Introduction to Hydraulic Systems

Introduction to Hydraulic Systems

 All machines require some type of power source
and a way of transmitting this power to the
point of operation

 There are three methods of transmitting power

are:
 Mechanical
 Electrical
 Fluid Fluid Power is the method of
using pressurized Fluid to
transmit energy

Liquid or Gas is referred to

as fluid
Introduction to Hydraulic Systems
 There are two branches of fluid power

Hydraulics
Pneumatics

 Hydraulic systems use compressed liquid to

transfer force
 Commonly used where require large forces and
precise control
 Examples of Hydraulic Systems

Vehicle Vehicle Aircraft

Brake Power Hydraulic Hydraulic
Hydraulic Steering Jack System
System
 Examples of Hydraulic Systems
VEHICLE BRAKE
HYDRAULIC SYSTEM
 To stop or slow down a
Brake pedal
moving vehicle Master
 When the brake pedal is cylinder

pressed, the hydraulic pressure

is transmitted to the piston of
the brakes Brake
 The pressure force the break lines

pads against the brake rotor, Front

brake
which is rotating with the wheel calipers
 The friction between the brake Rear wheel
pad and the rotor cause the cylinder
pistons
wheel to slow down and then Pads
Rotor
stop
 Examples of Hydraulic Systems
VEHICLE POWER
STEERING

Hydraulic pump
 It uses hydraulic oil, the hydraulic
pump supplies the oil through the
control valves to the power cylinder
 The major advantage of using the
this system is to turn the vehicle’s
wheel with less effort Control
Power cylinder valve
 Examples of Hydraulic Systems
Hydraulic Jack
 In a hydraulic jack, a small piston
(pumping piston) transmits pressure
through the coil to a large piston
(power piston) through a check valve,
resulting in the weight being lifted

Oil reservoir Handle

Weight

Pumping piston
Inlet check Power
valve (allows piston
the oil to Outlet check valve
move in only (allows the oil to move
one direction) in only one direction)
 Examples of Hydraulic Systems
AIRCRAFT HYDRAULIC
SYSTEM
 All modern aircraft contain hydraulic
system to operate mechanism such as:
1. Flaps
2. Landing Gear
 The hydraulic pump that is coupled Landing gears Flaps

to the engine provides hydraulic

power Transmission
lines

 Hydraulic power is converted to Hydraulic

pump Landing
gear
mechanical power by means of an Actuating

actuating cylinder or motor Cylinder

Engine
power
 Components of Hydraulic Systems

Power Power
Control Condu-
Input Output Liquid
Device ctors
Device Device
Components of Hydraulic Systems
Power Input Device:
The pump and motor together are called the power input device;
the pump provides power to the hydraulic system by pumping
oil from the reservoir/tank. The pump’s shaft is rotated by an
external force which is most often an electric motor as illustrated
in the below figure
Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Control Device
Power output device
Actuator
 Components of Hydraulic Systems
Control Device:
Valves control the direction, pressure, and flow of the hydraulic
fluid from the pump to the actuator/cylinder

Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Control Device
Power output device
Actuator
 Components of Hydraulic Systems
Power Output Device:
The hydraulic power is converted to mechanical power inside the
power output device. The output device can be either a cylinder
which produces linear motion or a motor which produces rotary
motion

Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Control Device
Power output device
Actuator
Components of Hydraulic Systems
Liquid:
The liquid is the medium used in hydraulic systems to transmit
power. The liquid is typically oil, and it is stored in a tank or
reservoir

Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Control Device
Power output device
Actuator
 Examples of Hydraulic Systems
Conductors:
The conductors are the pipes or hoses needed to transmit the oil
between the hydraulic components

Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Control Device
Power output device
Actuator
Advantages of Hydraulic Systems
 Easy to produce, regulate and control

 Higher Efficiency

 Absence of linkages

 Self lubricating & self cooling

 Leakage is less

 Extremely smooth and jerk free motions

 Good heat transfer characteristics

 Less noisy
Disadvantage of Hydraulic Systems
 Frictional losses

 Variation of viscosity due to change in

temperature

 Weight & size is more

 Bursting of pipe can cause injury

 The small impurities in the fluid can

permanently damage the complete system
 Comparison of Hydraulic &
Pneumatic Systems
Hydraulic Systems Pneumatic Systems

Working fluid is a liquid Working fluid is a gas

Works at very high pressure Works at very low pressure

Working fluid is incompressible Working fluid is compressible

Self lubricating effect No self lubricating effect

Very high working force can be Low to medium force can be

developed developed
Heavy tubes are required Light tubing would be sufficient
 Principles of Hydraulic Systems
 Anything that can flow is a fluid i.e. air,
oil and water can flow

 Concentrate only on oil as present day the

system uses oil

 The hydraulic system using oil is governed by

the basic physical laws of fluid flow as
developed by the great scientist Blaise Pascal
which is know as “Pascal’s law”
 Principles of Hydraulic Systems
Law of Hydrostatics

“ The pressure p of a liquid at rest increases on

increasing the depth ”

P = Pressure = wh where,

w= specific weight of the

liquid
h= depth or “head” of the
fluid
The pressure is dependent on
The height of the liquid
And its density irrespective
Of the shape or geometry of the container
 Principles of Hydraulic Systems
Law of Hydrostatics

Mathematically hydrostatic pressure is equal to

p = h x ρ x g
h = height of fluid column
ρ = densiy of liquid
g = acceleration of free
fall

Example: Calculate the

Hydrastatic pressure at the
Bottom of a hydraulic oil
Container filled with oil (ρ = 0.8 kg/dm3) up to a
height of 800 mm.
 Principles of Hydraulic Systems
Pascal’s Law

“ The pressure generated by exerting a force on a

confined mass of liquid at rest acts undiminished
in equal magnitude and in all direction normal to
the inside wall of the fluid container ”

If a force F is exerted on the

Confined liquid in the jar,
A pressure p is generated and this
Pressure p will act on the inside
Wall of the container in equal
Magnitude and at right angles to
The point where pressure acts on
The surface
 Principles of Hydraulic Systems
Bramah’s Press Principle

The principle Pascal’s law was successfully

applied by an English Engineer, Mr. Joseph Bramah
to develop a hydraulic press in which by applying
a small input force, a large output force was
generated
 Principles of Hydraulic Systems
Bramah’s Press Principle

If a force F1 is exerted on the smaller piston,

then according to Pascal’s law, pressure p will
be generated in the oil which is constant and act
equally in all directions
 Principles of Hydraulic Systems
Bramah’s Press Principle

P = F1 / A1 (A1= Π/ 4 * D12)
F2= P * A2 (A2= Π/ 4 * D22)

P = F2 / A2 P = F1 / A1= F2 / A2
F2: F1 = A2: A1= D22: D12

F2= F1* A2 / A1
But as A2 > A1, A2 / A1is > 1
or F2is higher than F1

By applying a smaller force F1on the smaller piston, a bigger

force F2 can be generated in the bigger piston
 Principles of Hydraulic Systems
Hydrostatics or Hydrokinetics

 Pascal’s law holds good when the fluid is in

rest or in the static state which is known as
“hydrostatics”

 The oil is in motion in hydraulic machines

 The hydrokinetic effect is taken into

consideration

 Due to motion of liquid inside the pipes, it

will introduce friction losses and effects due to
inertia
 Principles of Hydraulic Systems
Fluid Energy in Motion

It is defined as the ability of a liquid to do

work

The total energy in a liquid in motion may be

classified as

i. Potential energy
ii. Kinetic energy
iii.Pressure energy
 Principles of Hydraulic Systems
Fluid Energy in Motion

i. Potential energy

 Energy by virtue of the position of a body is

called potential energy or stored energy

Wpot = V x h x ρ x g

where,
V = volume of liquid
ρ = density of liquid
h = height of liquid column
g = acceleration due to gravity
Principles of Hydraulic Systems
 Principles of Hydraulic Systems
Fluid Energy in Motion
Principles of Hydraulic Systems
Principles of Hydraulic Systems
 Principles of Hydraulic Systems
Fluid Energy in Motion
 Principles of Hydraulic Systems
Flow Velocity

The velocity of a liquid flowing through a pipe

of variable cross section changes to maintain
continuity of flow
Flow rate = volume / time
Q = V / t
= A * S/t
= A * v
So, velocity v = Q / A

Example: Through a hydraulic pipe of 15 mm dia.

Flows oil at a flow rate of 12 l/min. Find the
flow velocity
 Principles of Hydraulic Systems
Friction

 When liquid flows, heat is produced due to

friction so that a part of the energy is lost I
the form of heat energy
 Causes of unnecessarily large friction losses
in hydraulic flow lines are:
a) Flow lines too long
b) Too many bends
c) Excessive velocities due to fittings
 Friction generates heat and heat can reduce the
oil viscosity which result in leakage and
reducing the pressure
Principles of Hydraulic Systems
 Hydraulic Oils and Properties
 The primary function of a hydraulic system is
the transfer of energy from one location to
another and the conversion of this energy to
useful work
 Hydraulic power is generated by pump and the
energy generated is converted to useful work by
hydraulic cylinders or motors
 The transmission of energy is accomplished by
movement of the fluid through pipes while the
control of the power is achieved by valves
 The hydraulic fluid perform the various tasks:
1. To transfer hydraulic energy
2. To lubricate all parts
3. To avoid corrosion
4. To remove impurities
5. To dissipate heat
 Hydraulic Oils and Properties
Hydraulic Fluid Properties
1. Good Lubricity

2. Stable Viscosity Characteristics

 It is considered as the resistance of the fluid
to flow or as a measure of internal friction
 It varies with temperature and pressure
 Fluids having large changes of viscosity with
temp. are called low viscosity index fluids and
those having small changes of viscosity with
temp. are called high viscosity index fluids
3. Stable Chemically and Physically
 Fluid characteristics should remain unchanged
during an extended useful life and storage
 Hydraulic Oils and Properties
Hydraulic Fluid Properties
4. Good Heat Dissipation
 Pressure drops, mechanical friction, leakages
all generate heat
 The fluid must carry the heat away and
dissipate it to the atmosphere or coolers
 Fluid has high thermal conductivity and high
specific heat
5. High Bulk Modulus
 It is a measure of the degree of
compressibility of the fluid and is the
reciprocal of compressibility
 The higher the bulk modulus, the lesser the
fluid will be compressed with increasing temp.
 Hydraulic Oils and Properties
Hydraulic Fluid Properties
6. Flash Point
 The temp. at which flashes will be
generated when the oil is brought
into contact with any heated matter,
e.g., a heated stick
7. Low Foaming Tendency
 A liquid has a property to absorb a portion of
air or gas with which it comes in contact
 The ability of a liquid to release air or other
gases without the formation of form
 Hydraulic Oils and Properties
Hydraulic Fluid Properties
8. Fire Resistant
 Petroleum based oil burn vigorously once they
pass the flash point so for critical
applications, artificial or synthetic hydraulic
oils are used which have high fire resistance.
 Various grades of fluids with high water
content are also available now a days
9. Prevent Rust Formation
 Moisture and oxygen cause rusting of parts in
the system
 Rust particles can cause abrasive wear of
system components
 Hydraulic Oils and Properties
Hydraulic Fluid Properties
10.Low in Volatility
 Should have low volatility, i.e. low vapour
pressure or high boiling point characteristic
and it changes with the temp.
 High vapor pressure may cause high back
pressure
11.Good Demulsibility
 Moisture or water may enter a system through
contamination or condensation and this water
may either dissolve in the fluid or form two
layers
 It refers to the ability of oil to separate
from water
 Hydraulic Oils and Properties
Hydraulic Fluid Properties
12.Good Demulsibility
 Dissolve water may produce corrosion and
rusting

13.Low Specific Gravity

 High specific gravity means more weight for a
given volume of fluid
 Heavy fluid can cause pump cavitation and
malfunction

14.Easy to Handle and Available

 The fluid be as sample to handle, available and
cheap as possible
Hydraulic Oils and Properties
Hydraulic Oils and Properties
 Hydraulic Oils and Properties
Hydraulic Fluid Physical Properties
4. Viscosity
 It is the measure of ability of a liquid to
flow or as resistance to flow

 One might have noticed that when a liquid kept

in a container is stirred and left to itself,
the motion will disappear after sometime and
this indicate that there is some kind of
frictional force which is called viscous force
Principles of Hydraulic Systems
 Principles of Hydraulic Systems
Reynolds Number
 Principles of Hydraulic Systems
Influence of Temperature on Viscosity

 The operating temp. of the hydraulic system

should be kept at a reasonably constant level
Otherwise there will be tremendous losses
 A thick fluid have a higher viscosity and flow
becomes sluggish and thinner fluid have a low
viscosity and flows more easily
 Higher viscosity generates more friction and
heat whereas low viscosity causes leakage
 Both are dependent on temp. of the system
 Better to opt for a high VI no which are
available VI0 – VI100>
 Principles of Hydraulic Systems
Viscosity Index

 The viscosity of oil changes with temp.

 This temp. dependent characteristics of oil is
expressed in Viscosity Index or “VI”
 The viscosity of high VI oil is less sensitive
to change n temp. and vice versa
 Principles of Hydraulic Systems
Types of Hydraulic Oil
 According to ISO there are three types of
fluids according their source of availability
and purpose of use
 Hydraulic Pumps
Introduction
 Pump is defined as a mechanical device which
rotates or reciprocates to move fluid from one
place to another
 Converts prime mover energy into mechanical
energy and then into hydraulic energy (flow,
pressure)
 Hydraulic Pumps
Introduction
 Inlet side is connected to the reservoir and
the outlet side is connected to the valves
 Used to pump liquid from LP to HP area
 To increase flow
 To move liquid from lower elevation to higher
elevation
 Hydraulic Pumps
Pump Classification
 Basically pumps can be classified as positive
and non-positive pumps
 Hydraulic Pumps
Pump Classification
 Hydraulic Pumps
Pump Classification
 Hydraulic Pumps
PD Pump
 Pumping volume changes from maximum to minimum
during each pumping cycle
 Used where pressure is the primary factor
 HP and LP areas are separated so the fluid
cannot leak back
 The pumping action is done by varying the
physical size of the sealed pumping chamber in
which the fluid is moved
 The discharged volume of fluid per cycle is
fixed and dependent on the no. of cycles made
by the pump per unit time
 Fluid enters and leaves at the same velocity so
no changes in kinetic energy
 Examples - Gear, vane, piston and screw pumps
 Hydraulic Pumps
PD Pump
 Are widely used in hydraulic system
 Generates high pressure
 Relatively small
 High power to weight ration
 High volumetric efficiency

 Has to generate continuous flow of liquid

 Has to supply necessary force to the flow of
fluid
 Fixed Delivery i.e. flow is constant for the
constant speed
 Variable displacement pump i.e. the flow rate
of the pump is variable in a certain range at
constant speed
 Hydraulic Pumps
NPD Pump
 The fluid can be displaced and transferred
using the inertia of the fluid in motion
 Examples - centrifugal, axial flow and radial
flow
 Normally used for low pressure (up to 40 bar)
and high volume systems
 Volume is dependent of the speed of the
rotating member
 Low cost and less maintenance as less no. of
moving parts
 Operate quietly
 Simple in operation and high reliable
 Hydraulic Pumps
NPD Pump
 These pumps are not self priming and must be
positioned below the fluid level
 Inlet port, involute shaped
pumping chamber, drive shaft,
impeller & outlet port
 Rotation of the impeller imparts
a centrifugal force to the
fluid to be directed outward
from the center
 The blades are curved opposite
to the direction of the flow
 Hydraulic Pumps
Gear Pump
 Consist of two meshed gears, a housing to
encompass the gears, two end plates that
enclose the end of the gears
 Each gear is mounted on a shaft, one is the
drive shaft is coupled to the prime mover
 Two ports – inlet and outlet which are on
opposite side of the gear case and open on
opposite side of the mesh point of the gears
 Hydraulic Pumps
Gear Pump
 The ports should be large,
straight and unobstructed
 The larger the pitch angle,
the pump operation is smooth
 Leakage between wear plates
and gear end faces must be
minimum
 Spur gear, helical gear and
herringbone gears can be used
 Hydraulic Pumps
Gear Pump Working
 As the gears rotates in opposite direction, the
teeth disengages. SO the space opens on the suction
side, trapping new quantities of liquid and carrying
it around the pump casing to the discharge
 Liquid travels around the interior of the casing in
the pockets between the teeth and the casing
 As the gears come back into mesh, the volume is
reduced and the liquid is forced out of the
discharged port
Hydraulic Pumps
Hydraulic Pumps
 Hydraulic Pumps
Muligear Pump
 3-4 gears in one housing
 The center gear is connected to the motor shaft
 It has two independent outputs and may be
connected together as one
 Hydraulic Pumps
Internal Gear Pump
 Operation is same as external gear pump
 Produce less noise
 The internal gear drives the outside gear which
is set off-center to each other
 There is a crescent shaped stationary part
between two gears around which oil is carried
 Hydraulic Pumps
Internal Gear Pump Working
 The internal gear drives the external gear and
rotation causes the teeth to unmesh near the inlet
port, the cavity volume increases and suction occurs
and oil is entered
 Oil is trapped between the internal and external
gear teeth on both sides of the crescent-shaped
spacer and is carried from the inlet to the outlet
cavity
 Meshing of the gear teeth reduces the volume near
the outlet port and delivered the oil from there
 Hydraulic Pumps
Gerotor Pump
 The main parts are outer ring, outer gerotor, inner
gerotor
 The inner gerotor is the driver and the outer is
idle
 The outer gerotor has always one teeth more and vary
 Both axis around which the gerotors rotate are
offset
 If the no. of teeth for the inner and outer gerotors
are 4 & 5, while the inner gerotor makes one
revolution, the outer one makes only 4/5 or 0.8
revolution
 Hydraulic Pumps
Lobe Pump
 Two lobes rotate in opposite direction and creating
two chambers between the lobes and the wall of the
pump chamber
 One lobe is driven by source of power and the other
through timing gears
 As the elements rotate, the fluid is caught between
each lobe and the wall chamber and carried from
suction to discharge
 Low pressure and high flow rate applications
 Hydraulic Pumps
Screw Pump
 Transfer the fluid by displacing the oil axially
through a closely fitted chamber formed between the
screw recess and housing wall
 The flow rate can be varied by varying the drive
motor speed only
 The only moving parts are screws
 Available in one, two or three screw designs
 No. of threads and size determine the flow quantity
 Hydraulic Pumps
Screw Pump
 In two screw pump design, timing gears are required
to maintain a running clearance between two meshing
screws
 The liquid does not rotate but moves linearly
 Same as gear pump, here the meshing of the thread
forces fluid to flow in the space between the rotor
and housing wall
 The volume of fluid moves forward uniformly with
rotation of screw and is discharged
 Hydraulic Pumps
Screw Pump
 Encounter an undue thrust load towards the inlet
port due to undesired pressure peaks and that is
balanced buy use of right and left handed thread so
that the pump inlets are on each side and outlet at
the middle
 One main bearing to support the driving rotor is
required to withstand the sideload
 Hydraulic Pumps
Screw Pump
 In three screw pump design, the drive motor is
connected to the middle screw and on its both sides
two idle screws are provided which are driven by the
pressure of the liquid and hence no need of timing
gears
 Use for special application where low flow rate, no
pressure pulsation and maximum noise elimination
required
 Hydraulic Pumps
Vane Pump
 Classified as
a) Fixed displacement, unbalanced pump
b) Fixed displacement, balanced pump
c) Variable displacement, unbalanced pump
d) Variable displacement pressure compensated
pump
 Pumping action is done by the vanes tracking
along a cam ring
 Hydraulic Pumps
FD Unbalanced Vane Pump
 Consists of following components
a) Driven rotor with slots for vanes
b) Sliding vanes
c) Stationary circular ring
d) Housing
 The rotor, vanes, ring and wear plates may form
a cartridge unit which can be easily replaced
 Hydraulic Pumps
FD Unbalanced Vane Pump
 Rotor axis is positioned eccentric to the circular
ring
 Vanes move outward due to centrifugal force,
they make contact with the inner ring wall, a
positive seal takes place between the vane tip
and the cam ring so the no. of chambers are
formed
 The chamber changes their volume continuously
 Hydraulic Pumps
FD Unbalanced Vane Pump
 A port plate which fits over the ring, rotor and
vanes separates the incoming oil from the outgoing
oil
 Both the ports are sealed
from each other at any
time by at lease one vane
 To obtain such sealing,
the track between two
ports is slightly wider
than the space between
two vanes
 With six vanes the angle between the end of
suction port and beginning of delivery port &
the angle between the end of delivery port and
beginning of suction port bust be at least 60˚
Hydraulic Pumps
Hydraulic Pumps
 Hydraulic Pumps
FD balanced Vane Pump
 A circular rotor with vane slots is concentrically
positioned with the axis of an elliptical cam ring
 Creates two inlet and two outlet
chambers opposite to each other
so forces acting on the shaft
are fully balanced
 Actually both inlet ports &
outlet ports are connected
together so pump housing has
one inlet and outlet pump
 Hydraulic Pumps
FD balanced Vane Pump
 Without a positive sealing, proper function of the
vane pump is difficult
 The vanes are displaced from the slots by
centrifugal force and achieve
positive sealing
 These pumps should not operate
below 600 rpm
 The leakage is dependent on vanes
and cams
 A portion of the system pressure
is directed to the underside of the
vanes, higher the system pressure,
the more force is developed to push the vane out
against cam-ring
 Higher force the vane and cam ring would wear and
the pump will malfunction
 Hydraulic Pumps
FD balanced Vane Pump
 For high pressure vane pump, use different types of
vanes
a) Dual vanes
b) Intra vanes
c) Pi vane
d) Spring loaded vanes
e) Angled vanes
 Hydraulic Pumps
FD balanced Vane Pump
 The pumping mechanism is designed and formed as an
integral assembly which called a “cartridge”
assembly
 Vanes, rotor and cam ring sandwiched between the
port plates
 Easy for maintenance, replacement and servicing when
the system malfunction
 Hydraulic Pumps
Variable Displacement Vane Pump
 The flow rate can be varied by varying the rpm of
the electric motor which is economically not
feasible and not practicable
 The displacement of the pump is proportional to the
eccentricity between the rotor axis and the cam ring
 Changing the geometric position of the ring will
change the delivery volume as per system need
 The main parts are
Cam ring
Rotor
Vanes
Screw for position adj.
Thrust bearing
Stop
 Hydraulic Pumps
Variable Displacement Vane Pump
 The rotor containing the vanes is positioned
eccentric with regard to the cam ring
 When rotor rotates, volume of the chamber is
increased and decreased inside the housing
 The screw is used to move the cam ring and the
eccentricity changes accordingly
 Fig shows three different positions of the
eccentricity e)
 When e is +e, Q is
maximum, e=0 then
Q =0 and when e = -e
then direction of
flow is reversed
 Hydraulic Pumps
Variable Displacement Vane Pump
 Hydraulic Pumps
Pressure Compensated Vane Pump
 When the predetermined pressure is reached, the
pump should stop pumping oil
 This pump consist of an additional spring which
is adjusted to offset the cam ring
 When the pressure acting on the inner contour
of the ring is more than the pressure excreted
by the spring , the cam ring becomes concentric
to the rotor and pumping action stops
 Hydraulic Pumps
Pressure Compensated Vane Pump
 The flow pressure relationship
is shown
 Here vanes are angular
 The leakage is hot and if
diverted to the inlet side,
the oil would be hotter
 The leakage oil is sent back
the reservoir externally is
called “case drain”
 Hydraulic Pumps
Piston Pump
 Pumping is done by a reciprocating piston in a
finished cylinder bore
 The piston while reciprocating allows oil to be
drawn inside the bore as it is retracted and
the oil is expelled from the bore during the
forward stroke
 Basically classified as,
I. Fixed displacement
II.Variable displacement
 As per geometry and physical arrangement of
piston classified as,
I. In-line crank shaft driven
II.Axial
III.Radial
 Hydraulic Pumps
Piston Pump
 Has finely machined cylinder barrel and piston
 The shaft of the piston is connected to prime
mover along with a cam
 Inlet and outlet ports are controlled by ball
valves which allows oil in one direction only
 Supply of oil in pulse which creates
undesirable effect
 A no. of cylinders and pistons are used in
parallel and operated by a crank shaft
 Hydraulic Pumps
Crank Shaft Driven Piston Pump
 Require parallel arrangement of cylinders so
require more space
 A typical 24-cylinder-- 12-cylinders in two
opposite rows each—to work at a very high
pressure of 400 to 450 bar with a flow rate of
40 l/min with 1200 rpm
 Hydraulic Pumps
Axial Piston Pump
 All axial piston pumps can be classified as
I. In-line axial piston pump
i. Swash plate axial piston pump
ii.Wobble plate axial piston pump
II.Bent axis piston pump
 All these pumps may be either fixed or variable
 Hydraulic Pumps
In-line Swash Plate Axial Piston Pump
 Pistons are arranged axially parallel to each
other around the circumferential periphery of
the cylinder block
 The pistons are driven to and fro inside a no.
of bores in the cylinder barrel
 Either the cylinder barrel or swash plate is
rotated
 the oil in and out is Controlled by ball valves
 Hydraulic Pumps
In-line Swash Plate Axial Piston Pump
 Flow rate is constant at a given speed but can
be changed by varying speed or vary the angle
between the axis of the swash plate and the barrel
 The pistons are arranged parallel to each other
(i.e. in-line) so it is called as in-line Axial pump
 Hydraulic Pumps
In-line Swash Plate Axial Piston Pump
 The cylinder body containing the axially placed
pistons, is made to rotate against a cam plate
 The cam plate is being kept fixed and
positioned at an angle
 The shoe plate to which the shoes which are
flexible links are fitted is part of the
rotating part follows the surface of the swash
plate when cylinder block rotates
 Hydraulic Pumps
In-line Swash Plate Axial Piston Pump
 As the swash plate at an angle, the piston has
to reciprocates within the cylinder bore and
oil is sucked during one half of the rotation
and during the other half of rotation, the oil
is forced out of the outlet port
 In fig (b), the location of fixed swash plate
the cylinder block is reversed
 Hydraulic Pumps
In-line Swash Plate Axial Piston Pump
 The delivery from the pump depends on the
number of cylinders (n), the speed (N), the
dia. Of the bore (d) and the stroke length of
the piston (h)
 The stroke length (h) is again dependent on the
angle of the swash plate with which the axis of
the cylinder block

Q = n.N.h.A
 Hydraulic Pumps
In-line Wobble Plate Axial Piston Pump
 When the cam plate rotates with the drive shaft
while the cylinder block is kept then the cam
plate is called a wobble plate
 Here the swash plate is rotating on the surface
of the shoe plate , produces a motion on it
that moves the pistons in and out while
reciprocating inside the bore
 Hydraulic Pumps
In-line Wobble Plate Axial Piston Pump
 When the cam plate rotates with the drive shaft
while the cylinder block is kept then the cam
plate is called a wobble plate
 Here the swash plate is rotating on the surface
of the shoe plate , produces a motion on it
that moves the pistons in and out while
reciprocating inside the bore
 Hydraulic Pumps
Variable Displacement Axial Piston Pump
 From the previous discussion about the axial
piston pump, it is clear that the stroke length
of a piston is determined by the swash plate
angle
 Large angle gives larger stroke and smaller
angle permits shorter stroke length
 Hydraulic Pumps
Variable Displacement Axial Piston Pump
 The swash plate angle can be varied
mechanically
 Max angle limited to 171/2°
 So the flow rate can be changed from zero to max. by
varying the angle
 Hydraulic Pumps
Pressure Compansated Variable Displacement Axial
Piston Pump
 The swash plate is mechanically connected to a
piston which sense the system pressure which is
called compensator piston and is biased against
a spring
 Initially the return spring position the plate
to full delivery and when the system pressure
is high enough then no flow
 Hydraulic Pumps
Pressure Compansated Variable Displacement Axial
Piston Pump
 If the pressure is falls off, the spool moves
back, oil is discharged from the piston to the
inside of the pump core and the spring return
to the plate to a max. angle
 Hydraulic Pumps
Bent Axis Axial Piston Pump
 Here the cylinder block is made to form an
angle (α) with the axis of the drive shaft
 Distance between the center line of cylinder
block and center line of the piston is r
 As the entire unit rotates, the piston is
forced into a reciprocating motion relative to
the cylinder block which is h
 Hydraulic Pumps
Bent Axis Axial Piston Pump
 As tilt angel α increases, stroke h also
increases
h = 2 r tanα where r = D/2
Q = n.h.π/4.d2
 The max. angle is kept to 30° and it may be 15°,
20°, 25° & 30°
 Hydraulic Pumps
Radial Piston Pump
 There are two types:
a) Radial piston pump with stationary
cylinder block
b) Radial piston pump with rotating cylinder
block
 In a stationary cylinder block design,
reciprocating motion is imparted by a rotating
cam
 The outer side of each
cylinder is connected to the
inlet and discharge check
valves which are opened by
suction and discharge
pressure
 Hydraulic Pumps
Radial Piston Pump
 The cylinder block and cam ring are positioned
eccentrically which make radially placed
pistons to and fro movement
 The pistons are thrown out by centrifugal force
and pushed back because of the eccentricity
between rotor ring and cylinder block
 Hydraulic Pumps
Flow Rate of Pump
 The pump has to generate hydraulic power and
also supply a volume of oil (Q) at a certain
pressure (P) to the system
Qth = i.v.n = cn
where Qth = theoretical flow rate
i = no. of pumping chamber
v = volume of each pumping chamber
n = pump r.p.m
c = iv = pump constant for each
revolution
Hydraulic Pumps
 Hydraulic Pumps
Oil Compatibility
 Oil compatibility depends upon clearances of
mating parts, oil viscosity, lubricity and wear
rate of pump parts, operating temperature and
pressure
Noise
 Noise levels vary with the pump, pump component
material, pump mountings, size, flow capacity
pressure, speed of rotation, pressure
pulsations and other components connected in
the circuit
 External gear and piston pumps are noisiest
 Screw pumps are very quiet and vane and
internal gear pumps somewhere in between
 Loud pump > 90db , quite , 90db
 Hydraulic Pumps
Pump Ripple
 PD pump cannot deliver constant flow
 Small variations of flow rate that take place
during pumping are called ripple
 For example vane pumps transport fluid volume
in the compartments between two vanes. As each
of these fluid compartments enters the pump
discharge side, its volume starts reducing
while the fluid is squeezed out. If the
discharge volume is plotted against the angular
position of the vanes, the shrinkage of flow,
produces a sinusoid curve as these variations
in output follow a sinusoidal pattern
 Hydraulic Pumps
Pump Ripple
 A delivery pattern of piston pumps with 4 & 5
pistons is shown in fig.
 The zero line separates suction from discharge
 Hydraulic Pumps
Comparison of Pumps
 Hydraulic Pumps
Selection Criteria for Pumps
 Many parameters are considered for selection
like flow rate, operating speed, pressure
rating, efficiency, noise, etc
1. Select the actuator that is appropriate based
on the loads encountered
2. Determine the flow rate necessary to drive the
actuator to move the load through a specified
distance within a given time limit
3. Select the system pressure that deal with the
actuator size and the resistive force produced
by the external load which decide the power
required by the pump
4. Determine the pump speed and select the prime
mover determine the pump size (volumetric
displacement)
 Hydraulic Pumps
Selection Criteria for Pumps
5. Select the pump type based on the application
6. Select the reservoir and associated plumbing
including piping, valving, filters, and
strainers and accumulators
7. Consider factors such as noise levels,
horsepower loss, need for a heat exchanger due
to generated heat, pump wear and scheduled
maintenance service
8. Calculate the overall cost of the system
 This procedure is repeated several times with
different sizes and types of components and
best system is selected for the application.
This process is called optimization
 Direction Control Valves
 The pump generates the flow of oil which is fed
to the cylinder or motor through a no. of
control blocks called valves
 Various valves are used to control or regulate
the flow medium
a) Stopping of flow
b) Direction of flow
c) Pressure of flow medium
d) Flow quantity
e) Other special function
 DCV is used to start, stop and reverse the
cylinder or motor movement
 DCVs are employed in a hydraulic system to
determine the direction of the fluid
 They are also used as a selector switch
 Direction Control Valves
 As per construction, there are two types
1. Seat or poppet valve
2. Sliding or spool valves
 In DCVs, the flow path
may connect a supply port
to an outlet port (P to A
or B) or may allow a
pressurized port to unload
to the tank (A or B to T)
 All ports may be closed
 This is done by shifting
the internal parts of the
valve
 Direction Control Valves
 The internal parts may be
a)A poppet lifting off or moving between sealed
them
b)Sliding plates moving across ports
c)Sliding spools with dynamic seals moving is a
bore
d)Spools moving in a bore with stationary seals
 Direction Control Valves
Poppet Valves
 A ball or a similar item like a plate is made
to sit over a finely machined and polished seat
 Hugh response and relative insensitivity to
contamination
 Suited for high pressure applications
 Less suitable for large size valves
 No leakage or very little leakage
 The internal design is complicated
 Direction Control Valves
Rotary Spool Valves
 The fluid is directed through longitudinal
grooves into a rotable piston
 Used in manually operated valves
 Rely on close contact being maintained between
a rotating plate and a backup member
 Difficult to produce adequate sealing for high
pressures
 More appropriate for low pressures
 Direction Control Valves
Sliding Spool Valves
 A small piston called spool slides inside the
valve thereby opening or closing the ports
 During operation, only spring force, frictional
force and flow forces are to be overcome
 Suitable for all actuation methods due to
linear motion
 Direction Control Valves
Parameters for Designing
i. Pressure force
ii.Valve size
iii.Valve body
iv.Friction forces
v. Material of internal parts
vi.Valve fittings and permissible clearance
vii.Sealing arrangement
viii.Leakage and pressure drop
 Direction Control Valves
Operating Methods of DCVs
 Various operating methods are used for
actuation of the valve spool
 The spool movement of DCVs can be actuated by
application of a direct force on the valve
spool
 The actuating force could be applied:
a) Manually
b) Mechanically
c) Hydraulically
d) Pneumatically
e) Electrically
f) Electro-pneumatically
g) Electro-hydraulically
h) Other means e.g. remote control
 Direction Control Valves
Manual Actuation
 Use muscle power to actuate the spool
 Like levers, push buttons, pedals, etc.
 In a lever operated valve, the angular movement
of the lever is transmitted to the spool
 The detents in the individual positions are
achieved with the use of balls which are
present into angular grooves in the tappet by
springs
 Pedal is used when hands of the operator need
to be kept free
 Direction Control Valves
Mechanical Actuation
 Various methods are used like roller, plunger,
roller tappet, spring, etc.
 Is used when shifting of DCV must occur at the
time a cylinder reaches a specific position
 A spring is often used to reset the valve
 The spool of DCV is made to return to its
original position by using a spring when the
earlier actuation force is withdrawn such valve
is known as spring offset valve
 Direction Control Valves
Pneumatic Actuation
 If require high actuation force or to eliminate
mechanical control, DCV can be actuated by oil
or air pressure
 The pressure is applied
at two extreme spool lands
if it is a 4-land spool or
to separate pilot pistons
if it is a 2 land spool
 The air pressure acts on
a piston with large effective
area which in turn transfers
the actuating force to the spool
 Care need to be taken that no leakage of air
pressure takes place to the main valve
 Direction Control Valves
Hydraulic Actuation
 The hydraulic pressure apply directly on end
face of the spool
 Hydraulic pilot valves provide pilot pressure
against the main valve spool ends
 Pilot pressure is low compared to the main
pressure
 Pilot valves are actuated by mechanical or
electrical methods
 Direction Control Valves
Electrical Actuation
 Uses a solenoid to operate the spool which can
be AC or DC
 Armature plunger presses on the spool when the
electromagnet is excited
 Ac Solenoid
Actuation time is 25-30 ms
Available in 120 or 220V, 50hz
Life cycle is 7200 to 7500 switching operations/hr
 DC Solenoid
Actuation time is 40-50 ms
Available in 12/24/36 V
Life cycle is 15000 switching operations
 Direction Control Valves
Electro-hydraulic / electro-pneumatic Actuation
 Combination of electrical and hydraulic or
pneumatic
 The valves like 3/2, 4/2 are actuated by
solenoids called pilot valves and control the
main valve
 Direction Control Valves
Control Technique
 The control techniques of DCV may be classified
in two groups:
1. Direct controlled method – The actuation is
carried on directly on the valve spool
2. Indirect controlled method – Contain two
parts
I. One pressure pressure oil controlled DC
valve
II.One direct controlled DC valve called a
pilot valve mostly using solenoid
 Direction Control Valves
Pilot operated DCV
 DCV may be direct operated or pilot operated
from a remote location
 Hydraulic machines are worked on moderate to
high pressure so bigger size DCV require high
actuating force
 The main valve spool is operated by oil
pressure by the pilot valve
 The outlet ports A & B are connected to the end
faces of the main valve
Pressure Loss
 The max. oil flow (Qmax/min) is fixed
 The pressure loss is dependent on the oil
quantity and the viscosity of the oil
 Direction Control Valves
2, 3 and 4-way DCV
 Way means flow path through the valve including
reverse flow
 1, 2, 3 & 4 way valves are common
 1 way valve allows flow only in one direction
and does not permit return flow
 A 2 way DCV consists of 2 ports P & A which are
connected and disconnected by the moving spool
 In one extreme spool position, the flow from P
moves to A and in the other extreme position no
flow allowed from P to A and flow stops
 Direction Control Valves
2, 3 and 4-way DCV
 3 way DCV has 3 ports P, A & T
 In one extreme spool position, the oil flows
from P to A to move the actuator, the tank port
T remaining closed
 In other extreme spool position, the oil from
the actuator is allowed to pass from A to T and
P remains closed
 The valve alternately connects and disconnects
oil supply to the tank
 The valve has 3 ports
and takes two distinct
positions it is called
3/2 DCV
 Direction Control Valves
2, 3 and 4-way DCV
 4 way DCV has 4 ports P, A, B & T
 In one extreme spool position, P connects to A
& B to T
 In other extreme spool
position, A connects to
T and P to B
 The valve is called
4/2 DCV
 Direction Control Valves
Position of The Valve
 It does not refer to the location and
orientation of the valve but refers to the
position of the internal moveable parts of the
valve
 2 OR 3 positions
0 position or Neutral position
1 operating position
2 operating position
 DCV with spring return, the neutral (0)
position is the position to which the valve
returns after the actuating force has been
removed
 Other positions are 1, 2, etc.
 Generally valve has 2 positions & sometimes 3
position with neutral position
 Direction Control Valves
Position of The Valve
 The starting position is defined as the
position taken up by the valve after being
fitted into an installation, when the pump is
switched on
 Direction Control Valves
Valve Spool
 Consists of a shaft with two, three or four
lands
 Mostly used 2-land for low rating or 4-land
spool for higher rating
 As per functional use the
spools are as follows:
i. Fully locking spool
ii.Open center spool
iii.Partial open center spool
iv.Fully by-pass spool
v. Partial by-pass spool
 Direction Control Valves
Centre Conditions of Spool Valves
 DCVs may have a centre position designed to
satisfy need or condition of the system
performance
 Varieties of centre positions are possible
 The valves can be classified as:
1.Open centre valve
2.Closed centre valve
3.Tandem centre valve
4.Float centred valve
 Apart from this these positions can be possible
1.T closed but P opened to A & B
2.P & B closed, A opened to T
3.A closed P, B and T opened
4.P opened to A, B and T closed, etc.
 Direction Control Valves
Open Centre Valve
 All ports P, A, B & T are open to each other
 Allow free movement of an actuator when flow
from the pump is returned to the tank at low
pressure
 Generate less heat
 No other cylinder can operate when the valve is
centred and mostly used for a single cylinder
 Direction Control Valves
Close Centre Valve
 All ports P, A, B & T are blocked to each other
 The motion of an actuator can be stopped
 A number of individual cylinders can be
operated independently from a single power
source
 The pump cannot be unloaded to the tank
 Leakage may take place through the land to the
ports A and B and even port T & reducing the
locking pressure
 Direction Control Valves
Close Centre Valve
 Direction Control Valves
Tandem Centre Valve
 Here P and T get connected and A and B get
blocked
 The pump flow is unloaded to the tank through
the port T without passing through the PRV and
thus generating less heat
 There exists a pressure differential between P
and T to the amount of 3 to 4 bar
 Direction Control Valves
Tandem Centre Valve
 When a no. of cylinders are operated from a
single source, the pressure difference for each
tandem centre valve will be 3-4bar
 Direction Control Valves
Float Centre Valve
 Allow independent operation of cylinders
connected to the same power source
 Facilitate free motion of each cylinder at
start
 No pressure will build up in the cylinder lines
 The load cannot be locked in the position
 Pilot operated check valve can be used to
ensure positive locking
 Direction Control Valves
Float Centre Valve
 Direction Control Valves
Other Centre Conditions
 Direction Control Valves
Overlap in Sliding Spool Valve
 Longitudinal difference between the land length
and port length
 Overlap in unoperated as well as operated
condition
 Underlap is opposite to overlap i.e. negative
overlap
 Direction Control Valves
Overlap in Unoperated Condition
 Leakage quantity between two pressure chambers
is dependent on geometrical accuracy of the
spool and amount of overlap
 Leakage is much higher if clearance is more
 Direction Control Valves
Negative Overlap in Operated Condition
 During operation all passages are momentarily
opened
 No pressure peak so no shock during start &
stop
 Soft switching
 Less stress of the parts
 Certain loss of pressure liquid
 Pressure collapse
 Direction Control Valves
Positive Overlap in Operated Condition
 All passages are momentarily closed
 No collapse of pressure
 No loss of liquid under pressure
 Ensured locking of connecting load
 Pressure peaks and hits during start of
switching
 Direction Control Valves
DCV Specification
1. Rated flow
2. Material – for body, spool or valving element,
seal
3. Rated pressure
4. Type of solenoids – AC or DC
5. Solenoid power – 12 VDC, 24 VDC, 120 VAC
6. Internal pilot supply
7. Spring centred or not
8. Outlet and inlet port size
9. Open or closed centre application
10.3-way or 4-way spool
11.Style of mounting
12.Pressure drop across the port – 2 to 2.5 bar
 Flow Control Valves
Non-return Valves
 Also known as check valves
 Block the reverse flow
 Check valve with a heavy spring may act as a
pressure control valve
 Consist inlet and outlet valve and an internal
moveable member biased by the spring
 Poppet is pushed off its seat allowing oil to
flow
 The spring pushes the poppet back on the seat
to block the flow
 Flow Control Valves
Non-return Valves
 Can be direct acting or pilot operated
 A pilot operated valve is used where the no-
flow characteristics of the valve is desired
only for a portion of the system cycle
 It has valve body with inlet & outlet ports,
moveable poppet or ball, a spring
 Opposing the valve poppet is a plunger and
plunger piston biased by a light spring
 When the pilot operated through the port, this
spring unseats the valve poppet permitting the
reverse flow
 Flow Control Valves
Non-return Valves
 Fig (a) and (b) show the application of check
valves in the pump suction and delivery line
 Fig (c) shows a check valve in the system
return line
 Fig (d), the check valve isolates the high
pressure from the low pressure pump
 Fig (e), a constant flow can be maintained in
both directions by using them in a bridge
 Flow Control Valves
Non-return Valves
 Flow Control Valves
Non-return Valves
 Pressure Control Valves
Pressure Control Valves
 Perform the following functions
1. Limiting max. system pressure
2. Regulating/Reducing pressure in certain
portion of the circuit
3. Unloading system pressure
4. Assisting sequential operation of actuators in
a circuit with pressure control
5. Any other pressure related function by virtue
of pressure control
 Classified according to their function, type of
connection, size and pressure operating range
as relief valve, sequence valve, unloading
valve, pressure reducing valve, etc.
 Pressure Control Valves
Pressure Relief Valve
 Found in every hydraulic system
 Normally closed valve connected between the
pressure line and the oil reservoir
 To limit the pressure in
a system to a prescribed
max. by diverting some or
all of the pump output to
the tank when the designed
set pressure is reached
 A ball or poppet held
seated in the valve body
by the compressive force
of a heavy spring
 Pressure Control Valves
Pressure Relief Valve
 When the pressure at the inlet is insufficient
to overcome the force of the spring the valve
remains closed
 When the preset pressure is reached, the ball
unseats and allows flow through the outlet to
the tank
 An adjustable screw is provided to vary the
spring force
 The pressure at which the valve first opens is
called the cracking pressure
 Pressure Control Valves
Pressure Relief Valve
 Flow through the valve increases, the poppet is
forced further, the resulting pressure
increasing
 The diff. between the full flow pressure and
initial pressure may be
objectionable to the system
 The cracking pressure and
closing pressure is not same
 Pressure Control Valves
Pilot Controlled Pressure Relief Valve
 Direct controlled PRV is used where the flow
rate and the system pressure are smaller or
there is not much variation in system pressure
or flow rate
 Indirectly operated valve or pilot operated
valve is used for large flow rate and high
pressure
 Also known as compound relief valve
 A small pilot relief valve and main relief
valve
 Operates in a two stage processes
1. The pilot relief valve opens when a preset max
pressure is reached
2. When the pilot relief valve opens, it makes
the main relief valve open
 Pressure Control Valves
Pilot Controlled Pressure Relief Valve
 The pilot-operated pressure-relief valve has a pressure port that is
connected to the pump line and the tank port is connected to the
tank
 The pilot relief valve is a poppet type
 The main relief piston has an orifice drilled through it. The
piston has equal areas exposed to pressure on top and bottom and
is in a balanced condition due to equal force acting on both the
sides
 It remains stationary in the
closed position
 The piston has a light bias spring to
ensure that it stays closed
 When the pressure is less than
that of relief valve setting, the
pump flow goes to the system
 Pressure Control Valves
Pilot Controlled Pressure Relief Valve
 If the pressure in the system becomes high enough, it moves the
pilot poppet off its seat
 A small amount of flow begins to go through the pilot line back
to the tank
 Once flow begins through the piston orifice and pilot line, a
pressure drop is induced across the piston due to the restriction of
the piston orifice
 This pressure drop then causes
the piston and stem to lift off
their seats and the flow goes
directly from the pressure port
to the tank
 Pressure Control Valves
Pilot Controlled Pressure Relief Valve
 Pressure Control Valves
Pressure Sequence Valve (PSV)
 Used in a hydraulic system to cause various
operations in a sequential order i.e. one after
another
 For example a PSV is used in a clamping and
machining circuit
 Will cause actions to take place in a definite
order and also to maintain a predetermined
minimum pressure in the primary line when the
secondary operation has to occur
 The fluid flows freely through the primary
passage to operate the first phase until the
pressure setting of the PSV is reached
 As the spool lifts, flow is diverted to the
secondary port to operate the second phase
 Pressure Control Valves
Pressure Sequence Valve (PSV)
 Pressure Control Valves
Pressure Sequence Valve (PSV)
 Pressure Control Valves
Counter Balance Valve
 Used in a hydraulic system to control over a
vertical cylinder so that it will not fall
freely because of gravity
 The primary port is
connected to the lower
cylinder port and the
secondary port to the
DCV
 The pressure setting is
slightly higher than is
required to hold the load
from falling
 Also known as back
pressure valve
 Pressure Control Valves
Counter Balance Valve
 When the pump delivery is delivered to the top
of the cylinder, the cylinder piston is forced
down causing pressure at
the primary port to
increase and raise the
spool, opening a flow
path for discharge through
the secondary port to the
DCV and to the tank
 When the cylinder is
being raised, the check
valve opens to permit
force flow for returning
the cylinder
 Pressure Control Valves
Pressure Reducing Valve
 Normally open valve
 To maintain reduced pressure in certain portion
of the system
 Actuated by the pressure
sense in the branch
circuit and tend to close
as it reaches the pressure
of the valve setting
preventing further build-
up of pressure
 A direct acting valve has
a spring loaded spool to control the down
stream pressure
 If the main supply pressure is below the valve
setting, fluid flow freely from inlet to outlet
 Pressure Control Valves
Pressure Reducing Valve
 AN internal connection from the outlet passage
transmits the outlet pressure to the spool end
opposite the spring
 When the outlet pressure
rises to the valve setting
the spool moves to partly
block the outlet port
 Only enough flow is passed
to the outlet to maintain
he preset pressure
 A separate drain passage
is provided to return the flow to the tank
 Pressure Control Valves
Pressure Reducing Valve
 Pressure Control Valves
Unloading Valve
 A PRV requires full system pressure to open
thereby causing higher quantity of energy loss
due to heat
 The unloading valve may be used to unload the
energy at a low pressure
 The primary port pressure in such a valve is
independent of the spring force because the
remote pressure operates the spool
 These valves are used in systems where two
pumps provides a large volume of oil at low
pressure and one of them must be unloaded
during a specific period requiring only a small
volume of oil at high pressure
 Save the system from undesired heat energy to a
great extent
 Pressure Control Valves
Unloading Valve
Pressure Control Valves
 Speed Control Device
 The speed of hydraulic actuators is changed by
varying the port opening of the FCV
 The FCV regulates the fluid flow by enlarging
or reducing the port area while the oil is
passing through the passage
 The FCVs could be either:
a) Throttle valve or flow restrictors which are
pressure dependent
b) FCVs which are pressure independent
 The fluid flowing to an actuator can be varied
i. By used of a VDP which is relatively simple
but quite an expensive method
ii.By using an orifice control i.e. by using a
simple flow restriction in the line of fluid
flow. The flow rate is influenced by the
pressure drop across the orifice i.e. the rate
 Speed Control Device
of flow varies as the load changes
iii. by using a pressure compensated FCV i.e.
maintain a constant flow rate regardless the
pressure drop across the orifice
 Flow Control Valve
Principle of Flow Control
 The flow rate Q and linear cylinder velocity is
related by the formula
v = Q / A
 For a constant speed require a constant flow
rate
 For a simple regulation of speed, a throttle
valve is used (depending on the pressure)
 The speed of the cylinder is to be constant and
independent of pressure drop, a pressure
compensated FCV is to be used
 Flow Control Valve
Throttle Valve
 Controls the flow rate Q by increasing or
decreasing the area of flow path
 Can be a fixed or variable throttle
 Q depends on the ΔP
 As the work resistance due to the load to be
moved by the actuators has influence on the
change in pressure, the velocity of flow cannot
be kept constant with a normal throttle valve
 Fixed throttles are generally inserted directly
in the pipe line
 The l/d ratio of the throttle orifice may
influence Q and ΔP
i. l/d ratio is large - Q and ΔP depends on the
viscosity of oil
ii. l/d ratio is small - Q and ΔP independent
 Flow Control Valve
Throttle Valve
 Flow Control Valve
Throttle Valve
 If the resistance due to
work is kept constant,
a constant speed is
possible by a throttle
valve only
 A non-return valve can be
in-built with a throttle
valve to provide regulated
flow in one direction and
full flow from the opposite
direction
 Flow Control Valve
Flow Regulation Valve (ΔP Independent)
 Precision machine tools and other equipment
need a constant speed free from influence of
external resistance and temperature
 A pressure compensated FCV provides a stepless
adjustable speed control
 Allow a constant predetermined amount of oil
(Q) independent of pressure drop and temp.
across the valve
 The following conditions must be fulfilled
i. Constant ΔP
ii.The form of the throttle should be such that
the influence of viscosity is minimum or
insignificant
 Flow Control Valve
Flow Regulation Valve (ΔP Independent)

Fsp
 Flow Control Valve
Flow Regulation Valve (ΔP Independent)
 The pressure compensated FCV has actually two
valves arranged in a series which are throttle
valve and pressure compensating valve
 Throttle, spring loader of spool (compensating)
and the spool
 The pressure compensation can be positioned
inside the valve before or after the throttle or
can also be arranged parallel to the throttle
 By equating the force against the spool, we get
P1 x A = A.P2 + Fsp
A.(P1-P2) = Fsp
ΔP = (P1-P2) = Fsp/A
= Constant as Fsp and A both are constant
 The spring force determines the position of the
spool and amount of oil allowed through the valve
 Flow Control Valve
Flow Regulation Valve (ΔP Independent)
 Flow Control Valve
Flow Regulation Valve (ΔP Independent)
 Flow Control Valve
Flow Regulation Valve (ΔP Independent)

If Fsp is constant, ΔP is also constant

And hence the adjusted Q is constant.
Therefore the cylinder speed will also
Be constant
 Flow Control Valve
Position of A FCV
1. Meter-in-to control:
2. Meter-out-flow
 Flow Control Valve
Proportional Pressure & Flow Control Valve
 A new range of valves are being developed and
used in hydraulic systems
 Proportional Remote Controlled electro hydraulic
pressure and flow controlled valves are new
addition
 To control the pressure and flow rate
proportionately and provide remote function
 The variation in pressure and flow is effected by
varying the electrical input signal to a
proportional solenoid which is used to actuate
the valves
 Hydraulic Reservoirs
 A reservoir is relatively simple and to perform
some important duties
1. Storage of oil
2. Cooling of oil
3. Expansion of fluid
4. Separation of contaminants
5. Structural support
6. Easy access
 Can be classified as
1. Pressurized reservoirs – In normal machine tools
and other equipment
2. Non-pressurized reservoirs – In aviation and
other critical hydraulic systems
 Hydraulic Reservoirs
 Non-pressurized hydraulic reservoirs can be sub-
divided again into two categories:
1. Open type reservoir
2. Closed type reservoir

 Closed type is mostly used and available in

various designs e.g. square, rectangle,
spherical, cylindrical etc.
 Should be mounted on legs to raise the bottom of
the reservoir by at least 150 mm from the ground
level for better air circulation, easier
servicing and draining of oil during servicing
Hydraulic Reservoirs
 Hydraulic Reservoirs
 The top lid is to set at the top tight with
gasket against the entrance of contaminants like
dust, dirt, etc.
 The filler cap is opened for filling up the oil
 The sight glass is used to check the oil level
 A separating plate separates the return line from
the inlet pipe to minimize the problem of
contamination
 The return pipe should be cut at 45˚
 The manhole covers are needed in a reservoir to
enable easy cleaning of the reservoir which are
designed such that it cab ne removed and replaced
by a single person easily
 A suction filter is connected to the inlet pipe
going to the pump
 Hydraulic Reservoirs
 All pipes entering the reservoir enter vertically
from the top for easy pipe disconnection
 For proper cleaning of the tank, the bottom of
the tank should be dished out with a drain plug
 It is made of mild steel plate having a thickness
of 3 mm or above
 The reservoir capacity should not be less than 3
times of flow rate of the FDP or 3 times the mean
flow rate for pressure compensated variable
displacement pump
 Accumulators
 To store hydraulic energy and on demand make the
energy available to the system
 Termed as the capacitance of the system
 Used for
1. Shock suppression
2. Eliminating pressure ripple
3. Leakage compensation
4. Source of emergency power in case of power
failure
5. Holding high pressure for long period without
keeping the pump running
 Used in large hydraulic press, farm machinery,
diesel engine starter, hospital beds, landing
gear mechanism on aeroplanes, lift, trucks, etc.
 Accumulators
 To store hydraulic energy and on demand make the
energy available to the system
 Termed as the capacitance of the system
 Used for
1. Shock suppression
2. Eliminating pressure ripple
3. Leakage compensation
4. Source of emergency power in case of power
failure
5. Holding high pressure for long period without
keeping the pump running
 Used in large hydraulic press, farm machinery,
diesel engine starter, hospital beds, landing
gear mechanism on aeroplanes, lift, trucks, etc.
 Accumulators
Dead Weight Type Accumulator
 Consists a piston loaded with dead weight and
moving within a cylinder which exerts pressure on
the oil
 The piston pressure will remain constant because
the load remains unchanged
 The weight may be heavy material such as iron,
concrete block or even water
 The piston must be a precision fit in the
accumulator cylinder to minimize leakage
 They are not very popular due to large size
 Advantage is that they supply oil at constant
pressure
Accumulators
 Accumulators
HYDRO-PNEUMATIC Accumulator
 Most Commonly used
 Apply force to the liquid by using a compressed gas
which acts as a spring
 Only dry nitrogen is to be used
 Four types are used
1. Non-separator type
2. Piston
3. Diaphragm
4. Bladder
 Accumulators
Non Separator Hydro-Pneumatic Accumulator
 Consists of a cylinder with hydraulic fluid and the
charging gas with no separation between them
 Generally used on die casting machines or other
similar places
 Always mounted vertically

Piston Type Hydro-Pneumatic Accumulator

 Consists of a cylinder body and a moveable piston
 The gas occupies the volume above the piston is
compressed as the cylinder body is charged with
liquid
 Accumulators
Diaphragm type Hydro-Pneumatic Accumulator
 Consists of two metal hemispheres which are
separated by a flexible, synthetic rubber diaphragm
 Proper material for diaphragm is selected
 The storing is effected by the compression of the
volume of nitrogen enclosed in the diaphragm

Bladder Type Hydro-Pneumatic Accumulator

 Consists of a synthetic polymer rubber bladder like
chloroprene, nitrile, etc.
 The bladder is filled with compressed gas
 A poppet valve located at the discharge port closes
the port when the accumulator is completely
discharged
 It responds quickly for receiving or expelling flow
of oil
 Accumulators
Accumulators as an Auxiliary Power Source
 To store oil delivered by the pump during a portion
of work cycle, the accumulator then release this
stored oil on demand to complete the cycle
 Accumulators
Accumulators as a Leakage Compensator
 Used as a compensator for internal or external
leakage during an extended period of time during
which the system is pressurized but not in operation
 Accumulators
Accumulators as an Emergency Power Source`
 In some cases, a cylinder be retracted even though
the normal supply of oil pressure is lost due to a
pump or electrical power failure
 Use of an accumulator as an emergency power source
 Accumulators
Accumulators as a Hydraulic Shock Absorber
 In some cases, a cylinder be retracted even though
the normal supply of oil pressure is lost due to a
pump or electrical power failure
 Use of an accumulator as an emergency power source