Propeller Type)

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Hydraulic Pumps

Hydrostatic Pumps or Positive Displacement Pumps

This type is used universally for fluid power systems

As the name implies, these pumps eject a fixed volume of flow

into the hydraulic system per revolution of pump shaft

They have large volumetric efficiency and high pressure

discharge output.

These pumps have the following advantages:

High pressure capacity, upto 700 bars
Small, compact size
Better performance characteristics, i.e., high efficiency over a
wide range of speed and pressure

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Pumping Theory

A partial vacuum is created at the pump inlet due to the

internal operation of the 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 the fluid
out of the discharge line.
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Pumping Theory

The piston pump shown in figure

contains two ball check valves

Check valve 1 is connected to

the pump inlet line and allows
fluid to enter the pump only at
this location

Check valve 2 is connected to the pump discharge line and

allows fluid to leave the pump only at this location

As the piston is pulled to the left, a partial vacuum is

generated in pump cavity 3

This vacuum holds the ball of check valve 2 against its seat
(lower position) and allows atmospheric pressure to push fluid
from the reservoir into the pump via check valve 1

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Pumping Theory

This inlet flow occurs because the

force of the fluid pushes the ball
of check valve 1 off its seat

When the piston is pushed to the

right, the fluid movement closes
inlet valve 1 and opens outlet
valve 2

The quantity of fluid, displaced by the piston, is forcibly

ejected out the discharge line leading to the hydraulic system

The volume of oil displaced by the piston during the discharge

stroke is called displacement volume of the pump

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Pump Classification
1. The type motion of the pumping element
Rotary Pumps Gear Pumps, Vane Pumps, Gerotor Pumps
Reciprocating Pumps- Piston Pumps

2. The displacement characteristics

Fixed Displacement Pumps Gear Pumps, Vane Pumps, Piston
Pumps
Variable Displacement Pumps- Vane Pumps and Piston Pumps

3. The type of pumping element

Gear Pumps External Gear Pump, Internal Gear Pumps, etc
Vane Pumps- Balanced type and Unbalanced Type
Piston Pumps- Axial Piston pumps (In-line and Bent axis type);
Radial Piston pumps (Stationary cylinder block and Rotating
Cylinder block)

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Gear Pump

The simplest and most robust positive displacement pump,

having just two moving parts, is the gear pump. Its parts
are non-reciprocating, move at constant speed and
experience a uniform force.

Types of gear pumps:

External gear pumps
Internal gear pumps
Lobe pumps
Gerotor pumps
Screw pumps

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External Gear Pump

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External Gear Pump

Volumetric displacement & theoretical flow rate

Let Do = outside diameter of gear teeth (m)

Di = inside diameter of gear teeth (m)
L = width of gear teeth (m), N = rpm of pump
VD = displacement volume of pump (m3 / rev)
QT = theoretical pump flow rate

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External Gear Pump

The graph below shows that the pump flow varies directly
with speed. Hence, theoretical flow is constant at a given
speed, as shown by the solid line in figure (b)

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Problem 1
A gear pump has gears of 75 mm outside diameter, 50
mm inside diameter and 25 mm width. If the actual
pump flow at 1800 rpm and rated pressure is 106
litres per minute, what is the volumetric efficiency ?

Problem 2:
A gear pump has gears of 75 mm outside dia, 50 mm
inside dia and 25 mm width. If the volumetric
efficiency is 90% at rated pressure, what is the
corresponding flow rate in litres/min ? The pump
speed is 1000 rpm.

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Solution for Problem 1

Displacement volume,
4

= 0.000061 m3 / rev

Theoretical flow rate, QT = VD.N = 0.1098 m3 / min

Volumetric efficiency, nV = QA X 100/QT = 96.54%

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Internal Gear Pump

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Lobe Pump

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Lobe Pump
This pump operates in a fashion
similar to the external gear pump

But, unlike external gear pumps,

both lobes are driven externally
so that they do not actually
contact each other

Therefore, they are quieter than

other types of gear pumps

Better volumetric displacement

than gear pump

But, lobe pump output will have

greater amount of pulsation

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Gerotor Pump

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It operates similar to an
internal gear pump

The inner gear has one tooth

less than the outer gear, and
the volumetric displacement
is determined by the space
formed by the extra tooth in
the outer rotor

The inner gear rotor (Gerotor element) is power driven and

draws the outer gear rotor around as they mesh together. This
forms inlet and discharge pumping chambers between the rotor
lobes

The tips of inner and outer rotors make contact to seal the
pumping chambers from each other

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Screw Pump

Screw pump is an axial flow positive displacement unit

Three precision ground screws, meshing within a closefitting

housing, deliver nonpulsating flow quietly and efficiently

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Screw Pump

The two symmetrically opposed idle rotors act as rotating

seals, confining the fluid in a succession of closures or
stages

The idle rotors are in rolling contact with the central power
rotor and are free to float in their respective housing bores
on a hydrodynamic oil film

There are no radial bending loads. Axial hydraulic forces on

the rotor set are balanced, eliminating any need for thrust
bearings

Screw pumps can generate hydraulic pressures from 25

bars, up to 250 bars, and maximum flow rate up to 6 litres
per minute

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Vane Pumps

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Vane Pumps

The rotor which contains radial slots, is splined to the drive shaft and
rotates inside a cam ring

Each slot contains a vane designed to mate with the surface of the
cam ring as the rotor turns

Centrifugal force keeps the vanes out against the surface of the cam
ring

During one-half revolution of rotor rotation, the volume increases

between the rotor and the cam ring. The resulting volume expansion
causes a reduction of pressure. This is the suction process which
causes fluid to flow through the inlet port and fill the void

As the rotor rotates through the second half rotation, the surface of
the cam ring pushes the vanes back into their slots, and the trapped
volume is reduced. This positively ejects the trapped fluid through the
discharge port

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Vane Pumps

Analysis of volumetric displacement

There is an eccentricity between the centreline of the

rotor and the centreline of the cam ring. If the
eccentricity is zero, there will be no flow.

Let,
DC = diameter of cam ring (m)
DR = diameter of rotor (m)
L = width of rotor (m)
VD = pump volumetric displacement (m3)
e = eccentricity (m)
emax = maximum possible eccentricity (m)
VDmax = maximum possible volumetric
displacement (m3)

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Vane Pumps

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Pressure Compensated Systems
Vane Pump

Some vane pumps have provisions for mechanically varying the

eccentricity, which will vary pump flow. Such a pump is called a
variable displacement pump. Either a hand wheel or a pressure
compensator can be used to move the cam ring to change the
eccentricity.

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Pressure Compensated Systems
Vane Pump

System pressure acts

directly on the cam ring

This forces the cam ring

against the compensator
spring-loaded piston on the
left side of the cam ring

If the discharge pressure is large enough, it overcomes the compensator

spring force and shifts the cam ring to the left

This reduces the eccentricity, which is maximum when discharge pressure is

zero. As the discharge pressure continues to increase, zero eccentricity is
finally achieved, and the pump flow becomes zero

The maximum pressure achieved is called Pdeadband, at which point the pump
is protected because it produces no more flow. As a result there is no power
wasted and fluid heating is reduced
NVRs sketch for dummys !

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Balanced Vane Pump

A balanced vane pump is one that has two intake and two outlet
ports diametrically opposite each other. This results in the
achievement of complete hydraulic balance.

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Balanced Vane Pump

One disadvantage of a
balanced vane pump is
that it cannot be designed
as a variable displacement
unit

Instead of having a circular

cam ring, a balanced
design vane pump has an

elliptical housing, which forms two separate pumping chambers on

opposite sides of the rotor. This eliminates the bearing side loads
and thus permits higher operating pressures.

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Numerical Problem
A vane pump has a rotor diameter of 50 mm, cam ring
diameter of 75 mm, and a vane width of 50 mm. if the
eccentricity is 8 mm, determine the volumetric
displacement

Piston pumps

Axial design Radial design

Bent-axis design Swash plate design

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Axial Piston pump Systems
Bent-axis design

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Axial Piston pump Systems
Bent-axis design
It consists of a cylinder block rotating
with the drive shaft

However, the centre line of the

cylinder block is set at an angle
relative to the centre line of the drive
shaft

The cylinder block contains a number

of pistons arranged along a circle

The piston rods are connected to the drive shaft flange by ball-and-
socket joints. The pistons are forced in and out of their bores as
the distance between the drive shaft flange and cylinder block
changes

A universal link connects the block to the drive shaft to provide

alignment and positive drive
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Axial Piston pump Systems
Bent-axis design

The volumetric displacement

of the pump varies with the
offset angle as shown in
figure

No flow is produced when

the cylinder block centre line
is parallel to the drive shaft
centre line. This angle can
vary from 00 to a maximum
of 300.

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Volumetric displacement and Systems
Theoretical flow rate

Let = offset angle, S = piston stroke,

D = piston circle diameter, y = no. of pistons,
A = area of piston, N = rpm of the drive shaft

From trignometry, tan() = S/D

S = D. tan() .(1)

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Volumetric displacement and Systems
Theoretical flow rate

The total displacement volume equals the no. of pistons

multiplied by the displacement volume per piston

Therefore, volumetric displacement, VD = yAS..(2)

From (1) & (2), VD = yAD tan()(3)

Theoretical flow rate, QT = DAyN.tan()(4)

Problem: Find the actual flow rate that an axial piston pump
delivers at 1000 rpm. The pump has nine 15 mm diameter pistons
arranged on a 125 mm diameter piston circle. The offset angle is
set at 100 and the volumetric efficiency is 94%.

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In-line Piston Pump Systems
(Swash Plate Design)

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In-line Piston Pump Systems
(Swash Plate Design)
In this type, the cylinder block and
drive shaft are located on the same
centre line

The pistons are connected to a shoe

plate which bears against an angled
swash plate

As the cylinder rotates, the pistons

reciprocate because the piston shoes
follow the angled surface of the swash

Plate. The outlet and inlet ports are located in the valve plate so that the
pistons pass the inlet as they are being forced back

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In-line Piston Pump Systems
(Swash Plate Design)

This type of pump can be designed to have variable displacement capability.

The swash plate is mounted in a movable yoke as shown in figure. The
swash plate angle can be changed by pivoting the yoke on pintles.
Positioning of the yoke can be accomplished by manual operation, servo
control, or a compensator control. The maximum swash plate angle is
limited to 17 0 by construction.

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 Fluid Power
Systems
Radial Piston Pump

The design consists of a pintle to direct fluid in and out of the cylinders, a
cylinder barrel with pistons, and a rotor consisting a reaction ring

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Systems
Radial Piston Pump

The pistons remain in constant

contact with the reaction ring due to
centrifugal force and back pressure
on the pistons

For pumping action, the reaction

ring is moved eccentrically with
respect to the pintle or shaft axis

As the cylinder block rotates, the

pistons on one side travel outwards

This draws in fluid as each cylinder passes the suction ports of the pintle

When a piston passes the point of max eccentricity, it is forced inwards by

the reaction ring. This forces the fluid to enter the discharge port of the
pintle. In some models, the displacement can be varied by moving the
reaction ring to change the piston stroke.

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Systems
Pump Performance

1. Volumetric efficiency nv

nv = actual flow rate X 100

theoretical flow rate

= QA X 100/QT

It indicates the amount of leakage within the pump. This

involves considerations such as manufacturing tolerances and
flexing of pump casing under fluid pressure

80% to 90% for Gear pumps

82% to 92% for Vane pumps
90% to 98% for Piston pumps

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Systems
Pump Performance

2. Mechanical Efficiency (nm)

It indicates the amount of energy losses that occur for reasons

other than leakage. This includes friction in bearings and between
other mating parts. It also includes energy losses due to fluid
turbulence. It is typically between 90% and 95%

nm = PQT X 100
TAN

Where P = pump discharge pressure (Pa)

QT = theoretical flow rate (m3/sec)
TA = actual torque delivered to the pump (N.m)
N = pump speed (rpm)

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Systems
Pump Performance

2. Mechanical Efficiency (nm)

Mechanical efficiency can also be computed in terms of torque

nm = theoretical torque required to operate the pump X 100

actual torque delivered to the pump

= TT X 100/TA

TT (N.m) = VD (m3) X P (Pa)

2

TA = actual power delivered to pump (W)

N (rad/sec)

Where N (rad/sec) = 2N (rpm)

60
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Systems
Pump Performance

3. Overall efficiency (no)

It considers all energy losses

no = actual power delivered by the pump X 100

actual power delivered to the pump

no = nv X nm
100

= (QA X 100)(PQT X 100) X 1/100

QT TA.N

= PQA X 100
TA.N

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Systems

Problem: A gear pump has a 82.6 mm outside diameter, 57.2 mm

inside diameter, and 25.4 mm width. If the actual pump flow at
1800 rpm and rated pressure is 0.00183 m3/sec, what is the
volumetric efficiency ?

Problem: A gear pump has a displacement volume of 100 c.c. It

delivers 1.5 litres per second at rotor speed of 1000 rpm and 70
bars pressure. If the prime mover input torque is 120 N.m,
calculate: i) the overall efficiency of the pump, and ii) the torque
lost within the pump

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 Fluid Power
Performance Curves: Systems
Radial Piston Pumps

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Systems

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Systems
Pump Noise

Noise originates from pumps, cylinders, hydraulic motors and

pipeline

The Occupational Safety and Health Administration (OSHA)

USA stipulates that 90 dB is the maximum sound level that a
person may be exposed to during an 8-hr period in the
workplace

Pumps are the main contributors of noise in fluid power

systems. The pump noise is a mixture of wear in the pump,
vibrations and fluid pulsations inside the pump

Since pumps are small in size, they are poor radiators of noise

To achieve the lowest noise level, use the lowest practical

speed and select the most advantageous combination of size
and pressure to provide the needed horsepower

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Systems
Pump Noise
Common sound levels
Condition/ Device dB Intensity
Whisper 10 Very faint

Quiet conversation 30 Faint

Average office 50 Moderate

Screw pump 60 Moderate

Piston pump 70 Loud

Vane pump(Vacuum cleaner) 80 Loud

Gear pump (noisy factory) 90 Very loud

Amplified rock band 110 Deafening

Hydraulic press 130 Threshold of pain

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Systems
Pump Cavitation
Another noise problem, called pump cavitation can occur due to
entrapped air bubbles in the hydraulic fluid or vaporisation of
hydraulic fluid

This occurs when the pump suction lift is excessive and the pump
inlet pressure falls below the vapour pressure of the fluid. As a
result, air or vapour bubbles which form in the low-pressure inlet
region of the pump, are collapsed when they reach the high
pressure discharge region

This produces high fluid velocity and impact forces, which can
erode the metallic components and shorten pump life

Following are the remedies:

Keep suction line velocities below 1.2 m/sec
Keep pump inlet lines as short as possible
Minimise the number of fittings in the inlet line
Mount the pump as close as possible to the reservoir
Use the proper oil as recommended by the pump
manufacturer
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Systems
Pump selection

Selection of pump typically entails the following sequence:

1. Select the actuator that is appropriate for the expected loads

2. Determine the flow rate requirements to drive the actuator
3. Select the system pressure. This ties in with the actuator size
and the magnitude of resistive force produced by the external
load. Most important is the total amount of power to be
delivered by the pump
4. Determine the pump speed and select the prime mover. This
together with the flow rate calculation determines the pump
size (volumetric displacement)
5. Select the pump type based on the application
6. Select the reservoir and associated plumbing, valving, filters,
etc
7. Consider factors such as noise levels, power loss, need for
heat exchangers, pump wear, etc to provide the desired life
for the system
8. Calculate the overall cost of the system
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