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
gas

Compressed

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.

PASCALS 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 Pascals

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.

PASCALS 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
overloading.
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 (3inch 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
Actuator (Cylinder/Motor)

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
components

Piston reverse
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

Now the control valve

is shifted to left

Direction
Control Valve

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
We need some thing more
Direction
Control Valve

Pump

Tank

Hydraulic System
Actuator

Piston at end
-No room to
move

Pressure
increases

Direction
Control Valve

yes

We need some thing more

Pump

Tank

We need to
control the
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
Actuator

Direction
Control Valve

Pressure
relief valve

A Reservoir contains oil

Filter cleans the system

Pump creates flow

Resistance creates pressure

Actuators perform the work

Hoses transmit the oil

D.C. Valves change direction of

oil flow

Relief valves control the

maximum system pressure.

Pump
Filter
Tank

Now we know :

Hydraulic System
Actuator

Few more facts:

Direction
Control Valve

Pressure
relief valve
Pump
Filter
Tank

Pressure increases the system

capacity

Flow increases the system

speed

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 electricallyoperated 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 Engine
hydraulic pump. For example the actual engine,
pump & sump
details
for this excavator is:
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, pressurecompensated 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 closetolerance 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