Hydraulics Applications

 Industrial: Electrohydraulics is the mechanism used for controlling the industrial applications of hydraulics. Precise and fast
response is an advantage of this. Plastic processing machinery, steel making and primary metal extraction applications,
automated production lines, machine tool industry, paper industries, loaders, crushers, presses, textile industry machinery,
etc. are some of the examples of industrial hydraulics.
 Mobile Hydraulics: In mobile hydraulics, the hydraulic system is controlled manually. Building and construction equipment
like cranes, excavators, backhoe, earth moving equipment, etc.,  tractors, irrigation system, material handling equipment,
tunnel boring equipment, rail equipment, etc. are some examples of mobile hydraulics.
 Automobiles: Hydraulics have many interesting applications in the automobile industry. Most of the important work using
the principle of hydraulics. Power steering, shock absorbers, windshields, and brake are the common applications of
hydraulics in vehicles. Two-post lifts and four-post lifts are used in the automobile industry to lift vehicles for servicing and
inspecting.
 Marine Applications: Hydraulics plays an important role in maintaining the stability and control of ships. Steering gears,
bow and stern thrusters, engine room maintenance systems including pumps and jacks, deck machineries like cranes, 
winches, hatch covers, mooring drums and others are examples of hydraulics in the marine industry.
 Aerospace Applications: Airplanes, rockets, spaceships, etc.. use hydraulic systems for various applications. Aerospace
industry uses hydraulics for adjusting wings, retraction and extension of landing gears, opening/closing of doors, brakes,
steering, etc.
 Mining: Hydraulic fracturing is one of the advanced mining technology used for extracting unused gases/oils beneath the
earth surface. In this approach, a high-pressure mixture of water, sand and other chemical additives are passed into the
cracks.

Pneumatics Applications

 Automobile: Automobile industry use pneumatic systems for dismantling vehicle tire, filling compressed air in the tire,
vehicle painting, opening and closing of doors, air brakes on heavy vehicles, etc.
 Transporting Goods: Pneumatics is used to transport goods from shelf to other location inside the company. The cylinder
will push the item on the shelf into the moving belt if the button is pushed.
 Industrial Applications: Material handling, drilling, sawing, filling, packaging, clamping, shifting, etc. are some of the
general applications of the pneumatic system.

Hydraulic System Maintenance Checklist

Before starting on this checklist, you may want to have your system's literature with you, to check manufacturer
specifications for things like filter schedules, oil specs and average temperatures.
Here is our collection of hydraulic system maintenance tips:

1. Oil Maintenance
Check your hydraulic oil on a consistent schedule — it needs to remain clean and free of any contaminants. You should
empty and replace the hydraulic oil after every 1,000 hours of work or per the manufacturer's instructions.
You can help minimize the risk of contamination by keeping the area around entry points, like dipsticks and fuel plugs,
clear of dust and debris.
Read the manufacturer specifications to confirm how often you should change the fluid and other factors of hydraulic fluid
care. It is essential to use the same type of hydraulic fluid every time you top off your levels. If possible, use the same
brand each time as well.

2. Changing Filters Regularly

Filters take on the task of removing even the most minuscule particles that could clog your hydraulic system. However,
the process of keeping particulates out of the system causes the filters themselves to become clogged over time. Your
filters will lose efficacy as they accumulate pollutants, so replace them often. If applicable, make sure to clean the filter
bowl as well.

3. Rod Conditions
Visually inspect the rod for wear, such as corrosion and pitting. These issues can lead to moisture within the fluid, which
compounds and can cause many problems for your hydraulic system, like increased wear and inadequate lubrication.

4. Seal Replacement
If rod corrosion occurs, it can damage the seal from excess friction. Other dangers to seals include excess pressure and
fluid contaminants. A worn seal may leak, causing equipment hazards and environmental health and safety concerns. If
there are signs the seal is damaged, check with your equipment manufacturer about proper replacement.

5. Regular Hydraulic Lines Checkup

Fluctuations in pressure or line thickness can lead to equipment damage. For example, excessive pressure from
the cylinder can cause ballooning, where the line dilates and allows too much high-pressure fluid to pass, thus wearing
out the seals. Regularly inspect the condition of the lines and make sure they are not ballooning.

6. Inspect Fluid Levels

For optimal functioning, you must watch your fluid levels, adding to them as needed. Too little hydraulic fluid can damage
your pumps. Just like when replacing contaminated oil, be sure to follow the specifications given by the manufacturer and
take care to avoid mixing oils.

7. Check Breather Caps, Fill Screens and Breather Filters

Breathers must be kept clean or risk contaminating the hydraulic system. Clean the breather regularly and inspect it for
holes or tears. Different types of breathers may have additional requirements, so check the manufacturer's instructions.
Spring types, for instance, may need to be replaced annually to avoid tension loss that allows contaminants. Others can
have indicators that tell you when to replace filters or caps. Be aware of any additional steps such as these.

8. Inspect Filter Indicators

Most filters have pop-out buttons that trigger when they become clogged. Check for any of these indications and replace
the filters as needed.

9. Visually Check All Pipes, Pipe Connections and System Hoses

If hoses are pinched, kinked, frayed, bubbling, stretched or otherwise damaged, they can restrict the flow of fluid or lead to
pressure leaks. Most of these problems are visible from the outside, but others occur internally, so inspect the inside for
damage that could cause a clog.
Additionally, check pipes, fittings and couplers for any dents or corrosion. Fittings should be snug, but not overly tight.
Couplers need to stay clean to prevent contamination or leaking.
Leaks cause excessive oil consumption, overheating and severe safety and environmental hazards. These can be difficult
to clean up and dangerous for employees, so watch out for signs to prevent leaks in the first place.

10. Check the System Temperature

If your system temperature gets too hot, it could indicate an issue with your cooler or relief valve. Low fluid levels could
also contribute to heat. Use built-in or infrared thermometers to check temperatures. Do not touch components that you
suspect may be hot, as this can lead to severe burns.
 11. Visually Inspect Inside the Reservoir
Aeration within the reservoir can cause overheating and wear on seals and system components. Aeration happens when
air bubbles enter the oil stream due to low fluid levels, low fluid temperatures, air leaks and bad seals. Foaming, loud
gurgling noises and whirlpools at the suction strainer indicate aeration.

12. Listen to the Pumps

Similar to aeration, cavitation is the result of gas bubbles experiencing rapid changes in pressure. The gas bubbles
implode, causing miniature shock waves. The shock waves generate repeated stress on the metal surfaces, damaging
the components.
If a pump is cavitating, it will release a high-pitched whining sound. Listening to the pumps gives you an idea of cavitation
that may be present.

13. Inspect a Sample of Hydraulic Fluid

To check your fluid for quality, take a small sample and inspect it. Do a quick visual inspection for color abnormalities and
visible contaminants. You may also want to inspect for any unusual odors. Performing a contamination test can offer a
more accurate review of the fluid's qualities. It offers detailed findings for particle contamination, water contamination,
viscosity, acidity and signs of overheating.

14. Perform Hydraulic Valve Maintenance

Scan electrically controlled Servo valves using an infrared thermometer and check the temperature of these valves. If it is
higher than 150℉, you may have a problem with the valve. Slow or errant operation at the valve points can be a sign of
contaminated fluid.

15. Check the Electric Drive Motor

Keep your infrared thermometer out and use it on the electric drive motor to detect any areas of high heat. These areas
could be on the housing or rotor bearings and require servicing to avoid further damage to the equipment.
Fluid Properties
When choosing a hydraulic fluid, consider the following characteristics: viscosity, viscosity index, oxidation stability and
wear resistance. These characteristics will determine how your fluid operates within your system. Fluid property testing is
done in accordance with either American Society of Testing and Materials (ASTM) or other recognized standards
organizations.
1. Viscosity (ASTM D445-97) is the measure of a fluid’s resistance to flow and shear. A fluid of higher viscosity will
flow with higher resistance compared to a fluid with a low viscosity. Excessively high viscosity can contribute to
high fluid temperature and greater energy consumption. Viscosity that is too high or too low can damage a
system, and consequently, is the key factor when considering a hydraulic fluid.
2. Viscosity Index (ASTM D2270) is how the viscosity of a fluid changes with a change in temperature. A high VI
fluid will maintain its viscosity over a broader temperature range than a low VI fluid of the same weight. High VI
fluids are used where temperature extremes are expected. This is particularly important for hydraulic systems that
operate outdoors.
3. Oxidation Stability (ASTM D2272 and others) is the fluid’s resistance to heat-induced degradation caused by a
chemical reaction with oxygen. Oxidation greatly reduces the life of a fluid, leaving by-products such as sludge
and varnish. Varnish interferes with valve functioning and can restrict flow passageways.
4. Wear Resistance (ASTM D2266 and others) is the lubricant’s ability to reduce the wear rate in frictional boundary
contacts. This is achieved when the fluid forms a protective film on metal surfaces to prevent abrasion, scuffing
and contact fatigue on component surfaces.

Energy losses in hydraulics

In every hydraulic system there are energy losses in the form of pressure and leakage losses in varying degrees. A differentiation is made between (Figure
E 31):
 pressure losses in lines due to friction and flow deflection,
 pressure losses in valves as well as accessories, such as filters and coolers,
 Pressure losses due to throttling, which on constant pressure systems are particularly high,
 Leakage losses at the points that must be sealed.
All these losses are converted into heat that is absorbed by the oil and housing. On systems without appreciable throttling approx. 15 % can be
expected on average, while in throttle circuits the loss element can be 25 to 30 % and higher.
Viscosity
Viscosity is a measure of a hydraulic fluid's resistance to flow. It is a hydraulic fluid's most important characteristic and has a significant
impact on the operation of the system.

When a hydraulic oil is too thin (low viscosity), it does not seal sufficiently. This leads to leakage and wear of parts. When a hydraulic oil is
too thick (high viscosity), the fluid will be more difficult to pump through the system and may reduce operating efficiency.

All hydraulic fluids must be able to retain optimum viscosity during operation in cold or hot temperatures, in order to consistently and
effectively transmit power.

Compressibility
Compressibility is a measure of the amount of volume reduction due to pressure. Although hydraulic oils are basically incompressible, slight
volume reductions can occur under certain pressure ranges.

Compressibility increases with pressure and temperature and has significant effects on high-pressure fluid systems. It causes servo failure,
efficiency loss, and cavitation; therefore, it is important for a hydraulic oil to have low compressibility.

Wear Resistance
Wear resistance is a hydraulic fluid's ability to reduce the wear rate in frictional boundary contacts. Antiwear hydraulic fluids contain
antiwear components that can form a protective film on metal surfaces to prevent abrasion, scuffing, and contact fatigue. Antiwear additives
enhance lubricant performance and extend equipment life.

Oxidation Stability
Oxidation stability is a hydraulic oil's resistance to heat-induced degradation caused by a chemical reaction with oxygen. Hydraulic oils must
contain additives that counteract the process of oxidation, improve the stability and extend the life of the fluid. Without these additives, the
quality of the hydraulic oil will deteriorate quickly.

Thermal Stability
Thermal stability is the ability to resist breakdown at elevated temperatures.  Antiwear additives naturally degrade over time and this process
can be accelerated at higher temperatures.  The result of poor thermal stability is the formation of sludge and varnish which can clog filters,
minimize flow and increase downtime.  In addition, as these antiwear agents decompose at high temperatures, acids are formed which attack
bronze and yellow metals in piston pumps and other hydraulic system components.  Hydraulic oils can be formulated with very high levels of
thermal stability to minimize these issues and help extend the life of the hydraulic fluid and the components of the hydraulic system.

Filterability
Water can react with additives in hydraulic fluids forming oil insoluble material.  These contaminants can precipitate from the lubricant and
block filters, valves and other components resulting in decreased oil flow or the system going on bypass.  Blockage can eventually result in
unplanned downtime.  Hydraulic fluids are designed to be filtered with modern filtration systems without fear of the additive being depleted
or removed from the system.  This enables systems to stay clean without sacrificing critical performance requirements such as antiwear, rust
protection or foam inhibition.

Rust and Corrosion Protection

In many systems, water can enter as condensation or contamination, and mix with the hydraulic oil. Water can cause rusting of hydraulic
components.  In addition, water can react with some additives to form chemical species which can be aggressive to yellow metals. 
Hydraulic oil formulations contain rust and corrosion inhibitors which prevent the interaction of water or other chemical species from
attacking metal surfaces.
Foam Resistance
Foam results from air or other gases becoming entrained in the hydraulic fluid. Air enters a hydraulic system through the reservoir or through
air leaks within the system.

A hydraulic fluid under high pressure can contain a large volume of dissolved or dispersed air bubbles. When this fluid is depressurized, the
air bubbles expand and produce foam. Because of its compressibility and poor lubricating properties, foam can seriously affect the operation
and lubrication of machinery.

Proper foam inhibitors modify the surface tension on air bubbles so they more easily break up.

Demulsibility
Water that enters a hydraulic system can mix or emulsify with the hydraulic oil. If this 'wet' fluid is circulated through the system, it can
promote rust and corrosion. Highly refined mineral oils permit water to separate or demulsify quickly. However, some of the additives used
in hydraulic oils promote emulsion formation, preventing the water from separating and settling out of the fluid. Demulsifier additives are
incorporated to promote water separation from hydraulic fluids.

Hydrolytic Stability
When hydraulic fluids come into contact with water, the water can interact with the additive system of the hydraulic oil resulting in the
formation of acids.  Hydraulic fluids that lack hydrolytic stability hydrolyze in the presence of water to form oil insoluble inorganic salts that
can block filters and valves inhibiting oil flow. This can result in hydraulic system failure.   Properly formulated hydraulic fluids are designed
to contain additives that are resistant to interactions with water, helping to extend the life of the equipment.

Seal Compatibility
Leaking hydraulic fluids can cause many issues from simple housekeeping problems to more serious safety concerns and lubrication failures. 
Most hydraulics systems utilize rubber seals and other elastomers to minimize or prevent hydraulic oil leakage.  Exposure of the elastomer to
the lubricant under high temperature conditions can cause the rubber seals to harden, crack and eventually leak.  On the other hand, hydraulic
oil exposure can seals to swell excessively preventing hydraulic valves and pistons from moving freely.  Hydraulic oils are tested against a
variety of seal materials to ensure that the hydraulic fluid will be compatible with seals under various conditions.

To select the most appropriate fluid for your hydraulic system, follow the next steps:

1. Select the right viscosity at the given operating temperatures to ensure the highest efficiency and to meet the
system requirements.
2. Select the suitable AW additives: Zn or Zn free anti-wear protection additives.
3. Check on viscosity index. In case of extreme temperature changes or harsh operation conditions, hydraulic
oils with a high viscosity are the best choice.
4. Choose the adequate contamination control and monitoring properties to secure the lifetime of hydraulic
components and fluid.
5. Check on special requirements or regulations such as the use of fire-resistant or environmentally friendly
hydraulic fluids. Often these conditions will have influence on the hydraulic fluid type.