Basics of Hydraulics

and Pneumatics
GNB
Contents

▪ Operational Principles and Application, Air Compressors,

▪ Pneumatic Cylinders and Air Motors,
▪ Pneumatic Valves,
▪ Design of Pneumatic Circuits.
▪ Principles of Hydraulics, Hydraulic Fluids,
▪ Hydraulic – Pumps, Valves and Actuators.
▪ Power Pack design layout,
▪ Basic Hydraulic Circuits.
Fluid Power

▪ Fluid power is the technology that deals with the generation, control, and transmission of power, using
pressurized fluids. It can be said that fluid power is the muscle that moves industry. This is because fluid
power is used to push, pull, regulate, or drive virtually all the machines of modern industry.
▪ Fluid power is called hydraulics when the fluid is a liquid; is called pneumatics when the fluid is a gas.
▪ Hydraulic systems use liquids such as petroleum oils, synthetic oils, and water.
▪ The first hydraulic fluid to be used was water because it is readily available. However, water has many
deficiencies in comparison to hydraulic oils.
▪ Pneumatic systems use air as the gas medium because air is very abundant and can be readily exhausted
into the atmosphere after completing its assigned task
Advantages of Fluid Power

▪ Ease and accuracy of control.

▪ Multiplication of force.
▪ Constant force or torque.
▪ Simplicity, safety, economy.

However closed piping

and Noise is disadvantage
of fluid power
Pneumatic System
Components of Pneumatic System

▪ An air tank to store a given volume of compressed air

▪ A compressor to compress the air that comes directly from the atmosphere
▪ An electric motor or other prime mover to drive the compressor
▪ Valves to control air direction, pressure, and flow rate
▪ An actuator to convert the pressure of the compressed air into mechanical force or torque to do useful
work. Actuators can either be cylinders to provide linear motion or motors (hydraulic) to provide rotary
motion
▪ Piping to carry the pressurized air from one location to another
Components of Pneumatic System

1. Tank/ Reservoir
2. Compressor
3. Electric Motor
4. Valves
5. Actuators
6. Connecting Hoses
Properties of Compressed Air
▪ Air is the only gas commonly used in fluid power systems because it is inexpensive and readily
available. Air also has the following desirable features as a power fluid:
– 1. It is fire resistant.
– 2. It is not messy.
– 3. It can be exhausted back into the atmosphere.
▪ The disadvantages of using air versus using hydraulic oil are:
▪ Due to its compressibility, air cannot be used in an application where accurate positioning or rigid
holding is required.
▪ Air can be corrosive, since it contains oxygen and water.
▪ A lubricant must be added to air to lubricate valves and actuators.
▪ Air pressures of greater than 250 psi are typically not used due to the explosion dangers involved if
components such as air tanks should rupture. This is because air (due to its compressibility) can store a
large amount of energy as it is compressed in a manner similar to that of a mechanical spring.
Air Compressor
 Air Compressor
▪ A Compressor is used to compress the air from an inlet pressure level to a higher desired pressure level.
▪ As per the law of perfect gas, the compressor increases the pressure of the air by reducing its volume.
Compressor
Positive Dynamic
Displacement Compressors

Reciprocating Rotary Centrifugal

1. Piston 1. Screw 1. Radial flow
2. Labyrinth 2. Vane 2. Axial flow
3. Diaphragm 3. Lobe
4. Liquid Ring
5. Gear
Positive Displacement Compressor
▪ It works on the principle of increasing the pressure of the compressed air by reducing its volume in a
closed chamber.
▪ Piston Type Reciprocating Compressor:
– Commonly used and it is similar to working of IC Engines.
– Cylinder, cylinder hear, piston, piston rings, inlet and outlet valves, crankshaft, connecting rod, bearings.
– Prime mover (electric motor) used to drive the compressor
– Inlet Stroke, piston moves downward, pressure goes below atmospheric level
– Inlet valve opens, air gets accumulated.
– Outlet Stroke; Inlet valve closes, piston moves upwards
– Pressure increases and compresses the air
– Escapes out via outlet valve
 Parts of Compressor (Multi Stage)

1. Single cylinder can provide pressure

up to 10 bar.
2. Multicylinder – 2 to 16
3. Pressure up to 350 bar
Screw Compressor

▪ Screw Compressors are preferred where the pressure range is below 10 bar.
▪ It consists of a unsymmetrical profile of screw rotors.
▪ Consists of two screw. One convex and other concave contour
▪ As the screw rotates, air is sucked inside through the inlet port and being compressed between the scres
and moves out at the outlet port.
▪ Simple in design
▪ Fewer moving parts
▪ Constant delivery
▪ Pressure up to 8 bar
Rotary vane Compressor
▪ Applicable for low pressure low volume applications.
▪ It consists of a rotor eccentrically outside the cylindrical casting.
▪ Rotor consists of spring loaded vanes
▪ Pressure between 3 to 10 bar
▪ As the rotor rotates, the air get accumulated int the vane gets compressed and moves out via outlet port
▪ Small in size and weight
▪ Can work at high speed
Pneumatic Valves
Functions and Types of Air Control Valves

▪ Functions:
– To start and stop the pneumatic energy
– To control the direction of the compressed air
– To control the flow of the compressed air
– To control the pressure of the compressed air
▪ Classification of valves based on their function:
– Directional Control Valve
– Flow Control Valve
– Pressure Control Valve
▪ Directional Control Valve is classified into: Check Valve; Shuttle Valve; Two way DC Valve; Three way
DC Valve; Four way DC Valve
▪ Classification of Valves based on their construction:
– Poppet or Scat Control Valve
– Sliding Spool Valve
– Rotary Spool Valve
Poppet type Check Valve
Poppet Valves
Directional Control Valves - Classification

▪ Based on the number of ports, DCV is classified into:

– Two way valves
– Three way valves
– Four way valves
▪ Based on the mode of actuation,
– Manually operated DCV
– Mechanically operated DCV
– Solenoid operated DCV
– Pilot operated DCV
▪ Based on construction,
– Check valve
– Position valve
– Shuttle valve
Check Valve

▪ Most common and simplest form of DCV

▪ This valve is a non return valve; two types – poppet type valve and pilot operated check valve
Ports Designation & Symbols
2/2 Push button type spring returned DCV
3/2 Solenoid operated Spring returned DCV
4/2 DCV
4/3 DCV
Specifications of DCV

▪ Rated Flow
▪ Rated Pressure
▪ Outed and Inlet Port Size
▪ 3 or 4 way spool
▪ Open or closed centre application
▪ Spring centred or not
▪ Solenoid type and power
Shuttle valve
Shuttle Valve

▪ Three ports (inlet, exhaust and cylinder) and two positions.

▪ One flow port is connected to either of the other two ports.
▪ This valve is used to pressure two ports (primary and secondary) and exhaust the other port.
4/2 DCV
Pressure Control valves

▪ It is used to control the pressure of the compressed air

▪ To limit the maximum pressure in various circuit components as a safety measure
▪ To maintain the desired pressure levels in various parts of the circuits
▪ To unload system pressure i.e., to change the direction of all or part if the flow when the pressure at a certain point
reaches a specific level.
▪ To assist sequential operation of actuators in a circuit with pressure control
▪ Types of PCV:
– Pressure limiting valve
– Pressure reducing valve
– Sequence Valve
– Counterbalance valve
– Unloading valve
– Pressure Switch
Pressure Relief Valve
Pressure Reducing Valve
Flow Control Valves

▪ Flow Control valves are known as volume control valves that are used to regulate the rate
of fluid flow to different parts of pneumatic system.
▪ Also called as speed control valves.
▪ Types: Globe valve and Needle Valve
Pneumatic Actuators
Pneumatic Actuators

▪ Pneumatic Actuators are devices used for converting the pressure energy of compressed air
into mechanical energy to perform useful work.
▪ The pneumatic actuators produce linear, rotary or oscillating motion.
▪ Based on the type of motion, pneumatic actuators are classified into Linear Actuator
(Pneumatic Cylinder) and Rotary actuator (Air motors).
▪ The pneumatic cylinders generate motion in a straight line to perform work.
▪ The air motors generate rotary output motion to perform work
Hydraulic System
Components of Hydraulic System

▪ A tank (reservoir) to hold the hydraulic oil

▪ A pump to force the oil through the system
▪ An electric motor or other power source to drive the pump
▪ Valves to control oil direction, pressure, and flow rate
▪ An actuator to convert the pressure of the oil into mechanical force or torque to do useful work.
Actuators can either be cylinders to provide linear motion or motors (hydraulic) to provide rotary
motion
▪ Piping, which carries the oil from one location to another
Components of Hydraulic System

1. Tank/ Reservoir
2. Pump
3. Electric Motor
4. Valves
5. Actuators
6. Connecting Hoses
Primary functions of Hydraulic Fluid
▪ 1. Transmit power

▪ 2. Lubricate moving parts

▪ 3. Seal clearances between mating parts

▪ 4. Dissipate heat
Properties of Hydraulic Fluid
▪ Good lubricity

▪ Ideal viscosity

▪ Chemical stability

▪ Compatibility with system materials

▪ High degree of incompressibility

▪ Fire resistance

▪ Good heat-transfer capability

▪ Low density

▪ Foam resistance

▪ Nontoxicity

▪ Low volatility
Pumps in Hydraulic System
▪ A pump, which is the heart of a hydraulic system, converts mechanical energy into hydraulic energy.
▪ The mechanical energy is delivered to the pump via a prime mover such as an electric motor. Due to
mechanical action, the pump creates a partial vacuum at its inlet.
▪ This permits atmospheric pressure to force the fluid through the inlet line and into the pump. The pump
then pushes the fluid into the hydraulic system.
▪ There are two broad classification of Pumps: Positive Displacement Pumps and Dynamic Pumps
▪ Dynamic Pumps are classified into Axial and Centrifugal Pumps
▪ Positive Displacement Pumps are classified into Gear Pumps, Vane Pumps and Piston Pumps
Pumps
Classification of Pumps
Positive Displacement Pump – Gear Pump

▪ Two mating gears – driver and follower. – rotate in opposite direction

▪ Driver connected to electric motor (prime mover)
▪ Two parts inlet and delivery part opposite to each other
▪ When the pump is rotating, the rotation of gears force the air out of the casing and
into the discharge pipe. Vacuum is created; Fluid entersthroug the inlet and
trapped between the teeth of the gear.
▪ Continued rotation of the gears forces the fluid out of the pump discharge.
▪ Light in weight and high volumetric efficiency
▪ Relief valves required. Lubrication needed.
▪ Spur gear, helical gear, herringbone gear can be used – upto 200 bar.
Internal Gear Pump – Crescent Seal Pump

▪ Compared to external, it produces less noise

▪ Gears rotate in same direction
▪ Pressure below 70 bar
▪ Consists of internal spur gear, outside ring gear, crescent shaped spacer and
external housing.
▪ Both gears are eccentric to eachother.
▪ The inner and outer gear are separated by a crescent shaped spacer, a stationary
part of the housing around which the oil is carried.
▪ Oil is transferred from inlet to outlet by gear meshing process.
▪ The internal gear is driver
Lobe Pump

▪ Gears are replaced by 2/3/4 lobes – less noise

▪ Used for pumping liquid, gas and air with low pressure and higher flow rate
▪ The lobes rotate creating chambers b/w the lobes and wall of the pump chamber.
▪ The lobes are rotated one being directly driven by source of power, the other
through timing gears.
▪ Volumetric efficiency is greater than gear pumps
▪ Less wear loss when compared to gear pumps
▪ Pressure upto 30 bar.
Gerotor Pump

▪ Another version of internal gear pump

▪ Consists of Gerotor and outer Gerotor and housing
▪ Outer Gerotor has one more tooth than inner Gerotor
▪ Both rotate at the same direction
▪ If the number of tooth is 5 and 6, one revolution is 0.83.
▪ They are designed of high precision
▪ Inner Gerotor is driver and outer Gerotor is driven.
▪ As the teeth disengage, the space between them increases, creating vacuum.
▪ Oil gets into the pump through inlet port and gets trapped.
▪ It forces the oil to discharge from the pump through the outlet port.
Screw Pump

▪ Axial flow, positive displacement gear pump. 2 rotor screw pump with helical
gear. Have two or more meshing screws. Meshing creates required pressure.
▪ Screws mesh to form a fluid tight seal b/w the screw recess and housing wheel.
▪ The driving screws are connected by timing gears – provides clearance.
▪ The liquid is introduced at the two ends and discharged at the centre.
▪ The working is similar to a nut moving along a threaded rod when the rod is
rotated.
▪ The liquid does not rotate but moves linearly.
▪ Most reliable; very quiet; long life.
▪ Bulky and heavy; difficult to manufacture; low volumetric efficiency
▪ Pressure upto 250 bar.
 Unbalanced Vane Pump

▪ Rotor is mounted off centre. At regular intervals around the curved surface of the rotor are rectangular vanes that
are free to move in a radial slot.
▪ As the rotor revolves, the vanes are thrown outwards by centrifugal force to form seal against the fixed casing.
▪ Pumping rates of these rotor pumps are varied by the speed of the rotor.
▪ Fixed Displacement rotor housing eccentricity is constant.
Balanced Vane Pump
Balanced Vane Pump

▪ It has two inlet and outlet ports which are diametrically opposite to each other.
▪ Has elliptical housing instead of circular cam ring
▪ They can pump in either direction
▪ Small and compact in size and weight
▪ Volumetric efficiency is high
▪ Foreign bodies can damage the pump
▪ Cannot handle abrasive liquids
▪ Difficult to design
▪ 175 bar pressure
Piston Pump – Axial Pump
Radial Piston Pump
Valves in Hydraulic System
▪ Fluid power is controlled primarily through the use of control devices called valves.
▪ The selection of these valves involves not only the type but also the size, actuating technique, and
remote-control capability.
▪ There are three basic types of valves:
1. Directional control valves,
2. Pressure control/relief valves, and
3. Flow control valves.
Actuators in Hydraulic System
▪ Actuators are the end effectors of the hydraulic system where, the applied hydraulic enerfy is converted
into equivalent movement/displacement.
▪ The displacement may be linear or angular.
▪ If the displacement is linear, then it is cylinder
▪ If the displacement is angular, rotary actuator or motor
Comparison of Hydraulic Vs Pneumatic