Hydraulic and Pneumatic general layout and system components

General layout of hydraulic system

Double acting cylinder

A
B
Flow control
valve

A B
4/2 Directional
Pressure control valve
gauge T
P

Pressure relief M
valve
Pump Filter

Oil reservoir
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• A tank ( reservoir ) to hold the hydraulic oil

• A pump to force the oil through the system Hydraulic actuator External load

• 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 to do useful work

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Basic Components of Hydraulic Systems
A fluid power system can be broken down into three segments. The power input segment
consisting of the prime mover and the pump. The control segment consisting of valves
that control the direction, pressure and flow rate. The power output segment, consisting
of the actuators and the load.

• Basic hydraulic systems has the following components

1, Oil reservoir 2, Rotary pump

3, Pressure relief valve 4, Directional control valve

5, Flow control valve 6, Double acting cylinder

7, Pressure gauge 8, Filter

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1, Oil reservoir

 The reservoir is a tank in which an adequate supply of fluid for the system is stored.
Fluid flows from the reservoir to the pump, where it is forced through the system and
eventually returned to the reservoir.

 The reservoir not only supplies the operating needs of the system, but it also
replenishes fluid lost through leakage.

 Reservoirs are either pressurized or nonpressurized. Baffles and/or fins are

incorporated in most reservoirs to keep the fluid within the reservoir from having
random movement, such as vortexing (swirling) and surging.
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 Many reservoirs incorporate strainers in the filler neck to prevent the entry of foreign
matter during servicing.

• Main function of oil reservoir is to store sufficient amount of hydraulic oil in the
system. Apart from these, it has important functions such as:-

• To cool the hot return oil

• Too settle down the contaminants

• To remove air bubbles

• To separate water from the oil etc.

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Figure : Non pressurized reservoirs

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2, Pumps

• Pumps are devices that expend energy to raise, transport, or compress fluids.

• 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.

• Pumps may be classified as either positive displacement or nonpositive displacement.

Most pumps used in hydraulic systems are positive displacement(hydrostatic). A
nonpositive displacement pump produces a continuous flow.
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• Positive displacement pump is universally used for fluid power systems. As the name
implies, a positive displacement pump ejects a fixed amount of fluid into the hydraulic
system per revolution of pump shaft rotation.

• Such a pump is capable of overcoming the pressure resulting from the mechanical
loads on the system as well as the resistance to flow due to friction.

• These pumps have the following advantages over non positive displacement pumps;
High-pressure capability (up to 10,000psi or higher), Small, compact size, High
volumetric efficiency, small changes in efficiency throughout the design pressure
range.

• Gear pump , Vane pump, Piston pump etc. are example of positive displacement pump.
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Figure : External gear pump Figure :Internal gear pump

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• 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

• 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

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• Hydrodynamic or non-positive displacement pump is generally used for low pressure,
high-volume flow applications. Because they are not capable of withstanding high
pressures, they are of little use in the fluid power field. Normally their maximum
pressure capacity is limited to 250 -300psi.

• This type of pump is primarily used for transporting fluids from one location to

another.

• It produces a continuous flow.

• Examples of this type are the centrifugal (impeller) and axial (propeller) pumps
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3, Valves

 A valve is a device or natural object that regulates, directs or controls the flow of a
fluid by opening, closing, or partially obstructing various passageways.

 Valves provide several functions, including:

• Starting or stopping flow based on the valve state

• Regulating flow and pressure within a piping system

• Controlling the direction of flow within a piping system

• Throttling flow rates within a piping system

• Improving safety through relieving pressure or vacuum in a piping system

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A fluid power system can be broken down into three segments. The control segment
consisting of valves that control the direction, pressure and flow rate.

a) Directional control valves

b) Pressure control valves

c) Flow control valves

a) Directional Control Valves

These valves are used to control the direction of flow in a hydraulic circuit. According to
the construction of internal moving parts it is classified as poppet type and sliding spool
type. It may be further classified as two way, three way and four way valves, depending
upon the number of port connections available.
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• On the basis of actuating devices, it can be classified as manually operated,
mechanically operated, solenoid operated and pilot operated.

Pilot operated check valve

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Two way directional control valve
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• Application of Two way DCV valves
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Three way direction control valves
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valve
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Four way directional control valves
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• Application of Four way, Two position DCV
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• Various methods used to shift the valve are shown in figure below. All shown
controlling a spring return four way two position valve.

• Manual lever is a popular method of actuation for DCVs used in mobile equipment
applications such as back hoes, bulldozers and farm equipment.

• Push button actuation is more prevalent in industrial applications.

Cont.…
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b) Flow Control Valves

• Flow control valves control the speed of fluid flow in the hydraulic system.

• Flow control valves control the flow rate of fluid in a circuit. They accomplish this by
incorporating a variable orifice into the circuit that acts like a faucet; closing the flow
control valve orifice reduces the flow rate and opening the orifice increases the flow
rate.

• Examples of flow control valves include: selector valves, check valves, sequence
valves, priority valves, and shuttle valves, quick disconnect valves, and hydraulic fuses.
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• The speed of an actuator depends directly upon the flow rate in the system. Controlling
the flow rate therefore allows us to control the speed of actuators.

Control valve can be classified into:

1. Needle flow control valve

2. Pressure compensated flow control valve

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• Needle flow control valve
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• Pressure compensated flow control valve
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• Meter-in flow control
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• Meter-out flow control
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• Bleed-off control valve
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c) Pressure Control Valves

 The safe and efficient operation of fluid power systems, system components, and related
equipment requires a means of controlling pressure.

 The force of a cylinder is proportional to the pressure in a system and the area over
which the pressure is applied.

 Controlling the pressure level in a circuit will therefore allow us to control the output
force of a cylinder pressure control valves control the max pressure level and also
protect the circuit from excessive pressure, which could damage components and
possibly cause serious injury.
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There are many types of automatic pressure control valves.
 Pressure relief valves:

1 direct acting pressure relief valve

2 pilot operated pressure relief valve

 Unloading valves

 Pressure reducing valve

 Sequence valves

 Counter balance valves

 Brake valves
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Relief Valves:

• A pressure relief valve is used to limit the amount of pressure being exerted on a
confined liquid. This is necessary to prevent failure of components or rupture of
hydraulic lines under excessive pressures.

• Pressure relief valves are adjusted by increasing or decreasing the tension on the spring
to determine the pressure required to open the valve.

• They may be classified by type of construction or uses in the system. The most common
types of valve are: Ball type , Sleeve type, Poppet type
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• Direct acting pressure relief valve
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• Pilot operated pressure relief valve
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Unloading Valves

 An unloading valve is a type of pressure control valve that is used to relieve excess
pressure in hydraulic system. Its primary function is to maintain the desired pressure by
diverting or releasing fluid when the system pressure exceeds a predetermined level.

 One purpose of the pressure regulator is to manage the output of the pump to maintain
system operating pressure within a predetermined range.

 The other purpose is to permit the pump to turn without resistance (termed unloading
the pump) at times when pressure in the system is within normal operating range. The
pressure regulator is located in the system so that pump output can get into the system
pressure circuit only by passing through the regulator.
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Pressure Reducers

 Pressure reducing valves are used in hydraulic systems where it is necessary to lower
the normal system operating pressure by a specified amount.

 Pressure reducing valves provide a steady pressure into a system that operates at a lower
pressure than the supply system. A reducing valve can normally be set for any desired
downstream pressure within the design limits of the valve.

• Once the valve is set, the reduced pressure is maintained regardless of changes in supply
pressure (as long as the supply pressure is at least as high as the reduced pressure
desired) and regardless of the system load, if the load does not exceed the designed
capacity of the reducer.
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• Pressure reducing valve
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Sequence valves
Is a type of hydraulic valve used in fluid power systems to control the sequence of
operation of multiple actuators or components. It ensures that one operation occurs
before another, often in applications where specific tasks must be completed in certain
order.
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• Sequence operation for Tube bending machine
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Counter balance valves
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Brake valves
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d) Shuttle valve
 In certain fluid power systems, the supply of fluid to a subsystem must be from more
than one source to meet system requirements. In some systems, an emergency system is
provided as a source of pressure in the event of normal system failure. The emergency
system usually actuates only essential components.

 The main purpose of the shuttle valve is to isolate the normal system from an alternate
or emergency system. It is small and simple; yet, it is a very important component. The
housing contains three ports - normal system inlet, alternate or emergency system inlet,
and outlet.

 A shuttle valve used to operate more than one actuating unit may contain additional
unit outlet ports.
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 A spring-loaded piston-type shuttle valve in normal configuration (A) and with
alternate/emergency supply (B).

The shuttle may be one of four types:

1. Sliding plunge
2. Spring-loaded piston
3. Spring-loaded ball
4. Spring-loaded poppet
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e) Shutoff Valves

• Shutoff valves are used to shut off the flow of fluid to a particular system or
component. In general, these types of valves are electrically powered.

• Shutoff valves are also used to create a priority in a hydraulic system and are
controlled by pressure switches.
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4, Actuators

 The hydraulic cylinder is the component of the hydraulic system that receives the fluid
(under pressure) from a supply line. The hydraulic oil in the cylinder acts on a piston
to do work in a linear direction. The work that is performed is the product of the fluid
pressure and the area of the cylinder bore.

 The quantity of fluid delivered into the cylinder determines the speed or rate of doing
work. The chief types of hydraulic cylinders are:

o Nonrotating

o Rotating
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• Schematic of a hydraulic cylinder.

• The applications for nonrotating cylinders are more common than for rotating
cylinders. There are three types of nonrotating cylinders:

o Double-acting

o Single-acting

o Plunger or ram-type
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Schematics of nonrotating cylinders: (A) double-acting; (B) single-acting spring-return; and (C) single-
acting ram-type.

• An actuating cylinder transforms energy in the form of fluid pressure into mechanical
force, or action, to perform work
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• Actuating cylinders are of two major types: single action and double action.

• The single-action (single port) actuating cylinder is capable of producing powered

movement in one direction only.

• The double-action (two ports) actuating cylinder is capable of producing powered

movement in two directions.

Figure: Linear actuator.

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Figure: Linear actuator operation.

 Rotary Actuators

 Rotary actuators can mount right at the part without taking up the long stroke lengths
required of cylinders
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• Rotary actuators are not limited to the 90° pivot arc typical of cylinders; they can
achieve arc lengths of 180°, 360°, or even 720° or more, depending on the
configuration.

• An often used type of rotary actuator is the rack and pinion actuator used for many nose
wheel steering mechanisms.

• . In a rack-and-pinion actuator, a long piston with one side machined into a rack engages
a pinion to turn the output shaft. One side of the piston receive fluid pressure while the
other side is connected to the return. When the piston moves, it rotates the pinion.
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Figure: Rack and pinion gear.

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5, Accumulators

o Accumulators are devices that store hydraulic fluid under pressure. Storing hydraulic
fluid under pressure is a way of storing energy for later use. Perhaps the most common
application for an accumulator is supplementing the pump flow in a hydraulic system in
which a high flow rate is required for a brief period of time.

o Types of accumulators

• Weight loaded accumulator • Spring loaded accumulator

• Piston type • Bladder type

• Diaphragm type
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• Weight loaded accumulator Spring loaded accumulator
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• Piston type accumulator Diaphragm accumulator
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 Applications of accumulators Accumulator as auxiliary power source

Accumulators are used as

• Leakage compensator

• Auxiliary power source

• Emergency power source

• Hydraulic shock absorber

• Fluid make-up device

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• Regenerative circuit
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Automatic cylinder reciprocating system
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Synchronizing hydraulic cylinders
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General layout of Pneumatic system
Double acting cylinder

A
B

Flow control valve

A B
4/2 Directional
control valve
T
F
R L P
Air receiver e u
Air dryer i Muffler
tank g b
l
u r
t
l i
e
Compressor a c
r
t a
o t
M
r o
r

From Atmosphere
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Basic Components of Pneumatics Systems

• Basic pneumatic systems has the following components:

1, Air compressor

2, Air dryer

3, Air receiver tank

4, FRL unit

5, Directional control valve

6, Flow control valve

7, Double acting cylinder

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1, Air compressor:

 It draws the air from atmosphere, compresses it and delivers compressed air to the
pneumatic system. An air compressor compresses air and stores it in a tank.

 The compressed air is released from the tank and flows through an air hose to the air
tool. The air tool has a valve system that controls the flow of air. When the trigger or
switch on the tool is activated, the valve opens and allows the compressed air to flow
through the tool.
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2, Air dryer:

 The compressed air delivered by the compressor contains moisture from atmosphere.
This moisture is separated and removed by the air dryer. Only the dry compressed air is
given to the pneumatic system.

 The purpose of the dryer is to reduce the relative humidity and dew point of the
compressed air from the compressor.
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3, Air receiver tank:

 It stores the compressed air. Apart from storing the compressed air, it has several other
function also,

• It acts as a cooler to cool the hot compressed air,

• It acts as a moisture separator to separate and remove water contained in the

compressed air.

• It acts as a support to mount compressor and other components.

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4, FRL unit

o This is the combination of three different units. Air is not clean and hence contamination
may result in pneumatic circuit. Also, due to time fluctuations, the receiver air pressure
does not remain constant. Also, some parts of the Pneumatic system have to be lubricated
for proper maintenance.

o For cleaning the air, regulating the pressure of air and lubricating pneumatic parts, three
units 'Filter - Regulator - Lubricator' (Trio unit) are put together and this combined unit -
Trio unit - is called FRL unit.

o Air filter: filters and removes dust particles from compressed air and allows clean dry
compressed air to the system.
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o The function of an air filter is to remove contaminants from air before it reaches the
pneumatic components such as valves and actuators.

o Air filters are used in pneumatic systems to remove contaminants and impurities from
the air before it enters the system. These impurities can include dust, dirt, moisture, and
oil, which can cause damage and wear to the system's components. By removing these
impurities, air filters help extend the system's life and improve its performance.

o They also help to reduce maintenance costs by preventing damage to the system's
components. In addition, air filters can improve the safety of a pneumatic system by
removing potentially harmful contaminants from the air.
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• For example, if the air in the system contains high levels of oil, it could cause a fire
hazard. By filtering out the oil, the risk of a fire is reduced.

• Overall, air filters are an essential component of a pneumatic system because they help
to ensure the cleanliness and purity of the air used in the system, which helps to improve
its performance and safety.

Air regulator: controls the pressure of compressed air.

• A regulator is a device that controls the air pressure in a pneumatic system. It is a crucial
component of the system because it helps ensure that the correct pressure is always
maintained.
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 There are several reasons why a regulator is required in a pneumatic system:

• To maintain consistent pressure: Maintaining consistent pressure is important because it

helps to ensure that the system's components are operating at the correct level. If the
pressure is too low, the system may not function properly. If the pressure is too high, it
can cause damage to the system's components.

• To optimize performance: Different pneumatic tools and devices have different pressure
requirements, and the regulator helps to ensure that the correct pressure is delivered to
each device. This helps optimize the system's performance and ensure that it runs
efficiently.
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• To reduce energy consumption: By maintaining the correct pressure, the regulator can
help to reduce energy consumption in the system. This is because the system will not
have to work as hard to generate the required pressure, which can save energy and
reduce operating costs.

• Overall, the regulator is an essential component of a pneumatic system because it helps

maintain consistent pressure and optimize its performance.

Air lubricator: adds lubricating oil to the compressed air.

• A lubricator is a device that adds lubrication to the air in a pneumatic system. It is an

essential component of the system because it helps to reduce friction and wear on its
components.
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 There are several reasons why a lubricator is required in a pneumatic system:
• To extend the life of the system's components: Friction and wear can cause damage to
the system's components, leading to premature failure. By adding lubrication to the air,
the lubricator helps to reduce friction and wear on these components, which can extend
their lifespan.

• To improve the system's performance: Lubrication can help improve the system's
performance by reducing friction and wear on the system's components. This can

increase the efficiency of the system and reduce energy consumption.

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• To reduce maintenance costs: By extending the system's components' life and improving
the system's performance, the lubricator can help reduce maintenance costs. This is
because the system will require less frequent repairs and replacements.

• Overall, the lubricator is an essential component of a pneumatic system because it helps

reduce friction and wear on the system's components, improving performance and
extending the system's lifespan. It is also essential that tool owners lubricate their
tools from time to time to extend their useful life.
Cont…
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Figure: FRL unit graphic symbol

5, Actuator:

This device converts the energy of the compressed air into mechanical movement.
Examples include cylinders and motors. Pneumatic cylinder are basically used for single-
purpose applications such as clamping, stamping, transferring, branching, allocating,
ejecting, metering, tilting, bending, turning and many other applications.
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 Different types of cylinder
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6, Control Valve:

• Control valves are used in pneumatic systems to control air flow. They are an essential
system component because they allow the system to be controlled and adjusted as
needed.

• Several types of control valves can be used in a pneumatic system, including on/off
valves, flow control valves, and pressure control valves. The type of control valve used
depends on the system's specific requirements.

6.1 Directional control valve: it controls the direction of flow of compressed air, by wich
it performs extension and retraction of the actuator (double acting cylinder).
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6.2, Flow control valve: it controls the rate of flow of compressed air, by wich speed of
extension or retraction of the actuator is controlled.

6.3, Pressure control valve: The primary purpose of pressure regulators is to control
pressure with close tolerances to ensure that compressed air in a pneumatic system is not
wasted. Pressure regulating valves accomplish this by maintaining constant output
pressure under various input pressures and output flows.

 There are several reasons why control valves are used in pneumatic systems:
• To control air flow: Control valves are used to regulate the flow of air within the
system. This allows the system to be adjusted and controlled as needed.
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• To optimize the system's performance: By controlling the flow of air, control valves can
help optimize the system's performance. For example, a flow control valve can be used
to adjust the flow of air to a pneumatic tool, which can help to improve its
performance.

• To improve the efficiency of the system: By controlling the flow of air, control valves
can help to improve the efficiency of the system. For example, a pressure control valve
can be used to adjust the pressure of the air in the system, which can help to reduce
energy consumption.
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• Overall, control valves are an important component of a pneumatic system because they
allow the system to be controlled and adjusted as needed, which helps to optimize its
performance and improve its efficiency.

7, Double acting cylinder: it is a linear actuator. It develops force and motion.

Force developed = Pressure of compressed air * Area of piston.

 Pneumatic air systems operate tools used in various applications such as shipbuilding,
mechanic workshops, the aviation industry in repairing airplanes, and even in the risky
oil and gas industry where a single mistake can cause a fire or explosion.