Fluid Power:

Fluid power is the technology that deals with the generation, control and transmission of
power, using pressurised fluid.
Advantages of fluid power systems:
 Power transmission: Fluid power systems can transmit power more economically
than mechanical systems, over a larger distance. As in the case with mechanical
systems, fluid power systems are not hindered by the geometry of surroundings and
components in the system.
 Ease and accuracy of control: By the use of simple levers and push buttons, the
operator of a fluid power system can easily start, stop, speed up and slow down.
 Multiplication of force: A fluid power system (without using cumbersome gears,
pulleys and levers) can multiply forces simply and efficiently from a fraction of a
Newton, to several thousand Kilo Newton of output.
 Constant force and torque: Only fluid power systems are capable of providing a
constant torque or force regardless of speed changes.
 Simple, safe and economical: In general, fluid power systems use fewer moving
parts in comparison with mechanical and electrical systems. Thus they become
simpler and easier to maintain.
Disadvantages of fluid power systems:
 Fluid power systems cannot transmit power more economically than electrical
systems, over a larger distance.
 Handling of hydraulic oils which can be quite messy. It is also very difficult to
completely eliminate leakage in a fluid power system (both hydraulic and pneumatic
systems).
 Hydraulic lines can burst causing serious human injuries.
 Most hydraulic fluids have a tendency to catch fire in the event of leakage, especially
in hot regions.
Fields of application of fluid power systems:
 Automobile drives (Example: High-wire overhead tram).
 Steering and breaking devices in automobile.
 Missile technology.
 Launching pad of spacecraft.
 Earth moving equipments (Example: Earth excavator).
 Crop harvesting equipments (Example: Elevator conveyor in crop harvesting).
 Coal mine equipments (Example: Bulldozer).
 Drives machine tools (Example: Drill, milling, shaping machines).
 Robotics (Example: Hydraulic powered robotic arm).
 Industrial lift trucks (Example: Fork lift truck).
 Aircraft control devices (Example: Landing gear).
 Automation (Example: Automated manufacturing or production system) etc.
Basic components of fluid power systems:

Figure shown above is indicating the schematic basic components diagram of fluid power
systems.
1. Prime mover: Prime mover (Example: Electric motor, engines etc) provides driving
energy (ie. Mechanical energy, rotational motion with torque) to the pressurising
devices (ie. Pumps or compressors) by utilising available form of energy.
2. Pressurising device: Pressurising devices pressurise the fluid and deliver the same to
the system or in other words impart hydraulic energy to the fluid by utilising
mechanical energy. Fluid power systems are classified into two categories, hydraulic
system and pneumatic system. In case of hydraulic system pump pressurise the
hydraulic fluid (ie. Hydraulic oils) and deliver the same to the system. In case of
pneumatic system compressor pressurise the pneumatic fluid (ie. Air) and deliver the
same to the system.
3. Control valves: Control valves control the fluid power system as desired by us.
 Pressure control valves: Pressure control valves maintain or increase or decrease
the system pressure, which in turn control the load withstanding capacity of the
system. It can also interpret pressure difference and act accordingly. It also
provide over pressure safety to the system.
 Flow control valves: Flow control valves control the quantity of fluid flowing to
the system, which in turn control the actuation speed of actuators.
 Direction control valves: Direction control valves control the start, stop and
direction in which the fluid is allowed to flow. It is actually control the direction
of actuation of actuators.
4. Actuators: Actuators do the useful work as desired by us by utilising hydraulic
energy.
 Linear Actuators: Linear Actuators produce linear motion with force by utilising
hydraulic energy.
 Rotary Actuators: Rotary Actuators produce rotary motion with torque by
utilising hydraulic energy.
5. Piping or Tubing: Piping or Tubing conveys fluid from one location to another
location.
Fluid power systems are classified into two categories, hydraulic system and pneumatic
system. Hydraulic system is such a system where oils used as working fluid. Pneumatic
system is such a system where air used as working fluid.

Basic components of hydraulic systems:

Figure shown below is indicating the schematic basic components diagram of hydraulic
systems.

1. Prime mover: Prime mover (Example: Electric motor, engines etc) provides driving
energy (ie. Mechanical energy, rotational motion with torque) to the pressurising
devices (ie. Pumps) by utilising available form of energy.
2. Pump: Pump pressurise the oil and deliver the same to the system or in other words
impart hydraulic energy to the oil by utilising mechanical energy.
3. Control valves: Control valves control the hydraulic system as desired by us.
 Pressure control valves: Pressure control valves maintain or increase or decrease
the system pressure, which in turn control the load withstanding capacity of the
system. It can also interpret pressure difference and act accordingly. It also
provide over pressure safety to the system.
 Flow control valves: Flow control valves control the quantity of oil flowing to the
system, which in turn control the actuation speed of actuators.
 Direction control valves: Direction control valves control the start, stop and
direction in which the oil is allowed to flow. It is actually control the direction of
actuation of actuators.
4. Actuators: Actuators do the useful work as desired by us by utilising hydraulic
energy.
 Linear Actuators: Linear Actuators produce linear motion with force by utilising
hydraulic energy.
 Rotary Actuators: Rotary Actuators produce rotary motion with torque by
utilising hydraulic energy.
 5. Reservoir: A tank (reservoir) used to hold the hydraulic oil which is re-circulated
again and again into the system.
6. Strainer: Strainer is used to separate suspended contaminants from hydraulic oil.
7. Piping or Tubing: Piping or Tubing conveys hydraulic oil from one location to another
location.
Advantages of Hydraulic system:
1. Large load capacity with almost high accuracy and precision.
2. Smooth movement.
3. Automatic lubricating provision to reduce to wear.
4. Division and distribution of hydraulic force are easily performed.
5. Limiting and balancing of hydraulic forces are easily performed.

Disadvantages of Hydraulic system:

1. A hydraulic element needs to be machined to a high degree of precision.
2. Leakage of hydraulic oil poses a problem to hydraulic operators.
3. Special treatment is needed to protect them from rust, corrosion, dirt etc.,
4. Hydraulic oil may pose problems if it disintegrates due to aging and chemical
deterioration.
5. Hydraulic oils are messy and almost highly flammable.

Basic components of pneumatic systems:

Figure shown below is indicating the schematic basic components diagram of pneumatic
systems.
1. Electric Motor: It is a prime mover which provides driving energy (rotary motion
with torque) to the compressor by utilising electrical energy.
2. Compressor: Compressor is a pressurising device which compresses the air as drawn
from the environment.
 Intake Filter: These are used to filter out the suspended contaminants from the
air as taken from the environment.
 Air Cooler: During compression operation, air temperature increases. Therefore
coolers are used to reduce the temperature of the compressed air.
 Air Dryer: The water vapour or moisture in the air is separated from the air by
using a dryer.
3. Air Receiver: Air receiver is tank where the compressed air coming from the
compressor is stored.
 Pressure Switch: It is mounted on the air receiver. In order to maintain the air
pressure inside the receiver within a specific range pressure switch sense the
same and automatically start or stop the compressor motor accordingly.
4. Secondary Treatment of air: It is a service pack comprising with filter, regulator and
lubricator (FRL) for conditioning of air prior to the delivery into the system.
 Filter: It filters out the suspended contaminants from the air prior to the delivery
into the system.
 Regulator: It regulates the pressure of the air to be delivered into the system.
 Lubricator: It converts the air into an excellent lubricator by adding a fine mist of
lubricating oil.
5. Control valves: Control valves control the pneumatic system as desired by us.
 Pressure control valves: Pressure control valves maintain or increase or decrease
the system pressure, which in turn control the load withstanding capacity of the
system. It can also interpret pressure difference and act accordingly. It also
provide over pressure safety to the system.
 Flow control valves: Flow control valves control the quantity of oil flowing to the
system, which in turn control the actuation speed of actuators.
 Direction control valves: Direction control valves control the start, stop and
direction in which the air is allowed to flow. It is actually control the direction of
actuation of actuators.
6. Actuators: Actuators do the useful work as desired by us by utilising pressurised air.
 Linear Actuators: Linear Actuators produce linear motion with force by utilising
pressurised air.
 Rotary Actuators: Rotary Actuators produce rotary motion with torque by
utilising pressurised air.
7. Piping or Tubing: Piping or Tubing conveys air from one location to another location.
Advantages of Pneumatic system:
1. Low inertia effect of pneumatic components due to light density of air.
2. System is light in weight.
3. Comparatively easy operations of valves.
4. Power losses and leakages are less in pneumatic systems.
5. Low cost.
6. Cylinder cushioning is not required.
7. Leakage does not influence the systems and is not harmful.

Disadvantages of Pneumatic systems:

1. Suitable only for low pressure and hence low force applications.
2. Availability of the assembly components is doubtful.
3. Generation of the compressed air is expensive compared to electricity.
4. Exhaust air noise is unpleasant and silence has to be used.
5. Rigidity of the system is poor.
6. Weight to pressure ratio is large.
7. Less precise.

Primary functions of hydraulic fluids:

 Transmit power.
 Lubricate moving parts.
 Seal clearances between mating parts.
 Dissipate heat.
The working fluid is the single most important component of any hydraulic system. It serves
as a lubricant, heat transfer medium, Sealant and most important of all, a means of energy
transfer.
Use of a clean, high-quality fluid, is an essential prerequisite for achieving efficient operation
of the hydraulic system. Although early hydraulic systems employed the medium of water
for transferring hydraulic energy, there are serious limitations attached to it such as:
1. Its relatively high freezing point (water freezes at 0 °C or 32 °F when the pressure is
atmospheric).
2. Its tendency to expand when frozen.
3. Its corrosive nature.
4. Its poor lubrication properties.
5. Its capacity to dissolve more oxygen leading to phenomena such as oxygen pitting.

Although hydraulic fluid types vary according to application, the four common types are:
1. Petroleum-based fluids which are the most common of all fluid types and widely
used in applications where fire resistance is not required.
2. Water glycol fluids used in applications which require fire resistance fluids.
3. Synthetic fluids used in applications where fire resistance and non-conductivity is
required.
 4. Environment-friendly fluids that end up causing minimal effect on the environment
in the event of a spill.

Desirable properties of hydraulic fluids:

Hydraulic fluids have the four essential primary functions of power transmission, heat
dissipation, lubrication and sealing to accomplish which, they should possess the following
properties:
1. Ideal viscosity.
2. Good lubricating property.
3. Low volatility.
4. Non-toxicity.
5. Low density.
6. Environmental and chemical stability.
7. High degree of incompressibility.
8. Fire resistance.
9. Good heat-transfer capability.
10. Foam resistance and most importantly.
11. Easy availability and cost-effectiveness.

It is quite obvious that no single fluid can meet all the above requirements and it is
therefore essential that only the fluid that comes closest to satisfying most of these
requirements be selected for a particular application.

Fire-resistant fluids:
It is important for a hydraulic fluid to neither initiate nor support fire. Most hydraulic fluids
will however bum under certain conditions. There are many hazardous applications where
concern for human safety demands the use of fire resistant fluids. Examples include coal
mines, hot metal processing equipments, aircraft and marine fluid power systems.
A fire resistant fluid is one, which can be ignited but will not support a flame when the
ignition source is removed. Flammability of a fluid is defined as the ease of ignition and the
ability to propagate a flame.
In order to determine the flammability of a hydraulic fluid, the following characteristics are
tested:
 Flash point: It is the temperature, at which the fluid surface gives off vapours, which
can ignite when a flame is passed over it.
 Fire point: It is the temperature of a fluid at which the fluid surface gives off vapours,
which are sufficient to support combustion for a time of 5 s, when a flame is passed
over it.
Various fire-resistant fluids have been developed in recent times, to reduce fire hazards.
There are basically three types of fire-resistant fluids that are commonly used in hydraulic
applications. They are discussed below.
Water-glycol solutions:
This solution contains about 40% water and 60% glycol. These solutions have high viscosity
index values, but the viscosity rises as the water evaporates. The operating temperature
range of these fluids is between -23 °C (-9.4 °F) and 83 °C (180 °F approx.). Most of the
newer synthetic seal materials are compatible with water-glycol solutions. Metals such as
zinc, cadmium and magnesium react with water-glycol solutions and hence it should not be
used.

Water-in-oil emulsions:
This type of fluid contains about 40% water completely dispersed in a special oil base. It is
characterized by small droplets of water completely surrounded by oil. Although water
provides good coolant properties, it makes the fluid more corrosive. As a result a greater
amount of corrosion inhibitor additives are necessary. The operating temperature range of
this fluid lies between -28 °C (-18.4 °F) and 83 °C (180 oF approx.). Even in the case of this
fluid, it is necessary to replenish the water to maintain proper viscosity of the fluid. These
types of fluids are compatible with most rubber seal materials found in petroleum base
hydraulic systems.

Straight synthetics:
It is a chemically formulated fluid designed to inhibit combustion and generally has the
highest fire-resistant temperature. Typical fluids belonging to this type are phosphate esters
and chlorinated hydrocarbons. The disadvantages of these types of fluids are their low
viscosity index, incompatibility with most natural and synthetic rubber seals and high costs.
In particular, the phosphate esters readily dissolve pipe thread compounds, paints and
electrical insulation.

Foam-resistant fluids:
Air can be dissolved or entrained in hydraulic fluids. 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. This
causes air bubbles to form in oil. If these bubbles rise to the surface too slowly, they can be
drawn into the pump intake, leading to cavitations and subsequent pump damage.
Similarly, a small leak in the suction line can cause entrainment of large quantities of air
from the atmosphere. This type of leak is difficult to detect since in this case air leaks in,
rather than the oil leaking out from the suction line. Another adverse effect of entrained or
dissolved air is a significant reduction in bulk modulus of the hydraulic fluid. This can have
serious consequences in terms of stiffness and accuracy of hydraulic actuators. The amount
of dissolved air can be significantly reduced by properly designing the reservoir, since this is
where most of the air is picked up.
Another method is to use a premium grade hydraulic fluid that contains foam-resistant
additives. These additives are chemical compounds, which break out entrained air and in
the process quickly separate the air from the oil, in the reservoir itself.
General types of fluids:

Petroleum-based fluids:
The first major category of hydraulic fluids is the petroleum-based fluid, which is the most
widely used type. The crude oil that is quality refined can be used for light services.
Additives should be added to these fluids in order to maintain the following characteristics:
 Good lubricating property.
 High viscosity index.
 Oxidation resistance.
The primary disadvantage of a petroleum-based fluid is that it is flammable. In order to take
care of this, fire-resistant hydraulic fluids have been developed, as already discussed in the
beginning.

Lubricating oils:
These are conventional engine type oils. Due to their better lubricating properties, they
enhance the life of the hydraulic components. These oils contain anti-wear additives used to
prevent engine wear on cams and valves. Their improved lubricating property also provides
wear resistance to heavily loaded hydraulic components such as pumps and valves.

Air:
Air is also one of the fluids used in hydraulic systems. However, systems that use air as the
medium are known as pneumatic systems. The advantages of using air are:
 Air does not bum.
 It can be easily made available in a clean form by the use of filters.
 Any leakage of air from the system is not messy as it simply breaks into the
atmosphere.
 Air can also be made into an excellent lubricator by adding a fine mist of oil using a
lubricator.
 Use of air in the system eliminates the return lines as air can be simply exhausted
back to the atmosphere.

Air also has certain major disadvantages, some of them being:

 Its compressibility.
 Its sluggishness and lack of rigidity.
 Its corrosivity on account of the presence of oxygen and water, so dryer is used to
remove moisture present in the air prior to the use in the system.
To summarize, the single most important component in a fluid power system is the working
fluid. No single fluid contains all the ideal characteristics required. The designer should
select the fluid having the properties closest to that required by a particular application.
Comparison between hydraulic and pneumatic systems:
Sl.
Hydraulic System Pneumatic System
No.
It employs a pressurized liquid as a It employs a compressed gas, usually
01
fluid air, as a fluid
An oil hydraulic system operates at A pneumatic system usually
02
pressures up to 700 bar operates at 5–10 bar
Generally designed as closed Usually designed as open system
03
system
The system slows down when Leakage does not affect the system
04
leakage occurs much
05 Valve operations are difficult Valve operations are easy
06 Heavier in weight Lighter in weight
Pumps are used to provide Compressors are used to provide
07
pressurized liquids compressed gases
The system is unsafe to fire The system is free from fire hazards
08
hazards
Automatic lubrication is provided Special arrangements for lubrication
09
are needed
Conditioning of hydraulic oils does Conditioning of air is essential prior
10
not required to the use into the system
Silencer does not required At all bleeding points of air silencer
11 must be installed to reduce the
noise level.