Fluid Power System

Chapter 1

Power Systems-Introduction
Power systems are used to transmit and control power. The following are the basic Parts of a
power system.

1. Source of energy, delivering mechanical power of rotary motion.

2. Energy transmission, transformation, and control elements.

3. Load requiring mechanical power of either rotary or linear motion.

Classification of Power systems

 Mechanical Power Systems

 Electrical Power Systems

 Fluid Power Systems

Fluid Power System -Introduction

Fluid power is the use of fluids under pressure to generate, control, and transmit power. Fluid
power is subdivided into hydraulics using a liquid such as mineral oil or water, and
pneumatics using a gas such as air or other gases. Compressed-air and water-pressure systems
were once used to transmit power from a central source to industrial users over extended
geographic areas; fluid power systems today are usually within a single building or mobile
machine.
Advantages of Hydraulic systems
1. High power-to-weight ratio.

2. Easy and remote control

3. Force Multiplication

4. Stopping loads at any intermediate position.

5. Simple protection against overloading.

6. Possibility of energy storage in hydraulic accumulators.

7. Flexibility of transmission compared with mechanical systems.

8. Availability of both rotary and rectilinear motions.

9. Safe regarding explosion hazards.

Disadvantages of Hydraulics
1. Hydraulic power is not readily available, unlike electrical. Hydraulic generators are

therefore required.

2. Hydraulic system drawing is circuit, schematic, and symbolic drawings.

3. High cost of production due to the requirements of small clearances and high

precision production process.

4. Limitation of the maximum and minimum operating temperature.

5. Fire hazard when using mineral oils.

6. Oil filtration problems.

Advantages of Pneumatics
• High Effectiveness – use of compressed air in not restricted by distance & can easily be
transported.

• High durability and reliability – Extremely durable and not damaged easily.

• Simple Design - more suitable for use in simple automatic control systems.

• High adaptability to harsh environments - compressed air is less affected by high

temperature, dust, corrosion, etc.

• Safety - Because they can work in inflammable environment without causing fire or
explosion.

• Easy selection of speed and pressure

• Environment friendly - The operation of pneumatic systems do not produce pollutants.

• Economical - The costs of pneumatic systems are quite low.

Disadvantages of Pneumatics
• Relatively low accuracy - The volume of air may change when compressed or heated, the
supply of air to the system may not be accurate.

• Low loading - As the cylinders of pneumatic components are not very large, a pneumatic
system cannot drive loads that are too heavy.

• Processing required before use - Compressed air must be processed before use to ensure
the absence of water vapour or dust.
 • Uneven moving speed - As air can easily be compressed, the moving speeds of the
pistons are relatively uneven

• Noise - Noise will be produced when compressed air is released from the pneumatic
components.

Structure of Fluid Power Systems

The physical appearance of fluid power systems vary considerably, depending on the

type of fluid used application, and power output.

■ Power unit.

■ Actuators.

■ Control valves

Iine Diagram of Fluid Power System

Pneuamtics

Power Unit Control Actuator

Valve Atmosphere

Hydraulics

 Power Unit
The power unit group of components deals primarily with the energy-conversion function of the
system. The unit consists of a prime mover, pump, and reservoir. The prime mover is the source
of energy for the system. The energy produced by the prime mover turns the pump, which
produces fluid flow that transmits energy through the system. The reservoir serves as a storage
unit for system fluid. It also performs fluid maintenance functions.

 Actuators

The actuators group of components performs the work done by the system. These
components convert the energy in the system fluid to linear or rotary motion. The basic
actuators are cylinders for linear motion and motors for rotary motion. A variety of
cylinder and motor designs are used to produce the specific motion needed to complete the work
required of the system.

 Control Valves

Three different types of valves are required to perform the fluid control function in a fluid

power system. The valves in the control valves group are:

 Directional control valves.

 Pressure control valves.

 Flow control valves.

Directional control valves provide control over fluid flow direction in sections of a system to
start, stop, and change the direction of actuator Movement.

Pressure control valves are used to limit the maximum pressure of the system or in a section of
the system.

Flow control valves provide control over fluid flow rate in a section of a system to control the
rate of movement (Speed) of an actuator.
Basic Hydraulic system

Cylinder and
Piston

Directional
Control
Safety valve
Valve

Pump Motor

Tank

Filter
 Cylinder and
Piston
Basic Pneumatic system

Directional
Inetr cooler Control
Pressure Opening valve
Filter Switch valve

Pr.Gauge
To Atmosphere

Compressor
FRL Unit

Tank

Drain Plug

Sl.No Hydraulic System Pneumatic System

1 Oil is the working medium Compressed air is the working medium

2 More load capacity Less load capacity

3 Slow Speed More Speed

4 Self Lubrication External Lubrication

5 Closed loop system Open loop System

 6 Heavy and costly Light weight and Cheap

7 Costly Cheap

8 Leakage can be easily indentified Difficult to find the leakage

9 Oil Leakage is dangerous No dangerous of leaking air

Comparison between Hydraulic and Pneumatic system

 Basic Fluid Power Formulas / Hydraulics / Pneumatics

Variable Word Formula / Units Simplified Formula

Fluid Pressure - P P = Force / Area P = F/A

P=mass density x g x column height P= ρ x g x h

Fluid Flow Rate - Q Q= Flow in m3 / Unit Time (or) Volume/Time Q=V/T

Q=Area xVelocity Q=A x v

Fluid Power in Horsepower - HP Horsepower = Pressure (Pa) × Flow (m3/sec) HP = PQ

Actuator Formulas

Variable Word Formula / Units Simplified Formula

Cylinder Area - A A = π × Radius 2 A = π × R2

A = π × Diameter 2 / 4 A = π × D2 / 4

Cylinder Force - F F = Pressure (Pa) × Area (sq. m.) F = P×A

Cylinder Speed - v v(m / sec.) = (Flow Rate (Q)) / (Area (A)) v = Q /A

Cylinder Volume Capacity - V Volume = Cross Section Area(m2) × Stroke (m) V = π × Dd /4 × L

(L = length of stroke)
Torque (N.m) = Pressure (Pa) × displacement/Rev T = P × Vd

Torque = HP / RPM T = HP /N
Fluid Motor Torque - T
Torque = Flow Rate × Pressure × / RPM T = Q × P /N

Fluid Motor Speed - N Speed (RPM) = Q / Disp. n = Q/Disp

Fluid Motor Horsepower - HP HP = Torque (N.m)× rpm Rev/sec) HP = T × N

Pump Formulas

Variable Word Formula / Units Simplified Formula

Pump Output Flow Q Q=Speed (rpm) × disp. (m3/rev) Q = Vd x N (m3/min)

Pump Output Horsepower - HP HP = Pressure (Pa) x Discharge(Q) HP = P x Q

HP= ρgh x Q

Pump Volumetric Efficiency - ηV Volumetric Efficiency = Actual Flow Rate Output (QA)/ ηV= QA. / QT. X 100
Theoretical Flow Rate Output (QT) × 100
Hydraulics Basic Problem 1
1. A hydraulic system having the following data
i. Pump flow is 0.001896 m3/sec
ii. Oil specific gravity=0.9
iii. The air pressure at station 1 in the hydraulic tank is atmospheric pressure
iv. The inlet line to the pump is 4 m above the oil level
v. The pipe has a 0.03 m inside diameter.
vi. There is a 8 m head loss between
stations 1 and 2
Find the pressure at station 2

2. A hydraulic system having the following data

i. Pump flow is 0.001896 m3/sec
ii. Oil specific gravity=0.9
iii. The air pressure at station 1 in the
hydraulic tank is atmospheric pressure
iv. The inlet line to the pump is 6.25 m above
the oil level
v. The pipe has a 0.03 m inside diameter.
vi. There is a 8 m head loss between stations
1 and 2
 vii. The power added by the pump is 3.7 kW
Find the pressure at station 2