BASIC HYDRAULICS

A SYSTEM STUDY

PINAKI ROY
 A TALK OVERVIEW

• This talk has been designed to provide instruction on the concept

and operation of the basic components of the hydraulic system.
• It also describes the various components of a typical hydraulic
system, their construction and functions, and their relationship to
each other. However to really appreciate & know about hydraulics
‘hands on’ experience, is a MUST.
 Fluid Power System
• Fluid Power Systems are power
transmitting assemblies employing
pressurised liquid or gas to transmit
energy.

• Fluid power can be divided into two

basic disciplines

> Hydraulics – Employing pressurised

liquid

> Pneumatics - Employing

Compressed gas
 What is Hydraulics?

• Hydraulics is derived from the Greek

word

- Hydor meaning Water

- Aulos meaning Pipe

 Definition of Hydraulics
In simple language:
Confined liquids under pressure made to do work.
OR
Science of transmitting force / motion through
medium of confined liquid
 HYDRAULICS DEFINED
FURTHER…
Fluid Mechanics is the physical science and technology of the static
and dynamic behavior of fluids.
• Hydraulics is a topic in applied science and engineering dealing with
the mechanical properties of liquids. Fluid mechanics provides the
theoretical foundation for hydraulics, which focuses on the
engineering uses of fluid properties.
 PASCAL’S LAW
Pascal Law – which is the basis for all
hydraulic systems, is named after the French
Scientist – Blaise Pascal, who established
the law.
Do you remember Pascal’s
Law?
It states that “ Pressure exerted anywhere in a confined
fluid is transmitted equally in all directions throughout the
fluid.
• The basic idea behind all hydraulic system is based upon that
principle & can be simply stated as:
• Force applied at one point is transmitted to another point
using an incompressible fluid.
PASCAL’S LAW
ILLUSTRATION
Working Principle of a Hydraulic
Press
Functions of Hydraulic Oil
• It transmits power.

• It lubricates moving parts

• It seals clearances
between moving parts

• It dissipates heat
 Advantages of oil in Hydraulics
• Variable speed : Possible to control speed through valve.
• Reversible : Instant reverse motion is possible. No
need to stop the system to change
direction.
• Over load protection : Protected through relief valve from
over- loading.
• Small package : Components are smaller than other
power transmitting system.
• Can be stalled : Not possible on direct drive system from
Electric motor / Diesel engine.
• Simple design : Pre-engineered components available.
• Self lubricated : Hydraulic oil lubricates the parts.
• Flexible : Flexible hoses virtually eliminate the
location problem of the hydraulic
components.
• Smooth : Incompressible, no vibration.
• Acts as coolant : It dissipates heat / cools the component,
• Acts as seal ; It seals clearances between two
mating parts.
• Noise free : No noise.
Force that is applied at one point is
transmitted to another point using an
incompressible fluid
• In this drawing, two pistons (green) fit into two glass
cylinders filled with oil (blue) and connected to one
another with an oil-filled pipe. If you apply a downward
force to one piston (the left one in this drawing), then the
force is transmitted to the second piston through the oil
in the pipe
•
Force Multiplication
Assume that the piston on the left is 2 inches in diameter (1-inch radius),
while the piston on the right is 6 inches in diameter (3-inch radius). The area
of the two pistons is Pi * r2 . The area of the left piston is therefore 3.14,
while the area of the piston on the right is 28.26. The piston on the right is 9
times larger than the piston on the left. What that means is that any force
applied to the left-hand piston will appear 9 times greater on the right-hand
piston. So if you apply a 100-pound downward force to the left piston, a 900-
pound upward force will appear on the right
Hydraulic System
• Reservoir

• Filter

• Hydraulic Pump

• Directional Control Valve

• Pressure Control Valve

 Reservoir- Properties
First a tank is needed to store the hydraulic oil

Tank / Reservoir
Storing oil

Compensates difference in volume

when actuators are used

It dissipates heat

It allows foreign particles to settle

down

Baffle separates inlet line with the

return line and allows the air
bubbles to escape
More Properties of Reservoirs
• It allows condensed water to settle at the
bottom of the tank

• Breather on the top of the tank allows to

maintain atmospheric pressure and avoid
creation of vacuum

• Sight glass will indicate the level of the oil.

Mercury bulb indicates the oil temperature

• Oil filling inlet will have a filter for avoiding

contamination.
PUMPS
• Hydraulic Pump is the most important
component in the hydraulic system.

• Function of the Hydraulic Pump is to convert

Mechanical Energy to Hydraulic Energy

• Hydraulic Pump are classified in two

categories:

- Hydro-dynamic

- Hydro-static
Pump
Now we need a pump to create flow

Tank

Pump

Two types of hydraulic pumps are

most commonly used:

- Rotary Pumps

- Reciprocating Pumps
ROTARY & RECIPROCATING
TYPES
• Common Pumps in Rotary type are:
- Gear Pumps
- Vane Pumps

• Common Pumps in Reciprocating type

are:
• Axial Piston Pump
Radial Piston Pump
 ACTUATORS

• An actuator is a mechanical device for

moving or controlling a mechanism or
system. An actuator typically is a
mechanical device that takes energy &
converts it to a desirable form for usage or
application.
Actuator

Tank

Pump
 ACTUATORS Contd…

• There are mainly two types of

Actuators:

- Linear actuators (single acting

cylinders, double acting cylinders)

- Rotary actuators (vane motors,

gear motors, piston motors etc.)
 Types of Valves
• There are three main types of
Valves:

- Pressure Control Valves (relief

valves, pressure regulating valve,
pressure reducing valve etc.)

- Directional Control Valves (check

valve, axial spool valve, ball valve
etc.)

- Flow Control Valves (needle valve,

throttle check valve etc.)
 Hydraulic System – some applications of
the basic components Actuator

Hoses to
connect the Piston reverse
components movement is not
possible

We need a direction
control valve to change
the direction of flow as
per requirement
Pump

Tank
Hydraulic System
Actuator

There are mainly two

design principles for
valves
Direction
Control Valve
- Spool valves

- Poppet valves

Pump

Tank
Hydraulic System
Actuator

Direction
Control Valve
The control valve is at
neutral position

Pump

Tank
Hydraulic System
Actuator

Direction
Control Valve Now the control valve
is shifted to left

Pump

Tank
Hydraulic System
Actuator

Direction
Control Valve
To change the piston
movement in opposite
direction the control
valve is now shifted to
right
Pump

Tank
Hydraulic System
Actuator

Is it a complete circuit ?
OR
Direction
Control Valve

We need some thing more

Pump

Tank
Hydraulic System
Actuator
Piston at end
-No room to
move
Pressure

yes
increases

Direction
Control Valve

We need some thing more

We need to
control the
Pump

Tank system pressure

Hydraulic System
Actuator

Direction
Control Valve

Pressure
relief valve
Pump

Tank
Hydraulic System
Actuator

Direction
Control Valve

Pressure
relief valve

Pump

Tank
Hydraulic System
Actuator

Direction
Control Valve

Pressure
relief valve Stops pressure increasing
beyond the preset value
Pump

Tank
Hydraulic System
Actuator
Now we have a system
which can work

But is this system protected

from dirt ?

Direction
Control Valve

Pressure
relief valve

Pump

Tank
Hydraulic System
Actuator

We need to protect the system

from dirt by installing a FILTER
in the system
Direction
Control Valve

Pressure
relief valve We have a system now which
can work safely
Pump

Filter
Tank
 FILTERS
• There are basically three
types of Filters

- Suction line filters

- Pressure line filters

- Return line filters

Why is filtration necessary?
• Impurities in the Hydraulic
system affect the components
of the hydraulic system and
shorten their service life.
• Reduction in service life of the
components occurs in two
ways:
- Wear and Tear
- Breakdown of component

Filters are used to remove the

smallest insoluble particles
and keep the hydraulic system
clean
Hydraulic System
Now we know :
Actuator

• A Reservoir contains oil

• Filter cleans the system
• Pump creates flow
Direction
Control Valve • Resistance creates pressure
• Actuators perform the work
Pressure • Hoses transmit the oil
relief valve
• D.C. Valves change direction of
Pump oil flow
Filter • Relief valves control the
Tank maximum system pressure.
Hydraulic System
Actuator

Few more facts:

• Pressure increases the system
Direction capacity
Control Valve
• Flow increases the system
speed
Pressure
relief valve

Pump

Filter
Tank
This Excavator weighs over 28 tons, but
has swift movements. The bucket can
effortlessly scoop out more than a cubic
meter of rock weighing about 2.0T
Transmission of Hydraulic
Power
• The engine is connected to a pair of pumps that can
generate 140 gallons per minute at 4,500 psi. You can
see from the picture that the arm has a pair of pistons
working in unison at the "shoulder" -- one at the "elbow"
and then one to rotate the bucket.
Transmission of Hydraulic
Power
• These pistons, along with the two track motors and the
rotating motor, are all controlled by two joy sticks and
four pedals in the cab. These controls send electrical
signals to an electrically-operated valve block located
next to the pump.
Transmission of Hydraulic
Power
• From the valve block, high-pressure hydraulic lines make
their way to the cylinders & they get activated whereby
the bucket can be moved as desired from the cabin with
the touch of a button.
 Some Basic Calculations
• A 4-inch piston has an area of 12.56 square inches. If the pump generates a
maximum pressure of 3,000 pounds per square inch (psi), the total pressure
available is 37,680 pounds, or about 20 tons.
• Another thing you can determine is the cycle time of the piston. To move a
4-inch-diameter piston 24 inches, you need 3.14 * 22 * 24 = 301 cubic
inches of oil. A gallon of oil is about 231 cubic inches, so you have to pump
almost 1.5 gallons of oil to move the piston 24 inches in one direction.
These form the basic criteria while selecting the hydraulic pump. For
example the actual engine, pump & sump details for this excavator is:
Engine
Cummins 6CT 8.3-C
8,270 cubic centimeters
340 horsepower at 1,900 rpm
Pump
Maximum pressure: 5,000 psi (4,500 psi)
Oil flow: 2x270 liters per minute
Capacities
Fuel: 530 liters
Engine oil: 22 liters
Hydraulic oil: 320 liters
DUMP TRUCKS or TIPPERS
• DUMPERS WITH TELESCOPIC
CYLINDERS & HYDRAULIC STEERING
 What exactly is "full
hydraulic steering?"

• The expression refers to any steering system

configurations where a vehicle is steered solely by
means of a hydraulic circuit comprising, as a minimum, a
pump, lines, fluid, valve, and cylinder (actuator). that is to
say, the vehicle is steered (usually via the front wheels)
purely by a hydraulically powered steering cylinder. This
is an important distinction from "hydraulically assisted"
steering, where hydraulic power serves only to assist a
mechanical steering system (as is the case with the
hydraulically assisted power steering on virtually every
light car / truck on the road today). It indicates that the
vehicle is steered ONLY by hydraulics, with no other
system (mechanical linkage) in place.
Why use hydrostatic steering?
• Because there are a number of distinct advantages :

• Power - depending on system design parameters (flow, pressure, cylinder size, etc.)
hydro steering can develop steering force FAR in excess of any other mechanical,
electrical, or hydraulically boosted system. This is a must for massive construction
equipment. It is also extremely advantageous to 4x4s with big tires, locker
differentials, low tire pressures, the must negotiate and be steered in extremely
challenging terrain. For a given amount of steering input effort, no other system can
match the power output of a hydro steering system.
• Flexibility - the very nature of fluid power (hydraulics) allows for great flexibility in
system design and mounting. The steering need not be constrained by the
requirements for mechanical linkages.
• Operator comfort - because of the power generated, required operator input levels
are very low in hydro steering systems.
• Control - depending on system design and tuning, precise, custom steering can be
arranged, (for example, a system with very few turns of the steering wheel from lock
to lock)
• Weight - the power to weight ratio of hydrostatic systems generally far outstrips
traditional hydraulically boosted mechanically actuated steering systems.
• Smoothness - hydro steering systems are smooth and quiet in operation. Vibration
is kept to a minimum. kickback, bump steer, and operator fatigue are all but
eliminated.
• Overload protection - when properly designed, automatic valves can guard the
system against a breakdown from overloading
The component in the top right of the picture is the
hydraulic steering directional control valve /
metering section; and is the heart of the system
Basic wrap-up & Re cap of the
system so far….
• Reservoir - this is the hydraulic fluid (or power
steering fluid) reservoir that stores the fluid
necessary for the system.
• Supply pump - this is the power steering
pump, note that in many automotive applications
the pump and reservoir are integrated into one
unit
How it works (tracing the
circuit).
• The reservoir supplies fluid to the pump. The pump pumps the fluid
to the steering unit. When the operator turns the steering wheel,
connected to the steering unit via the steering shaft, the steering
unit directs pressurized fluid to and from the cylinder. In response
the cylinder extends or retracts. The cylinder is connected to the
steered wheels and therefore the wheels steer. Fluid then returns to
the reservoir from the steering unit via the filter.

•
Relief valve

• - This is simply a pressure relief valve. If a

malfunction in the system causes the
pressure to rise too high, the relief valve
opens and the fluid simply passes back to
the reservoir. In virtually all automotive
power steering pumps, the relief valve is
built into the pump
Hydraulic Symbols
Definitions of LINES
continuous line - flow
line

dashed line - pilot, drain

envelope - long and short dashes around two or more

component symbols
Advanced Hydraulic Symbols
Hydraulic Symbols
Hydraulic & Pneumatic Symbols
• Some basic symbols:
Some Hydraulic & Pneumatic Symbols
Some more Hydraulic Symbols
Hydraulic Pumps & Motors
Symbols
• More Symbols
 Hydraulic Pumps
• Any hydraulic pump performs two functions. First, its
mechanical action creates a vacuum at the pump inlet
which allows atmospheric pressure to force liquid from
the reservoir into the inlet line to the pump. Second, its
mechanical action delivers this liquid to the pump outlet
and forces it into the hydraulic system.
• Shown below is a Variable-displacement, pressure-
compensated vane pump
Classification of pumps

• All pumps may be classified as either positive-

displacement or non-positive-displacement. Most pumps
used in hydraulic systems are positive-displacement.
• 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.
• In a positive-displacement pump , slippage is
negligible compared to the pump's volumetric output
flow. If the output port were plugged, pressure would
increase instantaneously to the point that the pump's
pumping element or its case would fail or the pump's
prime mover would stall.
Positive-displacement
principle

• A positive-displacement pump is one that

displaces (delivers) the same amount of
liquid for each rotating cycle of the
pumping element. Constant delivery
during each cycle is possible because of
the close-tolerance fit between the
pumping element and the pump case
 FAULT TRACING OF HYDRAULIC
SYSTEMS
• So in conclusion I may say that to a beginner
an hydraulic system or circuit may look
complicated & fault tracing difficult.
• But if one follows the root cause approach &
checks the system from the basic
parameters then fault tracing is actually
easy.
• However some tools like clip on flow &
pressure gauges, temperature gauges etc
are required.
 SO, IN HYDRAULICS, AS IN LIFE,
REMEMBER YOUR BASICS & NEVER
GIVE UP

AND LIFE SHALL BE FULL OF

HAPPINESS