BASIC HYDRAULICS

Definition of hydraulics
• Generation of forces and motion using
hydraulic fluids
• Hydraulic fluid represents the medium of
power transmission

(note pg: 7)
 Hydro-mechanics

1. Hydrostatics 2. Hydrodynamics

(note pg: 13)

 APPLICATIONS
Stationary hydraulics
• Production and assembly
machines of all types
• Transfer lines
• Lifting and conveying devices
• Presses
• Injection moulding machines
• Rolling lines
• Lifts

(note pg: 8-10)

 APPLICATIONS
Mobile hydraulics

• Construction machinery
• Tippers, excavators, elevating
platforms
• Lifting and conveying devices
• Agricultural machinery

(note pg: 8-9)

 Advantages of hydraulics
• Transmission of large forces using small
components, i.e. great power intensity
• Precise positioning
• Start-up under heavy load
• Even movements independent of load, since
liquids are scarcely compressible and flow
control valves can be used
• Smooth operation and reversal
• Good control and regulation
• Favourable heat dissipation
(note pg:10)
 Disadvantages of hydraulics
• Pollution of the environment by waste oil (danger
of fire or accidents)
• Sensitivity to dirt
• Danger resulting from excessive pressures
(severed lines)
• Temperature dependence (change in viscosity)
• Unfavourable efficiency factor

(note pg:10)
 BASIC PHYSICAL PRINCIPLES
• Hydrostatic pressure – Open vessel

ps = h.ρ.g

ps = hydrostatic pressure (gravitational pressure) [Pa]

h = level of the column of liquid [m]
ρ = density of the liquid [kg/m3]
g = acceleration due to gravity [m/s2]

(note pg:14)
Examples:

Column Reservoir Elevated tank

(note pg:15)
 BASIC PHYSICAL PRINCIPLES
Hydrostatic pressure – closed vessel
• Pascal’s law: pressure exists when a force F is imposed on
an enclosed fluid with a surface A, The pressure exerts an
equal effect on all points of the surfaces.

F
P= N/m2
A F
P

(note pg:17)
Example:
A cylinder is supplied with 100 bar pressure, its effective piston surface is
equal to 7.85 cm2. Find the maximum force which can be attained.

Given that: p = 100 bar = 1000 N/cm2

A = 7.85 cm2

P
Example:

F=15000N

D 2
A
4
4(20)
D2 

4(20)
D  5.05cm
 P
 BASIC PHYSICAL PRINCIPLES
Power transmission:
• The same pressure applies at every point in a closed
system

(note pg:22)
Example:

(note pg:23)
 BASIC PHYSICAL PRINCIPLES
Displacement transmission:

(note pg:25)
Example:
Calculate S2

Given:
A1 = 40 cm2
A2 = 1200 cm2
S1 = 15 cm

(note pg:26)
 BASIC PHYSICAL PRINCIPLES
FLOW RATE:
• Flow rate is the term used to describe the volume of liquid
flowing through a pipe in a specific period of time. For
example, approximately one minute is required to fill a 10
litre bucket from a tap. Thus, the flow rate amounts to 10
l/min.

(note pg:29)
 BASIC PHYSICAL PRINCIPLES
Flow measuring instruments:

(note pg:277)
 BASIC PHYSICAL PRINCIPLES
CONTINIUTY EQUATION
• If the time t is replaced by s/v (v = s/t) in the formula for
the flow rate (Q = V/t) and it is taken into account that
the volume V can be replaced by A⋅s, the following
equation is produced:

Q = A· v

Q = Flow rate [m3/s]

v = Flow velocity [m/s]
A = Pipe cross-section [m2]

(note pg:31)
Example:
Calculate the oil flow velocity in a pipeline
Given that:
3
Q = 4.2 l/min = 4.2dm = 0.07 ⋅10 -3m3/s
60s
A = 0.28 cm2 = 0.28 ·10-4m2 Q v
Example:
Calculate the flow rate needed for
the following movement

Given that: A = 8 cm2

s = 10 cm
t = 1 min
Q

(note pg:32)
 BASIC PHYSICAL PRINCIPLES
CONTINIUTY EQUATION
• The flow rate of a liquid in terms of volume per unit of time which flows
through a pipe with several changes in cross-section is the same at all
points in the pipe (see diagram). This means that the liquid flows
through small cross-sections faster than through large cross-sections.
The following equation applies:

Q1 = A1⋅v1 Q2 = A2⋅v2 Q3 = A3⋅v3 etc.…

• As within one line the value for Q is always the same, the following
equation of continuity applies:

Q1 = Q 2 = Q 3

A1⋅v1 = A2⋅v2 = A3⋅v3 = etc...

(note pg:34)
PRESSURE MEASUREMENT

(note pg:37)
 TYPE OF FLOW
Two types of flow
• Laminar, Re < 2300
• Turbulent, Re > 2300

Re = v x d / v
v is flow velocity in m/s
D is pipe diameter in m
v is kinetic viscocity in m2/s

(note pg:39)
Energy Loss By Turbulent Flow
 Hydraulic fluid
Types:
• Mineral based
– For low risk of fire
• Phosphate-ester based (Synthetic oil)
– For high risk of fire

(note pg:70)
 Hydraulic fluid

Tasks for hydraulic fluids

• pressure transfer,
• lubrication of the moving parts of devices,
• cooling, i.e. diversion of the heat produced by
energy conversion (pressure losses),
• cushioning of oscillations caused by pressure
jerks,
• corrosion protection,
• scuff removal,
• signal transmission.

(note pg:70)
 Hydraulic fluid
Hydraulic oil classes (DIN 51524 and 51525):
• Hydraulic oil HL
• Hydraulic oil HLP
• Hydraulic oil HV.

(note pg:71)
 Hydraulic fluid
Hydraulic fluids with low inflammability (HF liquids):

(note pg:72)
 Hydraulic fluid
Viscosity:
• The word “viscosity” can be defined as
“resistance to flow”. The viscosity of a
liquid indicates its internal friction,
• The international system of standards
defines viscosity as “kinematic viscosity”
(unit: mm2/s or Cst).
 Hydraulic fluid
ISO standard for Viscosity Grade:
 Hydraulic fluid
VG selection:
• If viscosity is too low (very fluid), more leakages occur.
The lubricating film is thin and, thus, able to break away
more easily resulting in reduced protection against wear.
• High viscosity results in increased friction leading to
excessive pressure losses and heating particularly at
throttle points. This makes cold start and the separation
of air bubbles more difficult and, thus, leads to cavitation.
 Hydraulic fluid
VG selection:
Hydraulic system
Hydraulic system
 Power supply section

The power supply section provides the energy required by

the hydraulic system. The most important components in
this section are:
• drive
• pump
• pressure relief valve
• coupling
• reservoir
• filter
• cooler
• heater
 Power supply unit (Power Pack)
Example:
 Hydraulic Pump
The pump converts the mechanical energy in a drive unit into hydraulic
energy (pressure energy).
•Types:
 Gear pump
• Gear pumps are fixed displacement pumps since the displaced
volume which is determined by the tooth gap is not adjustable.
Radial piston pump
Screw pump
Internal gear pump
Vane pump
Vane pump
Axial Piston Pump
Characteristic values for the most common constant pumps
Practical:
Pump characteristic
 Reservoir / Tank
The tank in a hydraulic system fulfils several tasks.
It:
• acts as intake and storage reservoir for the
hydraulic fluid required for operation of the
system;
• dissipates heat;
• separates air, water and solid materials;
• supports a built-in or built-on pump and drive
motor and other hydraulic components, such as
valves, accumulators, etc.
Reservoir / Tank
 Filters
• Filters are of great significance in hydraulic systems for the reliable
functioning and long service life of the components.
• The effects of polluted oil:
Filter arrangement
Filter Grades
Filter Grades
Filter designs
 Valve Symbols
Directional Control Valves

Switching position

Flow path

Flow path blocked

Connection ports

(note pg:92)
 2
2 - Way valve

Number of switching positions

Number of ports

3
2 - Way valve
Connection ports
P ; Pressure supply port

T ; Return port (Tank)

A, B ; Power/Output/working ports

L ; Leakage port

A B

4
2 - Way valve
P T
Methods of actuation:

(note pg:93)
 Hydraulic actuators
Linear actuators:
• single-acting and
• double-acting cylinders.

Rotary actuators:
• Hydraulic motors

(note pg:228)
 Single acting cylinder
• In single-acting cylinders, only the piston side is supplied
with hydraulic fluid. Consequently, the cylinder is only able
to carry out work in one direction.

(note pg:228)
 Single acting cylinder
• Types:

(note pg:230)
 Double-acting cylinder
• In the case of double-acting cylinders, both piston surfaces can be
pressurized. Therefore, it is possible to perform a working movement in both
directions.

(note pg:231)
Double-acting cylinder
 Double acting cylinder
• Types:

(note pg:233)
 Double acting cylinder
• End position cushioning

(note pg:235)
 Hydraulic motors
• They convert hydraulic energy into mechanical energy and
generate rotary movements (rotary actuator). If the rotary
movement only covers a certain angular range, the actuator is
referred to as a swivel drive.

(note pg:250)
 Hydraulic motors
•Types:

(note pg:253)
 Valves
Nominal sizes:

(note pg:148)
 Valves
Design:
• Poppet valves
• slide valves

(note pg:151)
 Valves
Poppet valves:

(note pg:152)
 Valves
slide valves

(note pg:154)
 Valves
Comparison of valve constructions:

(note pg:155)
 Valves
Control edges:

(note pg:160)
 Valves
Annular grooves:
• With the grooves, the piston of valve spool is
supported on a film of oil. On actuation, only the
fluid friction needs to be overcome.

(note pg:161)
 Directional control valves
2/2-way valve:

(note pg:180/184)
 Directional control valves
3/2-way valve

(note pg:188)
 Directional control valves

4/2-way valve

(note pg:190)
 Directional control valves
4/3-way valve with pump by-pass (re-circulating)

(note pg:195)
4/3-way valve with pump by-pass (re-circulating)

(note pg:191)
 Directional control valves
4/3-way valve, mid position closed

(note pg:197)
 Pressure valves

• Pressure relief valves

• Pressure regulator
• 2-way pressure
regulator

• 3-way pressure
regulator

(note pg:164)
 Pressure valves
Pressure relief valves

(note pg:166)
 Pressure valves
Pressure relief valve, internally controlled, cushioned:
• Cushioning pistons and throttles are often installed in
pressure relief valves to eliminate fluctuations in
pressure. The cushioning device shown here causes:
• fast opening
• slow closing of the valve.

(note pg:168)
 Pressure valves
Pressure relief valve, externally controlled

(note pg:170)
 Pressure valves
Pressure relief valves are used as:
• Safety valves
A pressure relief valve is termed a safety valve when it is attached to
the pump, for example, to protect it from overload. The valve setting
is fixed at the maximum pump pressure. It only opens in case of
emergency.
• Counter-pressure valves
These counteract mass moments of inertia with tractive loads. The
valve must be pressure-compensated and the tank connection must
be loadable.
• Brake valves
These prevent pressure peaks, which may arise as a result of mass
moments of inertia on sudden closing of the directional control valve.
• Sequence valves
These open the connection to other consuming devices when the set
pressure is exceeded. There are both internally and externally
controlled pressure relief valves. Pressure relief valves of poppet or
slide design may only be used as sequence valves when the
pressure is compensated and loading at the tank connection has no
effect on the opening characteristics.
(note pg:168/9)
(note pg:169/171)
 Pressure valves
Pressure regulators:
• Pressure regulators reduce the input pressure to a specified output
pressure. They are only used to good effect in systems where a number
of different pressures are required.

2-way pressure regulator

(note pg:172/3)
 Pressure valves
3-way pressure regulator

(note pg:176)
 Non-return valves / Check valves
• Non-return valves block the flow in one direction and
permit free flow in the other.

(note pg:201)
Pump protection

(note pg:203)
Other applications:

(note pg:204)
 Non-return valves / Check valves
Piloted non-return valve

Flow blocked from B to A Flow from A to B Flow from B to A with X signal

(note pg:205)
Exercise:
A scissor lift is used to lift heavy loads to the platforms of varying
heights. The loaded lift must be able to remain at given height over a
long period of time. The lift is powered by a double acting cylinder.

Position sketch

Load
Piloted non-return valve:

(note pg:207/8)
 Flow control valves
• Flow control valves are used to reduce the speed of a cylinder or
the r.p.m. of a motor.
• Flow control valves are classified as either:
• flow control valves or
• flow regulating valves.

(note pg:214)
 Flow control valves
One-way flow control valve

(note pg:219)
0bar
60bar

10bar >100bar
 Flow control valves
Two-way flow control valve
• To maintain a constant speed in the case of a changing load. the
pressure drop Δp via the throttle point can be kept constant.

(note pg:220)
 Flow control valves
Two-way flow control valve

(note pg:221)
 Accumulator

Accumulators perform special functions in

hydraulic systems:
• To act as an emergency power source, e.g. to
complete a working stroke in case of drive or
pump failure.
• To compensate for leakage losses.
• To compensate for variations in fluid volume due
to changes in temperature.
• Absorption of shock waves and pressure peaks
due to switching actions and applications.
 Accumulator
Design:
Diaphragm accumulator
Bladder accumulator
 Bladder accumulator
Operation:
 Accumulator applications
Reduce vibration and shock:
 Accumulator applications
Installation for emergency power source:
Thank you