HYDRAULIC

ARM
HYDRAULIC ARM Page 3
Materials used for Hydraulic Arm
Innovation components allow for greater alternative and innovative designs. They are not required, but are
suggested to bring more engineering and innovation to the activity. Only a few innovation components are
usually needed to create alternative designs, so your supply of innovation components can be used for many
hydraulic arms and other activities. Here are the components that are used in this project:

o Hydraulic cylinders (Syringe with clips and mounts)

o Hydraulic Lines (Vinyl Tubing)
o Perpendicular wooden blocks and Dowels
o Chip board
o Screws
o #10 square nuts
o #10 washers
o Connector strips
o Galvanised coloured wire
o Rubber band
o Anything else things like the recycling bin, wood, metal, plastic, broken toys, etc.

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INTRODUCTION TO FLUID POWER
Fluid power is a term which was created to include the generation, control, and application of
smooth, effective power of pumped or compressed fluids (either liquids or gases) when this power is
used to provide force and motion to mechanisms. This force and motion maybe in the form of pushing,
pulling, rotating, regulating, or driving. Fluid power includes hydraulics, which involves liquids, and
pneumatics, which involves gases. Liquids and gases are similar in many respects. The differences are
pointed out in the appropriate areas of this manual. This manual presents many of the fundamental
concepts in the fields of hydraulics and pneumatics. It is intended as a basic reference for all
personnel of the Navy whose duties and responsibilities require them to have a knowledge of the
fundamentals of fluid power.

Consequently, emphasis is placed primarily on the theory of operation of typical fluid power systems and
components that have applications in naval equipment. Many applications of fluid power are presented in
this manual to illustrate the functions and operation of different systems and components. However,
these are only representative of the many applications of fluid power in naval equipment. Individual training
manuals for each rate provide information concerning the application of fluid power to specific
equipment for which the rating is responsible.
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ADVANTAGES OF FLUID POWER
The extensive use of hydraulics and pneumatics to transmit power is due to the fact that properly
constructed fluid power systems possess a number of favourable characteristics. They eliminate the
need for complicated systems of gears, cams, and levers. Motion can be trans-mitted without the
slack inherent in the use of solid machine parts. The fluids used are not subject to breakage as are
mechanical parts, and the mechanisms are not subjected to great wear. The different parts of a fluid
power system can be conveniently located at widely separated points, since the forces generated are
rapidly transmitted over considerable distances with small loss. These forces can be conveyed up and
down or around corners with small loss in efficiency and without complicated mechanisms. Very large
forces can be controlled by much smaller ones and can be transmitted through comparatively small
lines and orifices. If the system is well adapted to the work it is required to perform, and if it is not
misused, it can provide smooth, flexible, uniform action without vibration, and is unaffected by variation
of load. In case of an overload, an automatic release of pressure can be guaranteed, so that the
system is protected against breakdown or strain. Fluid power systems can provide widely variable motions
in both rotary and straight-line trans-mission of power. The need for control by hand can be
minimized. In addition, fluid power systems are economical to operate. The question may arise as to
why hydraulics is used in some applications and pneumatics in others. Many factors are considered by
the user and/or the manufacturer when determining which type of system to use in a specific
application. There are no hard and fast rules to follow; however, past experience has provided
some sound ideas that are usually considered when such decisions are made. If the application requires
speed, a medium amount of pressure, and only fairly accurate control, a pneumatic system may be used.
If the application requires only a medium.

Fluid Power

Gas Liquid

Pneumatics Hydraulics

The word hydraulics is based on the Greek word for water, and originally covered the study of the
physical behaviour of water at rest and in motion. Use has broadened its meaning to include the
behaviour of all liquids, although it is primarily concerned with the motion of liquids. Hydraulics
includes the manner in which liquids act in tanks and pipes, deals with their properties, and
explores ways to take advantage of these properties.

Use of Hydraulics
The hydraulic press, invented by English man John Brahmah, was one of the first work-able pieces
of machinery developed that used hydraulics in its operation. It consisted of a plunger pump
piped to a large cylinder and a ram. This press found wide use in England because it provided a more
effective and economical means of applying large forces in industrial uses. Today, hydraulic power is

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used to operate many different tools and mechanisms. In a garage, a mechanic raises the end of an
auto-mobile with a hydraulic jack. Dentists and barbers use hydraulic power, through a few strokes of a
control lever, to lift and position their chairs to a convenient working height. Hydraulic doorstops
keep heavy doors from slamming. Hydraulic brakes have been standard equipment on auto-mobiles
since the 1930s. Most automobiles are equipped with automatic transmissions that are hydraulically
operated. Power steering is another application of hydraulic power. Construction workers depend upon
hydraulic power for the operation of various components of their equipment. For example, the blade
of a bulldozer is normally operated by hydraulic power. During the period preceding World War
II ,the Navy began to apply hydraulics to naval mechanisms extensively. Since then, naval
applications have increased to the point where many ingenious hydraulic devices are used in the solution
of problems of gunnery, aeronautics, and navigation. Aboard ship, hydraulic power is used to operate such
equipment as anchor windlasses, cranes, steering gear, remote control devices, and power drives for
elevating and training guns and rocket launchers. Elevators on aircraft carriers use hydraulic power to
transfer aircraft from the hangar deck to the flight deck and vice versa. Hydraulics and pneumatics
(chapter 11) are combined for some applications. This combination is referred to as hydro
pneumatics. An example of this combination is the lift used in garages and service stations. Air
pressure is applied to the surface of hydraulic fluid in a reservoir. The air pressure forces the
hydraulic fluid to raise the lift.

FORCES IN LIQUIDS

The study of liquids is divided into two main parts: liquids at rest (hydrostatics) and liquids in motion
(hydraulics).The effects of liquids at rest can often be expressed by simple formulas. The effects
of liquids in motion are more difficult to express due to frictional and other factors whose
actions cannot be expressed by simple mathematics. Liquids have a definite volume but take the shape
of their containing vessel. There are two additional characteristics we must explore prior to
proceeding. Liquids are almost incompressible. For example, if a pressure of 100 pounds per square
inch (psi) is applied to a given volume of water that is at atmospheric pressure, the volume will
decrease by only 0.03 percent. It would take a force of approximately 32 tons to reduce its
volume by 10 percent; however, when this force is removed, the water immediately returns to its original
volume. Other liquids behave in about the same manner as water. Another characteristic of a liquid is
the tendency to keep its free surface level. If the surface is not level, liquids will flow in the
direction which will tend to make the surface level.

LIQUIDS AT REST

In studying fluids at rest, we are concerned with the transmission of force and the factors which
affect the forces in liquids. Additionally, pressure in and on liquids and factors affecting pressure
are of great importance.

PRESSURE AND FORCE

The terms force and pressure are used extensively in the study of fluid power. It is essential
that we distinguish between the terms. Force means a total push or pull. It is the push or
pull exerted against the total area of a particular surface and is expressed in pounds or grams. Pressure
means the amount of push or pull (force) applied to each unit area of the surface and is expressed in
pounds per square inch (lb/in2) or grams per square centimetre (gm/cm2). Pressure maybe exerted in
one direction, in several directions, or in all directions.

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Computing Force, Pressure, and Area:-

A formula is used in computing force, pressure, and area in fluid power systems. In this
formula,
F=P×A . . . . . . . . . . . . . . . . . . . . . . . . equation (1)

P refers to pressure,

F indicates force,

and A represents area.

Force equals pressure times area.

Pressure equals force divided by area. By rearranging the formula this statement may be condensed into.

F
P=
A

Since area equals force divided by pressure, the formula is written

This figure illustrates a memory device for recalling the

different variations of this formula. Any letter in the triangle
may be expressed as the product or quotient of the other two,
depending on its position within the triangle. For example,
to find area, consider the letter A as being set off to itself,
followed by an equal sign. Now look at the other two letters.
The letter F is above the letter P; therefore,

NOTE: Sometimes the area may not be expressed in square units. If the surface is rectangular, you
can determine its area by multiplying its length (say, in inches) by its width(also in inches). The
majority of areas you will consider in these calculations are circular in shape. Either the radius or the
diameter may be given, but you must know the radius in inches to find the area. The radius is one-half
the diameter. To determine the area, use the formula for finding the area of a circle. This is written A
=where A is the area A=π r 2 , π is 3.1416 (3.14 or 3 1/7 for most calculations), and r2 indicates the radius
squared.

PNEUMATICS

The word pneumatics is a derivative of the Greek word pneumatic, which means air, wind, or
breath. It can be defined as that branch of engineering science that pertains to gaseous pressure
and flow. As used in this manual, pneumatics is the portion of fluid power in which compressed air, or
other gas, is used to transmit and control power to actuating mechanisms. This chapter discusses the
origin of pneumatics. It discusses the characteristics of gases and compares them with those of
liquids. It also explains factors which affect the properties of gases, identifies and explains the gas
laws, and identifies gases commonly used in pneumatics and their pressure ranges. It also discusses

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hazards of pneumatic gases, methods of controlling contamination, and safety precautions associated with
compressed gases

TRANSMISSION OF FORCES THROUGH LIQUIDS

When the end of a solid bar is struck, the main force of the blow is carried straight through the
bar to the other end (fig. 2-4, view A). This happens because the bar is rigid. The direction of the
blow almost entirely determines the direction of the transmitted force.

Figure 1 Effects of atmospheric pressure

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Pascal’s Law

The foundation of modern hydraulics was established when Pascal discovered that pressure in a fluid acts
equally in all directions. This pressure acts at right angles to the containing surfaces. If some type of
pressure gauge, with an exposed face, is placed beneath the surface of a liquid (fig. 2-6) at a
specific depth and pointed in different directions, the pressure will read the same. Thus, we can say that
pressure in a liquid is independent of direction. Pressure due to the weight of a liquid, at any level,
depends on the depth of the fluid from the surface. If the exposed face of the pressure gauges, figure 2-6, are
moved closer to the surface of the liquid, the indicated pressure will be less. When the depth is doubled,
the indicated pressure is doubled. Thus the pressure in a liquid is directly proportional to the depth.
Consider a container with vertical sides(fig. 2-7) that is 1 foot long and 1 foot wide. Let it be filled
with water 1 foot deep, providing 1cubic foot of water. We learned earlier in this chapter that 1
cubic foot of water weighs 62.4pounds. Using this information and equation, P = F/A, we can
calculate the pressure on the bottom of the container.

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Since there are 144 square inches in 1 square foot

This can be stated as follows: the weight of a column of water 1 foot high, having a cross-
sectional area of 1 square inch, is 0.433 pound. If the depth of the column is tripled, the weight of
the column will be 3 x 0.433, or 1.299pounds, and the pressure at the bottom will be1.299 lb/in2 (psi),
since pressure equals the force divided by the area. Thus, the pressure at any depth in a liquid is
equal to the weight of the column of liquid at that depth divided by the cross-sectional area of the
column at that depth. The volume of a liquid that produces the pressure is referred to as the fluid head of
the liquid. The pressure of a liquid due to its fluid head is also dependent on the density of the liquid. If
we let A equal any cross-sectional area of a liquid column and h equal the depth of the column, the
volume becomes Ah. Using equation2-4, D = W/V, the weight of the liquid above area A is equal to AhD.

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Since pressure is equal to the force per unit area, set A equal to 1. Then the formula pressure becomes
P = h D . . . . . . . . . . Equation (2).
It is essential that h and D be expressed in similar units. That is, if D is expressed in pounds per cubic
foot, the value of h must be expressed in feet. If the desired pressure is to be expressed in pounds per
square inch, the pressure formula, equation 2-5, becomes

. . . . . . . . . . . Equation (3).

Pascal was also the first to prove by experiment that the shape and volume of a container in no way
alters pressure. Thus in figure2-8, if the pressure due to the weight of the liquid at a point on horizontal
line H is 8 psi, the pressure is 8 psi everywhere at level H in the system. Equation 2-5 also shows
that the pressure is independent of the shape and volume of a container.

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Pressure and Force in Fluid Power Systems

Recall that, according to Pascal’s law, any force applied to a confined fluid is transmitted in all
directions throughout the fluid regardless of the shape of the container. Consider the effect of this in the
system shown in figure 2-9. If there is a resistance on the output piston and the input piston is pushed
downward, a pressure is created through the fluid, which acts equally at right angles to surfaces in all
parts of the container. If force 1 is 100 pounds and the area of the input piston is 10 square inches, then the
pressure in the fluid is 10 psi

NOTE: Fluid pressure cannot be created without resistance to flow. In this case, resistance is
provided by the equipment to which the output piston is attached. The force of resistance acts
against the top of the output piston. The pressure created in the system by the input piston
pushes on the underside of the output piston with a force of 10 pounds on each square inch. In this
case, the fluid column has a uniform cross section, so the area of the output piston is the same as the

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area of the input piston, or 10 square inches. Therefore, the upward force on the output piston is
100 pounds(10 psi x 10 sq. in.), the same as the force applied to the input piston. All that was accomplished
in this system was to transmit the 100-pound force around the bend. However, this principle under-lies
practically all mechanical applications of fluid power. At this point you should note that since
Pascal’s law is independent of the shape of the container, it is not necessary that the tube
connecting the two pistons have the same cross-sectional area of the pistons. A connection of any size,
shape, or length will do, as long as an unobstructed passage is provided. Therefore, the system shown in
figure 2-10, with a relatively small, bent pipe connecting two cylinders, will act exactly the same as the
system shown in Figure 2-9.

MULTIPLICATION OF FORCES.

Consider the situation in figure 2-11, where the input piston is much smaller than the output
piston. Assume that the area of the input piston is 2square inches. With a resistant force on the output
20
piston a downward force of 20 pounds acting on the input piston creates a pressure of or 10 psi in the
2
fluid. Although this force is much smaller than the force applied in figures 2-9 and 2-10, the pressure is the
same. This is because the force is applied to a smaller area.

This pressure of 10 psi acts on all parts of the fluid container, including the bottom of the output piston.
The upward force on the output piston is 200 pounds (10 pounds of pressure on each square inch).
In this case, the original force has been multiplied tenfold while using the same pressure in the fluid as
before. In any system with these dimensions, the ratio of output force to input force is always ten to
one, regardless of the applied force. For example, if the applied force of the input piston is 50 pounds,
the pressure in the system will be 25 psi. This will support a resistant force of 500 pounds on the
output piston.

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The system works the same in reverse. If we change the applied force and place a 200-pound force on the
output piston (fig. 2-11), making it the input piston, the output force on the input piston will be
one-tenth the input force, or 20pounds. (Sometimes such results are desired.)Therefore, if two
pistons are used in a fluid power system, the force acting on each piston is directly proportional to its
area, and the magnitude of each force is the product of the pressure and the area of each piston.

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HYDRAULIC FLUIDS

During the design of equipment that requires fluid power, many factors are considered in selecting the
type of system to be used—hydraulic, pneumatic, or a combination of the two. Some of the factors are
required speed and accuracy of operation, surrounding atmospheric conditions, economic conditions,
availability of replacement fluid, required pressure level, operating temperature range, contamination
possibilities, cost of transmission lines, limitations of the equipment, lubricity, safety to the operators,
and expected service life of the equipment. After the type of system has been selected, many of
these same factors must be considered in selecting the fluid for the system. This chapter is devoted to
hydraulic fluids. Included in it are sections on the properties and characteristics desired of hydraulic
fluids; types of hydraulic fluids; hazards and safety precautions for working with, handling, and
disposing of hydraulic liquids; types and control of contamination; and During the design of
equipment that requires fluid power, many factors are considered in selecting the type of system to be
used—hydraulic, pneumatic, or a combination of the two. Some of the factors are required speed and
accuracy of operation, surrounding atmospheric conditions, economic conditions, availability of
replacement fluid, required pressure level, operating tempera-ture range, contamination possibilities, cost
of transmission lines, limitations of the equipment, lubricity, safety to the operators, and expected
service life of the equipment. After the type of system has been selected, many of these same
factors must be considered in selecting the fluid for the system. This chapter is devoted to hydraulic fluids.
Included in it are sections on the properties and characteristics desired of hydraulic fluids; types of
hydraulic fluids; hazards and safety precautions for working with, handling, and disposing of
hydraulic liquids; types and control of contamination; and sampling.

PROPERTIES

If fluidity (the physical property of a substance that enables it to flow) and incompressibility were the
only properties required, any liquid not too thick might be used in a hydraulic system. However, a
satisfactory liquid for a particular system must possess a number of other properties. The most important
properties and some characteristics are discussed in the following paragraphs.

VISCOSITY

Viscosity is one of the most important properties of hydraulic fluids. It is a measure of a fluid’s
resistance to flow. A liquid, such as gasoline, which flows easily has a low viscosity; and a liquid, such
as tar, which flows slowly has a high viscosity. The viscosity of a liquid is affected by changes
in temperature and pressure. As the temperature of a liquid increases, its viscosity decreases. That is,
a liquid flows more easily when it is hot than when it is cold. The viscosity of a liquid increases as
the pressure on the liquid increases. A satisfactory liquid for a hydraulic system must be thick enough
to give a good seal at pumps, motors, valves, and so on. These components depend on close fits
for creating and maintaining pressure. Any internal leakage through these clearances results in loss of
pressure, instantaneous control, and pump efficiency .Leakage losses are greater with thinner
liquids(low viscosity). A liquid that is too thin will also allow rapid wearing of moving parts, or of parts that
operate under heavy loads. On the other hand, if the liquid is too thick (viscosity too high),the internal
friction of the liquid will cause an increase in the liquid’s flow resistance through clearances of
closely fitted parts, lines, and internal passages. This results in pressure drops throughout the system,
sluggish operation of the equipment, and an increase in power consumption.

Measurement of Viscosity

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Viscosity is normally determined by measuring the time required for a fixed volume of a fluid(at a
given temperature) to flow through a calibrated orifice or capillary tube. The instruments used to
measure the viscosity of a liquid are known as viscometers or viscosimeters. Several types of
viscosimeters are in use today. The Saybolt viscometer, shown in figure 3-1,measures the time
required, in seconds, for 60milliliters of the tested fluid at 100°F to pass through a standard orifice.
The time measured is used to express the fluid’s viscosity, in Saybolt universal seconds or Saybolt
furol seconds. The glass capillary viscometers, shown in figure 3-2, are examples of the second
type of viscometer used. These viscometers are used measure kinematic viscosity. Like the Saybolt
viscometer, the glass capillary measures the time in seconds required for the tested fluid to flow
through the capillary. This time is multiplied by the temperature constant of the viscometer in use to
provide the viscosity, expressed in centistokes. The following formulas may be used to convert
centistokes (cSt units) to approximate Saybolt universal seconds (SUS units).

For SUS values between 32 and 100

For SUS values greater than 100:

Viscosity Index

The viscosity index (V.I.) of oil is a number that indicates the effect of temperature changes on the
viscosity of the oil. A low V.I. signifies relatively large change of viscosity with changes of
temperature. In other words, the oil becomes extremely thin at high temperatures and extremely hick at
low temperatures. On the other hand, a high V.I. signifies relatively little change in viscosity over a
wide temperature range. Ideal oil for most purposes is one that maintains a constant viscosity
through out temperature changes. The importance of the V.I. can be shown easily by considering
automotive lubricants. An oil having a high V.I. resists excessive thickening when the engine is cold
and, consequently, promotes rapid starting and prompt circulation; it resists excessive thinning when the
motor is hot and thus provides full lubrication and prevents excessive oil consumption. Another example
of the importance of the V.I.is the need for a high V.I. hydraulic oil for military aircraft, since hydraulic
control systems may be exposed to temperatures ranging from below–65°F at high altitudes to
over 100°F on the ground. For the proper operation of the hydraulic control system, the hydraulic fluid
must have a sufficiently high V.I. to perform its functions at the extremes of the expected temperature
range. Liquids with a high viscosity have a greater resistance to heat than low viscosity liquids
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which have been derived from the same source. The average hydraulic liquid has a relatively
low viscosity. Fortunately, there is a wide choice of liquids available for use in the viscosity range
required of hydraulic liquids. The V.I. of an oil may be determined if its viscosity at any two
temperatures is known. Tables, based on a large number of tests, are issued by the American
Society for Testing and Materials (ASTM). These tables permit calculation of the V.I. from known
viscosities.

LUBRICATING POWER

If motion takes place between surfaces in contact, friction tends to oppose the motion.
When pressure forces the liquid of a hydraulic system between the surfaces of moving parts, the liquid
spreads out into a thin film which enables the parts to move more freely. Different liquids, including oils,
vary greatly not only in their lubricating ability but also in film strength. Film strength is the capability
of a liquid to resist being wiped or squeezed out from between the surfaces when spread out in an
extremely thin layer. A liquid will no longer lubricate if the film breaks down, since the motion of part
against part wipes the metal clean of liquid. Lubricating power varies with temperature changes;
therefore, the climatic and working conditions must enter into the determination of the lubricating
qualities of a liquid. Unlike viscosity, which is a physical property, the lubricating power and
film strength of a liquid is directly related to its chemical nature.

CHEMICAL STABILITY

Chemical stability is another property which is exceedingly important in the selection of a hydraulic
liquid. It is defined as the liquid’s ability to resist oxidation and deterioration for long periods. All
liquids tend to undergo un favourable changes under severe operating conditions. This is the case, for
example, when a system operates for a considerable period of time at high temperatures. Excessive
temperatures, especially extremely high temperatures, have a great effect on the life of a liquid. The
temperature of the liquid in the reservoir of an operating hydraulic system does not always indicate
the operating conditions throughout the system. Localized hot spots occur on bearings, gear teeth, or at
other points where the liquid under pressure is forced through small orifices. Continuous passage of the
liquid through these points may produce local temperatures high enough to carbonize the liquid or
turn it into sludge, yet the liquid in the reservoir may not indicate an excessively high temperature.
Liquids may break down if exposed to air, water, salt, or other impurities, especially if they are in
constant motion or subjected to heat. Some metals, such as zinc, lead, brass, and copper, have
undesirable chemical reactions with certain liquids. These chemical reactions result in the formation of
sludge, gums, carbon, or other deposits which clog openings, cause valves and pistons to stick or leak,
and give poor lubrication to moving parts.

FREEDOM FROM ACIDITY

An ideal hydraulic liquid should be free from acids which cause corrosion of the metals in the system. Most
liquids cannot be expected to remain completely noncorrosive under severe operating conditions. The
degree of acidity of a liquid, when new, may be satisfactory; but after use, the liquid may tend to become
corrosive as it begins to deteriorate.

Certain corrosion and rust-preventive additives are added to hydraulic liquids. Some of these additives are
effective only for a limited period. Therefore, the best procedure is to use the liquid specified for the system

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for the time specified by the system manufacturer and to protect the liquid and the system as much as
possible from contamination by foreign matter, from abnormal temperatures, and from misuse.

FLASHPOINT

Flashpoint is the temperature at which a liquid gives off vapour in sufficient quantity to ignite
momentarily or flash when a flame is applied. A high flashpoint is desirable for hydraulic liquids because it
provides good resistance to combustion and a low degree of evaporation at normal temperatures.
Required flashpoint minimums vary from 300°F for the lightest oils to 510°F for the heaviest oils.

FIRE POINT

Fire point is the temperature at which a substance gives off vapour in sufficient quantity to ignite
and continue to burn when exposed to a spark or flame. Like flashpoint, a high fire point is required of
desirable hydraulic liquids.

MINIMUM TOXICITY

Toxicity is defined as the quality, state, or degree of being toxic or poisonous. Some liquids contain
chemicals that are a serious toxic hazard. These toxic or poisonous chemicals may enter the body through
inhalation, by absorption through the skin, or through the eyes or the mouth. The result is sickness and, in
some cases, death. Manufacturer of hydraulic liquids strive to produce suitable liquids that contain no
toxic chemicals and, as a result, most hydraulic liquids are free of harmful chemicals. Some fire-resistant
liquids are toxic, and suitable protection and care in handling must be provided.

DENSITY AND COMPRESSIBILITY

A fluid with a specific gravity of less than 1.0is desired when weight is critical, although with proper system
design, a fluid with a specific gravity greater than one can be tolerated. Where avoidance of detection by
military units is desired, a fluid which sinks rather than rises to the surface of the water is desirable. Fluids
having a specific gravity greater than 1.0 are desired, as leaking fluid will sink, allowing the vessel with
the leak to remain undetected. Recall from chapter 2 that under extreme pressure a fluid may be
compressed up to 7 percent of its original volume. Highly compressible fluids produce sluggish system
operation. This does not present a serious problem in small, low-speed operations, but it must be considered
in the operating instructions.

CLEANLINESS

Cleanliness in hydraulic systems has received considerable attention recently. Some hydraulic systems,
such as aerospace hydraulic systems, are extremely sensitive to contamination. Fluid cleanliness is
of primary importance because contaminants can cause component malfunction, prevent proper valve
seating, cause wear in components, and may increase the response time of servo valves. Fluid
contaminants are discussed later. The inside of a hydraulic system can only be kept as clean as the fluid
added to it. Initial fluid cleanliness can be achieved by observing stringent cleanliness requirements ( or
by filtering all fluid added to the system.

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TYPES OF HYDRAULIC FLUIDS

There have been many liquids tested for use in hydraulic systems. Currently, liquids being used include
mineral oil, water, phosphate ester, water-based ethylene glycol compounds, and silicone fluids. The
three most common types of

Hydraulic
Fluids

Petrolium Synthetic water based

Based fire resistant fire-resistant

hydraulic liquids are petroleum-based, synthetic fire-resistant, and water-based fire-resistant.

PETROLEUM-BASED FLUIDs

The most common hydraulic fluids used in shipboard systems are the petroleum-based oils. These fluids
contain additives to protect the fluid from oxidation (antioxidant), to protect system metals from
corrosion (anticorrosion), to reduce tendency of the fluid to foam (foam suppressant),and to improve
viscosity. Petroleum-based fluids are used in surface ships’ electro hydraulic steering and deck
machinery systems, submarines’ hydraulic systems, and aircraft automatic pilots, shock absorbers,
brakes, control mechanisms, and other hydraulic systems using seal materials compatible with
petroleum-based fluids.

SYNTHETIC FIRE-RESISTANT FLUIDS

Petroleum-based oils contain most of the desired properties of a hydraulic liquid. However, they are
flammable under normal conditions and can become explosive when subjected to high pressures and a
source of flame or high temperatures. Non flammable synthetic liquids have been developed for use in
hydraulic systems where fire hazards exist.

WATER-BASED FIRE-RESISTANTFLUIDS

The most widely used water-based hydraulic fluids may be classified as water-glycol mixtures and water-
synthetic base mixtures. The water-glycol mixture contains additives to protect it from oxidation,
corrosion, and biological growth and to enhance its load-carrying capacity. There-fore, frequent
checks to maintain the correct ratio of water are important. The water-based fluid used in catapult
retracting engines, jet blast deflectors, and weapons elevators and handling systems conforms to
MIL-H22072.The safety precautions outlined for phosphate ester fluid and the disposal of phosphate
ester fluid also apply to water-based fluid conforming to MIL-H-22072.

Hydraulic cylinder

A Hydraulic cylinder (also called a linear hydraulic motor) is a mechanical actuator that is used to
give a unidirectional force through a unidirectional stroke. It has many applications, notably in engineering
vehicles.

Operation

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Hydraulic cylinders get their power from pressurized hydraulic fluid, which is typically oil. The hydraulic
cylinder consists of a cylinder barrel, in which a piston connected to a piston rod moves back and forth. The
barrel is closed on each end by the cylinder bottom (also called the cap end) and by the cylinder head
where the piston rod comes out of the cylinder. The piston has sliding rings and seals. The piston divides
the inside of the cylinder in two chambers, the bottom chamber (cap end) and the piston rod side chamber
(rod end). The hydraulic pressure acts on the piston to do linear work and motion.

Flanges, trunnions, and/or clevisses are mounted to the cylinder body. The piston rod also has mounting
attachments to connect the cylinder to the object or machine component that it is pushing.

A hydraulic cylinder is the actuator or "motor" side of this system. The "generator" side of the hydraulic
system is the hydraulic pump which brings in a fixed or regulated flow of oil to the bottom side of the
hydraulic cylinder, to move the piston rod upwards. The piston pushes the oil in the other chamber back to
the reservoir. If we assume that the oil pressure in the piston rod chamber is approximately zero, the
force F on the piston rod equals the pressure P in the cylinder times the piston area A:

The piston moves instead downwards if oil is pumped into the piston rod side chamber and the oil
from the piston area flows back to the reservoir without pressure. The fluid pressure in the piston rod
area chamber is (Pull Force) / (piston area - piston rod area):

where P is the fluid pressure, Fp is the pulling force, Ap is the piston face area and Ar is the rod
cross-section area.

Parts of a hydraulic cylinder

A hydraulic cylinder consists of the following parts

Cylinder barrel

The cylinder barrel is mostly a seamless thick walled forged pipe that must be machined internally. The
cylinder barrel is ground and/or honed internally
Cylinder base or cap

In most hydraulic cylinders, the barrel and the bottom portion are welded together. This can damage the
inside of the barrel if done poorly. Therefore, some cylinder designs have a screwed or flanged connection
from the cylinder end cap to the barrel. (See "Tie rod cylinder", below) In this type the barrel can be
disassembled and repaired.
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Cylinder head

The cylinder head is sometimes connected to the barrel with a sort of a simple lock (for simple cylinders). In
general, however, the connection is screwed or flanged. Flange connections are the best, but also the most
expensive. A flange has to be welded to the pipe before machining. The advantage is that the connection is
bolted and always simple to remove. For larger cylinder sizes, the disconnection of a screw with a diameter
of 300 to 600 mm is a huge problem as well as the alignment during mounting.
Piston

The piston is a short, cylindrical metal component that separates the two parts of the cylinder barrel
internally. The piston is usually machined with grooves to fit elastomeric or metal seals. These seals are
often O-rings, U-cups or cast iron rings. They prevent the pressurized hydraulic oil from passing by the
piston to the chamber on the opposite side. This difference in pressure between the two sides of the piston
causes the cylinder to extend and retract. Piston seals vary in design and material according to the pressure
and temperature requirements that the cylinder will see in service. Generally speaking, elastomeric seals
made from nitrile rubber or other materials are best in lower temperature environments, while seals made
of Viton are better for higher temperatures. The best seals for high temperature are cast iron piston rings.
Piston rod

The piston rod is typically a hard chrome-plated piece of cold-rolled steel which attaches to the piston and
extends from the cylinder through the rod-end head. In double rod-end cylinders, the actuator has a rod
extending from both sides of the piston and out both ends of the barrel. The piston rod connects the
hydraulic actuator to the machine component doing the work. This connection can be in the form of a
machine thread or a mounting attachment, such as a rod-clevis or rod-eye. These mounting attachments can
be threaded or welded to the piston rod or, in some cases, they are a machined part of the rod-end.
Rod gland

The cylinder head is fitted with seals to prevent the pressurized oil from leaking past the interface between
the rod and the head. This area is called the rod gland. It often has another seal called a rod wiper which
prevents contaminants from entering the cylinder when the extended rod retracts back into the cylinder. The
rod gland also has a rod wear ring. This wear ring acts as a linear bearing to support the weight of the piston
rod and guides it as it passes back and forth through the rod gland. In some cases, especially in small
hydraulic cylinders, the rod gland and the rod wear ring are made from a single integral machined part.
Other parts

 Cylinder base connection

 Seals
 Cushions

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Single acting vs. double acting

 Single acting cylinders are economical and the simplest design. Hydraulic fluid enters through a port at
one end of the cylinder, which then moves the piston to extend the rod. An external force returns the
piston to its normal position and forces the hydraulic fluid back through the supply tubing to the fluid
reservoir.
 Double acting cylinders have a port at each end, supplied with hydraulic fluid for both the retraction and
extension of the piston. They are used where an external force is not available to retract the piston or
where high force is required in both directions of travel.
An hydraulic cylinder should be used for pushing and pulling only. No bending moments or side loads
should be transmitted to the piston rod or the cylinder to prevent rapid failure of the rod seals. For this
reason, the ideal connection of an hydraulic cylinder is a single clevis with a spherical ball bearing. This
allows the hydraulic actuator to move and allow for any misalignment between the actuator and the load it is
pushing.
In our project we have used Syringes working as hydraulic cylinders.

Figure 2 Control Panel

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HYDRAULIC ARM Page 24
CONCLUSION:

Our design uses extremely simple ideas and mechanisms to achieve a complex set of actions and is intended
to imitate the actions of the operators. However, these hydraulic arms are expensive for small scale
industries. If the major problem of high initial cost is addressed, a robotic hydraulic arm can be introduced in
any industry to bring in automation. The mechanical links and parts that have been fabricated are extremely
simple.
That Hydraulic Arm will-

 Reach the greatest distance to deliver a given object.

 Pick up the heaviest possible object.

 Deliver the most objects in a given amount of time.

 Function in an assembly line.

 Have a system to weigh the object it picks up.

 Battle against another arm for an object.

 Rotate as well as reach and grab.

 Dig and recover objects.

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 REFERENCES:

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