Fundamentals of Fluid Power System

Introduction
• Most industrial processes require substances to
be transformed from one place to another.
• Final products should be shaped (or)
compressed (or) held by applying a great force.
Such activities are performed by using prime
movers.
• The prime movers are operated by (i) electrical
system (ii) Hydraulic system (iii) Pneumatic
system.
• In electrical system, the rotary motion is
provided by simple motors.
 Fundamentals of Fluid Power System
• The linear motions can be obtained by
converting rotary motions with the aid of screw
jack (or) Rack and pinon.
• In ‘Hydraulic system, enclosed water (or) oil
can be used to convey energy from one
location to another. In Greek, hydra means
water.
• In Pneumatic system, enclosed gas (normally
compressed air) is used to transfer energy from
one location to another). In Greek, Pneumatic
means wind.
 Fundamentals of Fluid Power System
Hydraulic Principles
• All liquids used are non-compressible and can be
used to transmit power.
• When ever any load to be lifted resists flow of liquid.
This resistance to flow is nothing but pressure.
• Larger the capacity of the pump larger the lifting of
the weight.
• If the force developed in the hydraulic cylinder is
more than the external load, then the actuator lifts
the external load. Otherwise it does not lift load.
• The flow rate is nothing to do with the load carrying
capacity of the hydraulic system.
 Fundamentals of Fluid Power System
• In the operation of a hydraulic system, the
liquid always chooses the path of least
resistance.
• Some example.
• Fluid
• Fluid power is a term describing hydraulics and
pneumatics technologies.
• Fluid is a substance which is capable of flowing
• Both technologies use a fluid (liquid or gas) to
transmit power from one location to another.
• Hydraulics, the fluid is a liquid (usually oil),
 Fundamentals of Fluid Power System
• Pneumatics uses a gas (usually compressed air).
• Both hydraulics and pneumatics used for power
transmission.
• This uses technology of converting available
power to a more useable form and distributing it
to where it is needed.
• The common methods of power transmission
are electrical, mechanical, and fluid power
systems.
• Let us discuss fluid power system in detail
 Fundamentals of Fluid Power System
Advantages of Fluid Power System
• High horsepower-to-weight ratio
• Safety in-hazardous environments
• Force or torque can be held constant
• High torque at low speed.
• Pressurized fluids can be transmitted over long
distances and through complex machine
configurations with only a small loss in power
• Multi-functional control
• Elimination of complicated mechanical trains of
gears, chains, belts, cams, and linkages
 Fundamentals of Fluid Power System
• Motion can be almost instantly reversed
Applications of fluid power System
• Construction
• Mining,
• Agriculture,
• Waste handling and Reduction,
• Utility Equipments,
• Marine,
• Offshore equipment's
• Energy,
• Metal forming,
• Machine Tools,
• Military & Aerospace and Other Applications.
 Fundamentals of Fluid Power System
Types of fluid system
• Fluid transport system
Transport of water from reservoir to various
destinations using pipe lines.
Transport of oil in pipe from one place to other or
between two countries.
• Fluid power system
Oil used in equipments to acquire desire movement.
Compressed air in pneumatics for crane and other
device movements
 Fundamentals of Fluid Power System
Properties of fluids
• Density
The density of a fluid is its mass per unit volume:
Liquids are essentially incompressible
Density is highly variable in gasses nearly
proportional to the pressure.
• Viscosity
Viscosity is a measure of a fluid’s resistance to flow.
It determines the fluid strain rate that is generated
by a given applied shear stress.
 Fundamentals of Fluid Power System
• Cohesion
Intermolecular attraction between molecules of same
liquid
• Adhesion
 Attraction between molecules of liquid and molecules
of solid boundary in contact with liquid.
• Cavitation
Cloud of vapour bubble will form when liquid pressure
drops below vapour pressure due to flow
phenomenon
• Capillarity
Liquid rises into a thin glass tube above or below its
general level.
 Fundamentals of Fluid Power System
• Vapour pressure
Pressure exerted by vapour which is in equilibrium
with liquid
• Compatibility
Ability of hydraulic fluid to be compatible with the
system.
• Volatility
The degree and rate at which it will vapourize under
given conditions of temperature and pressure.
• Corrosiveness
Tendency to promote corrosion in hydraulic system
 Fundamentals of Fluid Power System
Types of Hydraulic Fluids
• Petroleum based oils
• Non-petroleum based hydraulic oils
Water, Glycols, Emulsions, Water Glycols,
Phosphate esters, Silicate esters and Castor oils.
Electrical System:
Electrical system have three basic choices;
 Solenoid, DC motor and AC induction motor
 Fundamentals of Fluid Power System
• Electrical system arrangements

Hydraulic Systems [Fluid- Liquid]:

Hydraulic systems are power –transmitting
assemblies employing liquid as a fluid for
transmitting energy
Transmits energy from one place to other to
accomplish tasks.
 Fundamentals of Fluid Power System
 Figure shows the simple circuit of a hydraulic
systems with basic components.
 Fundamentals of Fluid Power System
Functions of Components:
Hydraulic Actuator: It is a device used to convert
the fluid power into mechanical power to do
useful work.
Hydraulic pump: It is used to force the fluid to the
rest of the hydraulic circuit from the reservoir.
Valves: valves are used to control the direction,
pressure and flow rate of a fluid flowing through
the circuit.
Motor: It is required to drive the pump.
Reservoir: It is used to hold the hydraulic liquid
usually hydraulic oil.
 Fundamentals of Fluid Power System
Piping systems: It carries the hydraulic oil from
one place to another.
Fitters: Fitters are used to clean the hydraulic oil
used in that circuit.
Pressure regulator: Pressure regulator regulates
i.e maintains the required level of pressure in the
hydraulic fluid.

Working Principle
 Fundamentals of Fluid Power System
Advantages:
Large load capacity with almost high accuracy and
precision.
Smooth movement
Automatic lubricating provision to reduce wear.
Division and distribution of hydraulic power is
simpler and easier than other forms of energy.
Limiting and balancing of hydraulic forces are
easily performed.
 Fundamentals of Fluid Power System
Disadvantages:
Hydraulic Elements needs to be machined to a
high degree of precision.
Leakage of Hydraulic Oil poses problems to
hydraulic operators.
Special treatment is needed to protect them from
rust, corrosion, dirt etc
Hydraulic oil may pose problems if it disintegrates
due to aging and chemical deterioration.
Hydraulic oils are messy and almost highly
flammable.
 Fundamentals of Fluid Power System
Pneumatic Systems [Fluid- Compressed Air]:
 Pneumatic system carries power by employing
compressed gas generally air as a fluid medium.
 Used for transmitting the energy from an energy –
generating source to an energy–use area to
accomplish the work.
 Fundamentals of Fluid Power System
• Figure shows the simple circuit of a pneumatic system with basic
components.

Functions of Components:
 Pneumatic actuator: It converts the fluid power into mechanical
power to do useful work.
 Compressor: It is used to compress the fresh air drawn from the
atmosphere.
 Fundamentals of Fluid Power System
 Storage / Reservoir: It is used to store a given volume of
compressed air.
 Valves: It is used to control the direction, flow rate and
pressure of compressed air.
 Motor: It is used to drive the compressor.
 Piping system: It carries the pressurized air from one
location to another.
Working Principle:
• It is a open loop type as the air after the work done is
simply vented to the atmosphere.
• Air is drawn from the atmosphere through air filter
and raised to required pressure by an air compressor.
 Fundamentals of Fluid Power System
• As the pressure rises, the temperature also rises and
hence air cooler is provided to cool the air with some
preliminary treatment to remove the moisture.
• Then the treated pressurized air needs to get stored
to maintain the pressure. With the storage reservoir,
a pressure switch is fitted to start and stop the
electric motor when pressure falls and reached the
required level, respectively.
• The three-position change over control valve
delivering air into the cylinder operates in a similar
any to its hydraulic circuit.
 Fundamentals of Fluid Power System
Advantages:
• Low inertia effect of pneumatic components due to
light density of air.
• Systems is light in weight.
• Comparatively easy operations of valves.
• Power losses and leakages are less in pneumatic
systems.
• Low Cost.
Disadvantages:
• Suitable only for light loads or small loads.
• 2) Availability of the assembly components is doubtful
 Fundamentals of Fluid Power System
Comparisons of Hydraulic, Pneumatic and Electrical
Systems
Description Electrical/ Hydraulic Pneumatic system
electromechanical system system
Energy Electrical energy is used to Electrical energy Electrical energy is
drive the electric motors is used to drive used to drive the
the hydraulic motor of the
pumps, which compressor, which
pressurizes the compresses the
liquid. air/gas
Medium There is no medium used in Pressurized liquid Compressed air/ gas
this system, rather the energy
is transmitted through the
mechanical components
Energy Batteries (Limited) Accumulator Reservoir (Good)
storage (Limited)
 Fundamentals of Fluid Power System
Description Electrical/ Hydraulic system Pneumatic
electromechanical system
system
Regulators Variable frequency Hydraulic valves Pneumatic valves
drives.
Transmitters Transmitted through the Transmitted Transmitted
Mechanical components through hydraulic through Pneumatic
like gears, cams, screw- cylinders, and cylinders,
jack, etc hydraulic rotary Pneumatic rotary
actuators. drives, and
Pneumatic rotary
actuators.
Distribution Excellent, with minimal Limited, basically Good, can be
system loss a local facility. Up treated as a plant
to 100 m, flow wide service. Up
rate(v)= 2-6 m/s to 1000 m, flow
rate(v) = 20-40
m/s
 Fundamentals of Fluid Power System
Description Electrical/ Hydraulic system Pneumatic system
electromechanical
system
Positioning Precision to up to ± μm Precision up to ±μm Without load
accuracy and easier to achieve. can be achieved change, precision of
depending on 0.1 mm is possible
expenditure.
Stability Very good values can be High, since oil is Low, since air is
achieved using almost compressible
mechanical links incompressible and
pressure level is
considerably high
Forces Not over-loadable. Poor Protected against Protected against
efficiency due to overload, with high overload. Forces are
downstream mechanical system pressure of up limited by
elements. Very high to 600 bars, very pneumatic pressure
forces can be realized large forces can be and cylinder
generated. F<3999 diameter. F < 30 k
kN N at 6 bar
 Fundamentals of Fluid Power System
Description Electrical/ Hydraulic system Pneumatic system
electromechanical
system
Energy cost lowest Medium Highest

Linear Short motion via solenoid, Hydraulic cylinders. Pneumatic

actuators otherwise via mechanical It can produce very cylinders. It can
conversion. high force. produce medium
force.
Rotary AC and DC motors – Hydraulic rotary Pneumatic rotary
actuators Simple and Powerful. drives and hydraulic drives and
AC motors – Cheap rotary actuators. Pneumatic rotary
DC motors – better control 1. Low speed actuators.
2. High turning 1. Wide speed range
moment 2. Accurate speed
3. Good control 3. Difficult to
control
 Fundamentals of Fluid Power System
Description Electrical/ Hydraulic system Pneumatic
electromechanical system
system
Controllable Possible with solenoid Controllable, Controllable,
force and DC motors. Needs high force medium force
cooling, hence
complicated.
Work Danger, because of Dangerous, Noisy
environment electric shock unsightly and fire
hazardous
because of
leakage
 Fundamentals of Fluid Power System
Pressure
• Pressure occurs in a fluid when it is subjected to a force.
• If a force F is applied to an enclosed fluid via a piston of area
A results in to pressure P in the fluid.
• Pressure in the fluid can therefore be defined as the force
acting per unit area.
• P = F/A
Pascal's law:
• Pascal's law states that, the fluid at rest in a closed container,
a pressure change in one part is transmitted without loss to
every portion of the fluid and to the walls of the container.
• The principle was first enunciated by the French
scientist Blaise pascal.
 Fundamentals of Fluid Power System
• According to Pascal’s principle, in a hydraulic system
a pressure exerted on a piston produces an equal
increase in pressure on another piston in the
system.
• If the second piston has an area 10 times that of the
first, the force on the second piston is 10 times
greater, though the pressure is the same as that on
the first piston.
• Pressure in an enclosed fluid can be considered
uniform throughout a practical system
• This is illustrated in below Figure(a).
 Fundamentals of Fluid Power System

Fig(a): Forces and pressure in closed tanks Fig(b): Mechanical advantage

• By pascal’s law fluid contained in a vessel exerts

equal pressure at each point of the container.
• So,in fig b : P1=F1/A1 = P2= F2/A2 hence, F2 =2000
kgf.
Components of Hydraulic and Pneumatic System
Hydraulic Pump:

(i)Operation of Pump (ii) Pump symbol

• A hydraulic pump takes oil from a tank and delivers

it to the rest of the hydraulic circuit.
• In doing so it raises oil pressure to the required
level.
Components of Hydraulic and Pneumatic System
• Hydraulic pumps are generally driven at constant
speed by a three phase AC induction motor
• Fluid is drawn at the axis of the pump, and forced
out to the periphery by centrifugal force.
• The fluid flow into the oil circuit and due to load the
pressure is maintained at the pump exit.
Types of hydraulic pumps:
• 1. Centrifugal pump
• 2. Positive displacement pump
 Components of Hydraulic and Pneumatic System
• Positive Displacement Pump Can be further
classified as
• (a) Gear Pump (b) Vane Pump (c) Piston Pump

• (a) Gear pump

• i) External gear pump
• ii) Lobe pump
• iii) Internal gear pump
• iv) Gerotor pump
 Components of Hydraulic and Pneumatic System
• (b) Vane pump
• i) Unbalanced vane pump
• ii) Balanced vane pump
• iii) Variable displacement vane pump
• (c) Piston pump
• i) Simple single piston pump
• ii) Radial piston pump.

• ii) Radial piston pump.

• a)Piston pump with stationary cam and rotating block.

• b)Piston pump with rotating cam and stationary block

Components of Hydraulic and Pneumatic System
1. Centrifugal Pump:

• Fluid is drawn into the axis of the pump, and flung

out to the periphery by centrifugal force.
• Flow of fluid into the load will maintains the
pressure at the pump exit.
• This device is also known as hydrodynamic pumps.
 Components of Hydraulic and Pneumatic System
2. Positive Displacement Pump:
a) Gear Pump:
i) External Gear Pump:

• The simplest and most robust positive displacement

pump, having just two moving parts,
• Its parts are non-reciprocating, move at constant
speed and experience a uniform force
 Components of Hydraulic and Pneumatic System
• Fluid is trapped between the outer teeth and the pump
housing, causing a continual transfer of fluid from inlet
chamber to outlet chamber where it is discharged to the
system.
• The gear pump obviously requires closely meshing
gears, minimum clearance between teeth and housing
and also between the gear face and side plates.
• Often the side plates of a pump are designed as
deliberately replaceable wear plates.
• Gear pumps are used at pressures up to about 150 bar
and capacities of around 150 gpm (6751 min-1).
• Volumetric efficiency of gear pumps at 90% is lowest of
the three pump types.
Components of Hydraulic and Pneumatic System
ii) Lobe Pump:

• There are some modifications of the basic gear

pump.
• The gears have been replaced by lobes giving a
pump name called a lobe pump.
• Working principle is same as external gear pump.
Components of Hydraulic and Pneumatic System
iii) Internal gear pump:

• It is another variation of gear pump is called the

internal gear pump.
• Where an internal driven gear wheel is connected
to an larger external gear.
• The fluid enters as the gears disengage being
performed by a crescent-shaped molding.
Components of Hydraulic and Pneumatic System
• Creates low pressure area and high pressure area
• At low pressure fluid enters the pump and due to
high pressure the fluid delivered.
iv) Gerotor pump:

• Another variation on the same theme is the gerotor

pump.
• Where the crescent molding is dispensed with by
using an internal gear with one less tooth than the
outer gear wheel.
Components of Hydraulic and Pneumatic System
• Internal gear pumps operate at lower capacities and
pressures (typically 70 bar) than other pump types.
b)Vane Pump

i)Un Balanced Vane Pump:

Working Principle:
Components of Hydraulic and Pneumatic System
ii) Balanced vane pump :

iii) Variable displacement vane pump

 Components of Hydraulic and Pneumatic System
(c) Piston pump
i) Simple single piston pump

ii) Radial piston pump.

a)Piston pump with stationary cam and rotating block.
Components of Hydraulic and Pneumatic System
b)Piston pump with rotating cam and stationary block
Components of Hydraulic and Pneumatic System

• Pressure regulation in Hydraulic system

 Components of Hydraulic and Pneumatic System

Simple Pressure Regulator Balanced Pressure Relief Valve

 Components of Hydraulic and Pneumatic System
Types of Compressors:
• 1. Centrifugal
• 2. Positive displacement
a)Reciprocating
• i)Piston
• ii)Diaphragm
b)Rotary
• i) Screw
• ii) Vane
• iii) Lobe
• iv) Gear
Components of Hydraulic and Pneumatic System

• Piston type reciprocating compressor

Components of Hydraulic and Pneumatic System

• Screw Compressor
Components of Hydraulic and Pneumatic System

• Rotary Vane Compressor

Components of Hydraulic and Pneumatic System
Filter Regulator and lubricating (FRL) Unit
• A pneumatic filter should be the first component at
the inlet of most air circuits.
• This unit usually is one part of a combination of
components that filters the air, regulates its pressure,
and adds lubricants to air stream for moving parts in
the circuit.
Components of Hydraulic and Pneumatic System
Pneumatic Filter
• Prevents foreign particles and cotamination entering
the pneumatic system
• Filters are classified as full flow or partial flow
 Components of Hydraulic and Pneumatic System
Pneumatic Regulator
• Once a minimum suitable operating pressure has been
determined for any compressed air application.
• It is essential to supply the air at a constant pressure,
regardless of upstream flow and pressure fluctuations.
• Air regulators are special valves that reduce supply pressure to
the level required for efficient operation pneumatic
equipment.
Components of Hydraulic and Pneumatic System
Lubricator
• The function of the lubricator is to insert drops of oil
into the air stream.
• The air-oil mixture starts moving towards toward its
final destination (Actuators).
 Components of Hydraulic and Pneumatic System
Air Dryers
• The function of air dryer is to remove all water/moisture
from the air leaving the compressor
• The moist air passes at one end, passes through
chemical agent and passes out at other end.
• The chemical agent absorbs moisture and slowly
dissolves it as a liquid. Then the liquid is collected/
drained at bottom of the unit.
Types of air dryer
• Refrigerated dryer
• Deliquescent dryer
• Absorption dryer
 CONTROL VALVES

Figure 2.1: Valves in a hydraulic system Figure 2.2: Valves in a Pneumatic system

Figure 2.3: Internal valve operation

 Valve Control Positions

Figure 2.4: Valve control positions Figure 2.5: Possible valve action for a 4/3 valve
 Graphic symbols
• Graphic symbols show component function without
showing the physical construction of each device.
• For example a 3/2 spool valve and a 3/2 rotary valve
with the same function have the same symbol; despite
their totally different constructions.
• A valve is represented by a square for each of its
switching positions

Figure 2.6: Basis of graphic symbols

 Port and its naming letters
Port and Designation
Port Designation
Working lines A, B, C and so on
Pressure (power) supply P
Exhaust/Return R, S, T and so on
(T normally used for hydraulic systems,
R and S for pneumatic systems)
Control (Pilot) Lines Z, Y, X and so on
 Valve Symbols
• Arrow-headed lines represent direction of
flow

Figure 2.7: Valve symbols

 Valve Symbols
• Figure 2.8 shows symbols for the various ways in which valves can be
operated
• Figure 2.9 thus represents a 4/2 valve operated by a pushbutton.
• 2.10 represents a solenoid-operated 4/3 valve, with spring return to
centre.

Figure 2.9: Pushbutton extend, spring retract

when pushbutton released

Figure 2.10: 4/3 valve, solenoid operated,

Figure 2.8: Actuation symbols spring return to centre. Pressure line unloads
to tank and load locked in centre position
 Infinite Position Valve

2. Infinite Valve

Figure 2.11: Infinite position valve symbol - Pressure relief valve

 Types of control valve:

• There are essentially three types of control valve

1. Poppet valves
i. Simple 2/2 poppet valve
ii. 3/2 poppet valve
iii. 4/2 poppet valve
2. Spool valves
i. Two-way spool valve
ii. Four-way spool valve
3. Rotary valves.
4. Two-stage (or) pilot operated valve
 Poppet Valves
• Different Types of Poppet Valves

Figure 2.12: 2/2 poppet valve Figure 2.13: 3/2 poppet valve Figure 2.14: 4/2 poppet valve
 Spool Valve
• Two way spool valve

Figure 2.15: Two-way spool valve

Four way Spool Valve
Rotary Valves
Pilot operated Valve
 Actuators
• Linear actuator
 Actuators
Rotary Actuators Symbols
 Actuators
Gear pump actuators
 Actuators
Vane pump actuators
 HYDRAULIC RESERVOIRS
• Oil tank

Figure 2.24: Construction of a hydraulic reservoir

 Hydraulic Accumulators
• Different Type Accumulators

Figure 2.22: Weight loaded Accumulator Figure 2.23: Spring loaded Accumulator
Shell and Tube Heat Exchanger
Cross Flow Heat Exchanger
Symbols
 PNEUMATIC PIPING, HOSES AND
CONNECTIONS

Figure 2.27: Manifold Figure 2.28: Ring Figure 2.29: Tap off
 HYDRAULIC PIPING, HOSING AND
CONNECTIONS

• Safety Factor = Bursting Pressure/operating Pressure

• If operating pressure is 60 bar the safety factor is 8

• If operating pressure is 60 to 150 Safety factor is 6
• If operating pressuring is above 150 bar safety factor is
4
Hydraulic Valves — Pressure — Flow — Direction Controls
Applications
• Fluid power is controlled primarily through the use of control
devices called valves.
• Hydraulic and pneumatic systems require control valves to direct
and regulate the flow of fluid from pump (or compressor to
hydraulic cylinders (or) hydraulic motors.
• The selection of these control devices depends on the type, size,
actuating technique and remote control capability. There are three
basic types of control valves.
(i) Direction control valves (ii) Pressure control valves (iii) Flow
control valves
• Direction control valves are used to determine the path of the fluid
through which it should travel within a given circuit.
• The control of fluid path is carried out by check valves, shuttle
valves and 2 way, 3 way and 4 way direction control valves.
 Hydraulic Valves — Pressure — Flow — Direction Controls

• Pressure control valves are used to protect the hydraulic system

against over pressure.
• The buildup of pressure is controlled by pressure relief, pressure
reducing, sequence, unloading and counter balance valves.
• The fluid flow must be controlled in the hydraulic circuits. The
control of actuator speeds depends on the flow rates. So to
control the actuator speed, the flow rate should be controlled
by using flow control valves.
• There are some practical differences between the hydraulic and
pneumatic direction control valves, even though the principle of
operation is the same.
• But the pressure and the flow control valves for both hydraulic
and pneumatic systems are same
 Speed Control Circuit

Meter-in circuit
Speed Control Circuit

Meter-out circuit
The Hydraulic Circuit of a Hydraulic Jack
 DESIGN OF PNEUMATIC CIRCUITS

• The pneumatic circuit of a Single-Acting Cylinder

Figure 2.33: Single-acting direct control circuit with shut-off valve, FRL unit, flow control return check of
filtered air and cushioning device.
 Pneumatic logic control systems
• Pnumatic logic circuits

Figure 3.1: AND Circuit Figure 3.2: OR Circuit Figure 3.3: NOT Circuit
On-delay timer and Off-delay timer

Timing-In Circuit
On-delay timer and Off-delay timer
Timing-Out Circuit
BACK PRESSURE SENSOR
PROXIMITY SENSOR
 SEQUENCE VALVES

Figure 3.8: Operating modes of a direct-

Figure 3.7: Direct-operated sequence valve
operated sequence valve
BASIC AIR LOGIC CIRCUIT DESIGN

Figure 3.6: Automatic cycling circuit

 Switches
Push button switches
Pressure switches
Limit Switches
Temperature switches
Solenoide:

Relays: