Hydraulics Intro PDF
Hydraulics Intro PDF
Hydraulics Intro PDF
In the industry we use three methods for transmitting power from one
point to another.
Fluid power is the technology that deals with the generation, control and
transmission of forces and movement of mechanical element or system with
the use of pressurized fluids in a confined system. Both liquids and gases are
considered fluids. Fluid power system includes a hydraulic system (hydra
meaning water in Greek) and a pneumatic system (pneuma meaning air in
Greek). Oil hydraulic employs pressurized liquid petroleum oils and synthetic
oils, and pneumatic employs compressed air that is released to the
atmosphere after performing the work.
Fluid Power Applications Can Be
Classified Into Two Major Segments
Stationary Hydraulics
Stationary hydraulic systems remain firmly fixed in one position. The
characteristic feature of stationary hydraulics is that valves are mainly solenoid
operated.
3. Multifunction control
A single hydraulic pump or air compressor can provide power and
control for numerous machines using valve manifolds and distribution systems.
The fluid power controls can be placed at a central station so that the operator
has, at all times, a complete control of the entire production line, whether it be a
multiple operation machine or a group of machines. Such a setup is more or less
standard in the steel mill industry.
4. Low-speed torque
Unlike electric motors, air or hydraulic motors can produce a large
amount of torque while operating at low speeds. Some hydraulic and pneumatic
motors can even maintain torque at a very slow speed without overheating.
2. The hydraulic pump is used to force the fluid from the reservoir to rest of
the hydraulic circuit by converting mechanical energy into hydraulic energy.
3. Valves are used to control the direction, pressure and flow rate of a fluid
flowing through the circuit.
6. Piping system carries the hydraulic oil from one place to another.
7. Filters are used to remove any foreign particles so as keep the fluid system
clean and efficient, as well as avoid damage to the actuator and valves.
This system consists of an input cylinder on the left and an output cylinder on the right
that is filled with oil. When the input force is Fin on the input piston, the pressure in
the system is given by
Disadvantages
• Manufacturing Cost is high – Precision
• Leakage of Oil
• Fire Hazards
Viscosity is very important fluid property from the point of view of actual
use. In general viscosity of the fluid varies with temperature and pressure.
Maximum and minimum operating temperatures, along with the system's
load, determine the fluid's viscosity requirements. The fluid must maintain
a minimum viscosity at the highest operating temperature. However, the
hydraulic fluid must not be so viscous at low temperature that it cannot be
pumped.
3. STABLE CHEMICALLY AND PHYSICALLY
Fluid characteristics should remain unchanged during an extended useful
life and during storage. The fluid in a working hydraulic system is
subjected to violent usage- large pressure fluctuations, shock, turbulence,
aeration, water and particulate contamination, high shear rates, large
temperature variations. During its service and storage period it should not
react with any of the parts of the hydraulics system components or
degrade
4. SYSTEM COMPATIBILITY
From the design point of view , it is expected that the hydraulic fluid should
be inert to those materials used in or near the hydraulic equipments. If the
fluid in anyway attacks, destroys , dissolves or change parts of the hydraulic
system , the system may lose its function efficiency and may start
malfunctioning.
Entrained air can cause more serious problems because this foam is
drawn into the system. In worst cases, it causes cavitations, a
hammering action that can destroy parts. Entrained air is usually
prevented by properly selecting the additive and base oils. Caution:
certain anti-foam agents, when used at a high concentration to reduce
surface foam, will increase entrained air.
Also linked to the foam problem, is fluid viscosity, which determines
how easily air bubbles can migrate through the fluid and escape.
10. PREVENT CORROSION AND RUST
Two potential corrosion problems must be considered: system rusting and
acidic chemical corrosion. System rusting occurs when water carried by the
fluid attacks ferrous metal parts. Most hydraulic fluids contain rust inhibitors
to protect against system rusting. The tests used to measure this capability are
ASTM D 665 A and B. To protect against chemical corrosion, other additives
must be considered. The additives must also exhibit good stability in the
presence of water (hydrolytic stability) to prevent break down and acidic
attack on system metals.
In fact, it is possible to completely block off the outlet while the pump is
running. For this and other reasons, non-positive displacement pumps
are seldom used in power hydraulic systems today.
These properties make it a more likely choice for a water pump in a car
engine, dishwasher or washing machine. It could also be used as a
supercharge pump for a positive displacement pump.
The positive displacement pump is most commonly used in
industrial hydraulic systems. A positive displacement pump delivers to the
system, a specific amount of fluid per stroke, revolution, or cycle. This type of
pump is classified as fixed or variable displacement.
Certain vane pumps and piston units can be varied from maximum to zero
delivery. Some are capable of reversing their flow as the control crosses a
center or neutral position.
The pressure is determined by the workload, and except for leakage losses,
the output is independent of outlet pressure. This makes the positive
displacement pump more appropriate for use in the transmission of power.
The inner gear 2 is driven in the direction of the arrow, and takes external gear
3 along with it in the same direction.
The rotary movement causes the gears to separate, so that the gear spaces are
free.
The negative pressure caused by this and the atmospheric pressure on the fluid
level in the tank cause fluid to run from the tank to the pump. One generally
says ―the pump sucks‖.
The fluid fills the gear spaces, which form closed chambers with the housing and
the crescent 4, during further movement, and is pushed to the pressure side
(red).
The gears then interlock once more and push the fluid from the gear chambers.
the figure above illustrates the operation of an external gear pump, which
develops flow by carrying fluid between the teeth of two meshing gears. one of
the gear is connected to a drive shaft connected to the prime mover. The second
gear is driven as it meshes with the driver gear. Oil chambers are formed
between the gear teeth, the pump housing , and the side wear plates. The
suction side is where the teeth come out of the mesh, and it is here that
bringing about a reduction in pressure to below atmospheric pressure. Fluid is
pushed into this void by atmospheric pressure because the oil supply tank is
vented to the atmosphere. The discharge side is where teeth go into mesh, and it
is here that the volume decreases between mating teeth.
Volumetric Displacement And Theoretical Flow Rate
VD = (D02 – Di2) L
there must be a small clearance (about 0.001 in) between the tip and
pump casing. As a result, some of the oil at the discharge port can leak
directly back towards the suction port.
This means that the actual flow rate QA is less than the theoretical
flow rate QT , which is based on volumetric displacement of the pump
speed. This internal leakage is called as pump slippage and is defined by
the term volumetric efficiency, which is about 90% for positive
displacement pumps operating at design pressure
hv =
A balanced vane type pump is one that has two intake and two outlet ports.
Diametrically opposite to each other. Thus pressure ports are opposite each
other and a complete hydraulic balance is achieved. Instead of having a
circular cam ring, a balanced design has an elliptical housing, which forms
two separate pumping chamber on opposite sides of the rotor.
Disadvantage:
Balanced vane pump cannot be designed as variable displacement unit.
Axial Piston Pump
In this type, the cylinder block and drive shaft are located on the
same centerline.
The pistons are connected to a shoe plate that bears against an
angled swash plate.
As the cylinder rotates, the pistons reciprocate because the piston
shoes follow the angled surface of the swash plate.
The outlet And inlet ports are located in the valve plate so that the
pistons pass the inlet as they are being pulled out and pass the
outlet as they are being forced back in.
Volumetric efficiency
Mechanical efficiency
Overall efficiency
Volumetric efficiency
It is the ratio of actual flow rate of the pump to
the theoretical flow rate of the pump.
Mechanical efficiency
It is the ratio of the pump output power assuming no
leakage to actual power delivered to the pump
Where
p is the pump discharge pressure in Pa or N/m2
Qt, is the theoretical flow rate of the pump in m3/s,
Ta is the actual torque delivered to the pump in Nm
N is the speed of the pump in rad/s.
In the balanced design shown in the below figure the system working pressure at
the inlet and the tank line pressure at the outlet are both forces in the system.
These opposing pressures are directed to two interconnected chambers within
the motor located 180 degrees apart. Any side loads which are generated
oppose and cancel each other. The majority of vane motors used in industrial
systems are the balanced design.
Piston motor