Chapter 4

Components Of A Hydraulic System

 CONTENTS

Components Of A Hydraulic System

4.1. Explain Hydraulic System

4.1.1 Explain the application of hydraulic system
4.1.2 Identify the advantages and disadvantages of hydraulics system

4.2 Explain Hydraulic Fluid

4.2.1 Task for hydraulic fluid
4.2.2 Types of hydraulic fluid
4.2.3 Characteristics of hydraulic fluid
4.2.4 Viscosity
4.3 Distinguish Graphic and Circuit Symbols
4.3.1 Sketch the ISO standard symbol of
hydraulic system’s components.
a. Pumps and motors
b. Directional control valves
i. Methods of actuation
ii. Port designation
c. Pressure valves
d. Flow control valves
e. Non-return valves
f. Cylinders
i. Single acting cylinder
ii. Double acting cylinder
g. Transfer of energy and conditioning of pressure
medium
i. Hydraulic pressure source
ii. Electric motor
iii. Reservoir
iv. Filter
v. Accumulator
h. Measuring devices
Pressure gauge
a. Combination of devices
i. Hydraulic power pack
4.4 Differentiate fixed and varied shifted pumps
4.4.1 Explain types of hydraulic pump
a. Gear pump
i. External gear pump
ii. Internal gear pump
a. Rotary vane pump
b. Piston pump

4.5 Differentiate types of valve.

4.5.1 Explain the function of hydraulic valves:
a. Directional control valve
b. Pressure control valve
c. Flow control valve
d. Non-return valve

4.6 Distinguish the types of actuator

4.6.1 Explain the functions of actuator:
a. Single acting cylinder
b. Double acting cylinder
 Basic Hydraulic Circuit

A simple open center hydraulic circuit The equivalent circuit schematic

The advantages of hydraulic systems over other methods of power transmission are-

•Simpler design.
In most cases, a few pre-engineered components will replace complicated mechanical linkages.

• Flexibility.
Hydraulic components can be located with considerable flexibility. Pipes and hoses instead of
mechanical elements virtually eliminate location problems.

• Smoothness.
Hydraulic systems are smooth and quiet in operation. Vibration is kept to a minimum.

• Control.
Control of a wide range of speed and forces is easily possible.

• Cost.
High efficiency with minimum friction loss keeps the cost of a power transmission at a minimum.

• Overload protection.
Automatic valves guard the system against a breakdown from overloading.

The main disadvantage of a hydraulic system is maintaining the precision parts when they are
exposed to bad climates and dirty atmospheres. [Protection against rust, corrosion, dirt, oil
deterioration, and other adverse environmental conditions is very important]
 The Four Primary Functions Of A Hydraulic
Fluid Include:

Task of a Transmit Power

Hydraulic Lubricate The System And Sealing The

Clearances, And Dissipating Heat .
Fluid
While Pressure Is Resistance Against Fluid Flow
In A Hydraulic Or Pneumatic System

Force Is Generated By The Application Of

Pressurized Fluid On Actuators. .
 Types of Hydraulic Fluid

HYDRAULIC FLUIDS HYDRAULIC FLUIDS HYDRAULIC FLUIDS SOME ENVIRONMENTS

BASED ON SYNTHETIC BASED ON MINERAL BASED ON VEGETABLE WITH SPECIAL
ESTERS OILS OILS REQUIREMENTS

HYDRAULIC FLUIDS AND

THE ENVIRONMENT
 • Synthetic esters are produced by a
chemical reaction between alcohol and
fatty acid.
• The environmental properties vary
HYDRAULIC significantly depending on which
FLUIDS alcohols and fatty acids are used.
• Modern hydraulic fluids that are
BASED ON biodegradable and have an
SYNTHETIC environmental classification tend to have
better technical properties than
ESTERS conventional mineral oils, and they can
also reduce energy consumption and
thereby contribute to lower carbon
dioxide emissions. This makes them an
efficient choice for many hydraulic
systems.
 • Mineral oil is the predominant base oil and is
HYDRAULIC generally divided into three groups: I, II and III.

FLUIDS • Group I is conventional solvent-refined mineral

oil.

BASED ON • Groups II and III are hydrocracked mineral oils,

purer in terms of sulphur impurities and with a
MINERAL higher viscosity than Group I.

OILS • Over the next few years we will see a transition

from Group I to Group II, as more refineries that
manufacture Group I oils are converted to
produce Group II or close down.
HYDRAULIC FLUIDS BASED ON VEGETABLE OILS

• A vegetable hydraulic oil is based on raw materials from the

plant kingdom, such as oil from rapeseed, turnip rape,
sunflower seeds or soy beans.
• Vegetable oils are always natural and have very good
environmental properties, but they are not currently widely
used due to their limited technical properties.
 • There are also hydraulic fluids designed for
SOME hydraulic systems in particularly demanding
areas.
ENVIRONMENTS
• One example is the food industry where, for
WITH SPECIAL obvious reasons, the fluids have to meet the
REQUIREMENTS very strictest demands on purity (they must
be approved for unintentional contact with
food), safety and technical performance.
• Other examples are mining, steel and aviation,
which all have extremely high demands on
fire safety.
 HYDRAULIC FLUIDS AND THE ENVIRONMENT

• A lot of the prejudices from the first generation of

inefficient environmental oils, which were based on
rapeseed, still remain today.
• Modern biodegradable, environmentally classified
hydraulic oils, which are usually based on synthetic
esters, generally offer better technical performance than
conventional mineral oils (which are not environmentally
classified), and now represent the most efficient choice
for most hydraulic systems.
 Characteristics of a Good Hydraulic
Fluid

• VISCOSITY • RUST AND CORROSION

• COMPRESSIBILITY PROTECTION
• WEAR RESISTANT • FOAM RESISTANCE
• OXIDATION STABILITY • DEMULSIBILITY
• THERMAL STABILTY • HYDROLYTIC STABILITY
• FILTERABILITY • SEAL COMPATIBILITY
• Viscosity
o Viscosity is a measure of a hydraulic fluid's
resistance to flow.
o It is a hydraulic fluid's most important
characteristic and has a significant impact on
the operation of the system.
o When a hydraulic oil is too thin (low
viscosity), it does not seal sufficiently. This
leads to leakage and wear of parts.
o When a hydraulic oil is too thick (high
viscosity), the fluid will be more difficult to
pump through the system and may reduce
operating efficiency.
o All hydraulic fluids must be able to retain
optimum viscosity during operation in cold
or hot temperatures, in order to consistently
and effectively transmit power.
 Compressibility

Compressibility is a measure of the amount of volume

reduction due to pressure. Although hydraulic oils are
basically incompressible, slight volume reductions can
occur under certain pressure ranges.

Compressibility increases with pressure and

temperature and has significant effects on high-
pressure fluid systems.

It causes servo failure, efficiency loss, and cavitation;

therefore, it is important for a hydraulic oil to have
low compressibility.
• Wear Resistance
o Wear resistance is a hydraulic fluid's ability to
reduce the wear rate in frictional boundary
contacts.
o Antiwear hydraulic fluids contain antiwear
components that can form a protective film on
metal surfaces to prevent abrasion, scuffing,
and contact fatigue.
o Antiwear additives enhance lubricant
performance and extend equipment life.
 Oxidation Stability

Oxidation stability is a hydraulic oil's

resistance to heat-induced degradation
caused by a chemical reaction with oxygen.

Hydraulic oils must contain additives that

counteract the process of oxidation, improve
the stability and extend the life of the fluid.

Without these additives, the quality of the

hydraulic oil will deteriorate quickly.
• Thermal Stability
o Thermal stability is the ability to resist breakdown at
elevated temperatures.
o Antiwear additives naturally degrade over time and this
process can be accelerated at higher temperatures.
o The result of poor thermal stability is the formation of
sludge and varnish which can clog filters, minimize flow and
increase downtime.
o In addition, as these antiwear agents decompose at high
temperatures, acids are formed which attack bronze and
yellow metals in piston pumps and other hydraulic system
components.
o Hydraulic oils can be formulated with very high levels of
thermal stability to minimize these issues and help extend
the life of the hydraulic fluid and the components of the
hydraulic system.
• Filterability
o Water can react with additives in hydraulic fluids
forming oil insoluble material.
o These contaminants can precipitate from the lubricant
and block filters, valves and other components
resulting in decreased oil flow or the system going on
bypass.
o Blockage can eventually result in unplanned
downtime.
o Hydraulic fluids are designed to be filtered with
modern filtration systems without fear of the additive
being depleted or removed from the system.
o This enables systems to stay clean without sacrificing
critical performance requirements such as antiwear,
rust protection or foam inhibition.
• Rust and Corrosion Protection
o In many systems, water can enter as
condensation or contamination, and mix with the
hydraulic oil.
o Water can cause rusting of hydraulic components.
In addition, water can react with some additives
to form chemical species which can be aggressive
to yellow metals.
o Hydraulic oil formulations contain rust and
corrosion inhibitors which prevent the interaction
of water or other chemical species from attacking
metal surfaces.
• Foam Resistance
o Foam results from air or other gases becoming
entrained in the hydraulic fluid.
o Air enters a hydraulic system through the
reservoir or through air leaks within the system.
o A hydraulic fluid under high pressure can contain
a large volume of dissolved or dispersed air
bubbles. When this fluid is depressurized, the air
bubbles expand and produce foam.
o Because of its compressibility and poor
lubricating properties, foam can seriously affect
the operation and lubrication of machinery.
Proper foam inhibitors modify the surface tension
on air bubbles so they more easily break up.
• Demulsibility
o Water that enters a hydraulic system can mix or
emulsify with the hydraulic oil. If this 'wet' fluid is
circulated through the system, it can promote
rust and corrosion.
o Highly refined mineral oils permit water to
separate or demulsify quickly. However, some of
the additives used in hydraulic oils promote
emulsion formation, preventing the water from
separating and settling out of the fluid.
o Demulsifier additives are incorporated to
promote water separation from hydraulic fluids.
• Hydrolytic Stability
o When hydraulic fluids come into contact with
water, the water can interact with the additive
system of the hydraulic oil resulting in the
formation of acids.
o Hydraulic fluids that lack hydrolytic stability
hydrolyze in the presence of water to form oil
insoluble inorganic salts that can block filters and
valves inhibiting oil flow. This can result in
hydraulic system failure.
o Properly formulated hydraulic fluids are designed
to contain additives that are resistant to
interactions with water, helping to extend the life
of the equipment.
• Seal Compatibility
o Leaking hydraulic fluids can cause many issues from
simple housekeeping problems to more serious safety
concerns and lubrication failures.
o Most hydraulics systems utilize rubber seals and other
elastomers to minimize or prevent hydraulic oil
leakage. Exposure of the elastomer to the lubricant
under high temperature conditions can cause the
rubber seals to harden, crack and eventually leak.
o On the other hand, hydraulic oil exposure can seals to
swell excessively preventing hydraulic valves and
pistons from moving freely.
o Hydraulic oils are tested against a variety of seal
materials to ensure that the hydraulic fluid will be
compatible with seals under various conditions.
 1. FILTERS.
• A filter removes small foreign particles
from a hydraulic fluid and is most effective
as a safeguard against contaminants.

2. ACCUMULATORS.
• Like an electrical storage battery, a

COMPONENTS hydraulic accumulator stores potential

power, in this case liquid under pressure, for
future conversion into useful work.
OF A
3. PUMPS.
HYDRAULIC • Hydraulic pumps convert mechanical
energy from a prime mover (engine or
SYSTEM electric motor) into hydraulic (pressure)
energy.

4. HYDRAULIC ACTUATORS.
• A hydraulic actuator receives pressure
energy and converts it to mechanical force
and motion.
 5. VALVES

Valves are used in hydraulic systems to

control the operation of the actuators.

COMPONENTS 6. DIRECTIONAL CONTROL VALVE

They allow fluid flow into different paths

OF A from one or more sources. They usually
consist of a spool inside a cylinder which is
HYDRAULIC mechanically or electrically controlled. The
movement of the spool restricts or permits
SYSTEM the flow, thus it controls the fluid flow

7.MOTOR

A hydraulic motor is a mechanical actuator

that converts hydraulic pressure and flow
into torque and angular displacement
(rotation).
 ISO
SYMBOLS
 Pumps &Motors

Electric Motor
DCV – DIRECTIONAL
CONTROL VALVE

• A directional control valve is the

extend and retract control for
your hydraulic cylinders.
• It provides a flow path from the
pump to the cylinders and a return
path from the cylinders to the fluid
reservoir.
 PRESSURE
CONTROL VALVE

• Pressure-control valves are

found in virtually every hydraulic
system, and they assist in a
variety of functions, from
keeping system pressures safely
below a desired upper limit to
maintaining a set pressure in
part of a circuit.
• Types include relief, reducing,
sequence, counterbalance, and
unloading.
Flow Control valve
• The purpose of a flow
control valve is to regulate
the flow rate in a specific
portion of a hydraulic
circuit. In hydraulic
systems, they're used
to control the flow rate to
motors and cylinders,
thereby regulating the
speed of those
components.
 Non Return
valve
• Non-Return
Valves (also known
as check valves or one-
way valves) normally
allow fluid (liquid or gas)
to flow through them in
only one direction.
• These two-
port valves have two
openings in the body, one
for fluid to enter and the
other for fluid to leave.
CYLINDERS & HYDRAULIC MOTOR
DOUBLE ACTING CYLINDER

HYDRAULIC MOTOR
 RESERVOIR/TANK
The purpose of the hydraulic reservoir/tank is to hold a volume of fluid,
transfer heat from the system, allow solid contaminants to settle and
facilitate the release of air and moisture from the fluid.

TANK
FILTER

• A hydraulic
filtration system
includes hydraulic
filters to remove dirt and
particles on a continuous
basis.
 ACCUMULATOR

• Accumulators usually are

installed in hydraulic systems to
store energy and to smooth out
pulsations.

• Typically, a hydraulic
system with an accumulator can
use a smaller pump because
the accumulator stores energy
from the pump during periods of
low demand.
 Pressure gauge

Pressure gauge, instrument for PRESSURE INDICATOR

measuring the condition of a fluid
(liquid or gas) that is specified by
the force that the fluid would exert,
when at rest, on a unit area, such
as pounds per square inch or
newtons per square centimetre.
P T

Hydraulic Power
Ts
Pack
• Hydraulic power units
(sometimes referred to as a
hydraulic power pack) is a self-
contained system that generally
includes a motor, a fluid
reservoir, and a pump.
• It works to apply the hydraulic
pressure needed to drive
motors, cylinders, and other
complementary parts of a given
hydraulic system.
 TYPES OF HYDRAULIC PUMPS
A. GEAR PUMP
B. VANE PUMP
 C. PISTON

THE AXIAL PISTON PUMP

INTERNAL RADIAL PISTON MOTOR:

D. SKREW

 Screw pumps carry fluid in the

spaces between the screw
threads.
 The fluid is displaced axially as
the screws mesh.
 Method of Moving Valves
• A valve is a device that regulates, directs or
controls the flow of a fluid (gases, liquids,
fluidized solids, or slurries) by opening,
closing, or partially obstructing various
passageways. Valves are technically pipe
fittings, but are usually discussed as a
separate category.
 Typical Mechanical Valve
• Cross-sectional diagram of an open globe valve.
• 1. body
2. ports
3. seat
4. stem
5. disc when valve is open
6. handle or handwheel when valve is open
7. bonnet
8. packing
9. gland nut
10. fluid flow when valve is open
11. position of disc if valve were shut
12. position of handle or handwheel if valve were shut
 Typical Pneumatic Valve
• Pneumatic actuators are commonly used to actuate control valves and are
available in two main forms; piston actuators and diaphragm actuators .
Piston actuators
Piston actuators are generally used where the stroke of a diaphragm actuator
would be too short or the thrust is too small. The compressed air is applied to
a solid piston contained within a solid cylinder. Piston actuators can be single
acting or double acting, can withstand higher input pressures and can offer
smaller cylinder volumes, which can act at high speed.
Diaphragm actuators
Diaphragm actuators have compressed air applied to a flexible membrane
called the diaphragm. Figure shows a rolling diaphragm where the effective
diaphragm area is virtually constant throughout the actuator stroke. These
types of actuators are single acting, in that air is only supplied to one side of
the diaphragm, and they can be either direct acting (spring-to-retract) or
reverse acting (spring-to-extend).
 Typical Electrical Valves
• A solenoid valve is an electromechanically operated
valve. The valve is controlled by an electric current
through a solenoid

4. Coil /
1. Valve Body 7. Plunger
Solenoid

2. Inlet Port 5. Coil Windings 8. Spring

3. Outlet Port 6. Lead Wires 9. Orifice

 Functions of Controlled Valves
• Control valves are valves used to control
conditions such as flow, pressure,
temperature, and liquid level by fully or
partially opening or closing in response to
signals received from controllers that compare
a "setpoint" to a "process variable" whose
value is provided by sensors that monitor
changes in such conditions
• Directional control valves are one of the most fundamental parts in
hydraulic machinery as well and pneumatic machinery. They allow fluid
flow into different paths from one or more sources. They usually consist of
a spool inside a cylinder which is mechanically or electrically controlled.
The movement of the spool restricts or permits the flow, thus it controls
the fluid flow.
A flow control valve regulates the flow or pressure of a fluid. Control valves
normally respond to signals generated by independent devices such as flow
meters or temperature gauges.
A pressure regulator is a valve that automatically cuts off the flow of a liquid
or gas at a certain pressure. Regulators are used to allow high-pressure fluid
supply lines or tanks to be reduced to safe and/or usable pressures for various
applications.
 Actuators
• Hydraulic cylinder (also called a linear hydraulic motor) is a mechanical
actuator that is used to give a unidirectional force through a unidirectional
stroke. It has many applications, notably in engineering vehicles.
A hydraulic motor is a mechanical actuator that converts hydraulic pressure
and flow into torque and angular displacement (rotation).
The hydraulic motor is the rotary counterpart of the hydraulic cylinder.
Conceptually, a hydraulic motor should be interchangeable with a hydraulic
pump because it performs the opposite function - much as the conceptual DC
electric motor is interchangeable with a DC electrical generator.
However, most hydraulic pumps cannot be used as hydraulic motors because
they cannot be backdriven.
Also, a hydraulic motor is usually designed for the working pressure at both
sides of the motor.