PUMPS AND

ACTUATORS

RAMESH BATAKURKI
Why Use Fluid Power ?
•Multiplication & variation of force
•Easy, accurate control
•One power source controls many operations
•High power / low weight ratio
•Low speed torque
•Provides constant force and torque
•Safe in hazardous environments
 What is Fluid Power ?
•A system that transmits and controls energy
through the use of fluid
Liquid or Gas?
•Pneumatics - the media used is air
•Hydraulics - the media used is oil or water
 What can Fluid Power Do ?
• Operation of system valves for air, water, or chemicals
• Operation of heavy or very hot doors
• Unloading of hoppers in building, steel making, mining and chemical
industries
• Ramming and tamping in concrete and asphalt laying
• Lift heavy loads (i.e. forklifts and loaders)
 What can Fluid Power Do ?
• Lifting and moving in slab molding machines
• Crop spraying
• Paint Spraying
• Holding and moving parts or assemblies in manufacturing
 What can Fluid Power Do ?
 Jig (guides cutting tool) and Fixture
(stationary work holding) clamping
 Forming operations of bending, drawing
and flattening
 Bottling and filling machines
 Machine tool changing
 What can Fluid Power Do ?
• Component and material conveyor transfer
• Robots
• Dentist drills
• Vacuum lifting for thin sheet materials
• Store Energy
• …and much..much..more
Fluid Power Examples
Basic Fluid Power Components

Reservoir and Receiver

• Stores fluid before and after use
Fluid Conductors
• Pipe, tube, or hose for flow between components
Pump / Compressor
• Converts mechanical power to fluid power
Valve
• Controls direction and amount of flow
Actuators
• Converts fluid power to mechanical power
Fluid Power Principles
Rate of Flow
Determines actuator speed
Measured in gallons per minute (gpm)
Generated by a pump
 Fluid Power Principles
Flow
Makes actuator operation possible

Retracted cylinder

To extend the cylinder, flow is directed into Port B

 Fluid Power Principles
Flow
Makes actuator operation possible

Flow is directed into Port B

and cylinder is extended.

To retract the cylinder, flow must be directed how?

 Fluid Power Principles
Flow
Makes actuator operation possible

The cylinder retracts when

flow is directed into Port A.

To retract the cylinder, flow must be directed how?

Fluid Power Principles
With a Given Flow Rate
Actuator volume affects actuator speed
The less volume, the faster the actuator
Example:
Will the actuator illustrated below travel the same speed as it
retracts and extends if a constant flow rate is maintained?

Almost. The actuator will travel

faster as it retracts. Less volume
for fluid due to presence of the
actuator shaft.
Fluid Power Principles
Pressure
• The resistance to flow
• Pumps produce flow, not pressure
- If you restrict the flow from the pump, pressure will result.
• All points of resistance in series contribute to total system
pressure
- i.e. long runs of pipe, tees, valves, elbows, etc.
Fluid Power Principles
Heat
• Law of conservation of energy states that energy can neither be
created nor destroyed, although it can change forms.
• Energy not transferred to work takes the form of heat energy.

Nerd note: Engineers calculate the

wasted horsepower in the system
by measuring the cooling
requirements.
Fluid Power Principles
Torque
• The generated work of a hydraulic or pneumatic motor
• Motor rpm at a given torque specifies energy usage or horsepower
requirement
Fluid Power Principles
Horsepower
Term gives relative meaning for measuring power
Unit measurement of energy
Hydraulic horsepower is expressed as:
HP = Flow (gpm) x Pressure (psi)
1714 (a conversion constant)
 Fluid Power Principles
Calculate the horsepower needed in the system below to lift a 10,000lb
force in 2 s.
 More Boring Fluid Power Crap
NOTE 1: Place all boring slides after this one

NOTE 2: This slide not for student viewing

Fluid Power Schematics
Schematics
Line drawing made up of a series of symbols and connections that
represent the actual components in a hydraulic system
Fluid Power Schematics
Symbols
Critical for technical communication
Not language-dependent
Emphasize function and methods of operation
Basic Symbols
Fluid Power Schematics
Lines
 Fluid Power Schematics
Reservoirs
 Fluid
Pumps
Power Schematics
 Fluid Power
Flow Control Valves
Schematics
 Fluid Power Schematics
Directional Control Valves
 Fluid Power
Check Valves
Schematics
 Fluid
Motors
Power Schematics
 Fluid
Cylinders
Power Schematics
Hydraulic Machinery Overview

• Types of Pumps
• Dimensionless Parameters for Turbomachines
• Power requirements
• Head-discharge curves
• Pump Issues
• Cavitation
• NPSH
• Priming
• Pump selection
Types of Pumps
• Positive displacement
• piston pump
• Diaphragm pump
• peristaltic pump
• Rotary pumps
• gear pump
• two-lobe rotary pump
• screw pump
• Jet pumps
• Turbomachines
• axial-flow (propeller
pump)
• radial-flow (centrifugal
pump)
• mixed-flow (both axial
and radial flow)
Reciprocating action pumps
• Piston pump diaphragm pump
• can produce very high pressures
• hydraulic fluid pump
• high pressure water washers
Peristaltic Pump
• Fluid only contacts tubing
• Tubing ___
ID and roller
velocity with respect to the
_______
tubing determine flow rate
• Tubing eventually fails from
fatigue and abrasion
• Fluid may leak past roller at
high pressures
• Viscous fluids may be
pumped more slowly
Rotary Pumps
• Gear Pump
• fluid is trapped between gear teeth and the housing
• Two-lobe Rotary Pump
• (gear pump with two “teeth” on each gear)
• same principle as gear pump
• fewer chambers - more extreme pulsation

trapped fluid
 Rotary Pumps
• Disadvantages
• precise machining
• abrasives wear surfaces rapidly
• pulsating output
• Uses
• vacuum pumps
• air compressors
• hydraulic fluid pumps
• food handling
Screw Pump
• Can handle debris
• Used to raise the
level of wastewater
• Abrasive material
will damage the seal
between screw and
the housing
• Grain augers use the
same principle
 Positive Displacement Pumps
• What happens if you close a valve on the effluent side of a positive
displacement pump?
• What does flow rate vs. time look like for a piston pump?

2.5

2
1st piston

total flow
1.5 2nd piston
3rd piston
1
3 pistons
0.5

0
0 0.5 1 1.5
revolutions

Thirsty Refugees
 Pressure Developed by Centrifugal Pumps
• Centrifugal pumps accelerate a liquid
• The maximum velocity reached is the velocity of the
periphery of the impeller
• The kinetic energy is converted into potential energy
as the fluid leaves the pump
• The potential energy developed is approximately equal
to the ________ ____ at the periphery of the impeller
• A given pump with a given impeller diameter and
speed will raise a fluid to a certain height regardless of V2
the fluid densityvelocity head hp =
2g
Radial Pumps
• also called _________
centrifugal pumps
• broad range of applicable flows and heads
• higher heads can be achieved by increasing the
diameter
_______ or the ________
rotational______
speed of the impeller
V2
hp =
2g

Flow Expansion
Discharge
Casing
Suction Eye Impeller
Impeller
Vanes
Axial Flow
• also known as __________
Propeller pumps
• low head (less than 12 m)
• high flows (above 20 L/s)
Dimensionless Parameters for Turbo machines
• We would like to be able to compare pumps with
similar geometry. Dimensional analysis to the
rescue...
• To use the laws of similitude to compare
performance of two pumps we need
• exact geometric similitude
• all linear dimensions must be scaled identically
• roughness must scale
• homologous - streamlines are similar
• constant ratio of dynamic pressures at corresponding
points
• also known as kinematic similitude
Q
same
D3
 Cavitation in Water Pumps
• water vapor bubbles
8000
form when the pressure 7000
is less than the vapor

Vapor pressure (Pa)

6000
pressure of water 5000
• very high pressures (800 4000

MPa or 115,000 psi) 3000

2000
develop when the vapor
1000
bubbles collapse
0
0 10 20 30 40
Temperature (C)
Self-Priming Centrifugal Pumps
• Require a small volume of liquid in the pump
• Recirculate this liquid and entrain air from the suction side of the
pump
• The entrained air is separated from the liquid and discharged in the
pressure side of the pump
Pump Selection

• Material Compatibility
• Solids
• Flow
• Head
• NPSHa
• Pump Selection software
• A finite number of pumps will come close to
meeting the specifications!
Pump Summary

• Positive displacement vs. turbomachines

• Dimensional analysis
• Useful for scaling
• Useful for characterizing full range of pump performance
from relatively few data points
• Turbomachines convert shaft work into increased
pressure (or vice versa for turbines)
• The operating point is determined by where the
pump and system curves intersect
• NPSH
 Water problem?
Early in my college days I took a break and spent 17 months in Salvadoran refugee
camps in Honduras. The refugee camps were located high in the mountains and for
several of the camps the only sources of water large enough to sustain the population of
6-10,000 were located at much lower elevations. So it was necessary to lift water to the
camps using pumps.

When I arrived at the camps the pumps were failing frequently and the pipes were
bursting frequently. Piston pumps were used. The refugees were complaining because
they needed water. The Honduran army battalion was nervous because they didn’t want
any refugees leaving the camp. There was only one set of spare parts (valve springs and
valves) for the pump and the last set of parts only lasted a few days. The pump repair
crew didn’t want to start using the pump until the real cause of the problem was fixed
because spare parts have to be flown in from Miami.
Water in Colomoncagua
Waiting for water
HYDRAULIC MOTORS

50
 HYDRAULIC MOTORS
DIFFERENT FORMS OF ENERGY
HYDRAULIC SYSTEM
TYPES OF ACTUATORS
WHAT IS A HYDRAULIC MOTOR ?
COMPARISON BETWEEN ELECTRIC & HYDRAULIC MOTORS
TYPES OF HYDRAULIC MOTORS
RADIAL PISTON MOTORS
CRANK SHAFT - RADIAL PISTON MOTORS
WORKING PRINCIPLE OF SAI MOTORS
APPLICATIONS OF HYDRAULIC MOTORS
CASE STUDY & QUESTION AND ANSWERS
STUDY OF RADIAL PISTON MOTOR COMPONENTS
ASSEMBLY / TESTING / MAINTENANCE

51
 HYDRAULIC MOTORS

DIFFERENT FORMS OF ENERGY

EEL  Electrical Energy
ETH  Thermal Energy
EM  Mechanical Energy produced by an
Electrical Motor or an Oil Engine
EHYD  Hydraulic Energy from Hydraulic Pump
in the system
EM  Mechanical Energy from Hydraulic
Actuator ( Hydraulic Motor)
EEL / ETH EM EHYD EM

Energy loss takes place at each step of energy conversion

52
 HYDRAULIC MOTORS
DIFFERENT FORMS OF ENERGY

Why do we study or use various form of energies ?

To suit our requirements
To make effective use of it
To control it
To make it flexible
To preserve it

53
 HYDRAULIC MOTORS
HYDRAULIC SYSTEM
Basic arrangement of a hydraulic system :
1. Prime mover - Electric Motor or Engine
2. Fluid Reservoir - Hydraulic Tank
3. Energy Transfer Medium - Hydraulic Oil
4. Fluid Transfer Unit - Hydraulic Pump
5. Fluid Transfer Medium - Hose and Pipes
6. Controls - Relief Valve, D.C Valve, Flow Control Vv
7. Actuators - Hydraulic Motor, Cylinder

54
 HYDRAULIC MOTORS
HYDRAULIC SYSTEM
What is Oil Hydraulics ?
Study of energy conversion from mechanical to
hydraulic energy (pressure and flow) and again into
mechanical energy (Torque and speed).

In Oil Motors :
Pressure (kg / cm2 or bar) gets converted into
Torque (kg-cm)
Flow (lpm) gets converted into speed (rpm)

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 HYDRAULIC MOTORS
TYPES OF ACTUATORS

Linear Actuator - Hydraulic Cylinder

Oscillatory Actuator - Restricted Rotation Motor

Rotary Actuator - Hydraulic Motor

56
 HYDRAULIC MOTORS
HYDRAULIC POWER TRANSMISSION
MOTOR OSCILLATORY LINEAR
ACTUATOR ACTUATOR

VALVING

PUMP PRIME
MOVER

57
 HYDRAULIC MOTORS
WHAT IS A HYDRAULIC MOTOR ?
It is a device which converts the
hydraulic energy (power) generated by a pump into
mechanical energy (power) in the form of
torque and rotation (rpm)

For a Hydraulic Pump, the main function is to -

Displace as much oil as possible per revolution.
To achieve this an optimum volumetric efficiency at the
cost of mechanical efficiency is required.
On the other hand, the Hydraulic Motors have to deliver
maximum mechanical power at the load point.

58
 HYDRAULIC MOTORS
HYDRAULIC MOTOR - Graphical Symbols

Envelope

In Out

Dotted Line Uni - Directional

for Drain Hyd. Motor
– Fixed Displacement
Solid
Triangle
( Hydraulic
)

Variable Displacement
Bi - Directional Bi - Directional
Hyd. Motor Hyd. Motor
– Fixed Displacement
59
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR

 Extreme range of speed adjustment possible.

 Torque control throughout the operating speed.
 Low Inertia.
 Compactness of space.
 The fact that they can be stalled indefinitely
without damage.
 Instant reversing of motor’s shaft.
 Dynamic braking easily accomplished.

60
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR

Rapid Reversal

The Rotor Mass of

Hydraulic Motor  Electric Motor

61
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR
Rapid Reversal

62
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR
Rapid Reversal

63
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR

Speed Variation

Electric Motor  Torque Converters

Hydraulic Motor  Simple Flow
Control Valve

Size Comparison

Power Density of
Hydraulic Motor  Electric Motor

64
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR

Stall Performance

Electric Motor  Trips / Stops

Hydraulic Motor  Stall Torque
possible to achieve

65
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR
Stall Performance

66
 HYDRAULIC MOTORS
SALIENT FEATURES OF A HYDRAULIC MOTOR
Unfavourable Environment
Fluid Motors can be used in Dangerous,
Difficult environment.

Speed Regulation
Speed = No Load - Loaded
Regulation Speed Speed x 100
No Load Speed
Speed Variations
Electric Motor  3 %
Most Hyd. Motors  10 - 15 %
( Except for Radial Piston Motors )
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 HYDRAULIC MOTORS
MAJOR APPLICATIONS

CONSTRUCTION
MINING
MATERIAL HANDLING
EARTH MOVING
PLASTICS
MACHINE TOOLS
AGRICULTURE
RAILWAY EQUIPMENT

68
 HYDRAULIC MOTORS
MAJOR APPLICATIONS

Special Purpose Vehicle using Hydraulic Drive

Winches

69
 HYDRAULIC MOTORS
MAJOR APPLICATIONS

Fan Drives

Batch Mixers

Conveyor
Drives

70
 HYDRAULIC MOTORS
WHILE REPLACING AN ELECTRIC MOTOR
WITH A HYDRAULIC MOTOR
Points to be considered :

3 Phase Squirrel cage

Electric Motor has twice the
starting torque of Hydraulic
Motor. The value of the
starting torque / running
torque to be known.

Do not consider HP as
comparison

The details of Gear Box ,

Pulley used at output of
Electric Motor to be known.
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 HYDRAULIC MOTORS
CLASSIFICATION OF HYDRAULIC MOTORS

GEOMETRY OF THE ACTUATING MECHANISM

SPEED AND TORQUE RATING

HIGH TORQUE LOW TORQUE

LOW SPEED MOTORS HIGH SPEED MOTORS
( HTLS ) ( LTHS )

RADIAL PISTON MOTORS AXIAL PISTON MOTORS

CRANKSHAFT SWASH PLATE

CAM - LOBE BENT AXIS

ORBIT MOTORS GEAR MOTORS

GEROTOR
VANE MOTORS
GEROLLER
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 HYDRAULIC MOTORS
GEAR MOTORS

COMPACT

LOW COST

LOW EFFICIENCY ( 60% - 70% )

SPEED RANGE ( 500 – 3000 rpm )

CANNOT BE USED FOR LOW SPEED

73
 HYDRAULIC MOTORS
GEAR MOTORS

74
 HYDRAULIC MOTORS
GEAR RING MOTORS ( ORBIT MOTORS )
 Higher power output for a given outer dimensions.

 Overall efficiency low.

 Volumetric efficiency low.

 Low cost.

 Rotation at low speed not smooth.

 Higher heat generation ( loss of energy )

75
 HYDRAULIC MOTORS
GEAR RING MOTORS ( ORBIT MOTORS )

76
 HYDRAULIC MOTORS
GEAR RING MOTORS ( ORBIT MOTORS )

77
 HYDRAULIC MOTORS
VANE MOTORS

 DESIGN COMPLICATED

 MANUFACTURING COMPLICATED

 HIGH COST

 MEDIUM TORQUE

 MEDIUM SPEED

 CHANGE OF SPEED WITH CHANGE OF TORQUE POSSIBLE

78
 HYDRAULIC MOTORS
VANE MOTORS

79
 HYDRAULIC MOTORS
AXIAL PISTON MOTORS
• LOW TORQUE
• HIGH SPEED
• COMPLICATED DESIGN
• MANUFACTURING DIFFICULT
• HIGH COST
• REVERSING SHAFT OUTPUT EASY
• SPEED CONTROL POSSIBLE
• TORQUE CONTROL POSSIBLE

80
 HYDRAULIC MOTORS
AXIAL PISTON MOTORS

Swash Plate Design

81
 HYDRAULIC MOTORS
AXIAL PISTON MOTORS
Bent Axis Design

82
 HYDRAULIC MOTORS
RADIAL PISTON MOTORS
 HIGH STARTING TORQUE
 HIGH RUNNING TORQUE
 COMPACT IN SIZE (SPECIFIC TORQUE HIGH)
 BI-DIRECTIONAL
 LOW SPEED POSSIBLE ( < 10 rpm)
 TORQUE VARIATION POSSIBLE
 LOW NOISE
 VIBRATION VERY LOW
 HIGH MECHANICAL EFFICIENCY
 HIGH VOLUMETRIC EFFICIENCY
 INSTANT REVERSING POSSIBLE
83
 HYDRAULIC MOTORS
RADIAL PISTON MOTORS

Crank Shaft Design

84
 HYDRAULIC MOTORS
RADIAL PISTON MOTORS

Radial type distributor

Small clearance

85
 HYDRAULIC MOTORS
RADIAL PISTON MOTORS

 Swivelling
Cylinder
 Double Piston
Support bearing.

86
 HYDRAULIC MOTORS
RADIAL PISTON MOTORS

87
 HYDRAULIC MOTORS
RADIAL PISTON MOTORS

88
 HYDRAULIC MOTORS
MOTOR RATINGS
The rating of hydraulic motors are done based on the following
operating parameters :
Displacement
Torque capacity
Speed
Operating Pressure

Displacement : of a hydraulic motor is defined as the

amount of fluid required to turn the motor shaft by one
revolution.

89
 HYDRAULIC MOTORS
MOTOR RATINGS
Torque : Torque is the turning force developed at the
motor shaft due to its rotation. The value of Torque
increases with an increase in operating pressure, and
decreases when the pressure decreases.

Speed : The speed of a hydraulic motor depends on its

displacement and the flow rate to it.

Operating Pressure : The pressure required by a hydraulic

motor depends on the torque requirement and its
displacement

90
 HYDRAULIC MOTORS
MOTOR SELECTION

OUTPUT PARAMETERS :  SPEED ( RPM )

 TORQUE ( KG – M )

MOTOR PARAMETER :  DISPLACEMENT ( CC / REV. )

HYD. PARAMETERS :  FLOW ( LPM )

 PRESSURE ( BAR )

TORQUE :  DISPLACEMENT X PR. X m

628

SPEED :  FLOW X 1000 X  V

DISPLACEMENT

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 HYDRAULIC MOTORS
EFFECT ON HYDRAULIC MOTOR DURING CHANGE IN
HYD. SETTINGS UNDER CONSTANT LOAD CONDITION

CHANGE SPEED EFFECT ON TORQUE

OPERATING AVAILABILITY
PRESSURE
Increase pressure setting No Effect No Effect Increases
Decrease pressure setting No Effect No Effect Decreases
Increase flow Increases No Effect No Effect
Decrease flow Decreases No Effect No Effect
Increase displacement (Size) Decreases Decreases Increases
Decrease displacement (Size) Increases Increases Decreases

92