MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER TECHNOLOGY MEM341: FLUID POWER

TECHNOLOGY

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1. INTRODUCTION

What is Fluid Power
Technology that deals with the generation, control and transmission of power
using pressurized fluids, usually oil or air.
Hydraulic systems oil (petroleum or synthetic) or water based fluids.
Pneumatic systems air.
Can be used to push, pull, regulate, drive virtually all types of modern industries
machines.

3 basic methods to transmitted power: electrical, mechanical and fluid power.
Fluid power is widely used because its versatility and manageability.

Advantages of Fluid power:
Ease and accuracy of control.
Multiplication of force.
High horsepower, low weight ratio
Low speed torque
Constant force or torque.
Simplicity, safety, economy.
Established standards and engineering

Multiplication and variation of forceLinear or rotary force can be multiplied
from a fraction of an ounce to several hundred tons of output.
Easy, accurate controlYou can start, stop, accelerate, decelerate, reverse or
position large forces with great accuracy. Analog (infinitely variable) and digital
(on/off) control are possible. Instantly reversible motionwithin less than half a
revolutioncan be achieved.
Multi-function controlA single hydraulic pump or air compressor can provide
power and control for numerous machines or machine functions when combined
with fluid power manifolds and valves.
High horsepower, low weight ratioPneumatic components are compact and
lightweight. You can hold a five horsepower hydraulic motor in the palm of your
hand.
Low speed torqueUnlike electric motors, air or hydraulic motors can produce
large amounts of torque (twisting force) while operating at low speeds. Some
hydraulic and air motors can even maintain torque at zero speed without
overheating.
Constant force or torqueThis is a unique fluid power attribute.
Safety in hazardous environmentsFluid power can be used in mines,
chemical plants, near explosives and in paint applications because it is inherently
spark-free and can tolerate high temperatures.
Established standards and engineeringThe fluid power industry has
established design and performance standards for hydraulic and pneumatic
products through NFPA, the National Fluid Power Association; ANSI, the
American National Standards Institute; and ISO, the International Organization
for Standardization.


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Disadvantages of fluid power
Messy, using oil as medium of transmission. Can leak to the surrounding.
Hydraulic lines can burst/fail. Improper design and care.
Loud noise, pump.
Compress air tank is a potential danger. Can explode if pressure is over the
design safety limits.

Fluid power applications
Mobile: Here fluid power is used to transport, excavate and lift materials as well
as control or power mobile equipment. End use industries include construction,
agriculture, marine and the military. Applications include backhoes, graders,
tractors, truck brakes and suspensions, spreaders and highway maintenance
vehicles.
Industrial: Here fluid power is used to provide power transmission and motion
control for the machines of industry. End use industries range from plastics
working to paper production. Applications include metalworking equipment,
controllers, automated manipulators, material handling and assembly equipment.
Aerospace: Fluid power is used for both commercial and military aircraft,
spacecraft and related support equipment. Applications include landing gear,
brakes, flight controls, motor controls and cargo loading equipment.

Fluid power products
Fluid power products are sold as individual components or as systems

Hydraulic pump or air compressor, which converts mechanical power to fluid
power.
Cylinder or motor, which converts fluid power to linear or rotary mechanical
power.
Valves, which control the direction, pressure and rate of flow.
Filters, regulators and lubricators, which condition the fluid.
Manifolds, hose, tube, fittings, couplings, etc., which conduct the fluid between
components.
Sealing devices, which help contain the fluid.
Accumulators and reservoirs, which store the fluid.
Instruments such as pressure switches, gauges, flow meters, sensors and
transducers, which are used to help monitor the performance of a fluid power
system.

Components of a Fluid Power System


Hydraulic
1. Tank (reservoir)
2. Pump
3. Electric/other power to drive pump.
4. Valves to control direction, pressure
and flow rate.
5. Actuator to convert pressure to useful
mechanical works.
6. Piping.
Pneumatic
1. Air tank (store compress air).
2. Compressor.
3. Electric motor or other prime mover.
4. Valves to control direction, pressure,
flow rate.
5. Actuators.
6. Piping.
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Difference between Hydraulics and Pneumatics System



Engineering science pertaining
to liquid pressure and flow
Use liquids such as petroleum
oils, water, synthetic oils and
molten metals.
Liquids provide a very rigid
medium for transmitting power
and utmost accuracy and
precision of motion.

Engineering science
pertaining to gaseous
pressure and flow.
Used air as the gas medium.
Exhibit spongy characteristics
due to compressibility of air.
Less expensive to build and
operate.
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Example of Fluid Power Machinary
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2. Principle of Hydraulics

Energy and Power in Hydraulic System

Introduction
Prime
Mover
Hydraulic
Pump
Hydraulic
Circuit
Hydraulic
Actuator
External
Load
Mechanical
Energy in
Mechanical
Energy out
Heat energy out
Hydraulic System
Follow the conservation of Energy Law:
INPUT ME LOST HE = OUTPUT ME
FRICTION

Analysis of hydraulic circuit The Basic Principle
Pascal Law
Extended Bernoulli Equation / Energy Equation
Considering All The Losses Hydraulic Pressure, Fluid Leakage, Mechanical
Inefficiency, etc..
Applying Mechanical Principals to find the available/required power, torque,
velocity, etc..

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Example of a simple hydraulic circuit. (Rexroth-Bosh)


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3. Hydraulic Fluid

Main function of hydraulic fluid is to transfer forces and movements (Transmit Power).
Other functions are:
Lubricate Moving Parts
Seal Clearances Between Mating Parts
Dissipate Heat
There are diverse range of applications and installations of hydraulic devices.
There is no one magic fluid that can do all the things, there for we must select the right
hydraulic fluid for the type and conditions of the application.


Hydraulics Fluid Requirements/Characteristics

Lubrication and Anti-Wear characteristics
Be able to covered all moving parts.
Why? High pressure, insufficient oil delivery, low viscosity, slow or fast
sliding movements.
Viscosity
Most important parameter.
Given in viscosity index; show haw thick or thin a hydraulic fluid is at a
given temperature.
Kinematics Viscosity measured in SI in mm2/s and changes with
temperature.
How to determine? Look at the manufactures documentation about the
minimum and maximum permissible viscosities.
Viscosity index is to DIN ISO 2909.
Behavior with respect to pressure.
Changes of viscosity of the fluid.
Compatibility with different materials.
Stability against shearing.
Occurred at metering notches and on the opening and closing of valve
seats.
What happen is that viscosity can become lower then the original value.
Stability against thermal loads
Fluid temperature can increase during operation (usually <80oC.
Stability against oxidation
Oxygen, heat, light and catalysis.
Can increase corrosion in the system.

Low compressibility
Accuracy of the hydraulic drive
Response times
Low temperature expansion
Little formation of foam
Foam can lead to pump failure.
High boiling point and low steam pressure.
High density.
Why? Cause higher the density the more power that can be transferred
with the same volume of fluid
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Low intake of air and good release of air.
Good thermal conductivity.
Good di-electric (non-conducting) characteristics.
Non-hygroscopic
Fire resistant (non flammable)
Non toxic as a fluid, vapor and after decomposition.
Good protection against corrosion.
No formation of sticky substances
Good filtration capability
Compatibility and exchangeability with other hydraulic fluids.
Formation of silt.
User friendly servicing.
Ecologically acceptable.
Costs and availability.

Viscosity of Hydraulic Fluid

Viscosity is the measure of a fluids resistance to flow.
High viscosity will results in:
High resistance to flow, cause sluggish operation.
Increased power consumption, friction loss up.
Increased pressure drop through valves and lines.
High temperatures, because friction.
Low viscosity will results in:
Increased oil leakage past seals.
Excessive wear to moving parts.
Absolute viscosity:
Unit is often expressed in Pa.s or kg/m.s. (SI unit)
But also in the unit centi-poise (cP).
1 cP = 0.001 Pa.s

Kinematics viscosity:
Unit is expressed in m2/s. (SI unit)
But also in the unit called centi-stoke (cS).
1 cS = 1 mm2/s or 1 stokes = 0.0001 m2/s

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Primary functions of Hydraulic Fluid
1. Transmit power
2. Lubricate moving parts
3. Seal clearances between mating parts
4. Dissipate heat
Desired properties of hydraulic fluid
1. Good lubricity
2. Ideal viscosity
3. Chemical stability
4. Compatibility with system
materials
5. High degree of incompressibility
6. Fire resistance
7. Good heat transfer capability
8. Low density
9. Foam resistance
10. Non-toxicity
11. Low volatility


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4. HYDRAULIC PUMPS

Hydraulic pump is a devices that convert mechanical energy into hydraulic energy (fluid
power) in the form of PRESSURE and VOLUME FLOW-RATE. The mechanical energy
is supply by prime mover usually electric motor or internal combustion engine).

There are two category of pumps: dynamic pumps/nonpositive displacement pumps and
Positive displacement pump.

NPD pumps generally used for low pressure, high volume flow applications. Function to
move fluid from one location to another. (centrifugal and axial flow propeller pump).

PD pumps, will ejects a fixes amount of fluid into hydraulic system per rev. can
overcome the pressure resulting from the mechanical loads and resistance to fluid flow.
High pressure, small, high volumetric efficiency, efficiency of the pump is stable for a
large range. (piston, gear, vane types of various design).

Pumping theory

Pump operate by creating a partial vacuum in a confine space. The atmospheric
pressure will push the fluid out of the oil tank into the pump intake. Pump will then
mechanically push the fluid out into the discharge line.

Type of pump
1. Gear pump external gear pump, internal gear pump, lobe pump, screw pump.
2. vane pump unbalanced vane pump, balanced vane pump.
3. piston pump axial design, radial design.

Pump Performance
Usually rated according to their volumetric output and pressure.
Volumetric output (delivery rate or capacity) is the amount of liquid that a pump
can deliver at its outlet port per unit of time at a given drive speed, usually
expressed in GPM or cubic inches per minute.
Sometimes rated according to displacement, that is the amount of liquid that
they can deliver per cycle or cubic inches per revolution.
Slippage is a measure of a pump's efficiency and usually is expressed in percent.
Some pumps have greater internal slippage than others; some pumps are rated
in terms of volumetric output at a given pressure.

Displacement
The amount of liquid transferred from a pump's inlet to its outlet in one revolution or
cycle. Either in cubic meter per rev or meter per cycle. Also know as the volumetric
displacement, V
D
.

Slippage
Slippage occur when there are oil that leaking from a pressure outlet to a low-
pressure area or back to an inlet.
A little slippage is usually design for lubrication purpose.
When pressure increase, leakage will increase.
Increase slippage is loss of efficiency.
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NPD pump

The volume of liquid delivered for each cycle depends on the resistance offered to flow.
A pump produces a force on the liquid that is constant for each particular speed of the
pump.
Resistance in a discharge line produces a force in the opposite direction.
When these forces are equal, a liquid is in a state of equilibrium and does not flow.
If the outlet of a nonpositive-displacement pump is completely closed, the discharge
pressure will rise to the maximum for a pump operating at a maximum speed. A pump
will churn a liquid and produce heat.




PD Pump







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Gear pump
One of the simplest type of positive displacement pump construction.
Seal chamber is created by the space between the gears teeth.
Using two matching gears as the key to the design.

External type

External gear pump

The Volumetric Displacement,

( )L D D V
i o D
2 2
4
=



Where D
o

is the outside diameter of the gear teeth
D
i
is the inside diameter of the gear teeth
L is the width of ear teeth

The theoretical flow rate

N V Q
D T
=

where N is the rpm of pump, how fast the pump is rotating.













D
0
D
i
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Internal type

Internal gear pump



Lobe pump


Vane Pump
A cam ring's shape is a true circle that is on a different centerline from a rotor's.
Pump displacement depends on how far a rotor and ring are eccentric.
The advantage of a true-circle ring is that control can be applied to vary the
eccentricity and thus vary the displacement.
A disadvantage is that an unbalanced pressure at the outlet is effective against a
small area of the rotor's edge, imposing side loads on the shaft.
Thus there is a limit on a pump's size unless very large hearings and heavy
supports are used.


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The volumetric displacement,

( )eL D D V
R C D
+ =
2

Where D
C
is the diameter of the cam ring
D
R
is the diameter of the rotor
L is the width of rotor
e is the eccentricity between the rotor and cam ring

When the eccentricity of the rotor and cam ring is at it maximum value, this will also
coincide with the maximum volumetric displacement.
When eccentricity is equal zero, then volumetric displacement is also zero.

The theoretical flow rate

N V Q
D T
=


Balance vane pump

Astationary, elliptical cam ring and two
sets of internal ports.
A pumping chamber is formed between
any two vanes twice in each revolution.
The two inlets and outlets are 180
degrees apart.
most universal in the mobile-equipment
field






Cam ring
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Piston Pumps

Two types of design axial or radial.

Radial design

In a radial piston pump the pistons are arranged like wheel spokes in a short
cylindrical block..
A drive shaft, which is inside a circular housing, rotates a cylinder block.
The block turns on a stationary pintle that contains the inlet and outlet ports.
As a cylinder block turns, centrifugal force slings the pistons, which follow a
circular housing.
A housing's centerline is offset from a cylinder block's centerline.
The amount of eccentricity between the two determines a piston stroke and,
therefore, a pump's displacement.
Controls can be applied to change a housing's location and thereby vary a
pump's delivery from zero to maximum.

pintle is a round bar that serves as a stationary shaft around which a
cylinder block turns.
A pintle shaft has four holes bored from one end lengthwise through part of its
length.
Two holes serve as an intake and two as a discharge.
Two slots are cut in a side of the shaft so that each slot connects two of the
lengthwise holes.
The slots are in-line with the pistons when a cylinder block is assembled on a
pintle.
One of these slots provides a path for a liquid to pass from the pistons to the
discharge holes bored in a pintle.
Another slot connects the two inlet holes to the pistons when they are drawing in
liquid.
The discharge holes are connected through appropriate fittings to a discharge
line so that a liquid can be directed into a system.
The other pair of holes is connected to an inlet line
Cylinder Block house pintle and pistons.
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Rotors./ reaction ring
Drive Shaft. A drive shaft is connected to a cylinder block and is driven by an
outside force such as an electric motor


Axial design
Piston and cylinder block are parallel to each others.
Can be bent axis configuration or swash plate design.
Pump displacement depends on the bore and stroke of a piston and the number
of pistons.

Swash plate design

Cylinder block and drive shaft is on the same centerline.
Pistons are connected to a shoe plate and bears against an angled swash plate.
The angle of swash plate determines the length of the piston stroke.
The inlet ant outlet ports are located in the valve plate.


Bent axis



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Drive shaft and cylinder block are set at an offset angle.
Piston rods are connected to the drive shaft flange by ball and socket joints.
Universal link connects the block to the drive shaft to provide alignment and
positive drive.

The volumetric displacement

) tan( DAY V
D
=

Where D is the piston circle diameter
A is the piston area
Y is the number of pistons
is the offset angle


The theoretical flow rate

N DAY N V Q
D T
) tan( = =



Pump Performance

Volumetric Efficiency of Pump

Efficiency is calculated using the ratio of the output over the initial input.
Volumetric efficiency indicates the amount of leakage that takes place within the pump.
There for the volumetric efficiency of any type of pump is given by,

T
A
v
Q
Q
rate flow l theoretica the
rate flow actual the
input
output
=

= =

Mechanical Efficiency

Mechanical efficiencies indicates the amount of energy losses that occur for reasons
other than leakage. This includes friction between moving components and also how the
oil moving inside the pump.

A
T
A
T
m
T
T
N T
pQ
pump to delivered power actual
leakage no if output power pump the
input
output
= = = =
Where p is the pump discharge pressure
T
A
is the actual torque delivered to the pump.
T
T
is the theoretical torque required to operate the pump based on design.

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2
p V
T
D
A

=

Overall Efficiency

Take into account all the losses between the inlet of the pump and the outlet of the pump.

N T
pQ
A
A
m v o
= =



Pump Performance Comparison

Gear pumps in general the least expensive but also provides the lowest level of
performance.
Gear pumps wear rapidly, but simple in design and compact.
Vane pumps performance and efficiency are between gear pumps and piston
pumps.
Piston pumps the most expensive and complex in design, but also provides the
highest level of overall performance. Can be driven at high speeds (rpm 5000).
Operate at high pressure.

Pump Noise

Pump created noise during operation.
Undesirable.
Loud noise is bad to health.
OSHA (Occupational Safety and Health Administration) stipulates 90dB(A) is the
max. sound level a person may be exposed to during 8-hr period in the
workplace. Noisy factory or gear pump.
Vane pump vacuum cleaner
What cause noise?
Fiction between moving components.
Misaligned pump to motor coupling.
Improper installation of pump or motor mounting plates.
Pump cavitations.
Pump operated at excessive speed or pressure.
To reduce noise, can use sound absorption materials.
Unusual pump noise can also indicate the performance of a pump. Increase
noise could indicates increased wear.








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Pump Cavitations

Pump cavitations is due to the entrained air bubbles in the hydraulic fluid or vaporization
of the hydraulic fluid.

Prevent cavitations:
keep suction line velocity low (1.2 m/s
<)
keep inlet lines short
minimize inlet line fittings
mount the pump close to the reservoir
use strainer or low-pressure drop[ inlet
filters
use the right hydraulic oil






Selecting Pump

Factors that need to consider when selecting a hydraulic pump for a circuit:

use the right components (actuator, motor, fittings, plumbing, reservoir etc)
determine the required flow-rate
select the right operation/system pressure
determine the pump speed and prime mover
select base on types of applications.
Consider noise levels, hp loss, need of heat exchanger.
Cost

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5. HYDRAULIC ACTUATOR

Pumps perform the function of adding energy to the fluid of a hydraulic system
for transmission to some output location.
Convert hydraulic energy to mechanical energy is the function of actuator.
Linear motion hydraulic cylinders / linear actuator. Provide a push or pull force
to move a load along a straight line.
Rotational motion Hydraulic motors / rotary actuator. Rotate a shaft to provide
torque to drive a load along a rotary path.

Objective: You should be able to
Describe the construction and design features.
Identify the various types of mountings and mechanical linkages for
transmitting power.
Calculate the load carrying capacity, speed and power.


Types of Hydraulic Actuator.

Hydraulic cylinders

Constructed of a piston or plunger that operate in a cylindrical housing (barrel) by
the action of liquid under pressure.
Many types of design to perform the desirable action.

HYDRAULIC
ACTUATOR
LINEAR
ACTUATOR
(LINEAR MOTION)
ROTARY
ACTUATOR
(ROTATIONAL MOTION)
SINGLE
ACTING
CYLINDER
DOUBLE
ACTING
CYLINDER
LIMITED
ROTATIONAL
MOTOR
CONTINUOUS
ROTATIONAL
MOTOR
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Rexroth



Hydraulic cylinder in action.









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A single acting cylinder
Design: a piston house in a barrel with and
opening in the dead end that allow pressurize
fluid to enter the space between piston and
inside the barrel to push the piston outward from
inside the barrel. Force can only act in one
direction only, which is to push the piston out. To
retract or extend (depend on design) the piston
into the barrel, gravity, outside force or spring is
used.






A 3D model of a single acting spring return hydraulic cylinder.


A double acting cylinder
Design: a piston house in a barrel with openings
in the dead end that allow pressurize fluid to
enter the space between piston and inside the
barrel to push the piston outward from inside the
barrel and out from another opening. The piston
and rod can extend or retract depend on the flow
of the pressurize oil.





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A telescopic hydraulic cylinder and its usage in forklift.


Double-acting hydraulic cylinder construction.


Hydraulic cylinder Analysis

- Cylinder force, velocity & power (Actual and Theoretical).
- Cylinder performance (overall efficiency, volumetric efficiency and
mechanical efficiency).
- During extension stroke and also retraction stoke they are different.


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area piston effective pressure ply Force = sup

area piston effective
rate flow volume
Velocity =

pressure ply rate flow volume Power sup =



Extension Retraction
piston
A p F = ( )
rod piston
A A p F =
piston
A
Q
v =
rod piston
A A
Q
v

=
v F Q p H = = v F Q p H = =

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Hydraulic mill type cylinder Hydraulic tie rod type cylinder

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Tie rod hydraulic cylinder


Double rod end hydraulic cylinder
Hydraulic motors
2 types, limited rotation hydraulic motors (oscillation motors or rotary actuators) &
continuous rotation hydraulic motors (hydraulic motors).
Hydraulic motors are redesigned pumps.

Types of hydraulic motors constructions: gear, vane or piston.

Example:
Hydraulic impact wrench, operates with flow-rate of 15 to 45 Lpm and
pressure of 70 to 140 bars.

Limited rotation hydraulic motors
Can rotate clockwise or counter-clockwise but not in a complete circle. Usually
using vane/vanes.




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Hydraulic motors
Gear motors
- Develops torque due to hydraulic pressure acting on the surfaces of the
gear teeth.
- Can be reversed by reversing the direction of fluid flow.
- Volumetric displacement is fixed.
- Max operating pressure ~ 14 MPa.
- Max flow-rate ~ 570 Lpm.
- Max rpm ~ 2400 rpm.
Vane motors
- develop torque by the hydraulic pressure acting on the exposed surfaces
of the vanes.
- Springs/pressure loaded vanes to hold the vanes to the cam ring.
- Usually fixed displacement, balanced design.
- Max operating pressure ~ 17 MPa.
- Max flow-rate ~ 950 Lpm.
- Max rpm ~ 4000 rpm.
Piston motors
- can be fixed or variable displacement units.
- Generated torque by pressure acting on the ends of pistons reciprocating
inside a cylinder block.
- In-line piston motor (swash plate design), Axial piston motor (bent-axis
design).
- Can operate at highest speeds and pressures.
- Max operating pressure ~ 35 MPa.
- Max flow-rate ~ 1700 Lpm.
- Max rpm ~ 12000 rpm.
-

Axial Piston Motor (Rextroth)





D
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UiTMPP FKM
29

Bent axis hydraulic motor.


Swash Plate design Hydraulic Motor with Planetary Gear and Break
Accessory.
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UiTMPP FKM
30

Different designs of hydraulic motor.

Hydraulic motors analysis
- theoretical - torque, power, flow-rate
- actual - torque, power, flow-rate
- performance motor efficiencies, volumetric efficiency, mechanical
efficiency, overall efficiency


Theoretical Torque,
2
p V
T
D
T
= [Nm]

Theoretical Power,

2
p V
T H
D
T T
= = [Watt]

Theoretical Flow-rate, N V Q
D T
= [ m
3
/s]

Actual values can be measured from the device directly.




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UiTMPP FKM
31

Hydrostatic transmissions
A system consisting of a prime mover, a hydraulic pump, a hydraulic motor, and
appropriate valves and pipes that can provide adjustable speed drives.
Can be found in tractors, rollers, front-end loaders, hoes and lift trucks.
Advantages:
- infinitely variable speed and torque in either direction and over the full
ranges.
- Extremely high power to weight ratio.
- Ability to be stalled without damage.
- Low inertia of rating members, fast starting and stopping with smoothness
and precisions.
- Flexibility and simplicity of design.






























Main component of a hydrostatic transmission.

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UiTMPP FKM
32



Diagram depicting a simplified hydraulic transmission.

pump
Prime
mover
motor
Reservoir
Input power
(torque &
rpm)
Pump output
(Operating
pressure &
oil flow-rate
Motor Output
(Torque &
rpm)
Oil leakage