APPLIED HYDRAULICS AND

PNEUMATICS
UNIT I : FLUID POWER
SYSTEMS AND
FUNDAMENTALS
 Introduction to fluid power
 Advantages of fluid power
 Application of fluid power system
 Types of fluid power systems,
 General types of fluids
◦ Properties of hydraulic fluids
◦ Fluid power symbols
 Basics of Hydraulics
◦ Applications of Pascal’s Law
◦ Laminar and Turbulent flow
◦ Reynolds’s number
◦ Darcy’s equation
◦ Losses in pipe, valves and fittings
Introduction to fluid power
 Fluid power is a term
describing hydraulics and pneumatics tech
nologies.
 Both technologies use a fluid (liquid or gas) to
transmit power from one location to another.
 hydraulics, the fluid is a liquid (usually oil),
 pneumatics uses a gas (usually compressed
air).
 Both are forms of power transmission, which
is the technology of converting power to a
more useable form and distributing it to
where it is needed.
 The common methods of  power transmission
are electrical, mechanical, and fluid power.
Advantages of fluid power
 high horsepower-to-weight ratio — You could probably hold
a 5-hp hydraulic motor in the palm of your hand, but a 5-hp
electric motor might weight 40 lb or more.
 safety in hazardous environments because they are
inherently spark-free and can tolerate high temperatures.
 force or torque can be held constant — this is unique to
fluid power transmission
 high torque at low speed — unlike electric motors,
pneumatic and hydraulic motors can produce high torque while
operating at low rotational speeds. Some fluid power motors
can even maintain torque at zero speed without overheating
 pressurized fluids can be transmitted over long
distances and through complex machine configurations with
only a small loss in power
 multi-functional control — a single hydraulic pump or air
compressor can provide power to many cylinders, motors, or
other actuators
 elimination of complicated mechanical trains of gears,
chains, belts, cams, and linkages
 motion can be almost instantly reversed
Application of fluid power
system
 Construction
 Mining
 Agriculture
 Waste Reduction
 Utility Equipment
 Marine
 Offshore
 Energy
 Metal Forming
 Machine Tools
 Military & Aerospace
 Other Applications
Types of fluid power
systems
Fluid transport system
◦ Transport of water from reservoir
using pipe lines
◦ Transport of oil in pipe to two
countries.
Fluid power system
◦ Oil used in equipments to acquire
desire movement.
◦ Compressed air in pneumatics for
crane movements
Properties of hydraulic
fluids
Density
◦ The density of a fluid is its mass per 
unit 
volume:
◦ Liquids are essentially incompressibl
e 
◦ Density is highly variable in gases ne
arly 
proportional to the pressure. 
Cavitation
◦ Cloud of vapour bubble will form
when liquid pressure drops below
vapour pressure due to flow
phenomenon
Capillarity
◦ Liquid rises into a thin glass tube
above or below its general level.
Vapour pressure
◦ Pressure exerted by vapour which is
in equilibrium with liquid
Compatibility
◦ Ability of hydraulic fluid to be
compatible with the system.
Volatility
◦ The degree and rate at which it will
vapourize under given conditions of
temperature and pressure.
Corrosiveness
◦ Tendency to promote corrosion in
hydraulic system.
Application of pascals law
Hydraulic press
Hydraulic jack
UNIT 2: HYDRAULIC SYSTEM
COMPONENTS
Sources of Hydraulic Power
◦ construction and working of pumps –
Variable displacement pumps
◦ Actuators: Linear hydraulic actuators
◦ Single acting and Double acting
cylinders
◦ Fluid motors.

Control Components:
 Direction control valve
 Flow control valves
 Electrical control -- solenoid valves. Relays,
Accumulators and Intensifiers.
Basic Pump Classifications
Hydraulic pumps can be
classified using three basic
aspects:
◦ Displacement
◦ Pumping motion
◦ Fluid delivery characteristics
 Basic Pump Classifications
Displacement relates to how the
output of the pump reacts to system
loads
◦ Positive-displacement pumps produce a
constant output per cycle
◦ Non-positive-displacement pumps
produce flow variations due to internal
slippage
Basic Pump Classifications
A non-positive-displacement
pump has large internal
clearances
◦ Allows fluid slippage in the pump
◦ Results in varying flow output as
system load varies
Basic Pump Classifications
Non-positive-displacement pump
Basic Pump Classifications
The basic pumping motions used
in hydraulic pumps are:
◦ Rotary
◦ Reciprocating
Basic Pump Classifications
Gear pumps are rotary pumps

Sauer-Danfoss, Ames, IA
 Basic Pump Classifications
Piston pumps are reciprocating
pumps

Reciprocating piston
movement
 Basic Pump Classifications
In a rotary pump, the pumping
action is produced by revolving
components
In a reciprocating pump, the
rotating motion of the pump input
shaft is changed to reciprocating
motion, which then produces the
pumping action
Basic Pump Classifications
Hydraulic pumps are classified as
either fixed or variable delivery
◦ Fixed-delivery pumps have pumping
chambers with a volume that cannot
be changed; the output is the same
during each cycle
◦ In variable-delivery designs,
chamber geometry may be changed
to allow varying flow from the pump
Basic Pump Classifications
Gearpumps are fixed-delivery
pumps
Basic Pump Classifications
Piston pumps may be designed
as variable-delivery pumps
 Basic Pump Classifications
When selecting a pump for a circuit,
factors that must be considered are:
◦ System operating pressure
◦ Flow rate
◦ Cycle rate
◦ Expected length of service
◦ Environmental conditions
◦ Cost
Pump Design, Operation,
and Application
Gear pumps are positive-
displacement, fixed-delivery,
rotary units
Gear pumps are produced with
either external or internal gear
teeth configurations
Pump Design, Operation,
and Application
Gear pumps are commonly used
Pump Design, Operation,
and Application
Pumping action of gear pumps
results from unmeshing and
meshing of the gears
◦ As the gears unmesh in the inlet area,
low pressure causes fluid to enter the
pump
◦ As the pump rotates, fluid is carried to
the pump discharge area
◦ When the gears mesh in the discharge
area, fluid is forced out of the pump into
the system
Pump Design, Operation,
and Application
Gear pumps are available in a
wide variety of sizes
◦ Flow outputs from below 1 gpm to
150 gpm
◦ Pressure rating range up to 3000 psi
Pump Design, Operation,
and Application
The gerotor pump design is an
internal-gear pump
◦ Uses two rotating, gear-shaped
elements that form sealed chambers
◦ The chambers vary in volume as the
elements rotate
◦ Fluid comes into the chambers as
they are enlarging and is forced out
as they decrease in size
Pump Design, Operation,
and Application
The gerotor is a common
internal-gear design
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Vane pumps are positive-
displacement, fixed or variable
delivery, rotary units.
◦ Design is commonly used in
industrial applications
◦ Delivery can range up to 75 gpm
◦ Maximum pressure of about 2000 psi
 Pump Design, Operation,
and Application
Vane pump consists of a slotted rotor,
fitted with moveable vanes, that
rotates within a cam ring in the pump
housing
◦ Rotor is off center in the ring, which
creates pumping chambers that vary in
volume as the pump rotates
◦ As chamber volume increases, pressure
decreases, bringing fluid into the pump
◦ As volume decreases, fluid is forced out
into the system
Pump Design, Operation,
and Application
Operation of a typical vane pump
Pump Design, Operation,
and Application
Parts of a typical vane pump
Pump Design, Operation,
and Application
Vane pump may be pressure
unbalanced or pressure balanced
◦ Unbalanced has only one inlet and
one discharge, which places a side
load on the shaft
◦ Balanced has two inlets and two
discharges opposite each other,
creating a pressure balance and,
therefore, no load on the shaft
Pump Design, Operation,
and Application
Piston pumps are positive-
displacement, fixed- or variable-
delivery, reciprocating units
◦ Several variations
◦ Many provide high volumetric
efficiency (90%), high operating
pressure (10,000 psi or higher), and
high-speed operation
Pump Design, Operation,
and Application
A basic piston pump consists of a
housing that supports a pumping
mechanism and a motion-converting
mechanism
◦ Pumping mechanism is a block
containing cylinders fitted with pistons
and valves
◦ Motion converter changes rotary to
reciprocating motion via cams, eccentric
ring, swash plate, or bent-axis designs
◦ Rotating the pump shaft causes piston
movement that pumps the fluid
Pump Design, Operation,
and Application
Piston pump classification is
based on the relationship
between the axes of the power
input shaft and piston motion
◦ Axial
◦ Radial
◦ Reciprocating
Pump Design, Operation,
and Application
Axialpiston pumps use two
design variations:
◦ Inline
◦ Bent axis
Pump Design, Operation,
and Application
Inlinehas the cylinder block and
pistons located on the same axis
as the pump input shaft
◦ Pistons reciprocate against a swash
plate
◦ Very popular design used in many
applications
 Pump Design, Operation,
and Application
An inline axial-piston pump
 Pump Design, Operation,
and Application
Bent axis has the cylinder block and
pistons set at an angle to the input
shaft
◦ Geometry of the axis angle creates
piston movement
◦ Considered a more rugged pump than
inline
◦ Manufactured in high flow rates and
maximum operating pressures
Pump Design, Operation,
and Application
A bent-axis axial-piston pump
Pump Design, Operation,
and Application
Radial piston pumps have the
highest continuous operating
pressure capability of any of the
pumps regularly used in hydraulic
systems
Models are available with
operating pressure ratings in the
10,000 psi range
 Pump Design, Operation,
and Application
Two variations of radial piston pumps:
◦ Stationary-cylinder design uses springs to
hold pistons against a cam that rotates
with the main shaft of the pump
◦ Rotating-cylinder design uses centrifugal
force to hold pistons against a reaction
ring
When the main shaft is rotated, each
piston reciprocates, causing fluid to
move through the pump
Pump Design, Operation,
and Application
 A stationary-cylinder radial-
piston pump
Pump Design, Operation,
and Application
Large, reciprocating-plunger
pump designs were widely used
when factories had a central
hydraulic power source
Today, plunger pumps are
typically found in special
applications requiring high-
pressure performance
Pump Design, Operation,
and Application
Screw pumps have pumping
elements that consist of one, two,
or three rotating screws
As the screws rotate, fluid is
trapped and carried along to the
discharge of the pump
The design of screw pumps
allows them to operate at a very
low noise level
Pump Design, Operation,
and Application
A typical screw pump
 Pump Design, Operation,
and Application
The lobe pump is a close relative of
the gear pump
◦ Two three-lobed, gear-shaped units are
often used to form the pumping element
◦ Output flow is larger than a gear pump
of comparable physical size because of
pumping chamber geometry
◦ Lower pressure rating than gear pumps
◦ Tend to have a pulsating output flow
Pump Design, Operation,
and Application
Operation of a lobe pump
 Pump Design, Operation,
and Application
Centrifugal pumps are non-
positive-displacement units
◦ Use centrifugal force generated by a
rotating impeller to move fluid
◦ Large clearances between the impeller
and the pump housing allow internal
pump slippage when resistance to
fluid flow is encountered in the system
◦ Typically used in hydraulic systems as
auxiliary fluid transfer pumps
Pump Design, Operation,
and Application
Operation of a centrifugal pump
Pump Design, Operation,
and Application
Propeller and jet pumps are non-
positive-displacement pumps
◦ Sometimes used to transfer fluid
within hydraulic systems
◦ Propeller pump consists of a rotating
propeller-shaped pumping element
◦ Jet pump creates flow by pumping
fluid through a nozzle concentrically
located within a venturi
Pump Design, Operation,
and Application
Construction of a propeller pump
Pump Design, Operation,
and Application
Construction of a jet pump
 Directional control valves

Check valve
Pilot operated check valve
Three-way and four-way valves
Manually-actuated valve
Pilot actuated valve
Solenoid actuated valve
Center flow path configuration
Shuttle valve
Directional control valves
Pilot operated check valve
Three-way valves
Four-way valves
Manually-actuated valve
Pilot actuated valve
Solenoid actuated valve
 Pressure control valves

Pressure relief valve

Compound pressure relief valve
Pressure-reducing valve
Pressure relief valve
Compound pressure relief
valve
Pressure-reducing valve
Flow control valve/ Needle
valve

Restrictor needle
valve
Weight loaded
accumulator
Spring loaded
accumulator
Diaphragm type
accumulator
Bladder type accumulator
Intensifier
UNIT 3: PNEUMATIC SYSTEM
COMPONENTS

Pneumatic Components:
 Properties of air. Compressors.
FRL Unit –
Air control valves,
Quick exhaust valves
pneumatic actuators- cylinders,
air motors.
Compressor construction
Types of compressor
 Piston type reciprocating
compressor
 Fig shows single-acting piston actions in the cylinder of a
reciprocating compressor.
 The piston is driven by a crank shaft via a connecting rod.
 At the top of the cylinder are a suction valve and a
discharge valve.
 A reciprocating compressor usually has two, three, four, or
six cylinders in it.
Screw compressor
 Screw compressors are also belong to the
positive displacement compressor family.
 In screw compressors, the compression is
accomplished by the enmeshing of two
mating helically grooved rotors suitably
housed in a cylinder equipped with
appropriated inlet and discharge ports
 Rotary vane compressor
 The rotor shaft is mounted eccentrically in a steel
cylinder so that the rotor nearly touches the
cylinder wall on one side, the two being separated
only by an oil film at this point.
 Directly opposite this point the clearance between

the rotor and the cylinder wall is maximum.

 Heads or end-plates are installed on the ends of

 the move
The vanes cylinder and
back and forthtoradially
holdinthe rotor shaft.
the rotor slots as they follow the contour of
the cylinder wall when the rotor is turning.
 The vanes are held firmly against the
cylinder wall by action of the centrifugal
force developed by the rotating rotor.
 In some instances, the blades are spring-
loaded to obtain a more positive seal
against the cylinder wall.
 Filter

Air In Air Out

Louver
Filter Element

Bowl Sight Gauge

Drain Cock
 Regulator
Adjustable
Locking
Knob Main Spring

Diaphragm
Assembly

Air In Air Out

Valve Valve Spring

Assembly
Lubricator
 2
Quick Exhaust Valve
 Port 2 is connected directly
2
to the end cover of a 1
cylinder
 Port 1 receives air from the
1
control valve
 Air flows past the lips of the
seal to drive the cylinder
 When the control valve is
exhausted, the seal flips to
the right opening the large 2
direct flow path
 Air is exhausted very
rapidly from the cylinder
for increased speed

1
Unit 4: FLUIDICS & PNEUMATIC CIRCUIT
DESIGN

Fluidics – Introduction to fluidic

devices, simple circuits Introduction
to Electro Hydraulic Pneumatic logic
circuits, PLC applications in fluid
power control, ladder diagrams
Fluid Power Circuit Design:
Sequential circuit design for simple
applications using classic, cascade,
step counter, logic with Karnaugh-
Veitch Mapping and combinational
circuit design methods.
Fluidic control of
pneumatic cylinders
PLC
Ladder diagram
PLC control of hydraulic
circuit
Cascading circuit
UNIT 5: FLUID POWER CIRCUITS

Speed control circuits, synchronizing

circuit, Pneumo hydraulic circuit,
Accumulator circuits, Intensifier circuits.
Servo systems – Hydro Mechanical
servo systems, Electro hydraulic servo
systems and proportional valves.
 Deceleration circuit, hydrostatics
transmission circuits, control circuits for
reciprocating drives in machine tools,
Material handling equipments. Fluid
power circuits; failure and
troubleshooting.
Speed control circuit
Regenerative circuit
Pressure intensifier circuit
Accumulator circuit
Pneumatic motor circuit
Regenerative drilling
machine
Hydraulic fault diagnosis
Pneumatics fault diagnosis
Thank you.