Industrial Hydraulics and Pneumatics

(IHP) 6512

Unit-I
Basics of hydraulic and Pneumatic systems

Dr. ANIL G. PATIL

Lecturer in Mechanical Engineering Department.

Government Polytechnic, Nashik
2/1/2023 1
 Unit-I
Basics of hydraulic and Pneumatic systems

Major Learning Outcomes

1a. Identify components
1b. list components
1c. Draw layout of components
Topics and Sub-topics
1.1 General layout, applications, merits and limitations
of hydraulic and Pneumatic systems
1.2 Essential Properties of oils
 Fluid Power and Its Scope
Fluid power is the technology that deals with the
generation, control and transmission of forces and
movement of mechanical element or system with the use
of pressurized fluids in a confined system.

Both liquids and gases are considered fluids. Fluid power

system includes a hydraulic system (hydra meaning
water in Greek) and a pneumatic system (pneuma
meaning air in Greek).

Oil hydraulic employs pressurized liquid petroleum oils

and synthetic oils, and pneumatic employs compressed
air that is released to the atmosphere after performing
the work.
 Methods for transmitting power

Mechanical transmission Electrical transmission Fluid power

eg:shafts, gears, chains, belts eg: wires, transformers eg: liquids or gas

Fluid Power:
Def: the technology that deals with the generation,
control and transmission of forces and movement
of mechanical element or system with the use of
pressurized fluids

- Both liquids and gases are considered as fluids

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 Hydraulic power transmission
• Hydraulic power transmission:
Hydro = water, aulos = pipe
The means of power transmission is a liquid (pneumatic  gas)

Hydrodynamic power Hydrostatic power transmission:

transmission:
• Positive displacement pump
• Turbo pump and turbine
• Creates high pressure and
• Power transmission by through a transmission line
kinetic energy of the fluid and control elements this
pressure drives an actuator
• Still the relative spatial
(linear or rotational)
position is fixed
• The relative spatial position is
• Compact units
arbitrary but should not be
very large because of losses (<
50 m)
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The following are the two types of hydraulic systems:

1. Fluid transport systems: Their sole objective is the

delivery of a fluid from one location to another to
accomplish some useful purpose. Examples include
pumping stations for pumping water to homes, cross-
country gas lines, etc.

2. Fluid power systems: These are designed to perform

work. In fluid power systems, work is obtained by
pressurized fluid acting directly on a fluid cylinder or a
fluid motor. A cylinder produces a force resulting in
linear motion, whereas a fluid motor produces a
torque resulting in rotary motion.
 Fluid power applications can be classified into two major
segments:
Stationary hydraulics: Mobile hydraulics:
fixed in one position move on wheels or tracks
valves are mainly solenoid valves are frequently manually
operated operated
Applications: Applications:
1. Machine tools and transfer 1. Automobiles, tractors ,
lines. aéroplanes, missile, boats ,
2. Lifting and conveying etc.
devices. 2. Construction machinery.
3. Metal-forming presses. 3. Tippers, excavators and
4. Plastic machinery such as elevating platforms.
injection-molding machines. 4. Lifting and conveying
5. Rolling machines. devices.
6. Lifts. 5. Agricultural machinery.
7. Food processing machinery.
8. Automatic handling
equipment and robots.
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 The advantages of a fluid power system are as
follows:
1. Fluid power systems are simple, easy to operate and can be
controlled accurately: Fluid power gives flexibility to equipment
without requiring a complex mechanism. Using fluid power, we
can start, stop, accelerate, decelerate, reverse or position large
forces/components with great accuracy using simple levers and
push buttons. For example, in Earth-moving equipment, bucket
carrying load can be raised or lowered by an operator using a
lever. The landing gear of an aircraft can be retrieved to home
position by the push button.
2. Multiplication and variation of forces: Linear or rotary force can
be multiplied by a fraction of a kilogram to several hundreds of
tons
3. Multifunction control: A single hydraulic pump or air
compressor can provide power and control for numerous
machines using valve manifolds and distribution systems. The
fluid power controls can be placed at a central station so that the
operator has, at all times, a complete control of the entire
production line, whether it be a multiple operation machine or a
group of machines. Such a setup is more or less standard in the
steel mill industry.
4. Low-speed torque: Unlike electric motors, air or hydraulic
motors can produce a large amount of torque while operating at
low speeds. Some hydraulic and pneumatic motors can even
maintain torque at a very slow speed without overheating.
5. Constant force or torque: Fluid power systems can deliver
constant torque or force regardless of speed changes.
6. Economical: Not only reduction in required manpower but also
the production or elimination of operator fatigue, as a production
factor, is an important element in the use of fluid power.
7. Low weight to power ratio: The hydraulic system has a low weight
to power ratio compared to electromechanical systems. Fluid power
systems are compact.
8. Fluid power systems can be used where safety is of vital
importance: Safety is of vital importance in air and space travel, in
the production and operation of motor vehicles, in mining and
manufacture of delicate products. For example, hydraulic systems
are responsible for the safety of takeoff, landing and flight of
aeroplanes and space craft. Rapid advances in mining and tunneling
are the results of the application of modern hydraulic and pneumatic
systems.
 Advantages of a Fluid Power System
1. Fluid power systems are simple, easy to operate
and can be controlled accurately
2. Multiplication and variation of forces
3. Multifunction control
4. Low-speed torque
5. Economical
6. Low weight to power ratio
7. Fluid power systems can be used where safety
is of vital importance
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Comparison of Hydraulic & Pneumatic System
Comparison of H&P system with conventional Transmission
system
 Components of Hydraulic System
Hydraulic systems are power-transmitting assemblies
employing pressurized liquid as a fluid for transmitting energy from
an energy-generating source to an energy-using point to accomplish
useful work. Figure shows a simple circuit of a hydraulic system
with basic components.
Functions of the components shown in Fig. are as follows:
1. The hydraulic actuator is a device used to convert the
fluid power into mechanical power to do useful work. The
actuator may be of the linear type (e.g., hydraulic cylinder)
or rotary type(e.g., hydraulic motor) to provide linear or
rotary motion, respectively.

2. The hydraulic pump is used to force the fluid from the

reservoir to rest of the hydraulic circuit by converting
mechanical energy into hydraulic energy.

3. Valves are used to control the direction, pressure and

flow rate of a fluid flowing through the circuit.

4. External power supply (motor) is required to drive the

pump.
6. Reservoir is used to hold the hydraulic liquid, usually hydraulic
oil.

6. Piping system carries the hydraulic oil from one place to

another.

7. Filters are used to remove any foreign particles so as keep the

fluid system clean and efficient, as well as avoid damage to the
actuator and valves.

8. Pressure regulator regulates (i.e., maintains) the required level

of pressure in the hydraulic fluid.
Components of Hydraulic System (Circuit)
A typical hydraulic system

1 – pump
2 – oil tank
3 – flow control valve
4 – pressure relief valve
5 – hydraulic cylinder
6 – directional control valve
7 – throttle valve
 Components of Pneumatic System
A pneumatic system carries power by employing compressed gas, generally
air, as a fluid for transmitting energy from an energy-generating source to an
energy-using point to accomplish useful work. Figure shows a simple circuit
of a pneumatic system with basic components.
The functions of various components shown in Fig. are as follows:

1. The pneumatic actuator converts the fluid power into

mechanical power to perform useful work.
2. The compressor is used to compress the fresh air drawn
from the atmosphere.
3. The storage reservoir is used to store a given volume of
compressed air.
4. The valves are used to control the direction, flow rate and
pressure of compressed air.
5. External power supply (motor) is used to drive the
compressor.
6. The piping system carries the pressurized air from one
location to another.
 Types of Hydraulic Fluids
There are five major types of hydraulic flow fluids
which meet various needs of the system
1. Petroleum-based fluids
2. Emulsions
3. Water glycol
4. Synthetic fluids
5. Vegetable oils
6. Biodegradable hydraulic fluids
1. Petroleum-based fluids:
Mineral oils are the petroleum-based oils that are the most
commonly used hydraulic fluids . They offer the best
lubrication ability, least corrosion problems and are
compatible with most seal materials.

The only major disadvantage of these fluids is their

flammability.

They pose fire hazards, mainly from the leakages, in high-

temperature environments such as steel industries, etc.
Mineral oils are good for operating temperatures below
50°C
2. Emulsions:

Emulsions are a mixture of two fluids that do not

chemically react with others. Emulsions of
petroleum-based oil and water are commonly used.
An emulsifier is normally added to the emulsion,
which keeps liquid as small droplets and remains
suspended in the other liquid. Two types of emulsions
are in use:

A)Oil-in-water emulsions ( 5%Oil+95%Water)

B) Water-in-oil emulsions (40%Oil +60% Water)
These emulsions are good for operations at 25°C, as
at a higher temperature, water evaporates and leads to
the loss of fire-resistant properties.
3. Water glycol:

Water glycol is another non-flammable fluid commonly

used in aircraft hydraulic systems.
It generally has a low lubrication ability as compared
to mineral oils and is not suitable for high-
temperature applications.
It has water and glycol in the ratio of 1:1.
Because of its aqueous nature and presence of air, it is
prone to oxidation and related problems.

It needs to be added with oxidation inhibitors

4. Synthetic fluids:
Synthetic fluid, based on phosphate ester, is another
popular fire-resistant fluid.

It is suitable for high-temperature applications, since it

exhibits good viscosity and lubrication
characteristics. It is not suitable for low-temperature
applications.

It is not compatible with common sealing materials such

as nitrile. Basically being expensive, it requires
expensive sealing materials (viton). In addition,
phosphate ester is not an environmental-friendly
fluid. It also attacks aluminum and paints.
5. Vegetable oils: The increase in the global pollution
has led to the use of more environmental-friendly
fluids. Vegetable-based oils are biodegradable and are
environmental safe. They have good lubrication
properties, moderate viscosity and are less expensive .

6. Biodegradable hydraulic fluids:Biodegradable

hydraulic fluids, alternatively known as bio-based
hydraulic fluids, Bio-based hydraulic fluids use
sunflower, rapeseed, soybean, etc., as the base oil and
hence cause less pollution in the case of oil leaks or
hydraulic hose failures. These fluids carry similar
properties as that of a mineral oil–based anti-wear
hydraulic fluid,
 Properties of Hydraulic Fluid
For a fluid to perform efficiently, it must possess certain properties. Various
properties required for an ideal hydraulic fluid are as follows:
1. Ideal viscosity & Viscosity Index
2. Good lubrication capability.
3. Demulsibility.
4. Good chemical and environmental stability.
5. Incompressibility.
6. Fire resistance.
7. Low flammability.
8. Foam resistance.
9. Low volatility.
10. Good heat dissipation.
11. Low density.
12. System compatibility.
1. Ideal viscosity:
It is a measure of a fluid’s resistance to flow.
Effect of High viscosity: High resistance to flow. Increased power
consumption due to frictional loss. High temperature caused by
friction. Increased pressure drop because of the resistance.
Possibility of sluggish or slow operation. Difficulty in separating air
from oil in a reservoir. Greater vacuum at the pump inlet, causing
cavitations. Higher system noise level.
Effect Of Low viscosity: Increased internal leakage. Excessive water.
Possibility of decreased pump efficiency, causing slower operation
of the actuator. Increased temperature resulting from leakage losses.
Therefore the hydraulic fluid should have an optimum viscosity.
Viscosity Index: The viscosity index (VI) is a relative measure of the
change in the viscosity of an oil with respect to a change in
temperature. An oil having a low VI is one that exhibits a large
change in viscosity with a small change in temperature. A high VI
oil does not change appreciably with a change in temperature.
2.Good lubrication capability:
Hydraulic fluids must have good lubrication to prevent friction and
wear between the closely fitted working parts such as vanes of
pumps, valve spools, piston rings and bearings .

3. Demulsibility:
The ability of a hydraulic fluid to separate rapidly from moisture and
successfully resist emulsification is known as “Demulsibility.

4.Good chemical and environmental stability:

Most fluids are vulnerable to oxidation, as they come in contact with
oxygen in air. Mineral oils or petroleum-based oils (widely used in
hydraulic systems) contain carbon and hydrogen molecules, which
easily react with oxygen
5. Incompressibility: the compressibility of a fluid is greatly
influenced by temperature and pressure. The incompressibility of a
fluid is a measure of its stiffness and is given by its bulk modulus.
The bulk modulus (B) of a fluid is the ratio of volumetric stress to
volumetric strain .
6. Fire resistance:. Flammability is defined as the ease of ignition
and ability to propagate the flame. The following are the usual
characteristics tested in order to determine the flammability of
hydraulic fluids:
1. Flash point: The temperature at which an oil surface gives off
sufficient vapours to ignite when a flame is passed over the surface.
2. Fire point: The temperature at which an oil releases sufficient
vapours to support
combustion continuously for 5 s when a flame is passed over the
surface.
7. Low flammability:
A fire-resistant fluid is one that can get ignited in the presence of
an ignition source but does not support combustion when the
source is removed. This characteristic is defined as
flammability.

8. Foam resistance:
Air can be present in a hydraulic fluid in two forms dissolved and
entrained. For example, if the return line to the reservoir is not
submerged, the jet of oil entering the liquid surface will carry
air with it.

9. Low volatility:
A fluid should possess low vapor pressure or high boiling point.
The vapour pressure of a fluid varies with temperature and
hence the operating temperature range of the system is
important in determining the stability of the fluid.
10. Good heat dissipation:
A hydraulic fluid should have a high heat dissipation
capability .
11. Low density:
The relative density of a mineral oil is 0.9 (the exact value
depends on the base oil and the additive used).
Synthetic fluids can have a relative density greater than
1.
12. System compatibility:
A hydraulic fluid should be inert to materials used in or
near the hydraulic equipment. If the fluid in anyway
attacks, destroys, dissolves or changes the parts of
hydraulic system, the system may lose its functional
efficiency and may start malfunction.
Thanks