BASIC HYDRAULICS

Prepared by : Vivekananda.Vege
 A TALK OVERVIEW

• This talk has been designed to provide instruction on the concept and operation of the basic components of
the hydraulic system.
• It also describes the various components of a typical hydraulic system, their construction and functions, and
their relationship to each other. However to really appreciate & know about hydraulics ‘hands on’ experience, is
a MUST.
 What is Hydraulics?

• Hydraulics is derived from the Greek word

- Hydor meaning Water

- Aulos meaning Pipe

 Definition of Hydraulics
In simple language : Confined liquids under pressure made to do work.
OR
Science of transmitting force / motion through medium of confined liquid
 HYDRAULICS DEFINED
FURTHER…
• Hydraulics is a topic in applied science and engineering dealing
with the mechanical properties of liquids.

• Fluid mechanics provides the theoretical foundation for hydraulics,

which focuses on the engineering uses of fluid properties.

• Fluid Mechanics is the physical science and technology of the

static and dynamic behavior of fluids.
 PASCAL’S LAW
French scientist Blaise Pascal formulated the basic law of hydraulics in the mid 17th
century.

Pascal Law – which is the basis for all hydraulic systems, that’s why its is named after
him.
 Do you remember Pascal’s Law?
It states that “ Pressure exerted anywhere in a confined fluid is transmitted equally in all
directions throughout the fluid.

• The basic idea behind all hydraulic system is based upon that principle & can be
simply stated as : Force applied at one point is transmitted to another point using an
incompressible fluid.

PASCAL’S LAW ILLUSTRATION

 Understanding of Hydraulics.
• Hydraulics is by far the simplest method to transmit energy to do work.
• It is considerably more precise in controlling energy and exhibits a broader adjustability range than
either electrical or mechanical methods.
• To design and apply hydraulics efficiently, a clear understanding of energy, work, and power is
necessary.
WORK.
Work is done when something is moved.
Work is directly proportional to the amount of force applied over a given distance according to
the following relation,

Work (N-m) = Distance (m) X Force (N)

POWER
Power is defined as the rate of doing work and has the units of foot-pounds
per second.
A more common unit of measure is “horsepower (hp).” Horsepower is
defined as the amount of weight in pounds that a horse could lift 1ft in 1s
By experiment, it was found that the average horse could lift 550 lbs. 1ft
in 1s.

The horsepower (hp) is a unit in the foot-pound-second ( fps ) or English system, sometimes
used to express the rate at which mechanical energy is expended. It was originally defined as
550 foot-pounds per second (ft-lb/s). A power level of 1hp is approximately equivalent to 746
watt s (W) or 0.746 kilowatt s (kW)
 ENERGY
• Energy is the ability to do work. It may appear in various forms, such as mechanical, electrical,
chemical, nuclear, acoustic, radiant, and thermal.
• In physics, the Law of Conservation of Mass and Energy states that neither mass nor energy
can be created or destroyed, only converted from one to the other.

https://www.lunchboxsessions.com/materials/fluid-power-basics/hydraulic-basics-lesson
 HYDRODYNAMICS VS HYDROSTATICS
Today, there are many thousands of pressure-operated machines and they are so distinct from
earlier devices we must divide hydraulics into two sciences – hydrodynamics and hydrostatics.

Hydrodynamics can be called the science of moving liquids

A water wheel or turbine represents a hydrodynamic device.
Energy is transmitted by the impact of a moving fluid against blades
or vanes. In other words, we are using the kinetic energy, or energy of
motion, that the liquid contains.

Hydrostatics the science of liquids under pressure.

In a hydrostatic device, power is transmitted by pushing on a confined
liquid
The liquid must move or flow to cause motion;
but the movement is incidental to the force output.
A transfer ofenergy takes place because a quantity of liquid is subject to
pressure.
 HYDROSTATIC APPLICATIONS

STATIONARY HYDRAULICS

• Production and assembly machines of all types

• Transfer lines
• Lifting and conveying devices
• Presses
• Injection moulding machines
• Rolling lines
• Lifts
MOBILE HYDRAULICS
• Road machinery, Construction
machinery
• Tippers, excavators, elevating
platforms
• Lifting and conveying devices
• Agricultural machinery
ADVANTAGES OF HYDRAULICS
• Transmission of large forces using small components, i.e. great power intensity
• Precise positioning
• Start-up under heavy load
• Even movements independent of load, since liquids are scarcely compressible and flow
control valves can be used
• Smooth operation and reversal
• Good control and regulation
• Favorable heat dissipation

DISADVANTAGES OF HYDRAULICS
• Pollution of the environment by waste oil (danger of fire or
accidents)
• Sensitivity to dirt
• Danger resulting from excessive pressures (severed lines)
• Temperature dependence (change in viscosity)
• Unfavorable efficiency factor
 THE FPA Triangle
There is a direct mathematical relationship between the force that a hydraulic
system is capable of transferring, the pressure of the system, and the surface area of
the component being driven.

This relationship is commonly expressed using the FPA Triangle.

Example:
A cylinder is supplied with 100 bar pressure, its effective piston surface is equal to 7.85 cm2.
Find the maximum force which can be attained.

Given that: p = 100 bar = 1000 N/cm2 A = 7.85 cm2

=100bar
 Hydraulic Pump
The pump converts the mechanical energy in a drive unit into hydraulic energy (pressure energy).
 HYDRAULIC MOTORS

• They convert hydraulic energy into mechanical energy and generate rotary movements
(rotary actuator).
• If the rotary movement only covers a certain angular range, the actuator is referred to as
a swivel drive.
 HYDRAULIC MOTORS
Type of motors
 RESERVOIR / TANK
The tank in a hydraulic system fulfils several tasks.
• It acts as intake and storage reservoir for the hydraulic fluid required for operation of the system
• dissipates heat;
• separates air, water and solid materials;
• supports a built-in or built-on pump and drive motor and other hydraulic components, such as
valves, accumulators, etc.
 FILTERS
• Filters are of great significance in hydraulic systems for the reliable functioning and
long service life of the components.
• The effects of polluted oil
FILTER ARRANGEMENT
Hydraulic
Hoses
Application
 Hydraulic hoses connects components and transfer hydraulic
energy.
Construction:

Inner tube Reinforcement Protective

layer outer layer

1. Inner tube must be compatible with working fluid and flexible. Material may
be synthetic rubber, Teflon or thermoplastics
2. Reinforcement layer consists of braided wire, textile yarn, or spiral-wound
wire
3. Protective outer layer is designed to resist weather, oil, or abrasions
 Hose Size
• The power transmitted by means of a pressurized fluid varies with pressure and rate of flow.
• The size of the components must be adequate to keep pressure drops to a minimum and avoid
aging due to heat generation or excessive fluid velocity.

• This size is a measurement of the inside tube of the hose – not the wall outer
diameter.
Hose Bending Radius
• The minimum bend radius of a hose refers to the minimum
radius that the hose may be bent through whilst operating at
the maximum allowable published working pressure.
• Bending radius is not a measurement or indicator of hose
flexibility.
• Bending the hose below the minimum bending radius leads to
loss of mechanical strength and hence possible hose failure.
• A minimum straight length of 1,5 times the hose’s outside
diameter (D) shall be allowed between the hose fitting and the
point at which the bend starts.
 HOSE SELECTION GUIDE

•Size: The I.D. of the hose must be adequate to keep pressure drop & turbulence to minimum
•Temperature: Hose should be capable of withstanding both minimum & maximum temperature seen
by system, and care should be taken while routing near hot zone( Heat protective cover is
recommended)
•Application: Before selecting the hose, study should be done on where used, type, application etc
parameters
•Material to be conveyed: Knowledge on medium to be conveyed is important to properly select
hose + end couplings
•Pressure: Hose should be selected based on system working pressure (recommendation from hose
manufactures should be considered)
•Ends couplings: End couplings are selected based on the size and type needed for the hose lay out
•Delivery: Hose selected should have enough volume to deliver volume of fluid with proper velocity
 NOMOGRAPH
Indicating Flow Capacity Of Hose Assemblies At Recommended Flow Velocities Selecting the Right Hose Size
With this nomograph, you can easily select the correct Hose ID size, Desired Flow Rate and Recommended Flow
Velocity.
If any two of these factors are known, the third can be determined.
To use this Nomograph:
1.Pick the two known values.
2.Lay a straightedge to intersect the two values.
3.Intersection on the third vertical line gives the value of that
factor.
Example:
To find the bore size for a Pressure Line consistent with a Flow
Rate of 100 litres per minute (26 US or 22 Imperial gallons per
minute), and a Flow Velocity of 4,5 metres per second (14.8 feet
per second), connect Flow Rate to Flow Velocity and read Hose
Bore on centre scale.
Answer:
The line crosses Hose Bore between -12 and -16 on “All Other
Dash Sizes” side of Hose Bore axis, so a -16 hose is required.
 THREAD TYPES
• There are different types of threads available in the hydraulics market that we can use on different
applications.

• Threads used on proprietary components like pumps, motors and valves are feasible of manufacturer
recommended.

DIFFERENRT TYPES OF THREADS

•Europe – DIN/BSP
•UK/Australia – BSP
•America – NPT/JIC/UNO/ORFS
•Japan – JIS
 HOSE ASSEMBLY NOMENCLATURE

Hose end connector

Hose end connector Hose end connector

1 2
•Both hose end connectors should not be angled ones
Hose routing recommendations SAEJ
1273
 Hose routing recommendations SAEJ
1273

•Avoid twisting, crushing abrading and pulling hose

•Don’t bend hose past minimum bend radius
•Give adequate space for hose to expand/contract during
pressure cycles
•Don’t Operate system below or above maximum or
minimum temperatures
•Don’t intermix hose fittings, sealing, assemblies
 Hose Guard

Hose guards are used to protect outer layer of the hose from outside environment
 APPLICABLE STANDARDS

SAE J1273 – Guideline to selection, routing & fabrication for

hydraulic hose

SAE J514 (JIC)(ORB) – tube adaptors details, thread details,

SAE J1453 – Thread & adaptors detail for ORFS

SAE J846 – coding system for identification of fluid conductors

SAE J517 – Hydraulic hose specification

SAE J343 – Hydraulic hose testing

Volvo specific:
 CLAMPING DEVICES
P-Clamp Worm Gear Hose-
Clamp

STAUFF Clamp TIE-WRAP