Basic hydraulics
pinaki50
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Dec 04, 2013
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About This Presentation
Hydraulics today has become a way of life as most applications have some form of system ingrained. This paper is an endevor to present the very basics of hydraulics and overcome its basic fear.
Slide Content
BASIC HYDRAULICS
A SYSTEM STUDY
PINAKI ROY
A SYSTEM STUDY
PINAKI ROY
A TALK OVERVIEW
•This talk has been designed to provide instruction on the concept
and operation of the basic components of the hydraulic system.
•It also describes the various components of a typical hydraulic
system, their construction and functions, and their relationship to
each other. However to really appreciate & know about hydraulics
‘hands on’ experience, is a MUST.
•This talk has been designed to provide instruction on the concept
and operation of the basic components of the hydraulic system.
•It also describes the various components of a typical hydraulic
system, their construction and functions, and their relationship to
each other. However to really appreciate & know about hydraulics
‘hands on’ experience, is a MUST.
Fluid Power System
•Fluid Power Systems are power
transmitting assemblies employing
pressurised liquid or gas to transmit
energy.
•Fluid power can be divided into two
basic disciplines
> Hydraulics – Employing pressurised
liquid
> Pneumatics - Employing
Compressed gas
•Fluid Power Systems are power
transmitting assemblies employing
pressurised liquid or gas to transmit
energy.
•Fluid power can be divided into two
basic disciplines
> Hydraulics – Employing pressurised
liquid
> Pneumatics - Employing
Compressed gas
What is Hydraulics?
•Hydraulics is derived from the Greek
word
- Hydor meaning Water
- Aulos meaning Pipe
•Hydraulics is derived from the Greek
word
- Hydor meaning Water
- Aulos meaning Pipe
Definition of Hydraulics
In simple language:
Confined liquids under pressure made to do work.
OR
Science of transmitting force / motion through
medium of confined liquid
In simple language:
Confined liquids under pressure made to do work.
OR
Science of transmitting force / motion through
medium of confined liquid
HYDRAULICS DEFINED
FURTHER…
Fluid Mechanics is the physical science and technology of the static
and dynamic behavior of fluids.
•Hydraulics is a topic in applied science and engineering dealing with
the mechanical properties of liquids. Fluid mechanics provides the
theoretical foundation for hydraulics, which focuses on the
engineering uses of fluid properties.
FURTHER…
Fluid Mechanics is the physical science and technology of the static
and dynamic behavior of fluids.
•Hydraulics is a topic in applied science and engineering dealing with
the mechanical properties of liquids. Fluid mechanics provides the
theoretical foundation for hydraulics, which focuses on the
engineering uses of fluid properties.
PASCAL’S LAW
Pascal Law – which is the basis for all
hydraulic systems, is named after the French
Scientist – Blaise Pascal, who established
the law.
Pascal Law – which is the basis for all
hydraulic systems, is named after the French
Scientist – Blaise Pascal, who established
the law.
Do you remember Pascal’s Do you remember Pascal’s
Law?Law?
It states that “ Pressure exerted anywhere in a confined It states that “ Pressure exerted anywhere in a confined
fluid is transmitted equally in all directions throughout the fluid is transmitted equally in all directions throughout the
fluid.fluid.
•The basic idea behind all hydraulic system is based upon that The basic idea behind all hydraulic system is based upon that
principle & can be simply stated as: principle & can be simply stated as:
•Force applied at one point is transmitted to another point Force applied at one point is transmitted to another point
using an using an incompressible fluid.incompressible fluid.
Law?Law?
It states that “ Pressure exerted anywhere in a confined It states that “ Pressure exerted anywhere in a confined
fluid is transmitted equally in all directions throughout the fluid is transmitted equally in all directions throughout the
fluid.fluid.
•The basic idea behind all hydraulic system is based upon that The basic idea behind all hydraulic system is based upon that
principle & can be simply stated as: principle & can be simply stated as:
•Force applied at one point is transmitted to another point Force applied at one point is transmitted to another point
using an using an incompressible fluid.incompressible fluid.
PASCAL’S LAW PASCAL’S LAW
ILLUSTRATIONILLUSTRATION
ILLUSTRATIONILLUSTRATION
Working Principle of a Hydraulic Working Principle of a Hydraulic
PressPress
PressPress
Functions of Hydraulic OilFunctions of Hydraulic Oil
•It transmits power.It transmits power.
•It lubricates moving partsIt lubricates moving parts
•It seals clearances It seals clearances
between moving partsbetween moving parts
•It dissipates heatIt dissipates heat
•It transmits power.It transmits power.
•It lubricates moving partsIt lubricates moving parts
•It seals clearances It seals clearances
between moving partsbetween moving parts
•It dissipates heatIt dissipates heat
•Variable speed Variable speed : Possible to control speed through valve. : Possible to control speed through valve.
•Reversible Reversible : Instant reverse motion is possible. No : Instant reverse motion is possible. No
need need to stop the system to change to stop the system to change
direction.direction.
•Over load protection : Protected through relief valve from Over load protection : Protected through relief valve from
over-over- loading. loading.
•Small packageSmall package : Components are smaller than other : Components are smaller than other
power power transmitting system. transmitting system.
•Can be stalledCan be stalled : Not possible on direct drive system from : Not possible on direct drive system from
Electric motor / Diesel engine. Electric motor / Diesel engine.
•Simple design Simple design : Pre-engineered components available. : Pre-engineered components available.
•Self lubricatedSelf lubricated : Hydraulic oil lubricates the parts. : Hydraulic oil lubricates the parts.
•FlexibleFlexible : Flexible hoses virtually eliminate the : Flexible hoses virtually eliminate the
location location problem of the hydraulic problem of the hydraulic
components.components.
•SmoothSmooth : Incompressible, no vibration. : Incompressible, no vibration.
•Acts as coolantActs as coolant : It dissipates heat / cools the component, : It dissipates heat / cools the component,
•Acts as sealActs as seal ; It seals clearances between two ; It seals clearances between two
mating parts.mating parts.
•Noise freeNoise free : No noise. : No noise.
Advantages of oil in Hydraulics
•Reversible Reversible : Instant reverse motion is possible. No : Instant reverse motion is possible. No
need need to stop the system to change to stop the system to change
direction.direction.
•Over load protection : Protected through relief valve from Over load protection : Protected through relief valve from
over-over- loading. loading.
•Small packageSmall package : Components are smaller than other : Components are smaller than other
power power transmitting system. transmitting system.
•Can be stalledCan be stalled : Not possible on direct drive system from : Not possible on direct drive system from
Electric motor / Diesel engine. Electric motor / Diesel engine.
•Simple design Simple design : Pre-engineered components available. : Pre-engineered components available.
•Self lubricatedSelf lubricated : Hydraulic oil lubricates the parts. : Hydraulic oil lubricates the parts.
•FlexibleFlexible : Flexible hoses virtually eliminate the : Flexible hoses virtually eliminate the
location location problem of the hydraulic problem of the hydraulic
components.components.
•SmoothSmooth : Incompressible, no vibration. : Incompressible, no vibration.
•Acts as coolantActs as coolant : It dissipates heat / cools the component, : It dissipates heat / cools the component,
•Acts as sealActs as seal ; It seals clearances between two ; It seals clearances between two
mating parts.mating parts.
•Noise freeNoise free : No noise. : No noise.
Advantages of oil in Hydraulics
Force that is applied at one point is Force that is applied at one point is
transmitted to another point using an transmitted to another point using an
incompressible fluidincompressible fluid
•In this drawing, two pistons (green) fit into two glass In this drawing, two pistons (green) fit into two glass
cylinders filled with oil (blue) and connected to one cylinders filled with oil (blue) and connected to one
another with an oil-filled pipe. If you apply a downward another with an oil-filled pipe. If you apply a downward
force to one piston (the left one in this drawing), then the force to one piston (the left one in this drawing), then the
force is transmitted to the second piston through the oil force is transmitted to the second piston through the oil
in the pipe in the pipe
transmitted to another point using an transmitted to another point using an
incompressible fluidincompressible fluid
•In this drawing, two pistons (green) fit into two glass In this drawing, two pistons (green) fit into two glass
cylinders filled with oil (blue) and connected to one cylinders filled with oil (blue) and connected to one
another with an oil-filled pipe. If you apply a downward another with an oil-filled pipe. If you apply a downward
force to one piston (the left one in this drawing), then the force to one piston (the left one in this drawing), then the
force is transmitted to the second piston through the oil force is transmitted to the second piston through the oil
in the pipe in the pipe
Force MultiplicationForce Multiplication
•Assume that the piston on the left is 2 inches in diameter (1-inch radius), Assume that the piston on the left is 2 inches in diameter (1-inch radius),
while the piston on the right is 6 inches in diameter (3-inch radius). The area while the piston on the right is 6 inches in diameter (3-inch radius). The area
of the two pistons is of the two pistons is Pi * r2Pi * r2. The area of the left piston is therefore 3.14, . The area of the left piston is therefore 3.14,
while the area of the piston on the right is 28.26. The piston on the right is 9 while the area of the piston on the right is 28.26. The piston on the right is 9
times larger than the piston on the left. What that means is that any force times larger than the piston on the left. What that means is that any force
applied to the left-hand piston will appear 9 times greater on the right-hand applied to the left-hand piston will appear 9 times greater on the right-hand
piston. So if you apply a 100-pound downward force to the left piston, a 900-piston. So if you apply a 100-pound downward force to the left piston, a 900-
pound upward force will appear on the rightpound upward force will appear on the right
•Assume that the piston on the left is 2 inches in diameter (1-inch radius), Assume that the piston on the left is 2 inches in diameter (1-inch radius),
while the piston on the right is 6 inches in diameter (3-inch radius). The area while the piston on the right is 6 inches in diameter (3-inch radius). The area
of the two pistons is of the two pistons is Pi * r2Pi * r2. The area of the left piston is therefore 3.14, . The area of the left piston is therefore 3.14,
while the area of the piston on the right is 28.26. The piston on the right is 9 while the area of the piston on the right is 28.26. The piston on the right is 9
times larger than the piston on the left. What that means is that any force times larger than the piston on the left. What that means is that any force
applied to the left-hand piston will appear 9 times greater on the right-hand applied to the left-hand piston will appear 9 times greater on the right-hand
piston. So if you apply a 100-pound downward force to the left piston, a 900-piston. So if you apply a 100-pound downward force to the left piston, a 900-
pound upward force will appear on the rightpound upward force will appear on the right
Hydraulic SystemHydraulic System
•ReservoirReservoir
•FilterFilter
•Hydraulic PumpHydraulic Pump
•Directional Control ValveDirectional Control Valve
•Pressure Control ValvePressure Control Valve
•Actuator (Cylinder/Motor)Actuator (Cylinder/Motor)
•ReservoirReservoir
•FilterFilter
•Hydraulic PumpHydraulic Pump
•Directional Control ValveDirectional Control Valve
•Pressure Control ValvePressure Control Valve
•Actuator (Cylinder/Motor)Actuator (Cylinder/Motor)
Tank / Reservoir
First a tank is needed to store the hydraulic oil
Reservoir- Properties
Storing oil
Compensates difference in volume
when actuators are used
It dissipates heat
It allows foreign particles to settle
down
Baffle separates inlet line with the
return line and allows the air
bubbles to escape
First a tank is needed to store the hydraulic oil
Reservoir- Properties
Storing oil
Compensates difference in volume
when actuators are used
It dissipates heat
It allows foreign particles to settle
down
Baffle separates inlet line with the
return line and allows the air
bubbles to escape
More Properties of ReservoirsMore Properties of Reservoirs
•It allows condensed water to settle at the It allows condensed water to settle at the
bottom of the tankbottom of the tank
•Breather on the top of the tank allows to Breather on the top of the tank allows to
maintain atmospheric pressure and avoid maintain atmospheric pressure and avoid
creation of vacuumcreation of vacuum
•Sight glass will indicate the level of the oil. Sight glass will indicate the level of the oil.
Mercury bulb indicates the oil temperatureMercury bulb indicates the oil temperature
•Oil filling inlet will have a filter for avoiding Oil filling inlet will have a filter for avoiding
contamination.contamination.
•It allows condensed water to settle at the It allows condensed water to settle at the
bottom of the tankbottom of the tank
•Breather on the top of the tank allows to Breather on the top of the tank allows to
maintain atmospheric pressure and avoid maintain atmospheric pressure and avoid
creation of vacuumcreation of vacuum
•Sight glass will indicate the level of the oil. Sight glass will indicate the level of the oil.
Mercury bulb indicates the oil temperatureMercury bulb indicates the oil temperature
•Oil filling inlet will have a filter for avoiding Oil filling inlet will have a filter for avoiding
contamination.contamination.
PUMPSPUMPS
•Hydraulic Pump is the most important Hydraulic Pump is the most important
component in the hydraulic system.component in the hydraulic system.
•Function of the Hydraulic Pump is to convert Function of the Hydraulic Pump is to convert
Mechanical Energy to Hydraulic EnergyMechanical Energy to Hydraulic Energy
•Hydraulic Pump are classified in two Hydraulic Pump are classified in two
categories:categories:
- Hydro-dynamic- Hydro-dynamic
- Hydro-static- Hydro-static
•Hydraulic Pump is the most important Hydraulic Pump is the most important
component in the hydraulic system.component in the hydraulic system.
•Function of the Hydraulic Pump is to convert Function of the Hydraulic Pump is to convert
Mechanical Energy to Hydraulic EnergyMechanical Energy to Hydraulic Energy
•Hydraulic Pump are classified in two Hydraulic Pump are classified in two
categories:categories:
- Hydro-dynamic- Hydro-dynamic
- Hydro-static- Hydro-static
Tank
Pump
Now we need a pump to create flow
Pump
Two types of hydraulic pumps are
most commonly used:
- Rotary Pumps
- Reciprocating Pumps
Pump
Now we need a pump to create flow
Pump
Two types of hydraulic pumps are
most commonly used:
- Rotary Pumps
- Reciprocating Pumps
ROTARY & RECIPROCATING ROTARY & RECIPROCATING
TYPESTYPES
•Common Pumps in Rotary type are:Common Pumps in Rotary type are:
- Gear Pumps- Gear Pumps
- Vane Pumps- Vane Pumps
•Common Pumps in Reciprocating type Common Pumps in Reciprocating type
are:are:
•Axial Piston PumpAxial Piston Pump
Radial Piston PumpRadial Piston Pump
TYPESTYPES
•Common Pumps in Rotary type are:Common Pumps in Rotary type are:
- Gear Pumps- Gear Pumps
- Vane Pumps- Vane Pumps
•Common Pumps in Reciprocating type Common Pumps in Reciprocating type
are:are:
•Axial Piston PumpAxial Piston Pump
Radial Piston PumpRadial Piston Pump
ACTUATORSACTUATORS
•An actuator is a mechanical device for An actuator is a mechanical device for
moving or controlling a mechanism or moving or controlling a mechanism or
system. An actuator typically is a system. An actuator typically is a
mechanical device that takes energy & mechanical device that takes energy &
converts it to a desirable form for usage or converts it to a desirable form for usage or
application.application.
Actuator
Pump
Tank
•An actuator is a mechanical device for An actuator is a mechanical device for
moving or controlling a mechanism or moving or controlling a mechanism or
system. An actuator typically is a system. An actuator typically is a
mechanical device that takes energy & mechanical device that takes energy &
converts it to a desirable form for usage or converts it to a desirable form for usage or
application.application.
Actuator
Pump
Tank
ACTUATORS Contd…ACTUATORS Contd…
•There are mainly two types of There are mainly two types of
Actuators:Actuators:
- Linear actuators (single acting - Linear actuators (single acting
cylinders, double acting cylinders)cylinders, double acting cylinders)
- Rotary actuators (vane motors, - Rotary actuators (vane motors,
gear motors, piston motors etc.)gear motors, piston motors etc.)
•There are mainly two types of There are mainly two types of
Actuators:Actuators:
- Linear actuators (single acting - Linear actuators (single acting
cylinders, double acting cylinders)cylinders, double acting cylinders)
- Rotary actuators (vane motors, - Rotary actuators (vane motors,
gear motors, piston motors etc.)gear motors, piston motors etc.)
Types of ValvesTypes of Valves
•There are three main types of There are three main types of
Valves:Valves:
- Pressure Control Valves (relief - Pressure Control Valves (relief
valves, pressure regulating valve, valves, pressure regulating valve,
pressure reducing valve etc.)pressure reducing valve etc.)
- Directional Control Valves (check - Directional Control Valves (check
valve, axial spool valve, ball valve valve, axial spool valve, ball valve
etc.)etc.)
- Flow Control Valves (needle valve, - Flow Control Valves (needle valve,
throttle check valve etc.)throttle check valve etc.)
•There are three main types of There are three main types of
Valves:Valves:
- Pressure Control Valves (relief - Pressure Control Valves (relief
valves, pressure regulating valve, valves, pressure regulating valve,
pressure reducing valve etc.)pressure reducing valve etc.)
- Directional Control Valves (check - Directional Control Valves (check
valve, axial spool valve, ball valve valve, axial spool valve, ball valve
etc.)etc.)
- Flow Control Valves (needle valve, - Flow Control Valves (needle valve,
throttle check valve etc.)throttle check valve etc.)
Tank
Pump
Actuator
Piston reverse
movement is not
possible
We need a direction
control valve to change
the direction of flow as
per requirement
Hoses to
connect the
components
Hydraulic System – some applications of
the basic components
Pump
Actuator
Piston reverse
movement is not
possible
We need a direction
control valve to change
the direction of flow as
per requirement
Hoses to
connect the
components
Hydraulic System – some applications of
the basic components
Tank
Pump
Actuator
Direction
Control Valve
Hydraulic System
There are mainly two
design principles for
valves
- Spool valves
- Poppet valves
Pump
Actuator
Direction
Control Valve
Hydraulic System
There are mainly two
design principles for
valves
- Spool valves
- Poppet valves
Tank
Pump
Actuator
Direction
Control Valve
The control valve is at
neutral position
Hydraulic System
Pump
Actuator
Direction
Control Valve
The control valve is at
neutral position
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Now the control valve
is shifted to left
Hydraulic System
Pump
Actuator
Direction
Control Valve
Now the control valve
is shifted to left
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
To change the piston
movement in opposite
direction the control
valve is now shifted to
right
Hydraulic System
Pump
Actuator
Direction
Control Valve
To change the piston
movement in opposite
direction the control
valve is now shifted to
right
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Is it a complete circuit ?
OR
We need some thing more
Hydraulic System
Pump
Actuator
Direction
Control Valve
Is it a complete circuit ?
OR
We need some thing more
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Piston at end
-No room to
move
Pressure
increases
yes
We need some thing more
We need to
control the
system pressure
Hydraulic System
Pump
Actuator
Direction
Control Valve
Piston at end
-No room to
move
Pressure
increases
yes
We need some thing more
We need to
control the
system pressure
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
Pressure
relief valve
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
Pressure
relief valve
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Stops pressure increasing
beyond the preset value
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
Stops pressure increasing
beyond the preset value
Pressure
relief valve
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Now we have a system
which can work
But is this system protected
from dirt ?
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
Now we have a system
which can work
But is this system protected
from dirt ?
Pressure
relief valve
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
We need to protect the system
from dirt by installing a FILTER
in the system
Filter
We have a system now which
can work safely
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
We need to protect the system
from dirt by installing a FILTER
in the system
Filter
We have a system now which
can work safely
Pressure
relief valve
Hydraulic System
FILTERSFILTERS
•There are basically three There are basically three
types of Filterstypes of Filters
- Suction line filters- Suction line filters
- Pressure line filters- Pressure line filters
- Return line filters- Return line filters
•There are basically three There are basically three
types of Filterstypes of Filters
- Suction line filters- Suction line filters
- Pressure line filters- Pressure line filters
- Return line filters- Return line filters
Why is filtration necessary?Why is filtration necessary?
•Impurities in the Hydraulic Impurities in the Hydraulic
system affect the components system affect the components
of the hydraulic system and of the hydraulic system and
shorten their service life.shorten their service life.
•Reduction in service life of the Reduction in service life of the
components occurs in two components occurs in two
ways:ways:
- Wear and Tear- Wear and Tear
- Breakdown of component- Breakdown of component
Filters are used to remove the Filters are used to remove the
smallest insoluble particles smallest insoluble particles
and keep the hydraulic system and keep the hydraulic system
clean clean
•Impurities in the Hydraulic Impurities in the Hydraulic
system affect the components system affect the components
of the hydraulic system and of the hydraulic system and
shorten their service life.shorten their service life.
•Reduction in service life of the Reduction in service life of the
components occurs in two components occurs in two
ways:ways:
- Wear and Tear- Wear and Tear
- Breakdown of component- Breakdown of component
Filters are used to remove the Filters are used to remove the
smallest insoluble particles smallest insoluble particles
and keep the hydraulic system and keep the hydraulic system
clean clean
Tank
Pump
Actuator
Direction
Control Valve
Filter
Now we know :
•A Reservoir contains oil
•Filter cleans the system
•Pump creates flow
•Resistance creates pressure
•Actuators perform the work
•Hoses transmit the oil
•D.C. Valves change direction of
oil flow
•Relief valves control the
maximum system pressure.
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
Filter
Now we know :
•A Reservoir contains oil
•Filter cleans the system
•Pump creates flow
•Resistance creates pressure
•Actuators perform the work
•Hoses transmit the oil
•D.C. Valves change direction of
oil flow
•Relief valves control the
maximum system pressure.
Pressure
relief valve
Hydraulic System
Tank
Pump
Actuator
Direction
Control Valve
Filter
Few more facts:
•Pressure increases the system
capacity
•Flow increases the system
speed
Pressure
relief valve
Hydraulic System
Pump
Actuator
Direction
Control Valve
Filter
Few more facts:
•Pressure increases the system
capacity
•Flow increases the system
speed
Pressure
relief valve
Hydraulic System
This Excavator weighs over 28 tons, but This Excavator weighs over 28 tons, but
has swift movements. The bucket can has swift movements. The bucket can
effortlessly scoop out more than a cubic effortlessly scoop out more than a cubic
meter of rock weighing about 2.0Tmeter of rock weighing about 2.0T
has swift movements. The bucket can has swift movements. The bucket can
effortlessly scoop out more than a cubic effortlessly scoop out more than a cubic
meter of rock weighing about 2.0Tmeter of rock weighing about 2.0T
Transmission of Hydraulic Transmission of Hydraulic
PowerPower
•The engine is connected to a pair of pumps that can The engine is connected to a pair of pumps that can
generate 140 gallons per minute at 4,500 psigenerate 140 gallons per minute at 4,500 psi. . You can You can
see from the picture that the arm has a pair of pistons see from the picture that the arm has a pair of pistons
working in unison at the "shoulder" -- one at the "elbow" working in unison at the "shoulder" -- one at the "elbow"
and then one to rotate the bucket. and then one to rotate the bucket.
PowerPower
•The engine is connected to a pair of pumps that can The engine is connected to a pair of pumps that can
generate 140 gallons per minute at 4,500 psigenerate 140 gallons per minute at 4,500 psi. . You can You can
see from the picture that the arm has a pair of pistons see from the picture that the arm has a pair of pistons
working in unison at the "shoulder" -- one at the "elbow" working in unison at the "shoulder" -- one at the "elbow"
and then one to rotate the bucket. and then one to rotate the bucket.
Transmission of Hydraulic Transmission of Hydraulic
PowerPower
•These pistons, along with the two track motors and the These pistons, along with the two track motors and the
rotating motor, are all controlled by two joy sticks and rotating motor, are all controlled by two joy sticks and
four pedals in the cab. These controls send electrical four pedals in the cab. These controls send electrical
signals to an electrically-operated valve block located signals to an electrically-operated valve block located
next to the pump. next to the pump.
PowerPower
•These pistons, along with the two track motors and the These pistons, along with the two track motors and the
rotating motor, are all controlled by two joy sticks and rotating motor, are all controlled by two joy sticks and
four pedals in the cab. These controls send electrical four pedals in the cab. These controls send electrical
signals to an electrically-operated valve block located signals to an electrically-operated valve block located
next to the pump. next to the pump.
Transmission of Hydraulic Transmission of Hydraulic
PowerPower
•From the valve block, high-pressure hydraulic lines make From the valve block, high-pressure hydraulic lines make
their way to the cylinders & they get activated whereby their way to the cylinders & they get activated whereby
the bucket can be moved as desired from the cabin with the bucket can be moved as desired from the cabin with
the touch of a button.the touch of a button.
PowerPower
•From the valve block, high-pressure hydraulic lines make From the valve block, high-pressure hydraulic lines make
their way to the cylinders & they get activated whereby their way to the cylinders & they get activated whereby
the bucket can be moved as desired from the cabin with the bucket can be moved as desired from the cabin with
the touch of a button.the touch of a button.
Some Basic CalculationsSome Basic Calculations
•A 4-inch piston has an area of 12.56 square inches. If the pump generates a A 4-inch piston has an area of 12.56 square inches. If the pump generates a
maximum pressure of 3,000 pounds per square inch (psi), the total pressure maximum pressure of 3,000 pounds per square inch (psi), the total pressure
available is 37,680 pounds, or about 20 tons. available is 37,680 pounds, or about 20 tons.
•Another thing you can determine is the cycle time of the piston. To move a Another thing you can determine is the cycle time of the piston. To move a
4-inch-diameter piston 24 inches, you need 3.14 * 22 * 24 = 301 cubic 4-inch-diameter piston 24 inches, you need 3.14 * 22 * 24 = 301 cubic
inches of oil. A gallon of oil is about 231 cubic inches, so you have to pump inches of oil. A gallon of oil is about 231 cubic inches, so you have to pump
almost 1.5 gallons of oil to move the piston 24 inches in one direction. almost 1.5 gallons of oil to move the piston 24 inches in one direction.
These form the basic criteria while selecting the hydraulic pump. For These form the basic criteria while selecting the hydraulic pump. For
example the actual engine, pump & sump details for this excavator is:example the actual engine, pump & sump details for this excavator is:
Engine
Cummins 6CT 8.3-C
8,270 cubic centimeters
340 horsepower at 1,900 rpm
Pump
Maximum pressure: 5,000 psi (4,500 psi)
Oil flow: 2x270 liters per minute
Capacities
Fuel: 530 liters
Engine oil: 22 liters
Hydraulic oil: 320 liters
•A 4-inch piston has an area of 12.56 square inches. If the pump generates a A 4-inch piston has an area of 12.56 square inches. If the pump generates a
maximum pressure of 3,000 pounds per square inch (psi), the total pressure maximum pressure of 3,000 pounds per square inch (psi), the total pressure
available is 37,680 pounds, or about 20 tons. available is 37,680 pounds, or about 20 tons.
•Another thing you can determine is the cycle time of the piston. To move a Another thing you can determine is the cycle time of the piston. To move a
4-inch-diameter piston 24 inches, you need 3.14 * 22 * 24 = 301 cubic 4-inch-diameter piston 24 inches, you need 3.14 * 22 * 24 = 301 cubic
inches of oil. A gallon of oil is about 231 cubic inches, so you have to pump inches of oil. A gallon of oil is about 231 cubic inches, so you have to pump
almost 1.5 gallons of oil to move the piston 24 inches in one direction. almost 1.5 gallons of oil to move the piston 24 inches in one direction.
These form the basic criteria while selecting the hydraulic pump. For These form the basic criteria while selecting the hydraulic pump. For
example the actual engine, pump & sump details for this excavator is:example the actual engine, pump & sump details for this excavator is:
Engine
Cummins 6CT 8.3-C
8,270 cubic centimeters
340 horsepower at 1,900 rpm
Pump
Maximum pressure: 5,000 psi (4,500 psi)
Oil flow: 2x270 liters per minute
Capacities
Fuel: 530 liters
Engine oil: 22 liters
Hydraulic oil: 320 liters
DUMP TRUCKS or TIPPERSDUMP TRUCKS or TIPPERS
•DUMPERS WITH TELESCOPIC DUMPERS WITH TELESCOPIC
CYLINDERS & HYDRAULIC STEERINGCYLINDERS & HYDRAULIC STEERING
•DUMPERS WITH TELESCOPIC DUMPERS WITH TELESCOPIC
CYLINDERS & HYDRAULIC STEERINGCYLINDERS & HYDRAULIC STEERING
What exactly is "full What exactly is "full
hydraulic steering?"hydraulic steering?"
•The expression refers to any steering system The expression refers to any steering system
configurations where a vehicle is steered solely by configurations where a vehicle is steered solely by
means of a hydraulic circuit comprising, as a minimum, a means of a hydraulic circuit comprising, as a minimum, a
pump, lines, fluid, valve, and cylinder (actuator). that is to pump, lines, fluid, valve, and cylinder (actuator). that is to
say, the vehicle is steered (usually via the front wheels) say, the vehicle is steered (usually via the front wheels)
purely by a hydraulically powered steering cylinder. This purely by a hydraulically powered steering cylinder. This
is an important distinction from "hydraulically assisted" is an important distinction from "hydraulically assisted"
steering, where hydraulic power serves only to assist a steering, where hydraulic power serves only to assist a
mechanical steering system (as is the case with the mechanical steering system (as is the case with the
hydraulically assisted power steering on virtually every hydraulically assisted power steering on virtually every
light car / truck on the road today). It indicates that the light car / truck on the road today). It indicates that the
vehicle is steered ONLY by hydraulics, with no other vehicle is steered ONLY by hydraulics, with no other
system (mechanical linkage) in place.system (mechanical linkage) in place.
hydraulic steering?"hydraulic steering?"
•The expression refers to any steering system The expression refers to any steering system
configurations where a vehicle is steered solely by configurations where a vehicle is steered solely by
means of a hydraulic circuit comprising, as a minimum, a means of a hydraulic circuit comprising, as a minimum, a
pump, lines, fluid, valve, and cylinder (actuator). that is to pump, lines, fluid, valve, and cylinder (actuator). that is to
say, the vehicle is steered (usually via the front wheels) say, the vehicle is steered (usually via the front wheels)
purely by a hydraulically powered steering cylinder. This purely by a hydraulically powered steering cylinder. This
is an important distinction from "hydraulically assisted" is an important distinction from "hydraulically assisted"
steering, where hydraulic power serves only to assist a steering, where hydraulic power serves only to assist a
mechanical steering system (as is the case with the mechanical steering system (as is the case with the
hydraulically assisted power steering on virtually every hydraulically assisted power steering on virtually every
light car / truck on the road today). It indicates that the light car / truck on the road today). It indicates that the
vehicle is steered ONLY by hydraulics, with no other vehicle is steered ONLY by hydraulics, with no other
system (mechanical linkage) in place.system (mechanical linkage) in place.
Why use hydrostatic steering?Why use hydrostatic steering?
•Because there are a number of distinct advantagesBecause there are a number of distinct advantages ::
•PowerPower - depending on system design parameters (flow, pressure, cylinder size, etc.) - depending on system design parameters (flow, pressure, cylinder size, etc.)
hydro steering can develop steering force FAR in excess of any other mechanical, hydro steering can develop steering force FAR in excess of any other mechanical,
electrical, or hydraulically boosted system. This is a must for massive construction electrical, or hydraulically boosted system. This is a must for massive construction
equipment. It is also extremely advantageous to 4x4s with big tires, locker equipment. It is also extremely advantageous to 4x4s with big tires, locker
differentials, low tire pressures, the must negotiate and be steered in extremely differentials, low tire pressures, the must negotiate and be steered in extremely
challenging terrain. For a given amount of steering input effort, no other system can challenging terrain. For a given amount of steering input effort, no other system can
match the power output of a hydro steering system.match the power output of a hydro steering system.
•FlexibilityFlexibility - the very nature of fluid power (hydraulics) allows for great flexibility in - the very nature of fluid power (hydraulics) allows for great flexibility in
system design and mounting. The steering need not be constrained by the system design and mounting. The steering need not be constrained by the
requirements for mechanical linkages.requirements for mechanical linkages.
•Operator comfortOperator comfort - because of the power generated, required operator input levels - because of the power generated, required operator input levels
are very low in hydro steering systems.are very low in hydro steering systems.
•ControlControl - depending on system design and tuning, precise, custom steering can be - depending on system design and tuning, precise, custom steering can be
arranged, (for example, a system with very few turns of the steering wheel from lock arranged, (for example, a system with very few turns of the steering wheel from lock
to lock) to lock)
•WeightWeight - the power to weight ratio of hydrostatic systems generally far outstrips - the power to weight ratio of hydrostatic systems generally far outstrips
traditional hydraulically boosted mechanically actuated steering systems. traditional hydraulically boosted mechanically actuated steering systems.
•SmoothnessSmoothness - hydro steering systems are smooth and quiet in operation. Vibration - hydro steering systems are smooth and quiet in operation. Vibration
is kept to a minimum. kickback, bump steer, and operator fatigue are all but is kept to a minimum. kickback, bump steer, and operator fatigue are all but
eliminated.eliminated.
•Overload protectionOverload protection - when properly designed, automatic valves can guard the - when properly designed, automatic valves can guard the
system against a breakdown from overloadingsystem against a breakdown from overloading
•Because there are a number of distinct advantagesBecause there are a number of distinct advantages ::
•PowerPower - depending on system design parameters (flow, pressure, cylinder size, etc.) - depending on system design parameters (flow, pressure, cylinder size, etc.)
hydro steering can develop steering force FAR in excess of any other mechanical, hydro steering can develop steering force FAR in excess of any other mechanical,
electrical, or hydraulically boosted system. This is a must for massive construction electrical, or hydraulically boosted system. This is a must for massive construction
equipment. It is also extremely advantageous to 4x4s with big tires, locker equipment. It is also extremely advantageous to 4x4s with big tires, locker
differentials, low tire pressures, the must negotiate and be steered in extremely differentials, low tire pressures, the must negotiate and be steered in extremely
challenging terrain. For a given amount of steering input effort, no other system can challenging terrain. For a given amount of steering input effort, no other system can
match the power output of a hydro steering system.match the power output of a hydro steering system.
•FlexibilityFlexibility - the very nature of fluid power (hydraulics) allows for great flexibility in - the very nature of fluid power (hydraulics) allows for great flexibility in
system design and mounting. The steering need not be constrained by the system design and mounting. The steering need not be constrained by the
requirements for mechanical linkages.requirements for mechanical linkages.
•Operator comfortOperator comfort - because of the power generated, required operator input levels - because of the power generated, required operator input levels
are very low in hydro steering systems.are very low in hydro steering systems.
•ControlControl - depending on system design and tuning, precise, custom steering can be - depending on system design and tuning, precise, custom steering can be
arranged, (for example, a system with very few turns of the steering wheel from lock arranged, (for example, a system with very few turns of the steering wheel from lock
to lock) to lock)
•WeightWeight - the power to weight ratio of hydrostatic systems generally far outstrips - the power to weight ratio of hydrostatic systems generally far outstrips
traditional hydraulically boosted mechanically actuated steering systems. traditional hydraulically boosted mechanically actuated steering systems.
•SmoothnessSmoothness - hydro steering systems are smooth and quiet in operation. Vibration - hydro steering systems are smooth and quiet in operation. Vibration
is kept to a minimum. kickback, bump steer, and operator fatigue are all but is kept to a minimum. kickback, bump steer, and operator fatigue are all but
eliminated.eliminated.
•Overload protectionOverload protection - when properly designed, automatic valves can guard the - when properly designed, automatic valves can guard the
system against a breakdown from overloadingsystem against a breakdown from overloading
The component in the top right of the picture is the The component in the top right of the picture is the
hydraulic steering directional control valve / hydraulic steering directional control valve /
metering section; and is the heart of the systemmetering section; and is the heart of the system
hydraulic steering directional control valve / hydraulic steering directional control valve /
metering section; and is the heart of the systemmetering section; and is the heart of the system
Basic wrap-up & Re cap of the Basic wrap-up & Re cap of the
system so far….system so far….
•ReservoirReservoir - this is the hydraulic fluid (or power - this is the hydraulic fluid (or power
steering fluid) reservoir that stores the fluid steering fluid) reservoir that stores the fluid
necessary for the system.necessary for the system.
•Supply pumpSupply pump - this is the power steering - this is the power steering
pump, note that in many automotive applications pump, note that in many automotive applications
the pump and reservoir are integrated into one the pump and reservoir are integrated into one
unitunit
system so far….system so far….
•ReservoirReservoir - this is the hydraulic fluid (or power - this is the hydraulic fluid (or power
steering fluid) reservoir that stores the fluid steering fluid) reservoir that stores the fluid
necessary for the system.necessary for the system.
•Supply pumpSupply pump - this is the power steering - this is the power steering
pump, note that in many automotive applications pump, note that in many automotive applications
the pump and reservoir are integrated into one the pump and reservoir are integrated into one
unitunit
How it works (tracing the How it works (tracing the
circuit).circuit).
•The reservoir supplies fluid to the pump. The pump pumps the fluid The reservoir supplies fluid to the pump. The pump pumps the fluid
to the steering unit. When the operator turns the steering wheel, to the steering unit. When the operator turns the steering wheel,
connected to the steering unit via the steering shaft, the steering connected to the steering unit via the steering shaft, the steering
unit directs pressurized fluid to and from the cylinder. In response unit directs pressurized fluid to and from the cylinder. In response
the cylinder extends or retracts. The cylinder is connected to the the cylinder extends or retracts. The cylinder is connected to the
steered wheels and therefore the wheels steer. Fluid then returns to steered wheels and therefore the wheels steer. Fluid then returns to
the reservoir from the steering unit via the filter.the reservoir from the steering unit via the filter.
•
circuit).circuit).
•The reservoir supplies fluid to the pump. The pump pumps the fluid The reservoir supplies fluid to the pump. The pump pumps the fluid
to the steering unit. When the operator turns the steering wheel, to the steering unit. When the operator turns the steering wheel,
connected to the steering unit via the steering shaft, the steering connected to the steering unit via the steering shaft, the steering
unit directs pressurized fluid to and from the cylinder. In response unit directs pressurized fluid to and from the cylinder. In response
the cylinder extends or retracts. The cylinder is connected to the the cylinder extends or retracts. The cylinder is connected to the
steered wheels and therefore the wheels steer. Fluid then returns to steered wheels and therefore the wheels steer. Fluid then returns to
the reservoir from the steering unit via the filter.the reservoir from the steering unit via the filter.
•
Relief valveRelief valve
•- This is simply a pressure relief valve. If a - This is simply a pressure relief valve. If a
malfunction in the system causes the malfunction in the system causes the
pressure to rise too high, the relief valve pressure to rise too high, the relief valve
opens and the fluid simply passes back to opens and the fluid simply passes back to
the reservoir. In virtually all automotive the reservoir. In virtually all automotive
power steering pumps, the relief valve is power steering pumps, the relief valve is
built into the pump built into the pump
•- This is simply a pressure relief valve. If a - This is simply a pressure relief valve. If a
malfunction in the system causes the malfunction in the system causes the
pressure to rise too high, the relief valve pressure to rise too high, the relief valve
opens and the fluid simply passes back to opens and the fluid simply passes back to
the reservoir. In virtually all automotive the reservoir. In virtually all automotive
power steering pumps, the relief valve is power steering pumps, the relief valve is
built into the pump built into the pump
Hydraulic SymbolsHydraulic Symbols
Definitions of LINESDefinitions of LINES
continuous line - flow
line
dashed line - pilot, drain
envelope - long and short dashes around two or more
component symbols
Definitions of LINESDefinitions of LINES
continuous line - flow
line
dashed line - pilot, drain
envelope - long and short dashes around two or more
component symbols
Advanced Hydraulic SymbolsAdvanced Hydraulic Symbols
Hydraulic SymbolsHydraulic Symbols
Hydraulic & Pneumatic SymbolsHydraulic & Pneumatic Symbols
•Some basic symbols:Some basic symbols:
•Some basic symbols:Some basic symbols:
Some Hydraulic & Pneumatic SymbolsSome Hydraulic & Pneumatic Symbols
Some more Hydraulic SymbolsSome more Hydraulic Symbols
Hydraulic Pumps & Motors Hydraulic Pumps & Motors
SymbolsSymbols
•More SymbolsMore Symbols
SymbolsSymbols
•More SymbolsMore Symbols
Hydraulic PumpsHydraulic Pumps
•Any hydraulic pump performs two functions. First, its Any hydraulic pump performs two functions. First, its
mechanical action creates a vacuum at the pump inlet mechanical action creates a vacuum at the pump inlet
which allows atmospheric pressure to force liquid from which allows atmospheric pressure to force liquid from
the reservoir into the inlet line to the pump. Second, its the reservoir into the inlet line to the pump. Second, its
mechanical action delivers this liquid to the pump outlet mechanical action delivers this liquid to the pump outlet
and forces it into the hydraulic system. and forces it into the hydraulic system.
•Shown below is a Variable-displacement, pressure-Shown below is a Variable-displacement, pressure-
compensated vane pump compensated vane pump
•Any hydraulic pump performs two functions. First, its Any hydraulic pump performs two functions. First, its
mechanical action creates a vacuum at the pump inlet mechanical action creates a vacuum at the pump inlet
which allows atmospheric pressure to force liquid from which allows atmospheric pressure to force liquid from
the reservoir into the inlet line to the pump. Second, its the reservoir into the inlet line to the pump. Second, its
mechanical action delivers this liquid to the pump outlet mechanical action delivers this liquid to the pump outlet
and forces it into the hydraulic system. and forces it into the hydraulic system.
•Shown below is a Variable-displacement, pressure-Shown below is a Variable-displacement, pressure-
compensated vane pump compensated vane pump
Classification of pumpsClassification of pumps
•All pumps may be classified as either positive-All pumps may be classified as either positive-
displacement or non-positive-displacement. Most pumps displacement or non-positive-displacement. Most pumps
used in hydraulic systems are positive-displacement.used in hydraulic systems are positive-displacement.
•A A non-positive-displacement pumpnon-positive-displacement pump produces a produces a
continuous flow. However, because it does not provide a continuous flow. However, because it does not provide a
positive internal seal against slippage, its output varies positive internal seal against slippage, its output varies
considerably as pressure varies. Centrifugal and considerably as pressure varies. Centrifugal and
propeller pumps are examples of non-positive-propeller pumps are examples of non-positive-
displacement pumps.displacement pumps.
•In a In a positive-displacement pumppositive-displacement pump, slippage is , slippage is
negligible compared to the pump's volumetric output negligible compared to the pump's volumetric output
flow. If the output port were plugged, pressure would flow. If the output port were plugged, pressure would
increase instantaneously to the point that the pump's increase instantaneously to the point that the pump's
pumping element or its case would fail or the pump's pumping element or its case would fail or the pump's
prime mover would stall.prime mover would stall.
•All pumps may be classified as either positive-All pumps may be classified as either positive-
displacement or non-positive-displacement. Most pumps displacement or non-positive-displacement. Most pumps
used in hydraulic systems are positive-displacement.used in hydraulic systems are positive-displacement.
•A A non-positive-displacement pumpnon-positive-displacement pump produces a produces a
continuous flow. However, because it does not provide a continuous flow. However, because it does not provide a
positive internal seal against slippage, its output varies positive internal seal against slippage, its output varies
considerably as pressure varies. Centrifugal and considerably as pressure varies. Centrifugal and
propeller pumps are examples of non-positive-propeller pumps are examples of non-positive-
displacement pumps.displacement pumps.
•In a In a positive-displacement pumppositive-displacement pump, slippage is , slippage is
negligible compared to the pump's volumetric output negligible compared to the pump's volumetric output
flow. If the output port were plugged, pressure would flow. If the output port were plugged, pressure would
increase instantaneously to the point that the pump's increase instantaneously to the point that the pump's
pumping element or its case would fail or the pump's pumping element or its case would fail or the pump's
prime mover would stall.prime mover would stall.
Positive-displacement Positive-displacement
principleprinciple
•A positive-displacement pump is one that A positive-displacement pump is one that
displaces (delivers) the same amount of displaces (delivers) the same amount of
liquid for each rotating cycle of the liquid for each rotating cycle of the
pumping element. Constant delivery pumping element. Constant delivery
during each cycle is possible because of during each cycle is possible because of
the close-tolerance fit between the the close-tolerance fit between the
pumping element and the pump casepumping element and the pump case
principleprinciple
•A positive-displacement pump is one that A positive-displacement pump is one that
displaces (delivers) the same amount of displaces (delivers) the same amount of
liquid for each rotating cycle of the liquid for each rotating cycle of the
pumping element. Constant delivery pumping element. Constant delivery
during each cycle is possible because of during each cycle is possible because of
the close-tolerance fit between the the close-tolerance fit between the
pumping element and the pump casepumping element and the pump case
FAULT TRACING OF HYDRAULIC FAULT TRACING OF HYDRAULIC
SYSTEMSSYSTEMS
•So in conclusion I may say that to a beginner So in conclusion I may say that to a beginner
an hydraulic system or circuit may look an hydraulic system or circuit may look
complicated & fault tracing difficult. complicated & fault tracing difficult.
•But if one follows the root cause approach & But if one follows the root cause approach &
checks the system from the basic checks the system from the basic
parameters then fault tracing is actually parameters then fault tracing is actually
easy. easy.
•However some tools like clip on flow & However some tools like clip on flow &
pressure gauges, temperature gauges etc pressure gauges, temperature gauges etc
are required. are required.
SYSTEMSSYSTEMS
•So in conclusion I may say that to a beginner So in conclusion I may say that to a beginner
an hydraulic system or circuit may look an hydraulic system or circuit may look
complicated & fault tracing difficult. complicated & fault tracing difficult.
•But if one follows the root cause approach & But if one follows the root cause approach &
checks the system from the basic checks the system from the basic
parameters then fault tracing is actually parameters then fault tracing is actually
easy. easy.
•However some tools like clip on flow & However some tools like clip on flow &
pressure gauges, temperature gauges etc pressure gauges, temperature gauges etc
are required. are required.
SO, IN HYDRAULICS, AS IN LIFE, SO, IN HYDRAULICS, AS IN LIFE,
REMEMBER YOUR BASICS & NEVER REMEMBER YOUR BASICS & NEVER
GIVE UPGIVE UP
AND LIFE SHALL BE FULL OF AND LIFE SHALL BE FULL OF
HAPPINESSHAPPINESS
REMEMBER YOUR BASICS & NEVER REMEMBER YOUR BASICS & NEVER
GIVE UPGIVE UP
AND LIFE SHALL BE FULL OF AND LIFE SHALL BE FULL OF
HAPPINESSHAPPINESS
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