Applied

Hydraulics &
Pneumatics

Unit 1 - FLUID POWER

PRINICIPLES AND HYDRAULIC
PUMPS
Syllabus
UNIT I - FLUID POWER PRINICIPLES AND HYDRAULIC PUMPS
Introduction to Fluid power – Advantages and Applications – Fluid power systems –
Types of fluids - Properties of fluids and selection – Basics of Hydraulics – Pascal’s Law
– Principles of flow - Friction loss – Work, Power and Torque Problems, Sources of
Hydraulic power : Pumping Theory – Pump Classification – Construction, Working,
Design, Advantages, Disadvantages, Performance, Selection criteria of Linear and
Rotary – Fixed and Variable displacement pumps – Problems.

Hours Required : 09

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Introduction to Fluid Power.

All machines require some type of power source and a way of transmitting this
power to the point of operation.
The three methods of transmitting power are:
– Mechanical
– Electrical
– Fluid
In this course we are going to deal with the third type of power transmission which
is the Fluid Power.

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Introduction to Fluid Power (Contd…)
– Fluid power is the method of using pressurized fluid to transmit energy.
– Fluid power is the technology that deals with the generation, control, and
transmission of power, using pressurized fluids.

– Liquid or Gas is referred to as a fluid. Accordingly, there are two branches of

fluid power; Pneumatics, and Hydraulics.

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History of Fluid Power.
– Ancient historical accounts show that water was used for centuries to produce
power by means of water wheels, and air was used to turn windmills and propel
ships.
– Pascal’s law [1647–48] and Bernoulli’s law [1738] operate at the very heart of all
fluid power.
– In 1906 when a hydraulic system was developed to replace electrical systems
for elevating and controlling guns on the battleship USS Virginia.
– In 1926 the United States developed the first unitized, packaged hydraulic
system consisting of a pump, controls, and actuator.

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Fluid Systems.

– Fluid transport systems

Fluid transport systems have as their sole objective the delivery of a fluid
from one location to another to accomplish some useful purpose
Example: pumping stations for pumping water to homes.
– Fluid power systems
Fluid power systems are designed specifically to perform work.
Example: Operating fluid cylinder or fluid motor.

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Types of Fluids.
– Hydraulic systems. (High Power Applications)
– Water Based (Water and Water Solutions)
– Oil Based (Petroleum oils and synthetic oils)

– Pneumatic Systems. (Low Power Applications)

– Air as the Gas medium.

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Introduction to Hydraulics.
– What is Hydraulic (from the Greek words hydra for water and aulos for a pipe)?
Hydraulics is the discipline that deals with the mechanical properties of
liquids, and applies the principles to solve engineering problems.
– Hydraulic systems are commonly used where mechanisms require large forces
and precise control.
– Examples include vehicle power steering and brakes, hydraulic jacks and heavy
earth moving machines.

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Basic Hydraulic System

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Introduction to Pneumatics.
– What is Pneumatic (from the Greek pneumn for wind or breath).?
Pneumatics is the discipline that deals with mechanical properties of gases
such as pressure and density, and applies the principles to use compressed gas
as a source of power to solve Engineering problems.

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Basic Pneumatic System

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Examples:
Landing gears Flaps

Mobile: Here fluid power is used to transport, excavate and lift materials as well as control or
power mobile equipment. End use industries include construction, agriculture, marine and
the military. Applications include backhoes, graders, tractors, truck brakes and suspensions,
spreaders and highway maintenance vehicles.
Industrial: Here fluid power is used to provide power transmission and motion control for the
machines of industry. End use industries range from plastics working to paper production.
Applications include metalworking equipment, controllers, automated manipulators,
material handling and assembly equipment.
Aerospace: Fluid power is used for both commercial and military aircraft, spacecraft and
related support equipment. Applications include landing gear, brakes, flight controls, motor
controls and cargo loading equipment.

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Advantages of Fluid Power.
– Fluid power systems provide many benefits to users including:
– Multiplication and variation of force
– Easy, accurate control
– Multi-function control
– High horsepower, low weight ratio
– Low speed torque
– Constant force or torque-This is a unique fluid power attribute.
– Safety in hazardous environments

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Disadvantages of Fluid Power.
– A hydraulic element needs to be machined to a high degree of precision.
– Leakage of hydraulic oil poses a problem to hydraulic operators.
– Special treatment is needed to protect them from rust, corrosion, dirt etc.,
– Hydraulic oil may pose problems if it disintegrates due to aging and chemical
deterioration.
– Hydraulic oils are messy and almost highly flammable.
– Hydraulic systems contain highly pressurized fluid. This can cause burns, bruises
or the accidental injection of fluid into the body.

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Fluids Properties.
–Viscosity:
It is a measured of the sluggishness with which a fluid moves. When the viscosity is
low, the fluid flows easily because it is thin and has low body.
–Viscosity Index:
A low V.I.  signifies a  relatively  large  change  of  viscosity  with  changes of
 temperature.  In other words, the oil becomes extremely thin at high temperatures
and extremely thick at low temperatures. On the other hand, a high V.I.  signifies
 relatively  little  change  in viscosity  over  a  wide  temperature  range.

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Fluids Properties. (Contd…)
Other important Properties

1. Oxidation. 2. Flash point.

3. Fire point. 4. Corrosion.
5. Demulsibility. 6. Flammability.

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Pascal’s Law
Pascal's law (also Pascal's principle or the principle of transmission of
fluid-pressure) is a principle in fluid mechanics that states that a pressure
change occurring anywhere in a confined incompressible fluid is transmitted
throughout the fluid such that the same change occurs everywhere.

A change in pressure at any point in an enclosed fluid at rest is

transmitted undiminished to all points in the fluid.

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Principles of Flow.
– Energy:
The ability to do work
– Energy Transfer:
From prime mover, or input source, to an actuator, or output device

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Principles of Flow. (Contd…)
– Work:

Force multiplied by distance - Measured in foot-pounds.

– Power:

The rate of doing work.

Work over time in seconds.
– Torque:

Twisting force x distance - Measured in foot-pounds.

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Properties of Air.
– Air has weight.
– Air is under pressure.
– Air has temperature.
– Air has a volume.
– Air usually contains some water vapour.
– Air usually has some velocity (speed).

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Perfect Gas Laws.
The gas laws were developed at the end of the 18th century, when
scientists began to realize that relationships between the pressure, volume and
temperature of a sample of gas could be obtained which would hold to a good
approximation for all gases.
Gases behave in a similar way over a wide variety of conditions because
they all have molecules which are widely spaced, and the equation of state for
an ideal gas is derived from kinetic theory.
The earlier gas laws are now considered as special cases of the ideal gas
equation, with one or more of the variables held constant.

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Perfect Gas Laws.(Contd…)
Boyle's Law
At constant temperature, the product of the pressure and volume of a
given mass of an ideal gas in a closed system is always constant. It can be
verified experimentally using a pressure gauge and a variable volume container.
Charles's law
It states that, for a given mass of an ideal gas at constant pressure, the
volume is directly proportional to its absolute temperature, assuming in a
closed system.

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Perfect Gas Laws.(Contd…)
Gay-Lussac's law:
Gay-Lussac's law, Amontons' law or the pressure law was found by Joseph Louis
Gay-Lussac in 1809. It states that, for a given mass and constant volume of an
ideal gas, the pressure exerted on the sides of its container is directly proportional
to its absolute temperature.
Combined and Ideal Gas Laws:
The Combined Gas Law or General Gas Equation is obtained by combining Boyle's
Law, Charles' Law, and Gay-Lussac's Law. It shows the relationship between the
pressure, volume, and temperature for a fixed mass (quantity) of gas:

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Hydraulic Pump.
A hydraulic pump is a mechanical source of power that converts
mechanical power into hydraulic energy (hydrostatic energy i.e. flow, pressure).
It generates flow with enough power to overcome pressure induced by the load
at the pump outlet.

A pump is a device that moves fluids (liquids or gases), or sometimes

slurries, by mechanical action.

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Pumping Theory.
The basic operating principle that moves fluid through a pump is similar
in all pumps.
– Enlarging the volume of a chamber allows fluid to enter the pump
– Reducing the chamber volume moves fluid to the system.
– Inlet and discharge valves or ports control fluid movement through the pump.

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Pump Classifications.
There are two broad classifications of pumps as identified by the fluid power
industry. They are described as follows.
– Hydrodynamic or non-positive pumps
• They are used for low-pressure, high-volume flow applications.
• Normally their maximum pressure capacity is limited to 250-300 psi.
– Hydrostatic or positive pumps (Gear, vane, piston pumps)
• High pressure capability (up to 10,000 psi or higher)
• Small compact size
• High volumetric efficiency

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Pump Classifications. (Cont…)
A positive displacement pump makes a fluid move by trapping a fixed
amount and forcing (displacing) that trapped volume into the discharge pipe.
Some positive displacement pumps use an expanding cavity on the suction side
and a decreasing cavity on the discharge side.
A non-positive-displacement pump. produces a continuous flow. However,
because it does not provide a positive internal seal against slippage, its output
varies considerably as pressure varies. Centrifugal and propeller pumps are
examples of non-positive-displacement pumps.
.

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Centrifugal Pump.
Centrifugal pumps are a sub-class of dynamic axisymmetric work-
absorbing turbomachinery, Centrifugal pumps are used to transport fluids by the
conversion of rotational kinetic energy to the hydrodynamic energy of the fluid flow.
The rotational energy typically comes from an engine or electric motor. The fluid enters
the pump impeller along or near to the rotating axis and is accelerated by the impeller,
flowing radially outward into a diffuser or volute chamber (casing), from where it exits.
Common uses include water, sewage, petroleum and petrochemical pumping.
Energy Transfer: the transfer of energy from the shaft to the impellor and from the
impeller to water
Centrifugal Force: the force used to throw the water from the impeller.

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Centrifugal Pump. (Cont…)
Three different configurations:
End Suction Centrifugal. – Center of the suction line is centered on the
impeller eye.
Split case pumps. – Volute Case is split horizontally.
Vertical Turbines. – Primarily mounted with a Vertical Shaft.

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Axial Flow (Propeller) Pump.

An axial-flow pump, or AFP, is a common type of pump that essentially consists of

a propeller (an axial impeller) in a pipe.
In axial flow centrifugal pumps the rotor is a propeller. Fluid flows parallel to the
axis as illustrated in Figure. Diffusion vanes are located in the discharge port of
the pump to eliminate the rotational velocity of the fluid imparted by the
propeller.
There is also the axial flow centrifugal pump which uses a curved propeller-
shaped impeller, whereas the impeller on a radial flow centrifugal pump looks
more like a fan. Axial flow pumps move fluid by drawing fluid into their axis and
using the impeller to send fluid out on the other side of the pump

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Gear Pump.

A gear pump (Fixed Displacement only by Geometrical Necessity) uses the

meshing of gears to pump fluid by displacement. They are one of the most
common types of pumps for hydraulic fluid power applications. Gear pumps are
also widely used in chemical installations to pump high viscosity fluids.
Types:
Internal (Gerotor) Gear Pump.
External Gear Pump.
Lobe Pump.
Screw Pump.

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Vane Pump.

A rotary vane pump is a positive-displacement pump that consists

of vanes mounted to a rotor that rotates inside of a cavity. In some cases
these vanes can have variable length and/or be tensioned to maintain contact
with the walls as the pump rotates.
Types:
Balanced Vane Pump. ( Fixed Displacement only)
Unbalanced Vane Pump. (Fixed or Variable Displacement)

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Piston Pump.

Piston pumps (Fixed or Variable Displacement)  and plunger pumps use a

mechanism (typically rotational) to create a reciprocating motion along an axis,
which then builds pressure in a cylinder or working barrel to force gas or fluid
through the pump. The pressure in the chamber actuates the valves at both the
suction and discharge points.
Types:
Radial Design.
Axial Design.

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Pump Performance.
QA
1. Volumetric efficiency (ᾐvol ): QT
 100

volumetric efficiency indicates the amount of leakage that takes place

within the pump. This involves considerations such as manufacturing
tolerances and flexing of the pump casing under design pressure operating
conditions:
Volumetric efficiencies typically run from 80% to 90% for gear pumps, 82%
to 92% for vane pumps, and 90% to 98% for piston pumps.

actual flow rate produced by pump

u   100
theoretical flow rate pump should produce

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Pump Performance. (Cont…)

2. Mechanical efficiency (ᾐmech):

Mechanical efficiency indicates the amount of energy losses that occur due
to reason other than leakage. This includes friction in bearings and between
other mating parts.
It also includes energy losses due to fluid turbulence. Mechanical
efficiencies typically run from 90% to 95%.
theoretical powe required to operate pump
m  PQT /1714 PQr
actual power delivered to pump m   100 m   100
TN / 63,000 TN
or
pump output power assuming no leakage
m 
input power delivered to pump

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Pump Performance. (Cont…)

3. Overall efficiency (ᾐoverall):

The overall efficiency considers all energy losses and is defined
mathematically as follows:

volumetric effeciency  mechanical efficieancy

overall efficiency=
100

om QA 100 PQ1 /1714

o    100
100 Q1 100 TN / 63,000

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Pump Performance. (Cont…)

PRESSURE SPEED OVERALL HP FLOW

PUMP RATING RATING EFFICIENCY PER LB CAPACITY COST (DOL
TYPE (PSI) (RPM) (PER CENT) RATIO (GPM) LARS PER HP)

EXTERNAL GEAR 2000-3000 1200-2500 80-90 2 1-150 4-8

INTERNAL GEAR 500-2000 1200-2500 70-85 2 1-200 4-8

VANE 1000-2000 1200-1800 80-95 2 1-80 6-30

AXIAL PISTON 2000-12000 1200-3000 90-98 4 1-200 6-50

RADIAL PISTON 3000-12000 1200-1800 85-95 3 1-200 5-35

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Pump Selection.
– Select the actuator (hydraulic cylinder or motor) that is appropriate based on the loads
encountered.
– Determine the flow-rate requirements. This involves the calculation of the flow rate necessary
to drive the actuator to move the load through a specified distance within a given time limit.
– Determine the pump speed and select the prime mover.
– Pump type based on the Application & Cost.
– Select the system pressure. This ties in with the actuator size and the magnitude of the resistive
force produced by the external load on the system.
– Select the reservoir and associated plumbing, including piping, valving, hy­draulic cylinders, and
motors and other miscellaneous components.

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