18MHC105J – FLUID POWER

SYSTEMS AND AUTOMATION

Unit – III
Hydraulic components

1
Topic covers
 What is Hydraulics?
 Components of Hydraulic system.
 Modules of hydraulic system.
 Applications of hydraulic system.
 Advantages of hydraulic system.
 Disadvantages of hydraulic system.
 Properties of fluid.
 Pascal’s law and its applications.
 Continuity equations and Bernoulli’s Principle.
 What is pump? Its classification
 Working Principle of Gear pump

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 What is Hydraulics?
 Hydraulics is the branch of science, that deals with the study of
generation, control and transmission of power using pressurized oil.
Components of Hydraulics system
Functions of Hydraulic fluids

 Transfer the power efficiently

 Lubricate the moving parts
 Absorbs, carry and transfer the heat generated with in the system
 Remains stable against the physical changes and chemical changes during
the storage and using of oil.

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Modules of hydraulic system
Hydraulic
system
Mechanical energy is convert into fluid
Input energy.
 used to give the input to the system.
module Eg: Pump, Prime mover.

Used to control the fluid direction,

Control pressure and flow rate.
module Eg: DCV, PRV, FRV.

Used to produce the output.

Output Fluid energy is convert into mechanical
module energy.
Eg: Cylinder, Motor.
 Components of hydraulic system
 Reservoir
 It is used to store the oil.
 The oil is pumped to the circuit using pump through piping and
valves finally it comes back to the reservoir.
 Pump
 It is a device, which is used to increase the pressure of oil.
 Eg: Gear pump, Vane pump, piston pump, Centrifugal pump and
axial pump.
 Motor
 It is a prime mover, which is connected with the pump to rotate the
pump.
 Components of hydraulic system
 Coupling
 It is used to connect the pump and electric motor.
 Suction strainer
 It is connected in the suction line of the pump.
 It is immersed in the oil in the reservoir.
 It acts as a filter
 Breather filler
 The level of the oil in the reservoir goes up and down when the syste
m is working.
 It serves as a breather for the reservoir to the outside atmosphere.
 Also used to fill up the oil in the reservoir.
 Components of hydraulic system
 Valves
 Valves are used to control the pressure, flow rate and direction of the
fluid.
 DCV - used to change the direction of oil.
 PRV - used to maintain the pressure in the system.
 FRV - used to regulate the flow rate of the oil.
 Hydraulic cylinder/Motor
 These are the final element in the hydraulic system.
 Hydraulic cylinder is a linear actuator, which will produce the linear
motion.
 Hydraulic motor is the rotary actuator, it will gives the rotary motion.
Application of Hydraulics system
Application of Hydraulics system
Applications of Fluid Power

Hydraulic Excavator
Applications of Fluid Power
Applications of Fluid Power
Applications of Fluid Power

Hydraulic Press
Applications of Fluid Power

Hydraulic Tapping machine

Applications of Fluid Power

Hydraulic Pallet Truck Hydraulic Scissor Lifting Table

Applications of Fluid Power

Hydraulic Jack Hydraulic Scissor Lifting Table

 Advantages of Hydraulics system
 Multiplication of force is high when compared to other system.
 It will produce smooth, uniform movement without vibration.
 In case of an overload, the excess pressure is released automatically, so
that the system protected against the breakdown or excessive strain.
 can provide variable motions in both linear and rotary transmission
of power.
 The power delivered per unit weight (called as Power/weight ratio) is
high when compared to other systems.
 Advantages of Hydraulics system (Contd.)
 Easy to stop and reverse the actuators with minimal shock to the system.
 Easy and accurate controlling the speed of the system.
 Require less space.
 Greater Efficiency (about 80-90%) and economy due to low wear and tear
 Disadvantages of Hydraulics system
 Fluid (Hydraulic oil) leakage and spills cause a slippery and messy work
environment around a hydraulic machine.
 Because of dirty environment more maintenance is required to reduce
frictional losses.
 A special handling and disposal procedure for hydraulic oil is required to
meet the environmental regulations.
 Hydraulics system is required prime mover (Like electric motor, engine
etc) to operate the system. So that the cost of the system will increase.
Comparison of Electrical, Mechanical, Hydraulics
and Pneumatics system
Comparison of Electrical, Mechanical, Hydraulics
and Pneumatics system (Contd.)
 Properties of fluid
 Density
 The quantity of matter contained in unit volume of the substance.
 Mass density
 It is defined as the mass of the fluid per unit volume.
 It is denoted as “ρ”
 Unit is Kg/m3
 Weight density (w)
 Weight of fluid per unit volume is called as the weight density.
 W=ρ*g
 Properties of fluid
 Specific gravity (S)
 It is defined as the ratio between the density of fluid to the density of
water.
 It is also known as relative density.
 No unit.
 Specific volume (v)
 It is the reciprocal of mass density.
 Unit for specific volume is m3/Kg
 Viscosity (ν)
 It is property of fluid which is offered a resistance to the movement of
fluid.
 Properties of fluid
 Newton’s law of viscosity
 This law states that the shear stress on a fluid element is directly
proportional to the velocity gradient.

 Significance of viscosity in hydraulic system

 If the fluid is too thick (ie Viscosity is more)
 Increased in load hence increased power loss.
 Internal friction will increase. So that temperature also will increase.
 Wear and tear becomes more.
 Reduces internal leakage.
 Properties of fluid
 Significance of viscosity in hydraulic system
 If the fluid is too thin (ie Viscosity is less)
 Less friction.
 Power loss will be less.
 More leakage.
 Lead to unnecessary wear and tear.
 Viscosity Index
 It is the number indicating the effect of a change in temperature on
viscosity.
 Properties of fluid
 Adhesion
 The attraction between the molecules of a liquid and the solid
boundary surface in contact with the liquid.
 Cohesion
 The attraction between the molecules of a liquid.
 Surface tension
 The tensile force acting on a surface of liquid is called as surface
tension.
 Capillarity
 The rise and fall of liquid level with in the small tube is called as
capillarity.
 Properties of fluid
 Cloud point
 It is the temperature at which the dissolved particles begins to
crystallize.
 Pour point
 It is the temperature at which it becomes semi solid and loses its flow
characteristics.
 Flash point
 It is the minimum temperature at which liquid is vaporize to form an
ignitable mixture in air.
 Fire point
 It is the temperature at which it will continue to burn for at least 5
seconds after ignition by an open flame
Types of hydraulic fluid

Hydraulic fluid

Petroleum Eg: Naphthenes, aromatics, paraffin, wax

and olefins
based oil

Non Eg: water, Glycol, Phospate easter, castor

Petroleum oil emulsions.

based oil
 Petroleum based hydraulic fluid
 Advantages:
 Good lubricating characteristics.
 Protection against rust, corrosion, sludge.
 Better heat transfer characteristics.
 Having high viscosity index. So that we can use at very high
temperature.
 Disadvantages:
 Easy to oxidize.
 Nonpetroleum based hydraulic fluid –water
 Advantages:
 Ideal fire resistance fluid.
 Viscosity is very less. Does not change with temperature.
 Inexpensive.
 Easily available.
 Disadvantages:
 Highly corrosive in nature.
 Evaporate easily at high temperature.
 Does not possess lubricating property.
 Nonpetroleum based hydraulic fluid –
Emulsion
 Advantages:
 High viscosity index.
 Good system cooling.
 Oxidation stability.
 Cost is less.
 Good lubricating property.
 Disadvantages:
 When the temperature increases, water will evaporate. So that the vis
cosity will reduce.
 Demulsification (separation of water/ oil) is the main problem.
 Nonpetroleum based hydraulic fluid –
Glycol
 Advantages:
 High viscosity index.
 Good antiwear property.
 Oxidation stability.
 Cost is less.
 Good lubricating property.
 Disadvantages:
 Not good for fire resistant.
 Nonpetroleum based hydraulic fluid –
water-Glycol
 Advantages:
 High viscosity index.
 Good antiwear property.
 Oxidation stability.
 Cost is less.
 Good lubricating property.
 Disadvantages:
 Low viscosity
 Poor corrosion resistance.
 Not suitable for high pressure applications.
 Pascal’s law
 It states that pressure exerted anywhere in a confined incompressible fluid
is transmitted equally in all directions throughout the fluid such that the
pressure variations (initial differences) remain the same
Applications of Pascal’s law
 Continuity equation
 It is the principle of conservation of mass.
 It states that if no fluid is added or removed from the pipe in any length
then the mass passing across different sections shall be same.
 Bernoulli’s principle
 It states that, in an ideal, incompressible fluid when the flow is steady
and continuous, the sum of potential energy, kinetic energy and pressure
energy is constant across all cross section of pipe.
 Hydraulic pump
 It is a device which is used to pump the water from one place to another
place
 Mechanical Energy is converted in to Hydraulic energy

Mechanical Hydraulic
Energy PUMP Energy

Hydraulic Motor
Hydraulic Mechanical
Energy MOTOR Energy
Classification of pumps
Differences
NONPOSITIVE
S.No POSITIVE DISPLACEMENT
DISPLACEMENT
1. Fluid pressure is used to transmit Fluid motion is used to transmit
power power
2. It ejects a fixed quantity of fluid per Quantity of fluid varies with respect
revolution of the shaft to speed of the shaft
3. Used for High pressure applications Used for low pressure applications
(12,000 psi) (250-300 psi)
4. Volume flow rate or discharge is less Volume flow rate or discharge is
more
5. Small in size Size is large

6. Eg: Gear pump, Vane pump, Screw Eg: Centrifugal pump, Axial flow
pump, Piston pump pump
 Gear pumps
 It is positive displacement pump.
 It consists of two spur or helical or herringbone gears.
 One gear is connected to the prime mover, is called as driving gear
 The gear connected to the prime mover (driving gear) engages the other
gear (driven gear).
 Fluid on the inlet side flows into and is trapped between the rotating
gear teeth and the housing.
 The fluid is carried around the outside of the gears to the outlet side of
the pump.
Pump
 Gear pumps
 As the gears come out of mesh, they create expanding volume on the
inlet side of the pump. Liquid flows into the cavity and is trapped by the
gear teeth as they rotate.
 Liquid travels around the interior of the casing in the pockets between
the teeth and the casing -- it does not pass between the gears.
 Finally, the meshing of the gears forces liquid through the outlet port
under pressure.
 Gear pumps
Advantages Disadvantages
1. High speed 1. No solids allowed
2. High pressure 2. Fixed End Clearances
3. No overhung bearing loads 3. Maintenance is more.
4. Relatively quiet operation
5. Design accommodates wide
variety of materials
Application
1. Various fuel oils and lub. oils
2. Chemical additive and polymer metering
3. Chemical mixing and blending (double pump)
4. Industrial and mobile hydraulic applications (log splitters, lifts, etc.)
5. Acids and caustic (stainless steel or composite construction)
Gear pumps
Volumetric displacement
Vd = π/4(Do2 - Di2 ) L (m3 / rev.)
Where
Do - Outer diameter of the Gear
Di - Inner diameter of the gear
L - Width of the gear

Theoretical discharge (QT) = Vd X N (m3 / min.)

Volumetric Efficiency (ƞv) = QA / QT

Where
QA - Actual discharge
Gear pumps
Gear pumps
Gear pumps
 Internal Gear pumps
 Its consists of internal spur gear, outside ring gear, a crescent shaped
spacer and external housing.
 The internal gear and outer ring gear are placed eccentrically and
separated by crescent shaped shaper.
 The inlet and outlet ports are located in the casing.
 Inner gear is connected with the prime mover and outer gear is follower.
 These two rotating gears are unmesh at the suction side of the pump to
create cavity, hence the volume increases and pressure decreases at the
suction side which allow atmospheric pressure to force fluid into the
pump.
 The oil is trapped between the external and internal gear teeth. On both
sides of the crescent.
 Internal Gear pumps
 When the gears rotates, due to meshing of gears
volume decreases and pressure increases.
 The oil is transferred from inlet port to outlet port.
Internal Gear pumps
Internal Gear pumps
Disadvantages
Advantages
 Usually requires moderate
 Only two moving parts
speeds
 Only one stuffing box
 Medium pressure limitations
 Non-pulsating discharge
 Overhung load on shaft
 Excellent for high-viscosity liquids
bearing
 Constant and even discharge
regardless of pressure conditions
 Operates well in either direction
 Can be made to operate with one
direction of flow with either rotation
 Single adjustable end clearance
 Easy to maintain
 Internal Gear pumps
 All varieties of fuel oil and lube oil
 Resins and Polymers
 Alcohols and solvents
 Asphalt, Bitumen, and Tar
 Polyurethane foam (Isocyanate and polyol)
 Food products such as corn syrup, chocolate, and peanut butter
 Paint, inks, and pigments
 Soaps and surfactants
 Glycol
 Lobe pumps
 It is similar to the gear pump, but the gear wheels are replaced by propell
ers of two, three or four lobes. So that it is called as lobe pump.
 Its consists of lobes and external housing.
 Both lobes are driven externally.
 The operation of the lobe pumps are similar to external gear pumps in
that fluid flows around the interior of the casing.
Lobe pumps
 Lobe pumps
Advantages
Disadvantages
1. Pass medium solids
1. Requires timing gears
2. No metal-to-metal contact
2. Requires two seals
3. Long term dry run (with
3. Reduced lift with thin liquids
lubrication to seals)
4. Non-pulsating discharge

Applications
1. Polymers 5. Rubber and adhesives
2. Paper coatings 6. Pharmaceuticals
3. Soaps and surfactants 7. Food applications
4. Paints and dyes
 Gerotor pump
 Its consists of internal spur gear, outside ring gear and external housing.
 The internal gear and outer ring gears are placed eccentrically. No
crescent shaped shaper in this pump.
 The inlet and outlet ports are located in the casing.
 Inner gear is connected with the prime mover and outer gear is follower.
 These two rotating gears are unmesh at the suction side of the pump to
create cavity, hence the volume increases and pressure decreases at the
suction side which allow atmospheric pressure to force fluid into the
pump.
 The oil is trapped between the external and internal gear teeth. On both
sides of the crescent.
Gerotor pump
 Gerotor pump
Advantages
1. High Speed
2. Only two moving parts
3. Only one stuffing box
4. Constant and even discharge regardless of pressure conditions
5. Operates well in either direction
6. Quiet operation
7. Can be made to operate with one direction of flow with either rotation

Disadvantages
1. Medium pressure limitations
2. Fixed clearances
3. No solids allowed
4. One bearing runs in the product pumped
5. Overhung load on shaft bearing
 Vane pump
 The operation of the vane pump is based on , the rotor which contain
radial slots rotate by a shaft and rotate in cam ring (housing), each slot
contain a vane design as to comes out from the slot as the rotor turns.
 During one half of the rotation the oil inters between the vane and the
housing then this area starts to decrease in the second half which permit
the pressure to be produced , then the oil comes out pressurizes to the
output port.
Classification: They are two types of vane Pumps, they are-
 Fixed Displacement vane pump
 Variable Displacement vane pump
 Vane pump
Fixed Displacement vane pump:
 In this type of pump the eccentricity between pump cam-ring and rotor
is fixed and pump discharge always remain same at a particular
pressure
 There are two types of fixed displacement Vane Pump-
 Unbalanced Vane Pump
 Balanced Vane Pump
 Fixed Displacement (Unbalanced) vane pump:
 A slotted rotor is eccentrically supported in a cycloidal cam.
 The rotor is located close to the wall of the cam so a crescent-
shaped cavity is formed.
 The rotor is sealed into the cam by two side plates.
 Vanes or blades fit within the slots of the impeller.
 As the rotor rotates and fluid enters the pump, centrifugal force,
hydraulic pressure, and/or pushrods push the vanes to the walls of the
housing.
 The tight seal among the vanes, rotor, cam, and side plate is the key to
the good suction characteristics common to the vane pumping principle.
 Fixed Displacement (Unbalanced) vane pump:
 The housing and cam force fluid into the pumping chamber
through holes in the cam.
 Fluid enters the pockets created by the vanes, rotor, cam, and side plate.
 As the rotor continues around, the vanes sweep the fluid to the opposite
side of the crescent where it is squeezed through discharge holes of the
cam as the vane approaches the point of the crescent.
 Fluid then exits the discharge port.
Fixed Displacement (Unbalanced) vane pump:
 Fixed Displacement (Unbalanced) vane pump:
 Advantages
 Handles thin liquids at relatively higher pressures
 Compensates for wear through vane extension
 Can run dry for short periods
 Can have one seal or stuffing box
 Develops good vacuum
 Disadvantages
 Complex housing and many parts
 Not suitable for high pressures
 Not suitable for high viscosity
 Fixed Displacement (Balanced) vane pump:
 This pump has an elliptical cam ring with two inlet and two outlet ports
diametrically opposite each other.
 Pressure ports are opposite each other and a complete hydraulic balance
is achieved. It leads to the zero net force on the shaft and bearings.
 Thus, lives of pump and bearing increase significantly. Also the sounds
and vibrations decrease in the running mode of the pump.
 One disadvantage of the balanced vane pump is that it can not be
designed as a variable displacement unit.
 It have elliptical housing which formed two separate pumping chambers
on opposite side of the rotor.
 This kind give higher operating pressure.
 Variable Displacement vane pump:
 In variable displacement the discharge of pump can be changed by
varying the eccentricity between rotor and pump cam-ring.
 As eccentricity increases pump discharge increases.
 With decrease in eccentricity discharge decreases and oil flow completely
stop when rotor becomes concentric to pump cam ring.
Variable Displacement Pressure compensated
vane pump:
Vane pump – fixed displacement and
balanced
Vane pump
Vane pump
 Piston pump
 It is one of the positive displacement pump.
 The pumping action is affected be a piston that reciprocates inside the
cylinder.
 The basic operations of the piston pump is very similar to the internal
combustion engine.

Piston pump

Axial piston pump Radial piston pump

Bent axis Swash plate

 Piston pump
 In axial piston pump, the number of pistons and cylinders are located
parallel with respect to the driving shaft.
 In radial piston pump, the number of pistons and cylinders are located
radially around the rotor.
 Radial piston pump
 Radial Piston pump include a rotating cylinder containing equally spaced

radial pistons arranged radial around the cylinder centre line.

 A springs pushes the pistons against the inner surface of an encircling

stationary ring mounted eccentric to the cylinder.

 The fluid flow at pressure causes the pistons to move out, resulting in

rotation, for half of a revolution and the pistons move in ,driving the fluid

out during the other half.

 The greater the ring eccentricity the longer the pistons stroke and the less

the rotation speed per unit fluid flow rate.

Radial piston pump
Radial piston motor
Advantage of Radial piston pump
 High efficiency
 High pressure (up to 1000 bar)
 Low flow rate (due to the small dead volume in the workspace of the
pumping piston)
 Low noise level
 Very high load at lowest speed due to the hydro-statically balanced parts
possible
 No axial internal forces at the drive shaft bearing
 High reliability

Disadvantage of Radial piston pump

Larger radial dimensions when compared with axial piston pumps
 Swash plate piston pump
 Swash plate pump have a rotating cylinder containing parallel pistons arra

nged radially around the cylinder centre line.

 A spring pushes the pistons against a stationary swash plate located at one end

of the cylinder , which sits at an angle to the cylinder.

 The fluid pressure causes the pistons to move out during half a revolution and

pistons drive the e fluid out during the other half.

 The greater the swash plate angle relative to the cylinder centre line the longer

the pistons stroke and the less the rotation speed per unit fluid flow rate.

 Maximum Swash plate angle is 17.5 deg

Swash plate piston motor
Swash plate piston motor
 Bent Axis piston pump
 The reciprocating action of the pistons is obtained by bending the axis of the
cylinder block.
 The cylinder block rotates at an angle which is inclined to the drive shaft.
 The cylinder block is turned by the drive shaft through a universal link.
 The cylinder block is set at an offset angle with the drive shaft.
 The cylinder block contains a number of pistons along its periphery.
 These piston rods are connected with the drive shaft flange by ball-and- sock
et joints.
 These pistons are forced in and out of their bores as the distance between the d
rive shaft flange and the cylinder block changes.
 A universal link connects the block to the drive shaft, to provide alignment and
a positive drive.
 The axis angle varies from 0 deg to 30 deg.
Bent Axis piston pump
Bent Axis piston pump
 Bent axis piston pump
 The offset angle can vary from 0° to 40°.
 There is no flow when the cylinder block centerline is parallel to the drive
shaft centerline (offset angle is 0°).
 The total fluid flow per stroke can be given as:
87