FLUID POWER

Functions of Hydraulic Fluids

1. Power transmission: To transmit power, which is the primary function.

2. Lubrication: To lubricate various parts, so as to avoid metal-to-metal contact and reduce friction, wear
and heat generation.

3. Sealing: To seal the moving elements to avoid leakage.

4. Cooling: To carry away the heat generated in the system and to dissipate the heat through a reservoir
or a heat exchanger.

5. Contaminant removal: To carry along the contaminations to the tank, where they can be removed
through filters.

 The various properties required for an ideal hydraulic fluid are as follows:
1. Ideal viscosity.
2. Good lubrication capability.
3. Demulsibility.
4. Good chemical and environmental stability.
5. Incompressibility.
6. Fire resistance.
7. Low flammability.
8. Foam resistance.
9. Low volatility.
10. Good heat dissipation.
11. Low density.
12. System compatibility
13. Oxidation stability
14. Pour Point
15. Neutralization number

Oxidation Stability: Oxidation is caused by the reaction between oxygen in dissolved air and oil. It results in
formation of impurities like sludge, soluble and insoluble products. These causes corrosion and make the
operation slow.
Demulsibility The ability of a hydraulic fluid to separate rapidly from moisture and successfully resist
emulsification is known as “demulsibility.”
 The following are the usual characteristics tested in order to determine the flammability of hydraulic fluids:
1. Flash point: The temperature at which an oil surface gives off sufficient vapours to ignite when a flame is
passed over the surface.
2. Fire point: The temperature at which oil releases sufficient vapours to support combustion continuously for 5
second when a flame is passed over the surface.
 Pour Point: Lowest temperature at which oil is able flow easily. It is of great importance where the system is
exposed to very low temperatures.

Applications of hydraulic systems

The hydraulic systems are mainly used for precise control of larger forces. The main applications of hydraulic
system can be classified in five categories:
1. Industrial: Plastic processing machineries, steel making and primary metal extraction applications, automated
production lines, machine tool industries, paper industries, loaders, crushes, textile machineries, R & D
equipment and robotic systems etc.

2. Mobile hydraulics: Tractors, irrigation system, earthmoving equipment, material handling equipment,
commercial vehicles, tunnel boring equipment, rail equipment, building and construction machineries and drilling
rigs etc.

3. Automobiles: It is used in the systems like breaks, shock absorbers, steering system, wind shield, lift and
cleaning etc.

4. Marine applications: It mostly covers ocean going vessels, fishing boats and navel equipment.

5. Aerospace equipment: There are equipment and systems used for rudder control, landing gear, breaks, flight
control and transmission etc. which are used in airplanes, rockets and spaceships.

6. Defense: Missile launching systems, navigation controls

Basic Components of a Hydraulic System

1. Oil Reservoir (Fluid Tank): Function is to store the oil which act as the working medium. Oil is drawn from
the reservoir to different parts of the system and after performing its function returns back.oil reservoir
is usually installed at the bottom of the system so that oil may flow back to the reservoir by gravity.
2. Oil Pump: The function is to draw the oil from reservoir and to deliver this oil under pressure to rest of
the hydraulic circuit. In doing so the pump raises oil pressure to the required level. The various types of
pumps used in hydraulic system are gear pump, vane pump, screw pump, lobe pump etc.
3. Electric Motor to drive the pump.
4. Actuator: An actuator converts the pressure of oil into mechanical force to do useful work. Actuators can
either be a cylinder to provide linear motion or a hydraulic motor to provide rotary motion.
5. Filter : Hydraulic fluid needs to be very clean, hence a filter is needed to remove dirt particles before the
fluid passes from the tank to the pump.
6. Control Valves : Valves are necessary to control pressure, flow rate and direction of the fluid. Functions of
valves are
i. To regulate flow of oil through a pipe line. E.g. Gate valve and Check valve
ii. To release pressure of oil in the system when it exceeds the maximum allowable limit.
This valve is called Relief valve.
iii. To prevent back flow of oil in to the reservoir when pump is not in operation. This valve is called
check valve or non return valve.
iv. To route the fluid to desired direction. Called directional control valve (DCV).
v. To reduce existing pressure of oil supplied by the oil pump. Called pressure reducing valve.
Positive displacement pumps:

A positive displacement pump makes a fluid move by trapping a fixed amount and forcing (displacing) that
trapped volume into the discharge pipe.

A Positive Displacement Pump has an expanding cavity on the suction side and a decreasing cavity
on the discharge side. Liquid flows into the pumps as the cavity on the suction side expands and the
liquid flows out of the discharge as the cavity collapses. The volume is a constant given each cycle of
operation.

The positive displacement pumps can be classified into two main classes. Reciprocating and rotary
pumps. Reciprocating pumps includes piston ,plunger and diaphragm pumps and rotary pumps include
gear, lobe, screw vane and cam pumps

Gear Pumps

A gear pump produces flow by carrying fluid in between the teeth of two meshing gears. One
gear is driven by the drive shaft and turns the other (idler) gear. The chamber formed between
adjacent gear teeth are enclosed by the pump housing and side plates.A partial vacuum is
created at the pump inlet as the gear teeth unmesh. Fluid flows in to fill the space and is carried
around the outside of the gears. As the teeth mesh again at the outlet end, the fluid is forced out.

Applications:

Various fuel oils and lube oils

 Chemical additive and polymer metering

 Chemical mixing and blending (double pump)
 Industrial and mobile hydraulic applications (log splitters, lifts, etc.)
 Low volume transfer or application
 Lubrication pumps in machine tools

 Fluid power transfer units and oil pumps in engines

ADVANTAGES

 High speed
 High pressure
  No overhung bearing loads
 Relatively quiet operation
 Design accommodates wide variety of material
 Low weight
 Relatively high working pressures
 Wide range of speeds
 Wide temperature and viscosity range (i.e. flexibility)
 Low cost

DISADVANTAGES

 Four bushings in liquid area

 No solids allowed

 Fixed End Clearances

Lobe Pump

The lobe pump is a rotary, external-gear pump. It differs from the conventional external-gear pump in
the way the "gears" are driven. In a gear pump, one gear drive the other; in a lobe pump, both lobes are
driven through suitable drives gears outside of the pump casing chamber. Woring is same as gear pump.

Screw Pump

A screw pump is an axial-flow gear pump. Three types of screw pumps are the single-screw, two-screw,
and three-screw.Flow through a screw pump is axial and in the direction of the power rotor. The inlet
hydraulic fluid that surrounds the rotors is trapped as the rotors rotate. This fluid is pushed uniformly
with the rotation of the rotors along the axis and is forced out the other end. The fluid delivered by a
screw pump does not rotate, but moves linearly.
APPLICATIONS

 chemical-processing
 liquid delivery
 marine
 biotechnology
 pharmaceutical
 food, dairy, and beverage processing.
 fuel-injection
 oil burners
 lubrication

ADVANTAGES
Slow Speed, Simple and Rugged design
Pumps raw water with heavy solids and floating debris
No collection sump required = minimum head
Long lifetime ( > 20-40 years)
Easy maintenance (no 'high skilled' staff required)
Constant high efficiency with variable capacity
Screw pumps allow a wide range of flows and pressures
They can also accommodate a wide range of liquids and viscosities
All the screw pumps are Self-priming
DISADVANTAGES
Cost of manufacturing is high because of close tolerances and
running clearances
Any changes in the viscosity of the fluid results in high fluctuations in the
performance.
A screw pump with high pressure capability will require high pumping
elements which increases the overall size of the pump.

Vane Pumps

In vane pumps, a number of vanes slide in slots in a rotor which rotates in housing. The housing may
be eccentric with the center of the rotor. In some designs, centrifugal force holds the vanes in contact
with the housing, while the vanes are forced in and out of the slots by the eccentricity of the housing. In
others, light springs hold the vanes against the housing.

During rotation, as the space or chamber enclosed by vanes, rotor, and housing increases, a
vacuum is created, and atmospheric pressure forces oil into this space, which is the inlet side of
the pump. As the space or volume enclosed reduces, the liquid is forced out through the
discharge ports.
APPLICATIONS
Aerosol and Propellants
Aviation Service - Fuel Transfer, Deicing
Auto Industry - Fuels, Lubes, Refrigeration Coolants
Bulk Transfer of LPG and NH3
LPG Cylinder Filling
Alcohols
Refrigeration – Freons, Ammonia
Solvents
Aqueous solutions

ADVANTAGES
Handles thin liquids at relatively higher pressures
Compensates for wear through vane extension
Sometimes preferred for solvents, LPG
Can run dry for short periods
Can have one seal or stuffing box
Develops good vacuum

Hydraulic Actuators

The function of hydraulic system or pneumatic system is to move, grip or apply force to an object. Devices which
actually achieve this objective are called actuators. In other words hydraulic actuators are the devices which
covert hydraulic energy into mechanical energy. The fluid from the pump is directed to the actuator. The actuator
converts the pressure energy of fluid into linear or rotary motion. When it converts the energy into reciprocating
motion they are termed as hydraulic cylinders and when they rotate and produce torque they are named as
motors. There are three basic types of hydraulic actuators.

1. Hydraulic Motors – Rotary motion type actuators

2. Semi-rotary motion type actuators
3. Hydraulic Cylinders - Linear motion type actuators

Hydraulic Motors

They use a pressurized, incompressible fluid to rotate mechanical components. The hydraulic motor is a
reversed hydraulic pump. They are three types i.e; gear type, vane type and piston type.

1. Gear type hydraulic motor

 Fluid enters at the bottom and pressurizes the bottom chamber. Pressure is applied to the gear faces and
thus creates an imbalance of forces on it, resulting the rotation of gears. Thus rotary motion is available
at the output side. The outlet low pressure fluid is connected to reservoir. At low speeds leakage will be
more pronounced. So they are used in medium speed and low torque applications.
2. Vane Motor
It is very similar to the construction of a vane pump. Vane motor develops power by the hydraulic
pressure that acts on the exposed surface of the vanes which slides in and out of the rotor. In vane motor
the vanes are held out by fluid pressure or by spring force since no centrifugal force exists unti motor
begins to rotate.

Control Valves

Three types

1. Directional Control Valves

2. Pressure Control Valves
3. Flow Control Valves

Functions of Control valves

1. To start or shut off the flow

2. To regulate the pressure through the system
3. To control and limit the flow to the actuator
4. To release the pressure of the systems when it exceeds allowable limit
5. To prevent back flow of oil to reservoir when pump is not in operation
6. To route the fluid to the desired direction
7. To reduce the existing pressure of oil supplied by the pump
8. To perform predetermined operations

Directional Control Valves

A DCV is mainly required for the following purposes:

1. To start, stop, accelerate, decelerate and change the direction of motion of a hydraulic actuator.
2. To permit the free flow from the pump to the reservoir 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
Classification of DCVs based Fluid Path
Based on fluid path, DCVs can be classified as follows:
1. Check valves.
2. Shuttle valves.
3. Two-way valves.
4. Three-way valves.
5. Four-way valves.

Classification of DCVs based on the Construction of Internal Moving Parts

Based on the construction of internal moving parts, DCVs can be classified as follows:
1. Rotary spool type: In this type, the spool is rotated to change the direction of fluid. It has longitudinal
grooves. The rotary spools are usually manually operated.
2. Sliding spool type: This consists of a specially shaped spool and a means of positioning the spool. The
spool is fitted with precision into the body bore through the longitudinal axis of the valve body. The lands
of the spool divide this bore into a series of separate chambers. The ports of the valve body lead into these
chambers and the position of the spool determines the nature of inter-connection between the ports.

Check Valve
The simplest DCV is a check valve. A check valve allows flow in one direction, but blocks the flow in the opposite
direction. It is a two-way valve because it contains two ports.

In Fig. 1.2, a light spring holds the ball against the valve seat. Flow coming into the inlet pushes the ball off the
seat against the light force of the spring and continues to the outlet. A very low pressure is required to hold the
valve open in this direction. If the flow tries to enter from the opposite direction, the pressure pushes the ball
against the seat and the flow cannot pass through.

Pilot Operated Check Valve

Pilot operated check valve is also termed as PO check valve. PO check valves will also work as other
conventional check valve i.e. they will permit the free flow in one direction and will prevent the fluid
flow in reverse direction. But in case of PO check valve, fluid flow in reverse direction will take place
after applying adequate pilot pressure by a pilot line.
Flowing fluid entering to the check valve via its inlet side will exert the pressure force against the
spring force and once flowing fluid pressure force overcomes the spring force, valve poppet will leave
the valve seat to permit the flow of fluid. There will not be any requirement of pilot pressure at this time.
Flowing fluid entering to the check valve via its outlet port will support the spring for holding the
poppet against the valve seat in order to avoid the flow of fluid in reverse direction. There will not be any
pilot pressure at this time.
For enabling reverse flow, pilot pressure is applied at pilot port for overcoming the spring force
and the net force acting at other port, poppet will leave the valve seat due to the action of pilot pressure
and hence fluid flow in reverse direction will be start.

Pressure Control Valves

This type of valves are used to control the pressure of hydraulic system or circuit and called pressure control
valves. It includes pressure reducing valve, pressure relief vale etc.

Pressure Relief Valve

 This type of valves is utilized to limit the maximum operating pressure in the
circuit. These are also called safety valves and protect the pump and other components from overloading, etc.
Pressure relief valve is provided in the circuit such that one port is connected to the pressure line and the other
port is connected to the reservoir. There is a poppet which is held on its seat with the spring force. The spring
force can be changed by rotating the adjusting screw. When the circuit pressure at the valve inlet is less than the
spring pressure, the poppet remains on its seat and the valve is closed and no flow takes place through it. As the
pressure in the circuit exceeds the adjusted spring force, the poppet is forced off its seat and the valve is opened.
Now the liquid flows from the pressure line through the valve to the reservoir. This diversion of flow continues till
the pressure decreases below the valve setting and hence the spring reseats the poppet and the valve is again
closed. In this way it prevents circuit and provides the safety.

Flow Control valves

Flow control valves are those which are used to control the flow rate of the fluid in the circuit and also called
volume control valves, like needle valve, globe valve, gate valve, etc. Flow-control valves are generally used to
control the speed of hydraulic motors or actuators in work spindles and the travel rates of tool heads, etc. Flow
control valves keeps uniform flow rate in the circuit with the help of pressure compensator. A non pressure,
compensated flow control, like in needle valve etc., there may be changes in the flow rate.

Needle valve

Needle valves are generally designated as non-compensated flow control or throttling valves. They are good
metering devices when the pressure differential across the valve remains constant. This type of valve is used in
the hydraulic system where there is no need of precise speed control because the flow may vary with pressure
difference. A needle valve and globe valve are similar in design and operation . In this type of valve there is a
long, tapered point at the end of a valve stem which can be raised or lowered to control the flow through it. A
long taper allows a needle valve to open or close gradually. A needle valve is used to control flow at points where
a small flow rate is desired or at other points where precise flow is required.

Globe Valve

In the globe valve there is a disc, which is attached to the end of the stem which controls flow of fluid through the
valve. The valve is closed by lowering a disc into a valve seat and opened by raising it off the seat. Since fluid
flows equally on all sides when a valve is open, there is no unbalanced pressure on a disc to cause uneven wear.
Gate Valve

This type of valves are normally used to allow or prevent the flow of liquids and also used for regulating the flow
of fluid. In this type of valve there is a wedge or sort of gate which controls the flow. Opening and closing of a
passage is done with the help of a hand wheel, which moves a wedge or gate up and down across a flow line. The
gate valve is provided with good sealing surfaces between the gate and seats. As the valve is opened, the gate
moves up within the bonnet and as it is closed, the gate blocks the flow by coming across the line where it rests
firmly against the seats. The gate valve permits the flow and offers small or no resistance to the fluid flow when
the valve is fully open. But if it is in the partially open it restrict the flow rate through the circuit.

Hydraulic Intensifiers

It is a device used for producing high pressure liquid by using the energy of larger amount of liquid at low
pressure.
Main components are

1. Fixed ram
2. Hollow Sliding cylinder or ram
3. Fixed inverted cylinder
4. Valves.

Applications :
Moulding Machine, Riveting machine, Spot Welding Machine and Hydraulic Presses.
Air operated hydraulic intensifier are used commonly for clamping ,holding, punching ,presses , jacks ,
torque wrenches and more.

Hydraulic Accumulators:
An accumulator is device that stores potential energy of an incompressible fluid by means of either
gravity, mechanical springs or by compressed gases. The stored potential energy is quick source of fluid
power capable of doing useful work. So an accumulator can store and release a quantity of fluid at the
required system pressure. It resembles the operation of a capacitor in a electric circuit. Three basic types
of accumulators are
1. Weight loaded or gravity type
2. Spring loaded type
3. Gas loaded type
Weight Loaded Accumulator
It consists of a vertical thick-walled steel cylinder housing a piston. The piston rod extending out of
cylinder supports the dead weight by raising the piston on admitting high pressure. The force of gravity
of the dead weight is used to store the potential energy. This accumulator generates a constant pressure of
fluid through full volume output of fluid independent of rate and quantity of energy supplied from prime
mover. Whereas for other types, the fluid output pressure decreases as a function of the flow rate output
of the accumulator. The main drawback being is its very large size and heavy weight which renders it
unsuitable for portable applications.

Spring loaded Accumulator

It is similar to a dead weight type except that piston is preloaded with a spring compression. The spring is
a source of energy acting against the piston. The pressure created by this type of accumulator depends
upon the stiffness and pre-loading of spring. The pressure exerted on the fluid is not constant. It typically
delivers a low flow rate of oil at low pressures, so for high pressure situations, these type of accumulator
are somewhat heavy. This are not suitable for application demanding high cycle rates as the spring may
fail in fatigue and lose its elasticity.

Gas loaded Accumulators

These are also known as hydro-pneumatic accumulators because in this type the force is applied to the oil
using compressed air. The storage of potential energy is due to the compressibility nature of the gas. The
expansion of the gas forces the oil out of the accumulator.
1. Non-separated type
The non separator type consists of an enclosed cylindrical shell having oil part at bottom and a gas
charging part at the top. The oil below is in free contact with the gas above without any separator. It is
always in a vertical position, so that the oil and gas always remain separated. It can handle large volumes
of oil, which is in advantage. The disadvantage is the immersion of gas into oil by absorption. This is not
suitable for high speed pumps as the entrapped gas in the oil promotes cavitation.
2. Separator type Gas Accumulator
Here the oil and gas are separated by an element or a diaphragm. The partition or separator allows the
effective utilization of the compressibility of the gas. Depending on the type of element used to separate
the oil and gas, they are further classified as,
 Piston Type Accumulator.
 Diaphragm Type Accumulator.
 Bladder or Bag type Accumulator.
Piston Type Accumulator

It consists of a cylinder housing a freely floating piston. The piston separates the gas and oil. The friction
between the piston and seals may adversely affect the working of particularly low pressures system.
Leakage past the piston is yet another problem requiring frequent pre-charging. Due to greater inertia and
seal friction, these accumulators are not suitable for damping, pressure pulsation or shock absorption.
Diaphragm Type Gas Accumulators
In this type the hydraulic fluid and nitrogen gas are separated by synthetic rubber diaphragm. At the
bottom of the diaphragm a shut-off button is provided, this button covers the inlet of the line connection
when the diaphragm is fully stretched. The advantage of the diaphragm accumulator over the piston
accumulator is that it has no sliding surface that requires lubrication and can be therefore used with the
fluid having poor lubricating qualities. It is less sensitive to contaminations due to lack of any close
fitting components.
Bladder Type Gas Accumulator
It functions in the same way as the other two accumulators. Here the gas and the hydraulic fluid are being
separated by synthetic rubber bladder. The bladder is filled with the nitrogen gas until the designed pre-charged
pressure is achieved. The hydraulic fluid is then pumped into the accumulator. The poppet valve closes the inlet
when the bladder is fully expanded, thus the pressing of the bladder into the opening is prevented.

Automatic Cylinder Reciprocating Circuit

Figures show a hydraulic circuit that produces continuous reciprocation of a hydraulic cylinder. This is achieved by
two sequential valves, each of which senses a stroke completion by the corresponding build up of pressure. Each
check valve and corresponding pilot line prevents the shifting of the four way valve until the particular stroke of
the cylinder has been completed. The check valves are needed to allow pilot oil to leave either end of the DCV
while pilot pressure is applied to the opposite side.
When DCV is in left position, the oil goes to the rod end of the cylinder and the piston retracts. The check valve
prevents the shifting of DCV until the completion of the stroke. At the end of the stroke , the pressure build up
and the sequence valve 1 opens. When the sequence valve 1 opens, the pilot signal shift the DCV to its right
position and the oil goes to the blank end of the cylinder and the piston extends. At the end of the extension
stroke, the pressure build up and opens the sequence valve 2 and the pilot signal shifts the DCV to its left
position. This sequence repeats and the cylinder reciprocates continuously.

Hydraulic Circuit for Robotic Arm

 Robot has to move its arm to the desired position to reach the work space. This can be done by providing a
hydraulic actuator. This can be used in hazardous and explosive environments.
Figure shows a hydraulic circuit for a robotic arm extension. When solenoid A is energized, the oil goes to the
blank end of cylinder and arm extends to the desired position. At the end of the extension stroke, the arm
touches a limit switch and a signal is sent back to the solenoid, causing the arm to retract. The accumulator helps
the system to send additional fluid to the cylinder if there is a demand for the fluid and it also acts as a shock
absorber.