Hydraulic Actuators

Hydraulic actuators

In these actuators high pressure fluid is used. The fluid is pressurized using
electrical pumps. Fluid used is non corrosive and if possible self lubricating. It is
more of mechanical system having valves, cylinders, pumps etc. Commonly used
fluid is air and oil. When air is used it is called pneumatic system. Air is freely
available, leakage is not hazardous, stored in big tanks and distributed where ever
required. Very common in packaging industry. When oil is used it is called
hydraulic system.
High power to weight ratio.
Hydraulic pumps are attached to the machinery.
Leakage is not permitted. Used where ever heavy duty performance is required.

Single-Acting Cylinder. This cylinder only has a head-end port and is operated
Cylinde
hydraulically in one direction. When oil is pumped into a port, it pushes on a plunger, thus
rextending it. To return or retract a cylinder, oil must be released to a reservoir. A plunger
returns either because of the weight of a load or from some mechanical force such as a
spring. In mobile equipment, flow to and from a single-acting cylinder is controlled by a
reversing directional valve of a single-acting type.
Double-Acting Cylinder. This cylinder must have ports at the head and rod ends. Pumping
oil into the head end moves a piston to extend a rod while any oil in the rod end is
pushed out and returned to a reservoir. To retract a rod, flow is reversed. Oil from a pump
goes into a rod end, and a head-end port is connected to allow return flow. The flow
direction to and from a double-acting cylinder can be controlled by a double-acting
directional valve or by actuating a control of a reversible pump

A hydraulic cylinder consists of the following parts:

Cylinder barrel

The cylinder barrel is mostly a seamless thick walled forged pipe that must be machined internally. The
cylinder barrel is ground and/or honed internally.
Cylinder Bottom or Cap

In most hydraulic cylinders, the barrel and the bottom are welded together. This can damage the inside of
the barrel if done poorly. Therefore some cylinder designs have a screwed or flanged connection from the
cylinder end cap to the barrel. (See "Tie Rod Cylinders" below) In this type the barrel can be disassembled
and repaired in future.
Cylinder Head

The cylinder head is sometimes connected to the barrel with a sort of a simple lock (for simple cylinders). In
general however the connection is screwed or flanged. Flange connections are the best, but also the most
expensive. A flange has to be welded to the pipe before machining. The advantage is that the connection is
bolted and always simple to remove. For larger cylinder sizes, the disconnection of a screw with a diameter
of 300 to 600 mm is a huge problem as well as the alignment during mounting.
Piston

The piston is a short, cylinder-shaped metal component that separates the two sides of the cylinder barrel
internally. The piston is usually machined with grooves to fit elastomeric or metal seals. These seals are
often O-rings,
O-rings, U-cups or cast iron rings. They prevent the pressurized hydraulic oil from passing by the
piston to the chamber on the opposite side. This difference in pressure between the two sides of the piston
causes the cylinder to extend and retract. Piston seals vary in design and material according to the pressure
and temperature requirements that the cylinder will see in service. Generally speaking, elastomeric seals
made from nitrile rubber or other materials are best in lower temperature environments while seals made of
Viton are better for higher temperatures. The best seals for high temperature are cast iron piston rings.

Tubes, Pipes and Hoses

Hydraulic tubes are seamless steel precision pipes, specially manufactured for hydraulics. The tubes
have standard sizes for different pressure ranges, with standard diameters up to 100 mm. The tubes are
supplied by manufacturers in lengths of 6 m, cleaned, oiled and plugged. The tubes are interconnected by
different types of flanges (especially for the larger sizes and pressures), welding cones/nipples (with o-ring
seal), several types of flare connection and by cut-rings. In larger sizes, hydraulic pipes are used. Direct
joining of tubes by welding is not acceptable since the interior cannot be inspected.
Hydraulic pipe is used in case standard hydraulic tubes are not available. Generally these are used for
low pressure. They can be connected by threaded connections, but usually by welds. Because of the larger
diameters the pipe can usually be inspected internally after welding. Black pipe is non-galvanized and
suitable for welding.
welding.
Hydraulic hose is graded by pressure, temperature, and fluid compatibility. Hoses are used when pipes or
tubes can not be used, usually to provide flexibility for machine operation or maintenance. The hose is
built up with rubber and steel layers. A rubber interior is surrounded by multiple layers of woven wire and
rubber. The exterior is designed for abrasion resistance. The bend radius of hydraulic hose is carefully
designed into the machine, since hose failures can be deadly, and violating the hose's minimum bend
radius will cause failure. Hydraulic hoses generally have steel fittings swaged on the ends. The weakest
part of the high pressure hose is the connection of the hose to the fitting. Another disadvantage of hoses is
the shorter life of rubber which requires periodic replacement, usually at five to seven year intervals.
Tubes and pipes for hydraulic applications are internally oiled before the system is commissioned. Usually
steel piping is painted outside. Where flare and other couplings are used, the paint is removed under the
nut, and is a location where corrosion can begin. For this reason, in marine applications most piping is
stainless steel

Hydraulic Circuits typically contain,

1.Hydraulic Fluid
2.An Oil Reservoir
3. A Pump

-to Move Oil, and Apply Pressure

4. Pressure Lines
5. Control Valves

- to regulate fluid flow

6. Piston and Cylinder - to actuate external mechanisms

reservoir

its volume should equal three times the rated output of the system's fixed-displacement pump or
mean flow rate of its variable-displacement pump
The reservoir should contain additional space equal to at least 10% of its fluid capacity. This allows
for thermal expansion of the fluid
A current design trend has the electric motor mounted vertically, with the pump submerged in
hydraulic fluid. This conserves space, because the reservoir can be made deeper and take up less
floor space than one with traditional "bathtub" proportions. The submerged-pump design also
eliminates external pump leakage, because any fluid leaking from the pump flows directly into the
reservoir. In addition, the power unit is quieter, because the hydraulic fluid tends to damp pump
noise.
An alternate configuration positions the reservoir above the pump and motor, This overhead
configuration provides the advantage of combining atmospheric pressure and the weight of the
fluid column to flood (force fluid into) the pump inlet, which helps prevent cavitation. The
reservoir's top cover can be removed to service internal components without disturbing the pump
and motor.
The overhead reservoir may cause a problem with gravity-return drain lines, so an auxiliary pump
may be needed to route fluid up to the reservoir. When noise is a problem, overhead tanks provide
the most convenient way to enclose the pump and electric motor within a noise suppression
chamber.

DEFINITION:

What is pump?
Pump is a device which converts
mechanical energy into hydraulic
energy.
Pump is used to impart motion to
liquid.
Instead of liquid, if gas is employed then other terms
may be used. If the primary objective is to increase
the pressure of the gas, the device is termed a
compressor. On the other hand, a device used
primarily for causing the movement of a gas is
known as fan or blower.

PROPERTIES OF FLUIDS:

Density It is the ratio of mass of the liquid to

the volume of the liquid.
Specific gravity It is the ratio of volume of
the liquid to the mass of the liquid.
Specific weight It is the ratio of the weight
of the liquid to the volume of the liquid.
Viscosity It is the resistance offered to the
flow of liquid.
Absolute viscosity It is the ratio of viscosity
to the density of the liquid.

Non-positive displacement
In non-positive displacement pumps, the
pumps:

fluid flow is achieved using the inertia of the

fluid in motion.
These applications are suitable for lowpressure (up to 40 bar) high-volume flow
applications.
They are used only for transporting fluid
from one place to another , so they are not
preferred in the industries.

Positive displacement
pumps:As the name implies, the functioning of a positive

displacement pump derives from changes of the

volume occupied by the fluid within the pump.
Since the operation of the pumps depend only on
mechanical and hydrostatic principles, these pumps
are also called as Hydrostatic displacement pumps.
They are used primarily where pressure development
is the primary requirement , so it is primarily used in
fluid power systems universally.
These pumps deliver a uniform quantity of fluid into
the hydraulic system per revolution of the pump
shaft rotation , so it is called as positive
displacement pumps.

Components:Reservoir
The hydraulic fluid reservoir holds excess hydraulic fluid to accommodate volume changes from: cylinder
extension and contraction, temperature driven expansion and contraction, and leaks. The reservoir is also
designed to aid in separation of air from the fluid and also work as a heat accumulator to cover losses in
the system when peak power is used. Design engineers are always pressured to reduce the size of
hydraulic reservoirs, while equipment operators always appreciate larger reservoirs.

Some designs include dynamic flow channels on the fluid's return path that allow for a smaller reservoir.
Accumulators

Accumulators are a common part of hydraulic machinery. Their function is to store energy by using
pressurized gas. One type is a tube with a floating piston. On one side of the piston is a charge of
pressurized gas, and on the is the life of the hydraulic circuit. It is usually petroleum oil with various
additives. Some hydraulic machines require other side is the fluid. Bladders are used in other designs.
Reservoirs store a system's fluid.

Examples of accumulator uses are backup power for steering or brakes, or to act as a shock absorber for
the hydraulic circuit.
Hydraulic fluid

Also known as tractor fluid, hydraulic fluid fire resistant fluids, depending on their applications. In some
factories where food is prepared, water is used as a working fluid for health and safety reasons.

In addition to transferring energy, hydraulic fluid needs to lubricate components, suspend contaminants
and metal filings for transport to the filter, and to function well to several hundred degrees Fahrenheit or
Celsius.
Filters

Filters are an important part of hydraulic systems. Metal particles are continually produced by mechanical
components and need to be removed along with other contaminants.

Filters may be positioned in many locations. The filter may be located between the reservoir and the pump
intake. Blockage of the filter will cause cavitation and possibly failure of the pump. Sometimes the filter is
located between the pump and the control valves. This arrangement is more expensive, since the filter
housing is pressurized, but eliminates cavitation problems and protects the control valve from pump
failures. The third common filter location is just before the return line enters the reservoir. This location is
relatively insensitive to blockage and does not require a pressurized housing, but contaminants that enter
the reservoir from external sources are not filtered until passing through the system at least once

External Gear Pump.

Impeller Mechanism Pump

Peristaltic Pump

Diaphragm Pump

Gear Pump

Gear Pump Balanced

Vane Pump

Piston Pump

Bent Axis Piston Pump

Swash Plate Piston Pump

COMPARISON BETWEEN HYDRAULIC AND

PNEUMATIC SYSTEMS:-

Hydraulic systems

It is suitable for heavy

payloads.
Highest power/weight
ratio.
High stiffness.
It is smooth in
operation.
Reliable and high
maintenance.
It is an expensive
system.

Pneumatic systems

It is suitable for medium

payloads.
Low power/weight ratio.
Very low stiffness and
inaccurate response.
It is noisy in operation.
Reliable and low
maintenance.
It is a cheaper system.

What is a valve?

A valve is a mechanical device which regulate

either the flow or the pressure of the fluid. Its
function can be stopping or starting the flow,
controlling flow rate, diverting flow, preventing back
flow, controlling pressure, or relieving pressure.
Basically, the valve is an assembly of a body with
connection to the pipe and some elements with a
sealing functionality that are operated by an
actuator. The valve can be also complemented whit
several devices such as positioners, transductors,
pressure regulators, etc.

Valves classification
The operative of the valve closure member
The kind of closure member movement defines both the geometry and operative
of the valve. Multi-turn valve (linear motion valves): the closure member has
a linear displacement generally by turning its threaded stem several times.
Valves: Diaphragm valve, Gate valve, Globe valve, Fixed cone valve, Needle
valve and Pinch valve.
Quarter-turn valve (rotary valve): the closure member as well its shaft turn 090; from the fully-open position to the fully-closed position. Quick
opening/closure.
Valves: Ball valve, Butterfly valve, Plug valve, Spherical valve.

The functionality of the valve

Control: pressure / flow rate regulation.
Closure at over-speed flow. (i.e. immediate closure if downstream pipeline is
broken by accident).
Overpressure protection.
Back flow prevention (check valve).
On/Off service.

Types of Valves

Electronic/Electrical Valves: In these valves, movement of the flap or ball is

controlled through digital electronics or electrical circuits. These valves have a
precise control and reaction time, which allow quick regulation of liquid flow. Such
valves are used in expensive automobiles, aircrafts, Space applications, ships,
high risk chemical processing and other critical areas.
Non-Return Valves: These valves are used in applications like chemical
processes, gas turbines, automotive and others where unidirectional flow is
required. The valves open in only one direction. When pressure in the opposite
direction is applied, the valves get closed.
Electromechanical Valves: Electro magnets control the opening and closing
mechanism of the valves. These valves may have only full open or full close
positions.
Mechanical Valves: Use mechanical energy for opening and closing mechanism.
A set of levers, pulleys, linkages, springs, threaded shafts, etc. are used to
operate the valve. Smaller valves may be operated manually by turning a wheel
or using a lever or handle. They are used in domestic water supply lines, taps for
water pipes, cooking ranges, fire-fighting equipment, etc.

Hydraulic Valves
Three main valve types:
On/off valves for manual control
Proportional valves: Control of
volume flow rate
Servo valves: Accurate control of
flow and pressure
Control Mode:
Electric over hydraulic
Hydraulic over hydraulic (pilot)
Manual

Needle Valve
It is called needle valve due to the shape of
the closure member. It consists on a
threaded stem with a conical end. Stems
with fine threaded have a slow linear
movement when they turn, therefore a
great number of turns are needed to have
a full flow section. This makes the needle
valve suitable for regulating flow, with a
minimal waste and without cavitations at
important differential pressures.
This valve is also placed in the bypass of the
turbine inlet valve. That valve is normally
butterfly or spherical type and not
prepared to open against all column
water pressure. The slow opening and
regulated closure of the needle valve
avoid cavitations and water hammer in
the pipeline system.

Butterfly Valve

Butterfly valves are quite versatile ones. They can be used at multiples industrial
applications, fluid, sizes, pressures, temperatures and connections at a relative low cost.
The development of this type of valve has been more recent than other ones.
A major conviction on saving energy in the installations was an advantage for its introduction,
due its head loss is small. At the beginning they were used in low pressure installations service,
but technologic improvements, specially in the elastomer field let their extension to higher
performances.
As any quarter turn valve, the operative of the butterfly valve is quiet easy. The closure member is a
disc that turns only 90 to be full opened/closed. This is a quick operation.
Few wear of the shaft, little friction and then less torque needed means a cheaper actuator. The
actuator can be manual, oleo hydraulic or electrical motorized, with automation available.
Butterfly valves geometry is simple, compact and revolute, therefore it is a cheap valve to manufacture
either
saving
material
and
post
mechanization.
Its reduced volume makes easy its installation. Gate and globe valves are heavier and more complex
geometry, therefore butterfly valve can result quiet attractive at big sizes regarding other types of
valves.
The head loss is small as the flow goes aerodynamically around the disc when valve is full open.
Although the head loss is slightly higher than in spherical and gate valves, because their flow sections
are totally free from obstacles, it is clearly lower than in globe valves.
Butterfly valves can work with any kind of fluid, gas, liquid and also with solids in suspension. As a
difference from gate, globe or ball valves, there are not cavities where solid can be deposit and difficult
the valve operative.
Pressure and temperature are determinant and correlated designing factors. At a constant pressure,
rising temperature means a lower performance for the valve, since some materials have lower capacity.
As well gate, globe and ball valves, the butterfly valve can be manufactured with metallic seats that can
perform at high pressure and extreme temperatures.

Gate Valve

Gate valve has an extended use in the

petrochemical industry due they can work
with metal-metal sealing.
They are used in clean flows.
When the valve is full opened, the free
valve area coincides with area of the pipe,
therefore the head lose of the valve is
small.
This valve is not recommended to regulate
or throttling service since the closure
member could be eroded. Partially opened
the valve can vibrate.
Opening and closing operations
are slow. Due to the high friction
wear it is not recommend their
use in often required openings.
This valve requires big actuators
which difficult automation. They
are not easy to repair on site.

Globe valve

A Globe valve is a type of valve

used for regulating flow in a pipeline,
consisting of a movable disk-type
element and a stationary ring seat in
a generally spherical body.[1]
Globe Valves are named for their
spherical body shape with the two
halves of the body being separated
by an internal baffle. This has an
opening that forms a seat onto
which a movable plug[2] can be
screwed in to close (or shut) the
valve. The plug is also called a disc
[3][4] In globe valves, the plug
or disk.[3][4]
is connected to a stem which is
operated by screw action in manual
valves. Typically, automated valves
use sliding stems. Automated globe
valves have a smooth stem rather
than threaded and are opened and
closed by an actuator assembly.
When a globe valve is manually
operated, the stem is turned by a
hand wheel

Open-loop hydraulic system

Open-loop: Pump-inlet and motor-return (via the
directional valve) are connected to the hydraulic
tank. The term loop applies to feedback; the
more correct term is open versus closed "circuit

Directional control
valves

Directional control valves route the fluid to the desired actuator. They usually consist of a spool
inside a cast iron or steel housing. The spool slides to different positions in the housing, intersecting
grooves and channels route the fluid based on the spool's position.
The spool has a central (neutral) position maintained with springs; in this position the supply fluid is
blocked, or returned to tank. Sliding the spool to one side routes the hydraulic fluid to an actuator and
provides a return path from the actuator to tank. When the spool is moved to the opposite direction
the supply and return paths are switched. When the spool is allowed to return to neutral (center)
position the actuator fluid paths are blocked, locking it in position.
Directional control valves are usually designed to be stackable, with one valve for each hydraulic
cylinder, and one fluid input supplying all the valves in the stack.
Tolerances are very tight in order to handle the high pressure and avoid leaking, spools typically have
a clearance with the housing of less than a thousandth of an inch (25 m). The valve block will be
mounted to the machine's frame with a three point pattern to avoid distorting the valve block and
jamming the valve's sensitive components.
The spool position may be actuated by mechanical levers, hydraulic pilot pressure, or solenoids which
push the spool left or right. A seal allows part of the spool to protrude outside the housing, where it is
accessible to the actuator.
The main valve block is usually a stack of off the shelf directional control valves chosen by flow
capacity and performance. Some valves are designed to be proportional (flow rate proportional to
valve position), while others may be simply on-off. The control valve is one of the most expensive and
sensitive parts of a hydraulic circuit.

Pressure control valves

Pressure relief valves are used in several

places in hydraulic machinery; on the return
circuit to maintain a small amount of pressure
for brakes, pilot lines, etc... On hydraulic
cylinders, to prevent overloading and hydraulic
line/seal rupture. On the hydraulic reservoir, to
maintain a small positive pressure which
excludes moisture and contamination.
Pressure reducing valves reduce the supply
pressure as needed for various circuits