Hydraulic System

UNIT 3
HYDRAULIC SYSTEMS
1
INTRODUCTION TO FLUID POWER
• In the industry we use three methods for
transmitting power from one point to another.
• Mechanical transmission is through shafts,
gears, chains, belts, etc.
• Electrical transmission is through wires,
transformers, etc.
• Fluid power is through liquids or gas in a
confined space.
2
• Fluid power is the technology that deals with the
generation, control and transmission of forces and
movement of mechanical element or system with the
use of pressurized fluids in a confined system.
• Both liquids and gases are considered fluids.
• Fluid power system includes a hydraulic system (hydra
meaning water in Greek) and a pneumatic system
(pneuma meaning air in Greek).
• Oil hydraulic employs pressurized liquid petroleum oils
and synthetic oils, and pneumatic employs compressed
air that is released to the atmosphere after performing
the work.
3
• By the term “fluid” we refer to air or oil, for it has
been shown that water has certain drawbacks in the
transmission of hydraulic power in machine operation
and control. Commercially, pure water contains various
chemicals (some deliberately included) and also
foreign matter, and unless special precautions are
taken when it is used, it is nearly impossible to
maintain valves and working surfaces in satisfactory
condition.
• Oil is commonly used, thus providing, in addition to
power transmission, benefits of lubrication not
afforded by water as well as increased life and
efficiency of packings and valves. It should be
mentioned that in some special cases, soluble oil
diluted with water is used for safety reasons. 4
HISTORY OF FLUID POWER
• Fluid power is as old as our civilization itself. Water
was used for centuries to produce power by means
of water wheels and air was used to turn windmills
and to propel ships. Chinese used wooden valves to
control water flow through bamboo pipes in 4000
BC. Ancient Egyptians have built a masonry dam across
Nile, 14 miles south to present Cairo, for the control
of irrigation water by canals, sluices, brick conduits
and ceramic pipes. During the Roman empire,
extensive water systems using aqueducts, reservoirs
and valves were constructed to carry water to cities.
However, these early uses of fluid power required the
movement of huge quantities of fluid because of the
relatively low pressures provided by nature.
5
• Fluid power technology actually began in 1650
with the discovery of Pascal’s law. Simply stated,
this law says that pressure in a fluid at rest is
transmitted undiminished equally in all directions
in a confined body of fluid. Pascal found that when
he rammed a cork down into a jug completely
full of wine, the bottom of the jug broke and fell
out. However, in order for Pascal’s law to be made
effective for practical use, it was necessary to
make a piston that would fit exactly. Not until
over 100 years later was this accomplished.
6
• It was in 1795 that Joseph Brahmah invented the cup
packing that led to the development of a workable
hydraulic press. Brahmah’s hydraulic press consisted of a
plunger pump piped to a large cylinder and a ram. This
new hydraulic press found wide use in England because it
provided a more effective and economical means of
applying large force to industrial applications.
• In 1750, Bernoulli developed his law of conservation of
energy for a fluid flowing in a pipeline. Both Pascal’s and
Bernoulli’s laws operate at the heart of all fluid power
applications and are used for analytical purposes. However,
it was not until the Industrial Revolution of 1850 in Great
Britain that these laws were actually applied to the industry.
7
• The first use of a large hydraulic press for foregoing
work was made in 1860 by Whitworth. In the next 20
years, many attempts were made to reduce the
waste and excessive maintenance costs of the
original type of accumulator. In 1872, Rigg patented a
three-cylinder hydraulic engine in which provision was
made to change the stroke of plungers to vary its
displacement without a throttle valve. In 1873, the
Brotherhood three-cylinder, constant- stroke
hydraulic engine was patented and was widely used
for cranes, winches, etc. Both the above-mentioned
engines were driven by fluid from an accumulator.
8
• Up to this time, electrical energy was not
developed to power the machines of
industry. Instead, fluid power was being used
to drive hydraulic equipment such as cranes,
presses, shearing machines, etc. With
electricity emerging dominantly in the 19th
century, it was soon found superior to fluid
power for transmitting power over great
distances.
9
• The modern era in fluid power began around the turn
of the century. Fluid applications were made to such
installations as the main armament system of USS
Virginia in 1906. In these applications, a variable-speed
hydrostatic transmission was installed to drive the
main guns. Since that time, marine industry has
applied fluid power to cargo-handling systems,
controllable pitch controllers, submarine control
system, aircraft elevators, aircraft- and
missile-launching system and radar/sonar-driven
systems. In 1926, the United States developed the
first unitized, packaged hydraulic system consisting of a
pump, controls and an actuator.
10
• Today fluid power is used extensively in
practically every branch of industry. The
innovative use of modern technology such as
electrohydraulic closed loops, microprocessors
and improved materials for component
construction continues to advance the
performance of fluid power systems. The military
requirements kept fluid power applications and
developments going at a good pace. Aviation and
aerospace industry provided the impetus for many
advances in fluid power technology
11
INTRODUCTION TO FLUID MECHANICS
• A fluid is any matter that flows, which can either
be a liquid or a gas.
• Archimedes' principle states that any object
completely or partially submerged in a fluid
experiences an upward force equal in magnitude
to the weight of the fluid displaced by the object,
as seen in Equation 1.
F B= m fg (Equation 1)
• Where F B is the buoyant force, m f is the mass of
the fluid displaced, and g is acceleration due to
gravity.
12
• A common experience is realizing that it is rather easy
to lift a person in a swimming pool. This is because the
water provides partial support in the form of an
upward force called the buoyant force.
• The buoyant force is equal to the weight of the fluid
displaced. Refer to Buoyancy & Pressure in Fluids: Soda
Bottle Cartesian Diver activity to have students
observe these variables in action.
• Ships float in water because the weight of the water
displaced by the ship's hull is greater than the ship's
weight, and if the weight of the water displaced was
less than that of the ship, it would sink.
13
• Earlier, it was mentioned that a fluid can be a
liquid or a gas. Air is everywhere, and even the
air surrounding us has a weight and exerts a
pressure.
• We do not realize how heavy the air is, or feel
the pressure it exerts upon us because we are
accustomed to the "atmospheric pressure."
• Pressure is defined as a measure of force over
a given area.
14
• Pascal's law states that a pressure applied to a
fluid in a closed container is transmitted equally to
every point of the fluid and the walls of the
container, as seen in Equation 2.
P=F/A (Equation 2)
• Where P is the pressure, F is the force, and A is
the area. Note that a closed system may have two
areas, so the force is different at the two
locations, but the pressure remains the same, as
stated by Pascal's law.
15
• This pressure is transmitted equally in all
directions and at right angles, and a change in
pressure disperses equally throughout the fluid.
• Pascal's law is used by engineers when designing
hydraulic systems that use liquid power to do
work.
• Some examples are hydraulic jacks that lift cars up
in repair shops and hydraulic brakes that apply a
pressure to a large area to stop a large vehicle
such as a train
16
• Primarily, two different types of fluid flow exist—laminar and
turbulent.
• Laminar flow occurs when fluid particles move along a uniform,
smooth path called a streamline and typically occurs in small pipes
or other low-flow media.
• Turbulent flow occurs when fluid particles flow irregularly and
cause a change in velocity and typically occurs in large pipes or
other high-flow media.
• Bernoulli's principle states that pressure and velocity are inversely
related, or that the pressure in a fluid decreases when the fluid's
velocity increases, as seen in Equation 3.
P 1 + ½ρ v 1 2 + ρ g h 1 = P 2 + ½ρ v 2 2 + ρgh 2 (Equation 3)
Where P 1 is the pressure at point 1, ρ is the density of the
fluid, v 1 is the velocity of the fluid at point 1, g is the acceleration
due to gravity, h 1 is the elevation of point 1, P 2 is the pressure at
point 2, v 2 is the velocity of the fluid at point 2, and h 2 is the
elevation of point 2.
17
• Bernoulli's equation remains equal at different points
in a horizontal pipe. In a pipe that is not consistent in
height, Bernoulli's equation still remains equal, but
takes into account height differences at different
points in a pipe, as noted by h in Equation 3.
• Engineers implement Bernoulli's equation in order to
specify optimal and efficient pipe sizes when designing
pipelines and transport systems.
• Bernoulli's equation is a main component in
aerodynamics, which is applied in the design of
automobiles, bridges, ventilation systems, gas piping,
aircraft and spacecraft.
18
The concepts of Pascal's law, Archimedes' principle and
Bernoulli's principle are important in engineering and
technology applications such as:
• aerodynamics and hydrodynamics, airplanes, aerospace
guidance and control,
• floating vessels, submersibles,
• automobiles,
• pipelines and transport systems,
• hydraulics,
Also for many research topics such as
• ocean-related flows,turbulence,reacting flows, global
climate, bio-fluid mechanics, flow over magnetic tapes and
disks, geophysical flows, kinetics of combustion systems,
vortex dynamics and many more.
19
• Aerodynamics is the study of the properties of
moving air, which is a main component in the
design of automobiles, bridges, heating and
ventilation, gas piping, aircraft and spacecraft.
• Hydrodynamics is the study of forces exerted on
or by fluids, which is the main component in naval
architecture or ship design, and ocean
engineering.
• Ocean and marine engineers are responsible
study the offshore environment in order to design
oil rigs and production platforms as well as
floating vessels and subsea pipeline systems
needed in the oil production process. 20
• Hydraulic engineers use hydraulics, or the use of liquid
power to do work, to design heavy machinery, water
distribution systems, sewage networks, storm water
management systems, bridges, dams, channels, canals
and levees.
• Various submersibles and remotely operated vehicles
designed by engineers are widely used by government
and scientific researchers and are essential in the
discovery of deep-water communities and the
exploration of the abysmal ocean because they can
reach depths much greater than previous satellite and
shipboard technologies
21
APPLICATIONS OF FLUID POWER
Fluid power applications can be classified into two major
segments:
Stationary hydraulics and Mobile hydraulics
• Stationary hydraulics: Stationary hydraulic systems
remain firmly fixed in one position. The
characteristic feature of stationary hydraulics is that
valves are mainly solenoid operated. The applications
of stationary hydraulics are as follows:
– Production and assembly machines of all types
– Transfer lines
– Lifting and conveying devices
– Presses
– Injection moulding machines
– Rolling lines
– Lifts 22
APPLICATIONS OF FLUID POWER
• Mobile hydraulics: Mobile hydraulic systems
move on wheels or tracks such as a tower crane or
excavator truck to operate in many different
locations or while moving. A characteristic feature
of mobile hydraulics is that the valves are
frequently manually operated. The applications
of mobile hydraulics are as follows:
– Construction machinery
– Tippers, excavators, elevating platforms
– Lifting and conveying devices
– Agricultural machinery
23
ADVANTAGES OF A FLUID POWER
SYSTEM
• Oil hydraulics stands out as the prime moving
force in machinery and equipment designed to
handle medium to heavy loads. In the early stages
of industrial development, mechanical linkages
were used along with prime movers such as
electrical motors and engines for handling
loads. But the mechanical efficiency of linkages
was very low and the linkages often failed under
critical loading conditions. With the advent of fluid
power technology and associated electronics and
control, it is used in every industry now
24
SYSTEM
The advantages of a fluid power system are as follows:
• Fluid power systems are simple, easy to operate and
can be controlled accurately: Fluid power gives
flexibility to equipment without requiring a complex
mechanism. Using fluid power, we can start, stop,
accelerate, decelerate, reverse or position large
forces/components with great accuracy using simple
levers and push buttons. For example, in
Earth-moving equipment, bucket carrying load can be
raised or lowered by an operator using a lever. The
landing gear of an aircraft can be retrieved to home
position by the push button.
• Multiplication and variation of forces: Linear or rotary
force can be multiplied by a fraction of a kilogram to
several hundreds of tons. 25
SYSTEM
• Multifunction control: A single hydraulic pump or air
compressor can provide power and control for numerous
machines using valve manifolds and distribution systems.
The fluid power controls can be placed at a central station
so that the operator has, at all times, a complete control of
the entire production line, whether it be a multiple
operation machine or a group of machines. Such a setup is
more or less standard in the steel mill industry.
• Low-speed torque: Unlike electric motors, air or hydraulic
motors can produce a large amount of torque while
operating at low speeds. Some hydraulic and pneumatic
motors can even maintain torque at a very slow speed
without overheating.
• Constant force or torque: Fluid power systems can deliver
constant torque or force regardless of speed changes
26
SYSTEM
• Economical: Not only reduction in required manpower but
also the production or elimination of operator fatigue, as a
production factor, is an important element in the use of
fluid power.
• Low weight to power ratio: The hydraulic system has a low
weight to power ratio compared to electromechanical
systems. Fluid power systems are compact.
• Fluid power systems can be used where safety is of vital
importance: Safety is of vital importance in air and space
travel, in the production and operation of motor vehicles, in
mining and manufacture of delicate products. For example,
hydraulic systems are responsible for the safety of takeoff,
landing and flight of aeroplanes and space craft. Rapid
advances in mining and tunneling are the results of the
application of modern hydraulic and pneumatic systems.
27
TYPES OF HYDRAULIC SYSTEMS
The following are the two types of hydraulic systems:
• Fluid transport systems: Their sole objective is the
delivery of a fluid from one location to another to
accomplish some useful purpose. Examples include
pumping stations for pumping water to homes,
cross-country gas lines, etc.
• Fluid power systems: These are designed to perform
work. In fluid power systems, work is obtained by
pressurized fluid acting directly on a fluid cylinder or
a fluid motor. A cylinder produces a force resulting in
linear motion, whereas a fluid motor produces a
torque resulting in rotary motion.
28
CLASSIFICATION OF FLUID POWER SYSTEMS
The fluid power system can be categorized as
follows:
Based on the control system:
• Open-loop system and
• Closed-loop system
Based on the type of control :
• Fluid logic control ,
• Electrical control and
• Electronic control
29
CLASSIFICATION OF FLUID POWER
SYSTEMS
• Open-loop system: There is no feedback in the open
system and performance is based on the
characteristics of the individual components of the
system. The open loop system is not accurate and
error can be reduced by proper calibration and
control.
• Closed-loop system: This system uses feedback. The
output of the system is fed back to a comparator by a
measuring element. The comparator compares the
actual output to the desired output and gives an
error signal to the control element. The error is used
to change the actual output and bring it closer to the
desired value. A simple closed- loop system uses
servo valves and an advanced system uses digital 30
electronics.
31
Fluid logic control: This type of system is controlled by
hydraulic oil or air. The system employs fluid logic
devices such as AND, NAND, OR, NOR, etc. Two types
of fluid logic systems are available:
– Moving part logic (MPL): These devices are
miniature fluid elements using moving parts
such as diaphragms, disks and poppets to
implement various logic gates.
– Fluidics: Fluid devices contain no moving parts and
depend solely on interacting fluid jets to
implement various logic gates.
32
CLASSIFICATION OF FLUID POWER
SYSTEMS
Electrical control: This type of system is
controlled by electrical devices. Four basic
electrical devices are used for controlling the
fluid power systems: switches, relays, timers
and solenoids. These devices help to control
the starting, stopping, sequencing, speed,
positioning, timing and reversing of actuating
cylinders and fluid motors. Electrical control
and fluid power work well together where
remote control is essential
33
Electronic control: This type of system is controlled by
microelectronic devices. The electronic brain is used to
control the fluid power muscles for doing work. This
system uses the most advanced type of electronic
hardware including programmable logic control (PLC)
or microprocessor ( P).
• In the electrical control, a change in system
operation results in a cumbersome process of redoing
hardware connections.
• The difficulty is overcome by programmable electronic
control. The program can be modified or a new
program can be fed to meet the change of operations.
A number of such programs can be stored in these
devices, which makes the systems more flexible.
34
HYDROSTATIC AND HYDRODYNAMIC SYSTEMS
• Hydraulics is the science of forces and movements
transmitted by means of liquids. It belongs alongside
hydro-mechanics. A distinction is made between hydrostatics
– dynamic effect through pressure times area – and
hydrodynamics – dynamic effect through mass times
acceleration
35
HYDROSTATIC AND HYDRODYNAMIC SYSTEMS
• A Hydrostatic system uses fluid pressure to

transmit power. Hydrostatics deals with the
mechanics of still fluids and uses the theory of
equilibrium conditions in fluid. The system
creates high pressure, and through a transmission
line and a control element, this pressure drives
an actuator (linear or rotational). The pump used
in hydrostatic systems is a positive displacement
pump. The relative spatial position of this pump is
arbitrary but should not be very large due to
losses (must be less than 50 m). An example of
pure hydrostatics is the transfer of force in
hydraulics.
36
HYDROSTATIC AND HYDRODYNAMIC
SYSTEMS
• Hydrodynamic systems use fluid motion to transmit
power. Power is transmitted by the kinetic energy of
the fluid. Hydrodynamics deals with the mechanics of
moving fluid and uses flow theory. The pump used in
hydrodynamic systems is a non-positive displacement
pump. The relative spatial position of the prime mover
(e.g., turbine) is fixed. An example of pure
hydrodynamics is the conversion of flow energy in
turbines in hydroelectric power plants.
• In oil hydraulics, we deal mostly with the fluid working
in a confined system, that is, a hydrostatic system.
37
COMPONENTS OF A HYDRAULIC SYSTEM
38
• Oil reservoir:- it is a storage tank for oil. It
consist of tank, filter, strainer, baffle plates &
drain plug.
• Oil pump:- the purpose of pump is to supply a
flow of fluid to hydraulic system.
• Pressure relief valve:- it is used to control
pressure. If pressure in a system increases
above a pre-set level, this valve opens to
release the fluid out of the system.
39
• Direction control valve:- it is used to control the
direction of flow of working fluid so as to control the
direction of motion of the actuator.
• Flow control valve:- it is used to control flow rate of
flow of working fluid so as to control the speed of
actuator.
• Pressure control valve:- it is used to maintain the
desired pressure level in the various parts of circuit.
• Actuators:- it is used to convert air pressure delivered
by air circuit into applied force and motion
40
41
COMPONENTS OF A HYDRAULIC
SYSTEM
Functions of the components shown in Fig are as follows:
1. The hydraulic actuator is a device used to convert the
fluid power into mechanical power to do useful work.
The actuator may be of the linear type (e.g., hydraulic
cylinder) or rotary type(e.g., hydraulic motor) to
provide linear or rotary motion, respectively.
2. The hydraulic pump is used to force the fluid from the
reservoir to rest of the hydraulic circuit by
converting mechanical energy into hydraulic energy.
3. Valves are used to control the direction, pressure and
flow rate of a fluid flowing through the circuit.
42
SYSTEM
4. External power supply (motor) is required to drive
the pump.
5. Reservoir is used to hold the hydraulic liquid, usually
hydraulic oil.
6. Piping system carries the hydraulic oil from one
place to another.
7. Filters are used to remove any foreign particles so as
keep the fluid system clean and efficient, as well as
avoid damage to the actuator and valves.
8. Pressure regulator regulates (i.e., maintains) the
required level of pressure in the hydraulic fluid
43
SYSTEM
• The piping shown in Fig. is of closed-loop type
with fluid transferred from the storage tank
to one side of the piston and returned back
from the other side of the piston to the tank.
• Fluid is drawn from the tank by a pump that
produces fluid flow at the required level of
pressure. If the fluid pressure exceeds the
required level, then the excess fluid returns
back to the reservoir and remains there until
the pressure acquires the required level.
44
SYSTEM
Cylinder movement is controlled by a three-position
change over a control valve.
1. When the piston of the valve is changed to upper
position, the pipe pressure line is connected to
port A and thus the load is raised.
2. When the position of the valve is changed to lower
position, the pipe pressure line is connected to port
B and thus the load is lowered.
3. When the valve is at center position, it locks the fluid
into the cylinder(thereby holding it in position) and
dead-ends the fluid line (causing all the pump
output fluid to return to tank via the pressure
relief).
45
46
SYSTEM
• In industry, a machine designer conveys the design of
hydraulic systems using a circuit diagram. Figure shows the
components of the hydraulic system using symbols.
• The working fluid, which is the hydraulic oil, is stored in a
reservoir.
• When the electric motor is switched ON, it runs a positive
displacement pump that draws hydraulic oil through a
filter and delivers at high pressure.
• The pressurized oil passes through the regulating valve and
does work on actuator.
• Oil from the other end of the actuator goes back to the
tank via return line.
• To and fro motion of the cylinder is controlled using
directional control valve.
47
SYSTEM
The hydraulic system discussed above can be broken
down into four main divisions that are analogous to
the four main divisions in an electrical system.
• The power device parallels the electrical generating
station.
• The control valves parallel the switches, resistors,
timers, pressure switches, relays, etc.
• The lines in which the fluid power flows parallel the
electrical lines.
• The fluid power motor (whether it is a rotating or a
non rotating cylinder or a fluid power motor) parallels
the solenoids and electrical motors
48
COMPARISON OF DIFFERENT POWER
SYSTEMS
• There are three basic methods of transmitting power:
electrical, mechanical and fluid power. Most
applications actually use a combination of the three
methods to obtain the most efficient overall system.
• To properly determine which method to use, it is
important to know the salient features of each type.
For example, fluid systems can transmit power more
economically over greater distances than
mechanical types.
• However, fluid systems are restricted to shorter
distances compared to electrical systems.
• Table lists the salient features of each type.
49
50
HYDRAULIC SYSTEMS
• The controlled movement of parts or a controlled
application of force is a common requirement in
the industries. These operations are performed
mainly by using electrical, Mechanical and
Hydraulic systems.
• Enclosed fluid based systems using pressurized
incompressible liquids as transmission media are
called as hydraulic systems.
• The hydraulic system works on the principle of
Pascal’s law which says that the pressure in an
enclosed fluid is uniform in all the directions
51
HYDRAULIC SYSTEMS
• The hydraulic systems consists a number of parts for its proper
functioning. These include storage tank, filter, hydraulic pump,
pressure regulator, control valve, hydraulic cylinder, piston and
leak proof fluid flow pipelines.
• The storage/fluid tank is a reservoir for the liquid used as a
transmission media.
• The liquid used is generally high density incompressible oil. It is
filtered to remove dust or any other unwanted particles and then
pumped by the hydraulic pump.
• The capacity of pump depends on the hydraulic system design.
These pumps generally deliver constant volume in each revolution
of the pump shaft.
• Therefore, the fluid pressure can increase indefinitely at the dead
end of the piston until the system fails.
• The pressure regulator is used to avoid such circumstances which
redirect the excess fluid back to the storage tank.
52
HYDRAULIC PUMPS
• The combined pumping and driving motor unit
is known as hydraulic pump. The hydraulic
pump takes hydraulic fluid (mostly some oil)
from the storage tank and delivers it to the
rest of the hydraulic circuit.
• In general, the speed of pump is constant and
the pump delivers an equal volume of oil in
each revolution. The amount and direction of
fluid flow is controlled by some external
mechanisms.
53
HYDRAULIC MOTORS
Hydraulic motors
• Hydraulic motors are continuous rotation type of
actuators.
• It is exactly opposite to that of pump.
• In hydraulic motor, a fluid energy is converted into
mechanical energy.
• A hydraulic motor is a mechanical actuator that
converts hydraulic pressure and flow into torque and
angular displacement i.e. rotation
• The rotary hydraulic motors are fixed displacement
type or variable displacement type. These are used in
many applications like- crane, military vehicles,
excavators & self driven cranes
54
HYDRAULIC MOTORS
• Types of Hydraulic motors
• Gear type
• Vane type
• Axial piston type
• Radial piston type
55
HYDRAULIC MOTORS
Gear type
• The pressurised fluid is supplied to the inlet of the
motor, which acts on the surface of gear teeth,
causing the gear shaft to rotate.
• The direction of rotation of the motor can be
reversed by changing the direction of flow.
• The gear motors are available for pressures upto
13 Mpa with output power 145 kW and rotates at
2400 rpm with maximum fluid discharge 6000
lit/min.
56
HYDRAULIC MOTORS
57
HYDRAULIC MOTORS
Vane type
• Vane motor work on the principle opposite to that
of vane pump
• It consist of cylindrical rotor with radial slots.
• The rotor is eccentrically mounted inside the
casing
• The vanes are moved out of the slot and remains
pressed against the outer casing by spring loading
or by applying oil pressure at the centre of the
rotor.
58
HYDRAULIC MOTORS
59
HYDRAULIC MOTORS
• When the rotor rotates, the vanes make sliding contact
with the casing.
• During rotation of the rotor, vane loading increases
caused by centrifugal forces produced due to rotation
of the vanes.
• Pressurized oil is supplied to the chamber in between
two vanes. When the pressurizedoil expands due to
increased volume, it applies a tangential force which
develops the rotating torque on the rotor
• It produces pressure up to 17 MPa androtates at 4000
rpm with maximum fluid discharge 10000 liters /min
60
HYDRAULIC MOTORS
Axial displacement type
• It consist of number of cylinders arranged around the
periphery of a cylinder block.
• Inside each cylinder piston reciprocates.
• High pressure oil enters from one side into each set of
cylinders
• This oil expands causing the piston to reciprocates.
• The reciprocating motion is converted into rotational
motion of the motor shaft by the swash plates.
61
HYDRAULIC MOTORS
62
HYDRAULIC MOTORS
Radial displacement type
• In this pistons are arranged radially around the
periphery of a cylinder block.
• The pistons reciprocates radially outward and
inward when the cylinder block rotates.
• Pressurized oil is admitted at the center of the
cylinder block and the piston rods make
contact with a concentric cylindrical ring
outside the cylinder block.
63
HYDRAULIC MOTORS
64
HYDRAULIC MOTORS
• The pressurized oil enters the cylinders radially
and expand thereby pushing their pistons
outwards.
• When the expansion is complete the low
pressure oil is removed from the opposite half
of the cylinder block through the outlet.
• The reciprocation of cylinder is converted into
rotational motion of cylinder block which
develops the required torque on the shaft.
65
HYDRAULIC MOTORS
Advantages of rotary hydraulic motors
• It provides step less variations in speed from zero
to maximum.
• Are compact and smooth in operation
• Does not require electrical connections
• Can be started and reverse quickly
• Can be stopped suddenly without any harm to the
system
• Suitable to operate machines where variable
torque and maximum torque is required.
66
HYDRAULIC MOTORS
Applications
• paper winding machines
• thread tapping machines
• indexing mechanisms
• Mining equipments
• Machine tools
• Drilling rigs
• Textile drives
• Hoists
• Elevators
• Conveyors
67
HYDRAULIC PUMPS
• The hydraulic pumps are characterized by its flow
rate capacity, power consumption, drive speed,
pressure delivered at the outlet and efficiency of
the pump. The pumps are not 100% efficient. The
efficiency of a pump can be specified by two ways.
One is the volumetric efficiency which is the ratio
of actual volume of fluid delivered to the
maximum theoretical volume possible. Second is
power efficiency which is the ratio of output
hydraulic power to the input mechanical/electrical
power. The typical efficiency of pumps varies from
90-98%.
68
HYDRAULIC PUMPS :Introduction
In a hydraulic system, the pump converts mechanical energy into
hydraulic energy.
This mechanical energy is delivered to the pump via a prime
mover. The prime mover used depends on the type of application
as indicated below:
(i) A.C. induction motor rotating at a constant speed of 1500 rpm
or at 1200 or 1800 rpm (at 50 Hz supply), are generally used.
Often pump and electric motor are supplied as one unit.
(ii) Mobile hydraulic application such as power steering units,
backhoe pumps, farm tractors and utility vehicles are driven at
varying speeds up to 3600 rpm. Depending on the size of the
equipment by power take off arrangements directly from the I.C.
engine or the transmission.
(iii) Air and space craft hydraulic systems, where weight
considerations are critical and substantial power must be
generated from small self contained units, high speed pumps
driven by D.C. electric motor to speeds of 12,000 rpm are used.
69
• Due to the mechanical action, the pump takes the
hydraulic fluid from the reservoir and delivers it to the
hydraulic circuit at system pressure. In doing so, it raises
the energy level of the fluid.
• This high energy fluid is then used to do work like
actuating an hydraulic cylinder or rotating an hydraulic
motor. The smooth and effective working of the hydraulic
system depends on the matching of the pump selected
with the required fluid power actuator regarding its
power requirements, pressure and flow characteristics,
the speed range required and operating characteristic.
Hence, a pump is known as the heart of a hydraulic
system.
70
Pumping theory
A fluid is said to be pumped when its volume is displaced and
transferred from one place to another. This pumping action is
achieved by using a pump. All pumps operate on the principle
whereby a partial vacuum is created at the pump inlet due to
the internal operation of the pump. This partial vacuum causes
the fluid to be sucked into the pump inlet from the oil
reservoir which is vented to the atmosphere. The pump then
mechanically pushes the fluid out into the discharge line.
The pumping action can be visualized by considering a simple
piston pump as shown in Fig. Essentially, a pump consists of a
inlet port connected to the hydraulic fluid source (i.e. and oil
reservoir), a pumping chamber attached to a drive mechanism
(prime mover) and an outlet port connected to the hydraulic
system.
71
72
The pump consists of two ball check valves:
Check Valve 1: It is connected to the pump inlet line and allows the
fluid to enter the pump only. It is the inlet valve.
Check Valve 2: It is connected to the pump outlet line and allows the
fluid to leave the pump only. It is the outlet valve.
Now, when the piston is pulled to the left, a partial vacuum is created
in the pumping chamber. This vacuum keeps the outlet valve 2 in a
closed position and allows the atmospheric pressure to push the fluid
from the reservoir into the pump via the inlet valve 1, which is open.
When the piston is pushed to the right, the fluid movement closes
the inlet valve 1 and forcibly ejects out the fluid via the outlet valve 2
which opens into the discharge line. Thus, the fluid is pumped.
Note:
1) A pump is not a source of power. The source of power is the prime
mover which drives the pump.
2) A pump does not pump pressure. It produces flow. The pressure is
developed due to the resistance afford by the hydraulic system to this73
flow.
Classification of Hydraulic Pumps
• These are mainly classified into two categories:
– Non-positive displacement pumps:
• Centrifugal pump
• Axial Propeler pump
• Mixed flow pump
– Positive displacement pumps:
• Gear pump
• Vane pump
• Piston pump
74
75
of pump shaft, it is referred to as
positive displacement pump.
76
77
78
Non-Positive Displacement Pumps
• These pumps are also known as hydro-dynamic
pumps. In these pumps the fluid is pressurized by the
rotation of the propeller and the fluid pressure is
proportional to the rotor speed. These pumps can not
withstanding high pressures and generally used for
low-pressure and high-volume flow applications.
• The fluid pressure and flow generated due to inertia
effect of the fluid. The fluid motion is generated due to
rotating propeller.
• These pumps provide a smooth and continuous flow
but the flow output decreases with increase in system
resistance (load). The flow output decreases because
some of the fluid slip back at higher resistance.
79
Non-Positive Displacement Pumps
• The fluid flow is completely stopped at very large system
resistance and thus the volumetric efficiency will become
zero. Therefore, the flow rate not only depends on the
rotational speed but also on the resistance provided by the
system.
• The important advantages of non-positive displacement
pumps are lower initial cost, less operating maintenance
because of less moving parts, simplicity of operation, higher
reliability and suitability with wide range of fluid etc.
• These pumps are primarily used for transporting fluids and
find little use in the hydraulic or fluid power industries.
Centrifugal pump is the common example of non-positive
displacement pumps
80
Positive displacement pump
• These pumps deliver a constant volume of fluid in a
cycle. The discharge quantity per revolution is fixed in
these pumps and they produce fluid flow proportional
to their displacement and rotor speed. These pumps
are used in most of the industrial fluid power
applications.
• The output fluid flow is constant and is independent of
the system pressure (load). The important advantage
associated with these pumps is that the high-pressure
and low-pressure areas (means input and output
region) are separated and hence the fluid cannot leak
back due to higher pressure at the outlets
81
• These features make the positive displacement pump
most suited and universally accepted for hydraulic
systems.
• The important advantages of positive displacement
pumps over non-positive displacement pumps include
capability to generate high pressures, high volumetric
efficiency, high power to weight ratio, change in
efficiency throughout the pressure range is small and
wider operating range pressure and speed.
• The fluid flow rate of these pumps ranges from 0.1
and 15,000 gpm, the pressure head ranges between 10
and 100,000 psi and specific speed is less than 500.
82
• It is important to note that the positive displacement pumps do not
produce pressure but they only produce fluid flow. The resistance
to output fluid flow generates the pressure.
• It means that if the discharge port (output) of a positive
displacement pump is opened to the atmosphere, then fluid flow
will not generate any output pressure above atmospheric pressure.
• But, if the discharge port is partially blocked, then the pressure will
rise due to the increase in fluid flow resistance.
• If the discharge port of the pump is completely blocked, then an
infinite resistance will be generated. This will result in the breakage
of the weakest component in the circuit.
• Therefore, the safety valves are provided in the hydraulic circuits
along with positive displacement pumps.
• Important positive displacement pumps are gears pumps, vane 83
pumps and piston pumps
Type of positive Displacement Pump
• Positive displacement pumps are further classified as fixed
and variable displacement type.
1. Fixed displacement Pump:
• displacement pump is the one in which the amount of fluid
ejected per revolution (displacement) is constant. Here, the
internal pump volume cannot be adjusted without replacing
certain components, and hence the pump is considered to
have a fixed displacement. A unidirectional fixed displacement
pump capable of delivering pressurised fluid from either port
is indicated by the symbol of Fig
• Note: The volume flow rate can also be varied by varying the
drive speed. However, this is a less desirable alternative than
varying the internal displacement to change the pump output.
84
Fixed Delivery, Displacement Pump Symbol
85
2. Variable Displacement Pump:
• A variable displacement pump is the one in
which the amount of fluid ejected per
revolution (displacement) can be varied even
though the pump speed remains constant.
This displacement is varied by varying the size
of the pumping chamber, using external
controls
86
• A slash arrow across the fixed displacement pump
symbol indicates that the pump displacement can
be varied. Fig. (a) shows the simplified symbol,
while Fig. (b) shows the complete symbol
indicating manual control by the parallel lines at
the left with the vertical terminating line. The
drain if included is always shown in the complete
symbol Direction of rotation is also included, if
pertinent.
• Bi-directional, variable displacement pumps are
illustrated as in Fig. (c) & Fig. (d)
87
88
Gear Pumps
• Gear pump is a robust and simple positive displacement
pump. It has two meshed gears revolving about their
respective axes. These gears are the only moving parts in
the pump.
• They are compact, relatively inexpensive and have few
moving parts. The rigid design of the gears and houses
allow for very high pressures and the ability to pump
highly viscous fluids. They are suitable for a wide range
of fluids and offer self-priming performance.
• Sometimes gear pumps are designed to function as
either a motor or a pump. These pump includes helical
and herringbone gear sets (instead of spur gears), lobe
shaped rotors similar to Roots blowers (commonly used
as superchargers), and mechanical designs that allow the
stacking of pumps. 89
Gear Pumps
• Based upon the design, the gear pumps are
classified as:
– External gear pumps
– Lobe pumps
– Internal gear pumps
– Gerotor pumps
– Screw pumps
90
Gear Pumps
Generally gear pumps are used to pump:
• Petrochemicals: Pure or filled bitumen, pitch, diesel
oil, crude oil, lube oil etc.
• Chemicals: Sodium silicate, acids, plastics, mixed
chemicals, iso-cyanates etc.
• Paint and ink
• Resins and adhesives
• Pulp and paper: acid, soap, lye, black liquor, kaolin,
lime, latex, sludge etc.
• Food: Chocolate, cacao butter, fillers, sugar, vegetable
fats and oils, molasses, animal food etc
91
Gear Pumps : External gear pump
• The external gear pump consists of externally meshed
two gears housed in a pump case.
• One of the gears is coupled with a prime mover and is
called as driving gear and another is called as driven
gear.
• The rotating gear carries the fluid from the tank to the
outlet pipe.
• The suction side is towards the portion whereas the
gear teeth come out of the mesh.
• When the gears rotate, volume of the chamber
expands leading to pressure drop below atmospheric
value.
• Therefore the vacuum is created and the fluid is
pushed into the void due to atmospheric pressure. 92
93
• The fluid is trapped between housing and rotating
teeth of the gears.
• The discharge side of pump is towards the portion
where the gear teeth run into the mesh and the
volume decreases between meshing teeth.
• The pump has a positive internal seal against leakage;
therefore, the fluid is forced into the outlet port.
• The gear pumps are often equipped with the side wear
plate to avoid the leakage. The clearance between
gear teeth and housing and between side plate and
gear face is very important and plays an important role
in preventing leakage. In general, the gap distance is
less than 10 micrometers. 94
• The amount of fluid discharge is determined by the
number of gear teeth, the volume of fluid between
each pair of teeth and the speed of rotation.
• The important drawback of external gear pump is the
unbalanced side load on its bearings.
• It is caused due to high pressure at the outlet and low
pressure at the inlet which results in slower speeds
and lower pressure ratings in addition to reducing the
bearing life.
• Gear pumps are most commonly used for the
hydraulic fluid power applications and are widely used
in chemical installations to pump fluid with a certain
viscosity.
95
96
97
Most gear pumps are spur, helical or herringbone designs
i. Spur type gear pumps are generally less expensive but are
noisy at relatively high speeds.
ii. Helical type gear pumps are relatively less noisy, but they
are limited to low pressure applications (below 15 bar)
because they develop excessive end thrust.
iii. Herringbone gear pumps are the quietest; provide greater

flow rates with much less pulsating action. They eliminate
the thrust action and used to develop a much higher
pressure (above 50 bar)
98
Gear Pumps : Internal gear pump
• Internal gear pumps are exceptionally versatile. They are often used
for low or medium viscosity fluids such as solvents and fuel oil and
wide range of temperature. This is non- pulsing, self-priming and
can run dry for short periods. It is a variation of the basic gear
pump.
99
• It comprises of an internal gear, a regular spur gear, a
crescent-shaped seal and an external housing. The
schematic of internal gear pump is shown in figure .
• Liquid enters the suction port between the rotor (large
exterior gear) and idler (small interior gear) teeth.
Liquid travels through the pump between the teeth and
crescent. Crescent divides the liquid and acts as a seal
between the suction and discharge ports.
• When the teeth mesh on the side opposite to the
crescent seal, the fluid is forced out through the
discharge port of the pump. This clearance between
gears can be adjusted to accommodate high
temperature, to handle high viscosity fluids and to
accommodate the wear. 100
• These pumps are bi-rotational so that they can be
used to load and unload the vessels.
• As these pumps have only two moving parts and
one stuffing box, therefore they are reliable,
simple to operate and easy to maintain.
• However, these pumps are not suitable for high
speed and high pressure applications. Only one
bearing is used in the pump therefore overhung
load on shaft bearing reduces the life of the
bearing.
101
Applications
• Some common internal gear pump applications are:
• All varieties of fuel oil and lube oil
• Resins and Polymers
• Alcohols and solvents
• Asphalt, Bitumen, and Tar
• Polyurethane foam (Iso-cyanate and polyol)
• Food products such as corn syrup, chocolate, and peanut butter
• Paint, inks, and pigments
• Soaps and surfactants
• Glycol
102
Gear Pumps : Gerotor pump
• Gerotor is a positive displacement pump. The name Gerotor is
derived from "Generated Rotor". At the most basic level, a Gerotor
is essentially one that is moved via fluid power. Originally this fluid
was water, today the wider use is in hydraulic devices.
• The schematic of Gerotor pump is shown in figure .
• Gerotor pump is an internal gear pump without the crescent. It
consists of two rotors viz. inner and outer rotor. The inner rotor
has N teeth, and the outer rotor has N+1 teeth. The inner rotor is
located off-center and both rotors rotate.
• The geometry of the two rotors partitions the volume between
them into N different dynamically-changing volumes. During the
rotation, volume of each partition changes continuously.
Therefore, any given volume first increases, and then decreases.
An increase in volume creates vacuum. This vacuum creates
suction, and thus, this part of the cycle sucks the fluid. As the
volume decreases, compression occurs. During this compression
period, fluids can be pumped, or compressed (if they are gaseous
fluids). 103
104
The operation of the gerotor pump is as shown in Figure During
the initial half of the cycle, the gradual enlarging chamber is
exposed to the inlet port, creating a partial vacuum into which
the hydraulic fluid flows. During the next 180 of the revolutions
the chamber gradually decreases in size as the teeth mesh, and
the fluid is forced out through the outlet port into the system.
105
• The close tolerance between the gears acts as a seal
between the suction and discharge ports. Rotor and idler
teeth mesh completely to form a seal equidistant from the
discharge and suction ports. This seal forces the liquid out
of the discharge port. The flow output is uniform and
constant at the outlets.
• The important advantages of the pumps are high speed
operation, constant discharge in all pressure conditions,
bidirectional operation, less sound in running condition and
less maintenance due to only two moving parts and one
stuffing box etc. However, the pump is having some
limitations such as medium pressure operating range,
clearance is fixed, solids can’t be pumped and overhung
load on the shaft bearing etc.
106
Applications
• Gerotors are widely used in industries and are
produced in variety of shapes and sizes by a number of
different methods. These pumps are primarily suitable
for low pressure applications such as lubrication
systems or hot oil filtration systems, but can also be
found in low to moderate pressure hydraulic
applications. However common applications are as
follows:
• Light fuel oils
• Lube oil
• Cooking oils
• Hydraulic fluid
107
Gear Pumps : Lobe pump
• Lobe pumps work on the similar principle of working as that
of external gear pumps. However in Lobe pumps, the lobes
do not make any contact like external gear pump.
• Lobe contact is prevented by external timing gears located
in the gearbox. Similar to the external gear pump, the lobes
rotate to create expanding volume at the inlet.
• Now, the fluid flows into the cavity and is trapped by the
lobes. Fluid travels around the interior of casing in the
pockets between the lobes and the casing.
• Finally, the meshing of the lobes forces liquid to pass
through the outlet port. The bearings are placed out of the
pumped liquid. Therefore the pressure is limited by the
bearing location and shaft deflection
108
109
• Because of superb sanitary qualities, high efficiency,
reliability, corrosion resistance and good clean-in-place
and steam-in-place (CIP/SIP) characteristics, Lobe
pumps are widely used in industries such as pulp and
paper, chemical, food, beverage, pharmaceutical and
biotechnology etc.
• These pumps can handle solids (e.g., cherries and
olives), slurries, pastes, and a variety of liquids. A
gentle pumping action minimizes product degradation.
• They also offer continuous and intermittent reversible
flows. Flow is relatively independent of changes in
process pressure and therefore, the output is constant
and continuous.
110
• Lobe pumps are frequently used in food applications
because they handle solids without damaging the
product. Large sized particles can be pumped much
effectively than in other positive displacement types.
As the lobes do not make any direct contact therefore,
the clearance is not as close as in other Positive
displacement pumps. This specific design of pump
makes it suitable to handle low viscosity fluids with
diminished performance.
• Loading characteristics are not as good as other
designs, and suction ability is low. High- viscosity
liquids require reduced speeds to achieve satisfactory
performance. The reduction in speed can be 25% or
more in case of high viscosity fluid
111
Screw Pumps
• The screw pump is an axial flow positive
displacement unit.
• It consists of three precision ground screws,
meshing within a close fitting housing. One screw
transmits power and is known as power rotor. The
remaining two screws act as idlers.
• The two symmetrically opposed idler rotors turn
because of the action of the fluid transferred
through the pump.
• They act as the rotating sealing elements and
perform no work themselves
112
Screw Pumps
113
Screw Pumps
• Pumping action occurs when the meshing of the
rotors seal and enfold the fluid and then transfer it
to the enclosures continuously in an uniform
manner.
• The idlers are in rolling contact with the central
power rotor and are free to float in their
respective housing bores on an hydrodynamic oil
film. There are no radial bending loads.
• Axial unbalanced forces on the rotor set are
supported by balance piston and thrust cage as
shown in Figure
114
Vane Pumps
• The Gear pumps have a disadvantage of small
leakage due to gap between gear teeth and the
pump housing.
• This limitation is overcome in vane pumps.
• The leakage is reduced by using spring or
hydraulically loaded vanes placed in the slots of
driven rotor.
• Capacity and pressure ratings of a vane pump are
generally lower than the gear pumps, but reduced
leakage gives an improved volumetric efficiency of
around 95%.
115
Vane Pumps
• Vane pumps are available in a number of vane
configurations including sliding vane, flexible vane,
swinging vane, rolling vane, and external vane etc.
• Each type of vane pump has its own advantages.
For example, external vane pumps can handle large
solids. Flexible vane pumps can handle only the
small solids but create good vacuum. Sliding vane
pumps can run dry for short periods of time and
can handle small amounts of vapor.
• The vane pumps are known for their dry priming,
ease of maintenance, and good suction
characteristics. The operating range of these
pumps varies from -32 °C to 260 °C. 116
Vane Pumps
117
Vane Pumps
• The schematic of vane pump working principle is
shown in figure. Vane pumps generate a pumping
action by tracking of vanes along the casing wall.
• The vane pumps generally consist of a rotor, vanes,
ring and a port plate with inlet and outlet ports.
• The rotor in a vane pump is connected to the prime
mover through a shaft.
• The vanes are located on the slotted rotor.
• The rotor is eccentrically placed inside a cam ring as
shown in the figure.
• The rotor is sealed into the cam by two side plates.
118
Vane Pumps
• When the prime mover rotates the rotor, the vanes are
thrown outward due to centrifugal force.
• The vanes track along the ring. It provides a tight hydraulic
seal to the fluid which is more at the higher rotation speed
due to higher centrifugal force.
• This produces a suction cavity in the ring as the rotor
rotates.
• It creates vacuum at the inlet and therefore, the fluid is
pushed into the pump through the inlet.
• The fluid is carried around to the outlet by the vanes whose
retraction causes the fluid to be expelled.
• The capacity of the pump depends upon the eccentricity,
expansion of vanes, width of vanes and speed of the rotor.
• It can be noted that the fluid flow will not occur when the
eccentricity is zero. 119
Vane Pumps
• These pumps can handle thin liquids (low
viscosity) at relatively higher pressure.
• These pumps can be run dry for a small duration
without any failure.
• These pumps develop good vacuum due to
negligible leakage.
• However, these pumps are not suitable for high
speed applications and for the high viscosity fluids
or fluids carrying some abrasive particles.
• The maintenance cost is also higher due to many
moving parts
120
Vane Pumps
These pumps have various applications for the
pumping of following fluids:
– Aerosol and Propellants
– Aviation Service - Fuel Transfer, Deicing
– Auto Industry - Fuels, Lubes, Refrigeration Coolants
– Bulk Transfer of LPG and NH3
– LPG Cylinder Filling
– Alcohols
– Refrigeration - Freons, Ammonia
– Solvents
– Aqueous solutions
121
Vane Pumps
• Vane pumps are classified as fixed or variable
displacement types and unbalanced or
balanced design. Three pump combinations
are available:
1. Unbalanced, Fixed displacement vane
pump
2. Unbalanced, Variable displacement Vane
pump
3. Balanced, Fixed displacement Vane pump
122
Vane Pumps : Unbalanced Vane pump
• In practice, the vane pumps have more than one vane as
shown in figure .
• The rotor is offset within the housing, and the vanes are
constrained by a cam ring as they cross inlet and outlet
ports.
• Although the vane tips are held against the housing, still a
small amount of leakage exists between rotor faces and
body sides.
• Also, the vanes compensate to a large degree for wear at
the vane tips or in the housing itself.
• The pressure difference between outlet and inlet ports
creates a large amount of load on the vanes and a
significant amount of side load on the rotor shaft which can
lead to bearing failure.
• This type of pump is called as unbalanced vane pump.
123
124
• The essential components of the vane pump include the
inlet and outlet ports, the driven rotor, sliding vanes, and a
stationary cam ring.
• The rotor, vanes and cam ring, and sometimes the end wear
plates, are replaceable as a cartridge unit. The rotor is
eccentrically mounted on the stationary cam-ring.
• The rotor is splined to the pump shaft and rotates within
the cam ring. The vanes are located in the radial rotor slots
and follow the contour of the cam-ring.
• During startup only the centrifugal force and during
operation both the centrifugal and the force due to system
pressure are responsible to move the vanes against the
hardened and ground contour of the cam ring.
• The wear plates are against both sides of the cam-ring thus
making up the pumping element
125
• While passing over the inlet port, the sliding vanes are
extended out of the rotor slots, thereby increasing the
volume of the suction side.
• The increasing volume creates suction at the inlet port and
causes the fluid to enter the low pressure inlet cavity.
• The inlet and outlet ports are isolated from each other by
the spacing of the vanes.
• As the rotor turns, this fluid gets trapped between the
rotating vanes and is transferred to the outlet port.
• While passing over the outlet port, the sliding vanes are
retracted back into the rotor slots, thereby decreasing the
crescent shaped space between the rotor and cam-ring.
• This decreasing volume causes the fluid to be ejected out of
the outlet port into the system
126
• This pump permits the pumping action on one
side of the rotor only.
• Now, there is a large difference in pressure
between the inlet and outlet ports.
• This pressure difference creates a severe load on
the vanes and a large side load on the bearings of
the rotor shaft. Hence, it is said to be ‘unbalanced
design’.
• Note: This same undesirable side load exist for the

gear pump also. Hence, they are also unbalanced
design type
127
Vane Pumps : Balanced Vane pump
128
Vane Pumps : Balanced Vane pump
• Figure shows the schematic of a balanced vane pump.
• This pump has an elliptical cam ring with two inlet and
two outlet ports.
• Pressure loading still occurs in the vanes but the two
identical pump halves create equal but opposite forces
on the rotor.
• It leads to the zero net force on the shaft and bearings.
• Thus, lives of pump and bearing increase significantly.
• Also the sounds and vibrations decrease in the running
mode of the pump.
129
Vane Pumps : Adjustable Vane pump
• The proper design of pump is important and a challenging
task. In ideal condition, the capacity of a pump should be
exactly same to load requirements.
• A pump with larger capacity wastes energy as the excess
fluid will pass through the pressure relief valve. It also leads
to a rise in fluid temperature due to energy conversion to
the heat instead of useful work and therefore it needs some
external cooling arrangement.
• Therefore, the higher capacity pump increases the power
consumption and makes the system bulky and costly.
• Pumps are generally available with certain standard
capacities and the user has to choose the next available
capacity of the pump. Also, the flow rate from the pump in
most hydraulic applications needs to be varying as per the
requirements
130
• Therefore, some vane pumps are also available
with adjustable capacity as shown in figure.
• This can be achieved by adjusting a positional
relationship between rotor and the inner casing
by the help of an external controlling screw.
• These pumps basically consist of a rotor, vanes,
cam ring, port plate, thrust bearing for guiding the
cam ring and a discharge control screw by which
the position of the cam ring relative to the rotor
can be varied.
• In general, the adjustable vane pumps are
unbalanced pump type
131
132
• The amount of fluid that is displaced by a vane pump
running at a constant speed is determined by the maximum
extension of the vanes and the vanes width.
• However, for a pump running in operation, the width of
vanes cannot be changed but the distance by which the
vanes are extended can be varied.
• This is possible by making a provision for changing the
position of the cam ring (adjustable inner casing) relative to
the rotor as shown in figure.
• The eccentricity of rotor with respect to the cam ring is
adjusted by the movement of the screw.
• The delivery volume increases with increase in the
eccentricity. This kind of arrangement can be used to
achieve a variable volume from the pump and is known as
variable displacement vane pump.
133
• In general, the adjusted vane pumps are pressure
compensated. It means that the discharge is controlled by
pre-adjusted value and when the discharge pressure
reaches a certain (adjusted) value; the pumping action
ceases.
• This mechanism is accomplished by using a compensating
spring to offset the cam ring.
• Initially, the eccentricity is maximum because the discharge
pressure is zero and spring force keeps the cam ring at the
extreme right position. As the discharge pressure increases,
it acts on the inner contour of the cam ring. It pushes the
cam ring towards the left against the spring force and hence
the eccentricity reduces and hence the discharge through
the pump reduces.
134
• When the discharge pressure becomes high enough to
overcome the entire spring force; the compensator spring
will compress until the zero eccentricity is achieved.
• In this condition, the pumping action ceases and the fluid
flow (except small leakages) does not occur.
• Therefore, the system pressure can be adjusted by setting
the compensator spring.
• These pumps ensure their own protection against excessive
system pressure and do not rely on the safety control
devices of the hydraulic system.
• These pumps are used as energy savings devices and have
been used in many applications, including automotive
transmissions.
135
Piston Pumps
• Piston pumps are meant for the high-pressure applications.
These pumps have high- efficiency and simple design and
needs lower maintenance.
• These pumps convert the rotary motion of the input shaft to
the reciprocating motion of the piston. These pumps work
similar to the four stroke engines.
• They work on the principle that a reciprocating piston draws
fluid inside the cylinder when the piston retracts in a
cylinder bore and discharge the fluid when it extends.
• Generally, these pumps have fixed inclined plate or variable
degree of angle plate known as swash plate (shown in
Figure).
• When the piston barrel assembly rotates, the swash plate
in contact with the piston slippers slides along its surface.
• The stroke length (axial displacement) depends on the
inclination angle of the swash plate. 136
Piston Pumps
• When the swash plate is vertical, the reciprocating motion
does not occur and hence pumping of the fluid does not
take place.
• As the swash plate angle increases, the piston reciprocates
inside the cylinder barrel.
• The stroke length increases with increase in the swash plate
angle and therefore volume of pumping fluid increases.
• During one half of the rotation cycle, the pistons move out
of the cylinder barrel and the volume of the barrel
increases. During another half of the rotation, the pistons
move into the cylinder barrel and the barrel volume
decreases.
• This phenomenon is responsible for drawing the fluid in and
pumping it out. These pumps are positive displacement
pump and can be used for both liquids and gases.
137
Piston Pumps
• Piston pumps are basically of two types:
– Axial piston pumps
– Radial piston pumps
Radial Piston Pump: Here the pistons are arranged radially

in a cylinder block. It operates by converting the rotary shaft
motion to radial reciprocating piston motion.
Axial Piston Pump: Here the pistons are arranged parallel

to each other and to the axis of the cylinder block. This
pump operates on the principle of converting rotary shaft
motion into axial reciprocating piston motion. Piston pumps
are available in both fixed displacement design and variable
displacement design.
138
Piston Pumps : Axial Piston Pump
• Axial piston pumps are positive displacement pumps which
converts rotary motion of the input shaft into an axial
reciprocating motion of the pistons.
• These pumps have a number of pistons (usually an odd number) in
a circular array within a housing which is commonly referred to as
a cylinder block, rotor or barrel.
• These pumps are used in jet aircraft. They are also used in small
earthmoving plants such as skid loader machines. Another use is
to drive the screws of torpedoes.
• In general, these systems have a maximum operating temperature
of about 120 °C. Therefore, the leakage between cylinder housing
and body block is used for cooling and lubrication of the rotating
parts. This cylinder block rotates by an integral shaft aligned with
the pistons.
• These pumps have sub-types as:
– Bent axis piston pumps
– Swash plate axial piston pump 139
Bent-Axis Piston Pumps
• Figure shows the schematic of bent axis piston pump.
• In these pumps, the reciprocating action of the pistons is
obtained by bending the axis of the cylinder block.
• The cylinder block rotates at an angle which is inclined to
the drive shaft. The cylinder block is turned by the drive
shaft through a universal link. The cylinder block is set at an
offset angle with the drive shaft. The cylinder block contains
a number of pistons along its periphery.
• These piston rods are connected with the drive shaft flange
by ball-and- socket joints. These pistons are forced in and
out of their bores as the distance between the drive shaft
flange and the cylinder block changes.
• A universal link connects the block to the drive shaft, to
provide alignment and a positive drive.
140
141
• The volumetric displacement (discharge) of the pump is
controlled by changing the offset angle. It makes the system
simple and inexpensive.
• The discharge does not occur when the cylinder block is
parallel to the drive shaft.
• The offset angle can vary from 0° to 40°.
• The fixed displacement units are usually provided with 23°
or 30° offset angles while the variable displacement units
are provided with a yoke and an external control
mechanism to change the offset angle.
• Some designs have arrangement of moving the yoke over
the center position to reverse the fluid flow direction.
• The flow rate of the pump varies with the offset angle q .
There is no flow when the cylinder block centerline is
parallel to the drive shaft centerline (offset angle is 0°).
142
143
Swash Plate Axial Piston Pump
• A swash plate is a device that translates the rotary
motion of a shaft into the reciprocating motion. It
consists of a disk attached to a shaft as shown in
Figure 5.3.6. If the disk is aligned perpendicular to the
shaft; the disk will turn along with the rotating shaft
without any reciprocating effect. Similarly, the edge of
the inclined shaft will appear to oscillate along the
shaft's length. This apparent linear motion increases
with increase in the angle between disk and the shaft
(offset angle). The apparent linear motion can be
converted into an actual reciprocating motion by
means of a follower that does not turn with the swash
plate
144
145
• In swash plate axial piston pump a series of pistons are aligned
coaxially with a shaft through a swash plate to pump a fluid.
• The schematic of swash plate piston pump is shown in Figure.
• The axial reciprocating motion of pistons is obtained by a swash
plate that is either fixed or has variable degree of angle.
• As the piston barrel assembly rotates, the piston rotates around
the shaft with the piston shoes in contact with the swash plate.
• The piston shoes follow the angled surface of the swash plate and
the rotational motion of the shaft is converted into the
reciprocating motion of the pistons.
• When the swash plate is perpendicular to the shaft; the
reciprocating motion to the piston does not occur.
• As the swash plate angle increases, the piston follows the angle of
the swash plate surface and hence it moves in and out of the 146
barrel.
• The piston moves out of the cylinder barrel during one half of
the cycle of rotation thereby generating an increasing volume,
while during other half of the rotating cycle, the pistons move
into the cylinder barrel generating a decreasing volume.
• This reciprocating motion of the piston results in the drawing in
and pumping out of the fluid.
• Pump capacity can be controlled by varying the swash plate
angle with the help of a separate hydraulic cylinder. The pump
capacity (discharge) increases with increase in the swash plate
angle and vice-versa.
• The cylinder block and the drive shaft in this pump are located
on the same centerline. The pistons are connected through
shoes and a shoe plate that bears against the swash plate.
• These pumps can be designed to have a variable displacement
capability. It can be done by mounting the swash plate in a
movable yoke. The swash plate angle can be changed by
pivoting the yoke on pintles 147
Axial Piston Swash Plate Pump:
1. Cylinder
2. Piston
3. Swash plate
4. Slipper pad
5. Port plate
6. Slipper pad holder
Piston Pumps : Radial Piston Pump
• The typical construction of radial piston pump is
shown in Figure .
• The piston pump has pistons aligned radially in a
cylindrical block. It consists of a pintle, a cylinder
barrel with pistons and a rotor containing a reaction
ring. The pintle directs the fluid in and out of the
cylinder. Pistons are placed in radial bores around the
rotor.
• The piston shoes ride on an eccentric ring which
causes them to reciprocate as they rotate. The
eccentricity determines the stroke of the pumping
piston. Each piston is connected to inlet port when it
starts extending while it is connected to the outlet
port when start retracting.
149
• This connection to the inlet and outlet port is
performed by the timed porting arrangement in the
pintle. For initiating a pumping action, the reaction
ring is moved eccentrically with respect to the pintle or
shaft axis.
• As the cylinder barrel rotates, the pistons on one side
travel outward. This draws the fluid in as the cylinder
passes the suction port of the pintle. It is continued till
the maximum eccentricity is reached.
• When the piston passes the maximum eccentricity,
pintle is forced inwards by the reaction ring. This
forces the fluid to flow out of the cylinder and enter in
the discharge (outlet) port of the pintle.
150
151
• The radial piston pump works on high pressure (up to
1000 bar).
• It is possible to use the pump with various hydraulic
fluids like mineral oil, biodegradable oil, HFA (oil in
water), HFC (water-glycol), HFD (synthetic ester) or
cutting emulsion.
• This is because the parts are hydrostatically balanced.
It makes the pump suitable for the many applications
such as machine tools (displace of cutting emulsion,
supply for hydraulic equipment like cylinders), high
pressure units (overload protection of presses), test
rigs, automotive sector (automatic transmission,
hydraulic suspension control in upper-class cars),
plastic (powder injection molding) and wind energy
etc. 152
1.Fixed Displacement, Radial Piston Pump:
• As the cylinder barrel rotates, the piston on one side
travel outwards thereby increasing the volume in the
pintle opening. This is the inlet port. Due to increase in
volume, a partial pressure in created which sucks in
the fluid from the reservoir as each cylinder passes the
suction port.
• When the piston passes the point of maximum
eccentricity, it is forced in wards by the reaction ring.
This decrease in the volume, forces the fluid to enter
the discharge port of the pintle. This fluid is then
ejected into the system. Pump displacement is
determine by the size and the number of pistons (as
there may be more than one bank in a single cylinder
block) and the length of their stroke. 153
154
2. Variable Diplacement Radial Piston Pump:
• The piston displacement and volume flow rate in
radial piston pump design is varied by changing
the position of the reaction ring w.r.t. the center
line of the supporting pintle.
• This is accomplished either mechanically,
electrically or hydraulically to cause varying
conditions of flow. If the cam ring is moved over
center, the action of the pump reversed the
direction of fluid flow, even though the pump
continues to rotate at constant speed in the same
direction
155
156
157
Applications of Hydraulic Pumps
• Hydraulic pumps are used to transfer power via hydraulic liquid. These
pumps have a number of applications in automobiles, material handling
systems, automatic transmissions, controllers, compressors and
household items.
• The hand operated hydraulic pump is used in a hydraulic jack where
many strokes of the pump apply hydraulic pressure to lift the ram.
• A backhoe uses an engine driven hydraulic pump to drive the
articulating parts of the mechanical hoe.
• The hydraulic pumps are commonly used in the automotive vehicles
especially in power steering systems.
• The lift system of tractor is operated by the hydraulic pumps. These are
used in automatic transmissions and material handling systems in
industries.
• Many precise controllers are developed by using hydraulic pumps. The
commonly used compressor is operated by reciprocating pumps.
• The hydraulic pumps are also used in routine household systems like
power lift and air-conditions. Therefore, it can be said that the hydraulic
pumps have significant applications in industries as well as ones routine
life.
158
Types of Pumps Video
External Gear Pump - https://youtu.be/cMmwb3JmL00
Internal Gear Pump - https://youtu.be/y7_AtJoUY6g
Lobe Pump - https://youtu.be/wJmYEh7jBqI
Vane pump - https://youtu.be/L30JpM8Lv_A
Balance Vane Pump - https://youtu.be/b0_bGKHHHPM
Axial piston pump - https://youtu.be/t16h3Z1F7mY
Swash plate pump - https://youtu.be/_VSOgJn-3wo
Radial piston Pump - https://youtu.be/2T-6jDm_ebI
159
Pump Performance
The performance of a pump is a function of the precision of its manufacture.
An ideal pump is one having zero clearance between all mating parts. Because
this is not possible, working clearances should be as small as possible while
maintaining proper oil films for lubrication between rubbing parts. The
performance of a pump is determined by the following efficiencies:
1. Volumetric efficiency (ƞv ):It is the ratio of actual flow rate of the pump to the
theoretical flow rate of the pump. This is expressed as follows:
Volumetric efficiency (ƞv ) indicates the amount of leakage that takes place within the
pump. This is due to manufacture tolerances and flexing of the pump casing under
designed pressure operating conditions.
For gear pumps, = 80%–90%.
For vane pumps, = 92%.
For piston pumps, = 90%–98%.
160
Pump Performance
2. Mechanical efficiency ( ƞm): Itis the ratio of the pump output power assuming no
leakage to actual power delivered to the pump:
Mechanical efficiency(ƞm ) indicates the amount of energy losses that occur

for reasons other than leakage. This includes friction in bearings and between
mating parts. This includes the energy losses due to fluid turbulence.
Mechanical efficiencies are about 90%–95%. We also have the relation
Where p is the pump discharge pressure in Pa or N/m2,

QT is the theoretical flow rate of the pump in m3/s,
TA is the actual torque delivered to the pump in Nm and
N is the speed of the pump in rad/s.
161
Pump Performance
The actual torque (TA ) is determined as follows
162
Pump Performance
163
Pump Performance
Example 1
A gear pump has an outside diameter of 82.6 mm, inside diameter of 57.2 mm and a
width of 25.4 mm. If the actual pump flow is 1800 RPM and the rated pressure is
0.00183 m3 /s, what is the volumetric efficiency?
Do=82.6 mm= 0.0826 m

Di = 57.2 mm = 0.0572m
d = 25.4mm = 0.0254 m
N = 1800 RPM
QA= 0.00183 m^3/s
Ƞv = QA/QT
QT = ∏/4(Do^2 – Di^2) x d m3/Rev.
QT = ∏/4(Do^2 – Di^2) x d x 1800/60
QT = 2.125 X10^-3 m^3/s
Ƞv = 0.00183/2.125 X10^-3
= 0.8611x 100= 86.11%
164
Pump Performance
Example 2
A pump having a volumetric efficiency of 96% delivers 29 LPM of oil at 1000 RPM.
What is the volumetric displacement of the pump?
Solution:
Ƞv = 96%
QA = 29 LPM = 29 X 10^-3 m^3/min
N = 1000RPM
Ƞv = QA/QT
0.96 = 29/QT
QT = 29/0.96
QT = 30.203LPM
Volumetric displacement =
= QT/N
= 30.203 X 10^-3 (m^3/min)/1000
= 30.208 x 10^-6 m^3/Rev.
= 30.208 x 10^-6 m^3/Rev. x 1000
= 0.03021 L/Rev.
165
Pump Performance Curve
Pump performance characteristics are first analyzed
independently of the rest of hydraulic system and then as a part
of the system. Both sets of data are valuable to the designer.
Analyzing the pump by itself gives an indication of its capabilities
and performance based on the speed of rotation, internal
geometry, cost factors, etc., whereas analyzing pump
performance in system essentially determines pump system
compatibility. In the first case, the system designer may observe
performance curves to see if a specific pump has the pressure
and volume flow rate to operate a given set of actuators.
166
Figure shows a graphical
representation of a typical
positive displacement pump.
Figure represents the
relationship between input
power and pump output flow of
a variable displacement piston
pump as a function of pump
speed. Observe the linear
relationship between the
discharge flow and pump speed.
167
Figure gives curves of overall and

volumetric efficiencies as a function of
speed.
168
Discharge flow of these

pumps is nearly constant over
a broad pressure range.
Discharge flow can be varied
infinitely between the point of
inflection on the constant
discharge portion of the curve
and zero flow.
169
Pump Noise
Pump noise is an important parameter used to
determine the performance. Any increase in noise
indicates increased wear and eventually pump
failure. Pumps are good generators but poor
radiators of noise. Noise is not just the sound
coming directly from the pump, but also from the
vibration and fluid pulsation produced by the
pump. Pumps are small in size and hence, they are
poor radiators of noise. Reservoirs, electric motors
and piping being larger in size are better radiators.
Hence, a pump-induced vibration can cause
audible noise greater than that coming from the
pump. Fixed displacement pumps are less noisy
than variable displacement pumps because of their
rigid construction. As can be seen from Fig. the
pump speed has a strong effect on noise compared
to displacement and pressure. To reduce the noise
levels, electric motors are used and the most
advantageous combination of size and pressure is
selected to produce the needed power.
170
Pump Cavitation
During the working of a positive displacement pump, vacuum is created at the
inlet of the pump. This allows atmospheric pressure to push the fluid in. In some
situations, the vacuum may become excessive, and a phenomenon known as
cavitation occurs.
When the pressure of the liquid reaches a low enough level, it vaporizes or boils.
Cavitation is the formation of oil vapor bubbles due to a very low pressure (high
vacuum) on the inside of the pump.
The low pressure also causes air, which is dissolved in the oil to come out of the
solution and form bubbles.
These air and oil vapor bubbles collapse when they reach the outlet side of the
pump, which is under a high pressure. The collapsing of these vapor bubbles
causes extremely high localized pressure and fluid velocity.
These pressures are so high that they cause pitting of metal and consequently
decrease the life and efficiency of the pump.
171
Pump Cavitation
Cavitation is caused by the following factors:
1. Undersized plumbing.
2. Clogged lines or suction filters.
3. High fluid viscosity.
4. Too much elevation head between the reservoir and the pump
inlet.
Following are the rules to control cavitation:
1. Keep suction line velocities below 1.2 m/s.
2. Keep the pump inlet lines as short as possible.
3. Minimize the number of fittings in the inlet line.
4. Mount the pump as close as possible to the reservoir.
5. Use low-pressure drop inlet filters.
6. Use proper oil as recommended by the pump manufacturer.
172
Pump Selection
The main parameters affecting the selection of a particular type of pump are as
follows:
1. Maximum operating pressure.
2. Maximum delivery.
3. Type of control.
4. Pump drive speed.
5. Type of fluid.
6. Pump contamination tolerance.
7. Pump noise.
8. Size and weight of a pump.
9. Pump efficiency.
10. Cost.
11. Availability and interchangeability.
12. Maintenance and spares.
173
Pump Selection
1.Maximum Operating Pressure
This is determined by the power requirement of the circuit, the particular
application, availability of components, type of fluid and to some extent the
environment and level of labor both using and maintaining the equipment.
In general, the higher the operating pressure, the higher the component cost and
the lower the choice of components. The main advantage of higher working
pressures is the reduction in fluid flow rates for a given system power, resulting in
smaller pumps, smaller bore pipes and smaller components. The disadvantage is
that at higher working pressures, the compressibility of the fluid used can have
considerable adverse effects where precision control is required over a wide
range of loads.
The general tendency is toward increased operating pressures. The operating
pressures of pumps depend to some extent on the fluid used. A fire-resistant
fluid is generally not as good lubricant as a mineral oil. So to give a reasonable
pump life expectancy when using a fire-resistant fluid, the maximum operating
pressure must be reduced and it is advisable to consult the pump manufacturer.
174
Pump Selection
2.Maximum Delivery
The pump system selected must be capable of delivering the maximum flow rate
demanded by the circuit. If the circuit demand is reasonably constant, a fixed
displacement pump is chosen. When the demand is at a series of fixed levels, a
multi-pump system is used. For demands which vary within a relatively narrow
band, a variable displacement pump is used. If there is a wide variance in system
demand, an accumulator circuit may best satisfy the requirements.
Pump capacities are stated by manufactures for a particular viscosity fluid at
given operating temperatures and pressures. Any increase in temperature and
hence a reduction in viscosity or an increase in operating pressure causes more
leakage across the pump and consequently reduces the pump delivery. As the
pump wears the leakage will increase.It is usual to select a pump with a capacity
about 10% higher than that required to make an allowance for the reduction in
volumetric efficiency with wear. Pumps are available with flows from a fraction of
1 LPM to–1000 LPM and above.
175
Pump Selection
3. Type of Control
Various types of pump controls are available such as manual servo

control, pressure compensated control, constant power control and
constant flow control. The choice of control is dependent upon the
circuit requirement such as complexity, accuracy of control, cost, type of
machining operation, etc. The designer has to choose carefully the type
of control after a detailed study of system characteristics.
176
Pump Selection
4. Pump Drive Speed
A majority of pumps are driven directly from the prime mover –

electric motor or internal combustion engine–so the proposed
drive speed is known. The fluid delivery rate is proportional to the
speed of rotation. Each design has a minimum and maximum
operating speed: the faster the pump runs, the shorter its life.
177
Pump Selection
5.Types of Fluid
Pumps are designed to operate within a particular range of fluid
viscosity. Mineral oils of the correct viscosity work satisfactory
with most pumps provided the oil is clean. Operating with
synthetic or water-based fluids reduces the working life of a pump
that relies on the hydraulic fluid to lubricate the bearings and
moving parts. When any fluid other than a mineral oil is to be
used, it is advisable to seek the pump manufacturer’s advice.
178
Pump Selection
6.Fluid Contamination
Any fluid contamination causes pump damage. Precision pumps
with very fine clearances are more susceptible to damage. If a
contaminated fluid has to be pumped, such as in a cleanup loop,
particular attention must be paid to pump selection.
Non-precision gear pumps, lobe pumps and gerotor pumps are
the most dirt tolerant. Whichever type is used, a strainer must be
fitted in the suction line. In the case of precision pumps, the
manufacturer’s recommendation on filtration must be followed;
otherwise the life of pump will be drastically reduced and the
maker’s warranty voided.
179
Pump Selection
7.Pump Noise
Noise has become increasingly important environmentally.
Operating levels vary considerably between the pumps of the
same type but of different makes. The manufacturers are working
on those aspects which most affect the emission of noise– port
plate design, bearings, flow passages, pressure controls, materials
and methods of mounting. Generally, the sound generated
increases with speed and pressure. Certain kinds do, however,
propagate lower noise levels, in particular, those with internal
gears. A multi-stage internal gear pump is marketed by one
manufacturer under the name Q pump, with Q signifying quiet.
180
Pump Selection
8. Size and Weight of a Pump
Generally, not only the overall size and weight of a hydraulic
system is important in mobile installations, but also the whole
system is important, as the size and weight of a pump is only part
of the whole system. In a mobile hydraulic field, the trend is to
reduce the weight of the hydraulic system by increasing the
operating pressure, reducing the size of the reservoir and using
efficient oil coolers.
The best power-to-weight ratios can usually be achieved in the
200–300 bar operating pressure range. The actual size and weight
of a pump depend upon the particular manufacture’s design. Very
light compact units have been developed for use in the aerospace
industry but these tend to be extremely expensive. 181
Pump Selection
9. Efficiency
Reciprocating pumps tend to have higher efficiencies than rotary
pumps. The actual efficiency depends on design, operating
pressure, speed and fluid viscosity.Table1.5gives an indication of
the range of efficiencies of various types of pumps.
10. Cost
The initial cost of a pump is usually of secondary importance to
running and maintenance costs.Gear pumps are cheaper, vane
and piston pumps are expensive.
182
Pump Selection
11. Availability and Interchangeability
A number of gear pump manufacturers produce units to CETOP and SAE
standards so far as the external dimensions are concerned. This gives
direct interchangeability between gear pumps of different
manufacturers. The shafts, mounting flanges and port connections of
most of the other types also comply with various international
standards allowing a degree of interchangeability.
12. Maintenance and Spares
In every type of pump, the components involved in pumping worn out

after a time and need replacing. In gear pumps, it is usual to replace the
entire pump. With some types of vane pumps, the wear parts are
grouped together as a cartridge that can easily be replaced without
dismantling the pump drive. In the case of piston pumps, it may be
advisable to ensure that the manufacturer offers a fast overall service
for critical applications to carry a spare pump in stock.
183
Accumulator and Pressure Intensifiers
INTRODUCTION
An hydraulic accumulator is a
device that stores the potential
energy of an incompressible
fluid held under Pressure by an
external source against som
dynamic force. This dynamic
force can come from three
different sources: gravity,
mechanical springs and
compressed gases. The stored
potential energy in the
accumulator is a quick
secondary source of fluid
power capable of doing useful
work as required by the
system.
The are three basic types of
accumulators used in the
hydraulic system as shown in
the accumulator classific
ation tree in Fig.
184
Pressure accumulators are primarily used in many hydraulic circuits to
(1) Store fluid under pressure, and / or
(2) Cushion shock waves in the circuit piping
1. Diaphragm type Accumulator
A typical diaphragms type accumulator is as

shown in Figure. It consists of a flexible rubber
diaphragm, secured in a steel shell. The
diaphragm acts as an elastic barrier between the
oil and gas. A shut off button, which is secured
to the diaphragm base, covers the inlet of the
line connection when the diaphragm is fully
stretched. This prevents the diaphragm from
being pressed into the opening during
precharge period. On the gas side, the screw
plug allows the charging of the accumulator by
means of a charging device.
185

Figure illustrates the operation of a diaphragm type accumulator. The hydraulic pump
delivers oil into the accumulator and deforms the diaphragm. As the system pressure
increase, the gas gets compressed thus storing potential energy. Now, when the system
pressure decreases and an additional oil is required to be pumped into the system, this
stored potential energy in the accumulator forces the additional required oil into the
system.
186

Advantages:
(1) It has a small weight to volumratio. Hence, it is exclusively used for airborne
applications.
(2) The inertia of the device is very small since there are no pistons, ram or spring.
2. Bladder type accumulator:
187
2. WEIGHT LOADED ACCUMULATOR
The weight loaded accumulate shown in Figure is
historically the oldest type consists of a vertical heavy
wall steal cylinder, which incorporates a piston with
packing to prevent leakage. Dead weight in the from
of large ballast is attached on top of the piston. The
force of gravity of the dead weight provides the
potential energy in the accumulator which provides a
constant fluid pressure, regardless of whether the
chamber in full or near empty and the rate and
quantity of output. In the other types of
accumulators, the fluids output pressure decreases as
a function of volume on heavy presses where
constant pressure is required, or in applications
where usually large volumes are necessary. The main
disadvantage of this type is that they are extremely
large is size and heavy weight, which makes it
unsuitable for mobile equipment.
188
2. ACCUMULATOR APPLICATION / FUNCTION CIRCUITS
Since hydraulic accumulators store pressurized fluid for system use on
demand, they
can be used to serve a variety of system functions. Typical of these
functions are maintain system pressure, absorbing hydraulic shocks,
supplementing pump delivery, providing an emergency source of power,
balancing loads and acting as a barrier between dissimilar fluids.
Accumulator as an auxiliary power source:
Accumulator are used as an auxillary power source in a system where
intermittent operations are preformed. These accumulators store the oil
delivered by the pump during a portion of work cycle, and then release this
stored oil an demand, thereby serving as a secondary power source to
assist the pump. Thus, the accumulator reduces the input horse-power by
storing energy during idle times of the machine and also facilitates the use
of a smaller sized pump.
189
ACCUMULATOR APPLICATION / FUNCTION
CIRCUITS
This application is depicted in Figure in which a
4/2 manually operated, spring return D.C valve is
used in conjunctions with an accumulator. When
the 4/2 D.C valve is manually actuated to position
I, oil flows from the accumulator to the blank end
of the cylinder. This extends the piston unit it
reaches the end of its stroke. When the desired
operation is occurring (when the cylinder is in
fully extended position), the accumulator is being
charged by the pump. When the accumulator is
fully charged, the pump. When the accumulator is
fully charged, the pilot operated relief or
unloading valve opens and allows the pump
delivery to return to the reservoir at very low
pressure. The accumulator maintains its charge
since it is isolated by check valve.
190
Accumulator:
An accumulator is a pre-pressurized storage tank which is able of
releasing the stored amount of oil into the system in case of a
pressure-drop. Pre pressurized means that one part of the accumulator
is filled with a gas. Gas and oil are separated from each other by a
separation wall. What the separation wall is made of depends on the
type of accumulator. In most cases a so called diaphragm is used and in
this type of accumulator the separation wall is made of a rubber
membrane.
Accumulators that are to be discarded must not constitute a hazard. Thi
is completed by carefully puncturing the accumulator with a Ø3 mm
drill.
1 Nitrogen gas space
2 Rubber diaphragm
3 Connection port for oil
A Drill here with 3 mm drill
• In case of a piston accumulator, which is used in the boom
suspension and Full Suspension systems on Volvo machines,
the separation wall is shaped as a steel piston inside the
accumulator housing. The compressibility of the gas gives the
accumulator its storage and release capacity. Special tools are
needed to pre-charge an accumulator. The gas is filled through
a special valve on one side of the steel housing.
• A third type of accumulator is the spring accumulator. This
type of accumulator has a spring located behind a steel piston.
Compressing the spring gives this accumulator its storage
capacity.
• Nitrogen gas is always is used. The pre-pressure of the
accumulator depends on its purpose and might differ from 15
to 150 bar. Nitrogen is used because it is a safe,
non-explosive natural gas. Never ever use oxygen to
pre-charge an accumulator. Oxygen in contact with oil creates
an explosion.
192
PRESSURE INTERNSIFIERS
A pressure intensifier is a device that is used to increase the
pressure in a hydraulic system to a valve several times above the
pump discharge pressure. It accepts a high volume flow at
relatively low pump pressure and converts a portion of this flow
to required valve of high pressure. due to this pressure boosting
capacity. it is also known as pressure booster. Intensifiers are
basically used in applications such as hydraulic presses rivelting
machines, sport welding machines where a great force is
required to be applied through a relative short distance.
193
Single Acting Intensifier
A Single acting pressure intensifier is as shown in Figure. The intensifier unit has a high
pressure piston with an effectively larger area. The direction control valve directs the
low pressure fluid into the left hand side of larger piston. The low pressure acting on
the larger piston generates a force F. Now, when this force is transmitted to the
smaller piston it generates a considerably high pressure on the fluid located on the
right side of smaller piston. Although high pressure fluid is one available to do work, it
should be noted that the volume of fluid discharged at the high pressure end will be
proportionately less than that required a large end.The increase in pressure is in direct
proportion to the ration of the larger piston area and the smaller piston area. The
volume output is inversely.
194
Double Acting Intensifiers
A Double acting intensifier is as shown in
Figure. It consists of an automatically
reciprocating large piston that has two
small rod ends. The piston has its large
area exposed to the low pressure oil. The
force of this low pressure oil moves the
piston and causes the small area of piston
rod to force the oil out at intensified high
pressure. This device is symmetrical about
a vertical center line. Thus, as the large
piston reciprocates each other during each
strake of the unit duplicate each other
during each stroke of the large piston. Thus
in effect the double acting intensifier
stimulates the operation of two single
acting intensifiers.
195
Double acting intensifiers are used for applications needing
longer work strokes or for maintaining high pressures for a
longer period of time. The working of a double acting
intensifier is as shown in Fig. The D.A. intensifier is
actuated by a 4/2 solenoid operated D.C. valve. Valve E
check valves A and B are installed an either side on the
high pressure outlet line, while check valves C and D are
installed on the low pressure outlet lines. When valve E is
actuated and position I is attained then the low pressure oil
from the pump is directed to the left intensifier cylinder. It
pushes the major piston to the right discharging fluid in the
right end of intensifier cylinder to the tank. As the ram
moves to the right fluid is intensifier in Booster II. This
intensified fluid closed the check valve D and check valve
A. Thus, the high pressure is delivered I for intensification
in next cycle when the main piston reaches the end of its
stroke on the right, the solenoid gets energized in the
opposite direction and valve E now attains position II. The
major piston starts moving towards left. The fluid in the
Booster cylinder I gets intensified. This high pressure fluid
closes check valves V and C and is then delivered to the 196
output through check valve A.
197
Air Oil Intensifier

In an air oil intensifier, there are two cylinders The air
cylinder with large piston and the booster hydraulic
cylinder with a small piston. Both eh piston are connected
by a piston rod. Air is directed into the top end of
intensifier (i.e. the head end of air cylinder). This forces
the hydraulic piston (ram) through the lower seal and into
the lower booster cylinder.
In the bottom end of the intensifier (i.e. the head end of
booster cylinder), the hydraulic fluid gets trapped by the
retreating hydraulic piston and generates high pressure.
the degree if the pressure boost is determined by the area
ratios of the air piston to the hydraulic ram.
This type of air oil intensifier are capable of producing
output hydraulic pressure upto 200 bar. In applications
such as punch press, it is necessary to extend a hydraulic
cylinder rapidly using little pressure to get the ram near
the sheet metal strip as possible. The cylinder must exert
a large force is needed to punch the work piece from the
sheet metal strip. Since the strip is thin, only a small flow
rate is required. After the completion of punching
operation, the fast retraction of cylinder is required. This
application requires an air over hydraulic intensifier as
explained below.
198
Air Oil Intensifier
199
Air Oil Intensifier
Figure shown an air over oil intensifier circuit.

Shop air at 6 bar pressure is used to extend and
retract the cylinder during the low pressure
portion of the cycle. The air oil intensifier is used
to provide the required high pressure oil during
the critical operation cycle. The system operation
is as follows Valve A extends and retracts the
working cylinder using shop air. Valve B appres
shop air pressure to the top end of intensifier (i.e.
head end of air cylinder). This produces a high
hydraulic pressure at the bottom end of the
intensifier (i.e. head end of booster cylinder).
Actuation of valve A directs the air to the
approach tank. This forces oil at 6 bar pressure
through the booster cylinder to the head end of
the working cylinder.
200
Air Oil Intensifier
When the working cylinder contacts the work

piece, it experiences load and the high pressure
portion of the cycle is initiated. Valve B is
actuated directing the shop air to the top end of
intensifier, which inturn intensifier. This high
pressure oil cannot return to the approach tank
because, it part is blocked off by the downward
motion of the booster cylinder piston. Thus, the
working cylinder receives high pressure oil at the
head end to overcome the load. When valve B is
released, the shop air is blocked and the top end
of the intensifier is vented to the atmosphere.
This terminates the high pressure portion of the
cycle.
201
Air Oil Intensifier
When valve A is released, the air in the

approach tank is vented and the shop air is
directed to the return tank. This delivers oil at
shop pressure to the rod end of the working
cylinder causing it to retract. At the same time
shop air enters the rod end of air cylinder,
thereby causing the intensifier piston to move
up. The oil from the head end of the retracing
working cylinder enters the bottom end of
intensifier and flows back to the approach
tank. This competes the entire cycle.
202
Advantages of Intensifier
There are reasons other than economic, that the use of an intensifier rather than high
pressure pumps for certain applications. The reasons which justify the use of an
intensifier are
1) Decompression of fluid under pressure can be at lower pressures values, permitting
softer action with less expensive components.
2) High pressure fluid is localized in what can normally be a low pressure machine. So
there are minimum number of high pressure seals to maintain and also high stresses are
developed only in these high-pressure piping. Hence maintenance is simple.
3) Pressure can be maintained over a period of time with low horsepower input.
4) Input fluid to the intensifier or booster can be different from the working fluid in the
circuit such as shop air steam, raw-water, etc….
5) Fluid pressure can be quickly dissipated in the event of a line breakage.
6) Shock loading from punch and shear operations can be more easily controlled.
7) High pressure can be varied with more sensitive low pressure devices, according to
size ratio.
203

Hydraulic System

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UNIT 3

• A Hydrostatic system uses fluid pressure to

Fixed Delivery, Displacement Pump Symbol

iii. Herringbone gear pumps are the quietest; provide greater

• Note: This same undesirable side load exist for the

Radial Piston Pump: Here the pistons are arranged radially

Axial Piston Pump: Here the pistons are arranged parallel

Mechanical efficiency(ƞm ) indicates the amount of energy losses that occur

Where p is the pump discharge pressure in Pa or N/m2,

The actual torque (TA ) is determined as follows

Do=82.6 mm= 0.0826 m

Figure gives curves of overall and

Discharge flow of these

Various types of pump controls are available such as manual servo

A majority of pumps are driven directly from the prime mover –

12. Maintenance and Spares

In every type of pump, the components involved in pumping worn out

A typical diaphragms type accumulator is as

1. Diaphragm type Accumulator

1. Diaphragm type Accumulator

2. Bladder type accumulator:

Air Oil Intensifier

Air Oil Intensifier

Figure shown an air over oil intensifier circuit.

When the working cylinder contacts the work

When valve A is released, the air in the

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