1

HYDRAULICS
 2

French philosopher Blaise Pascal discovered 17th century that liquids cannot be compressed. He
discovered a law which states: Pressure applied on a confined fluid is transmitted in all directions
with equal force.
 3

P=F\A
 4

A small force can lift a large weight if the small force is applied through a greater
distance than the large weight.
 5

METHODS OF POWER TRANSMISSION:

•MECHANICAL
•ELECTRICAL
•HYDRAULIC
•PNEUMATIC
 6

WHY HYDRAULICS ?
 7

ADVANTAGES OF HYDRAULICS:

•HIGH POWER TO WEIGHT RATIO.

•SAFE IN OVERLIMIT POWER TRANSMISSION.
•FLEXIBILITY.

DISADVANTAGES
•HIGH COST.
•PRONE TO CONTAMINATION,CAVITATION
AND FLASHING.
 8

HYDRAULICS
 9

BASIC HYDRAULIC SYSTEM:

 10

WHAT IS RESPONSIBLE FOR PRESSURE

GENERATION IN HYDRAULIC SYSTEM?
 11

FLOW CONTROLS THE LINEAR SPEED OF CYLINDER AND

MOTOR RPM.

PRESSURE CONTROLS THE FORCE OF LINEAR ACTUATOR

AND MOTOR TORQUE.
 12

HYDRAULIC SYSTEM:
.OPEN LOOP SYSTEM

.CLOSED LOOP SYSTEM

PUMP MOTOR
 13

DISPLACEMENT V/S FLOW

DISPLACEMENT: VOLUME OF OIL PUSHED OUT BY THE

PUMP IN SINGLE REVOLUTION…………..49CC,35CC.

FLOW:VOLUME OF OIL PUSHED OUT BY THE PUMP PER

MINUTE………….40LPM,100LPM.

FLOW (LPM) : DISPLACEMENT X R.P.M X EFFICIENCY /1000

 14

VARIOUS COMPONENTS:

•PRIME MOVER(ENGINE,ELECTRIC MOTOR ETC.)

•ENERGY CONVERTER(PUMP,HYDRAULIC CYLINDER,MOTOR ETC.)
•CONTROLERS(DCV,FLOW CONTROL VALVE ETC.)
•SAFETY DEVICES(REFIEF VALVE,CHECK VALVE ETC.)
•FLUID CARRIERS(HOSES AND CDS TUBES)
•RESERVOIR
•ACCUMULATOR
•FILTER
•OIL COOLER
 15

HOW TO INTERPRET HYDRAULIC LINES:

CONTINUES LINE:

DASHED LINE:

DOTTED LINE: ………………………………

PHANTOM LINE:
 16

PRIME MOVER:THE COMPONENTS WHICH PROVIDES POWER

TO RUN THE SYSTEM.

ENGINE

ELECTRIC MOTOR

M
IMPORTANT PARAMETERS: POWER AND RPM.
 17

*ENSURE THE TRIANGLE

ENERGY CONVERTER:
IS FILLED
•PUMP:

30CC 30CC 30CC

TANDEM AXIAL
GEAR PUMP AXIAL PISTON PUMP
PISTON PUMP
 18
DIFFERENT TYPE OF PUMPS:

•GEAR PUMP

*MOUNTING OPTIONS:
-INLINE MOUNTING WITHOUT BEARING
-OFFSET MOUNTING WITH BEARING
 19

AXIAL PISTON PUMP

 20

VANE PUMP
 21

Typical Pump Performance Parameters

Hydraulic Pump Type Flow Maximum pressure(psi) Maximum speed(rpm) Efficiency(%)

External Gear Fixed 3600 500-5000 85-90

Internal Gear Fixed 3000 900-1800 90

Vane Fixed 2500 900-3000 86

Vane Variable 1000-2300 750-2000 85

Radial Piston Fixed 10000 1000-3400 90

Axial Piston (bent axis) Fixed 5100-6500 950-3200 92

Axial Piston (bent axis) Variable 5800 500-4100 92

Axial Piston (swash plate) Variable 4600-6500 500-4300 91

 22

PUMP SELECTION PARAMETERS:

•MAX RPM
•DISPLACEMENT
•MAX PRESSURE
-CONTINIOUS PRESSURE
-INTERMITTENT PRESSURE
-PEAK PRESSURE
•PORT SIZE
•MOUNTING DETAIL
•SHAFT DETAIL
•EFFICIENCY
•MAX ALLOWED CONTAMINATION
•TEMPRATURE LIMITS
 23
TANK:

FUNCTION:
•SERVES OIL WHENEVER IT IS REQUIRED
•OIL COOLING
•REDUCES THE AIR BUBBLE FORMATION
MAIN CONSTITUENTS:
•BREATHER
•SUCTION STRAINER
•OIL LEVEL INDICATOR
•INLET AND OUTLET PORTS
•RETURN LINE FILTER
•DRAIN PLUG
 24
PRESSURE RELIEF VALVE:

180 BAR

FUNCTION OF RELIEF VALVE:

IT LIMITS THE SYSTEM PRESSURE TO AVOID ACCIDENT
 25

FEW RELATED PARAMETERS:

-FULL FLOW PRESSURE:

•THE PRESSURE AT RATED FLOW IS TERMED AS FULL FLOW
PRESSURE

-CRACKING PRESSURE:
•THE PRESSURE AT WHICH RELIEF VALVE FIRST BEGINS TO OPEN
IS CALLED CRACKING PRESSURE

-PRESSURE OVERRIDE:
•THE DIFFERENCE BETWEEN CRACKING PRESSURE AND FULL
FLOW PRESSURE IS CALLED PRESSURE OVERRIDE
 26
CHECK VALVE:

ALLOWS UNIDIRECTIONAL FLOW AND PROTECTS THE SYSTEM

FROM ACCIDENT.

IMPORTANT PARAMETERS WHILE SELECTING CHECK VALVE:

•FLOW CAPACITY
•CRACKING PRESSURE
•FULL FLOW PRESSURE
•PORT SIZE
 27

PILOT OPERATED CHECK VALVE:

ALLOWS BIDIRECTIONAL / UNIDIRECTIONAL FLOW AS PER NEED .

 28

QUESTION:

CAN WE USE PRESSURE RELIEF VALVE INSTEAD OF CHECK

VALVE OR VICE VERSA????????
 29
PUMP CONTROL PANELS/MANIFOLDS:

THESE ARE THE METTALIC BLOCKS WHICH PROVIDE OPTIMUM

LODGE TO MOUNT HYDRAULIC COMPONENTS IN CONFINED SPACE.

CARTRIDGE VALVES ARE AVAILABLE FOR THIS TYPE OF

ARRANGEMENT
 30
DIRECTION CONTROL VALVES:

A B

P T
FUNCTION:
IT ALLOWS DIFFERENT PATH FOR OIL TO FLOW AS PER REQUIREMENT.
 31
DIFFERENT CONFIGURATIONS OF CENTRE POSITION:

A B A B

P T P T
CLOSE CENTER TANDEM

A B A B

P T P T
OPEN CENTER FLOAT CENTER
H SPOOL
 32

ILLUSTRATION:
 33

IMPORTANT PARAMETERS TO BE FREEZED WHILE SELECTING

DCV:

•MRV(MAIN RELIEF VALVE) SETTING

•ARV (AUXILLARY RELIEF VALVE)SETTING (IF REQUIRED)
•FLOW CAPACITY
•PRESSURE DROP ACROSS P-A,P-B,P-T,A&B-T.
•SPOOL LEAKAGE
•CLEANLINESS LEVEL RECOMMENDATION
•TEMPRATURE RANGE
•MAX PRESSURE
 34

LOAD

DAMAGED SEAL
 35
CYLINDERS:

SINGLE ACTING DOUBLE ACTING(DIFFRENTIAL)

DOUBLE ACTING DOUBLE ROD

 36
HYDRAULIC MOTORS:

30CC 30CC 30CC

TYPES OF HYDRAULIC MOTORS:

•RADIAL PISTON MOTOR

•GEROTOR MOTOR
•GEAR MOTOR
•AXIAL PISTON MOTOR
 37

WHAT IS MOTOR DRAIN????

 38

DRAIN:
ALL LEAKAGES HAPPENING INSIDE THE MOTOR ARE PUSHED OUT THROUGH
DRAIN LINE TO PREVENT SHAFT SEAL.THE OIL THROUGH
DRAIN IS ALSO UTILIZED FOR THE LUBRICATION OF DYNAMIC PARTS.

30CC

DRAIN LINE
 39

PURGE VALVE:

A B A B
 40

ROTARY ACTUATOR:

THESE TYPE OF ACTUATORS ARE USED FOR ROTARY MOTION

LESS THEN 360⁰
 41

FILTER:

FUNCTION:TO MAINTAIN CLEANLINESS IN HYDRAULIC SYSTEM

 42

FEATURES:

•BYE PASS CHECK VALVE

•CLOGGING INDICATOR
•INBUILT BREATHER

TYPES OF FILTERS:

•PRESSURE LINE FILTER(IN LINE)

•RETURN LINE FILTER(IN LINE AND TANK TOP MOUNTED)
•SUCTION STRAINERS

PARAMETERS TO BE FREEZED WHILE SELECTING FILTER:

•FLOW CAPACITY
•BYE PASS VALVE SETTING
•MAX PRESSURE DROP
•PARTICAL SIZE TO BE DEFINED IN MICRONS
 43

CONTAMINATION:

CAN WE ELIMINATE CONTAMINATION????

 44

VARIOUS CONTAMINATION STANDARDS:

•ISO 4406
•NAS 1638 (NATIONAL AEROSPACE STANDARD)
•MILLIPORE
 45

ISO 4406:

THREE DIFFERENT SCALES IN A SAMPLE OF 1 ML:

•FIRST SCALE-ALL PARTICALS EQUAL TO OR MORE THEN 4 MICRONS

•SECOND SCALE-ALL PARTICALS EQUAL TO OR MORE THEN 6 MICRONS

•THIRD SCALE-ALL PARTICALS EQUAL TO OR MORE THEN 14 MICRONS

CONTAMINATION REPRESENTATION:

22/18/13
46
 47

NAS 1638:
 48

WHAT IS PARTICAL COUNTER????

 49

BETA RATIO:IT SIGNIFIES THE FILTRATION EFFICIENCY.

IT IS THE RATIO OF NUMBER OF PARTICALS UPSTREAM TO THE NUMBER

OF PARTICALS DOWNSTREAM ACROSS THE FILTER.

β (10µ)= 1000

1000 PARTICALS 1 PARTICAL

FILTER
 50

OIL COOLER:

FUNCTION: TO MAINTAIN SYSTEM TEMPRATURE.

IMPORTANT PARAMETERS WHILE SELECTION OF OIL COOLER:

•FLOW CAPACITY
•WATTAGE AS PER HEAT LOAD CALCULATION
•MAX PRESSURE
•BYE PASS CHECK VALVE
 51

FLOW CONTROL VALVES:

FIXED FLOW CONTROL VALVE (ORIFICE):

VARIABLE FLOW CONTROL VALVE :

-IN LINE VALVE
-CARTRIDGE TYPE VALVE
 52

LOAD
METER OUT FLOW
 53

LOAD
METER IN FLOW
 54

LOAD
METER IN AND OUT FLOW:
 55

FLUID CARRIERS:

HOSES:
THESE CARRIERS ARE DEFINED AS PER WORKING PRESSURE AND
INTERNAL DIAMETER.

STANDARD:
SAE J517.

*WORKING PRESSURE.
*TEST PRESSURE
*BURST PRESSURE
 56

HOW TO FIND LINE ID?

 57

LINE ID: 4.61√Q / V

Q=FLOW

FOR PRESSURE LINE V=7

FOR RETURN LINE V=3.22
FOR SUCTION LINE V=1.21
 58

CDS(COLD DRAWN SEAMLESS) TUBES,NUT AND FERRULE:

FITTING (ELBOW,TEE,MALE STUD COUPLING ETC)-STANDARD:ISO-8434

 59

HYDROSTATIC TRANSMISSION
60
 61

THANK YOU