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    Hydraulics and Hydraulic Circuits
    Hydraulics and Hydraulic Circuits
    Hydraulics and Hydraulic Circuits
    Ebook293 pages2 hours

    Hydraulics and Hydraulic Circuits

    By Dr.Ilango Sivaraman

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    About this ebook

    Hydraulics and Hydraulic circuits is a book on Fluid Power. Hydraulics here refer to the oil Hydraulics.Mineral oil is generally used as a medium to generate control and transmit power in Hydraulic machines.These hydraulic machines use different components and accessories. These components and accessories are connected together in a particular manner ( referred as a circuit) and the fluid ( Oil) is pumped into this system. Under a predetermined pressure, the oil transmits the power to activate cylinders or motors ( referred as actuators).

    In a simple and clear manner, the book explains the theories and concepts that govern the fluid power. Then, the components and accessories used in the system are explained focussing on their functions and working principles.

    Then, step by step process for understanding and building hydraulic circuits is explained for different applications.
    The author's experience in manufacturing Hydraulic power packs and hydraulic actuators in his earlier career underscores this publication.

    LanguageEnglish
    PublisherDr.Ilango Sivaraman
    Release dateJan 22, 2017
    ISBN9781370804283
    Hydraulics and Hydraulic Circuits
    Author

    Dr.Ilango Sivaraman

    The author is a Mechanical Engineering graduate from Madras University( Guindy Engineering College, Chennai, India).Then came, IIFT, MBA and Finally PhD in Management from Jain University, Bangalore.Work Experience - Starting with Greaves Cotton,Hyderabad Industries,Ashok Leyland, Best Crompton and Sundaram Clayton - Finally on my own with SEA Hydropower Pvt Ltd.,Hands on experience in managing/ manufacturing hydraulic cylinder/ Power packs and Pneumatic cylinders and control units at SEA Hydropower.Past few years teaching Engineering and Management subjects in Caledonian Engineering College at Muscat,Sultanate of Oman.Living in Muscat with wife, Sandhya.Introduction to Hydraulics and Pneumatics is a print version of my other book( Co authored) and published by PHI learning, India.

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      Book preview

      Hydraulics and Hydraulic Circuits - Dr.Ilango Sivaraman

      Table of Contents

      COPYRIGHTS

      1.FLUID POWER SYSTEMS

      1.1LEARNING OUTCOMES

      1.2 TERMINOLOGY OF FLUIDS

      1.3COMPARISON OF SYSTEMS

      1.4TYPES OF HYDRAULIC SYSTEMS

      1.5 POINTS TO RECALL

      2. UNITS IN HYDRAULIC SYSTEMS

      3. FLOW OF HYDRAULIC FLUIDS

      3.1 LEARNING OUTCOMES

      3.2FLUID FLOW IN HYDRAULIC SYSTEM

      3.3 LAMINAR AND TURBULENT FLOW

      3.4BERNOULLI’S PRINCIPLE

      3.5REYNOLDS NUMBER

      3.6DARCEY-WEISBACH FORMULA

      3.7POINTS TO RECALL

      4. HYDRAULIC FLUIDS

      4.1LEARNING OUTCOMES

      4.2THE CHOICE OF HYDRAULIC FLUIDS

      4.3HYDRAULIC OIL CHARACTERISTICS

      4.4TYPES OF OIL GENERALLY USED IN HYDRAULIC SYSTEMS

      4.5POINTS TO RECALL

      5. AN OVERVIEW OF A HYDRAULIC SYSTEM

      5.1LEARNING OUTCOMES

      5.2HYDRAULIC SYSTEM SET UP

      5.3HYDRAULIC SYSTEM CIRCUIT LAYOUT

      5.4POINTS TO RECALL

      6.HYDRAULIC PUMPS

      6.1LEARNING OUTCOMES

      6.2TYPE OF PUMPS

      6.3PUMP PARAMETERS

      6.4PUMP CLASSIFICATION

      6.5 RECIPROCATING PUMP – OPERATING PRINCIPLE

      6.6ROTARY PUMPS

      6.6.1External gear pumps

      6.6.2 Lobe pump

      6.6.3Internal gear pumps

      6.6.4Vane pump

      6.7PISTON PUMPS

      6.7.1Radial Piston pumps

      6.7.2Axial Piston pumps

      6.7.3Bent axis pump

      6.8USAGE OF PUMPS IN OPEN AND CLOSE HYDRAULIC SYSTEMS

      6.8.1Closed Loop Hydraulic system

      6.8.2Open loop Hydraulic system

      6.9POINTS TO RECALL

      7.HYDRAULIC ACTUATORS

      7.1 LEARNING OUTCOMES:

      7.2 CLASSIFICATION OF HYDRAULIC ACTUATORS

      7.2.1 Hydraulic cylinders

      7.2.2 Working Principle of Hydraulic cylinders

      7.2.3 Specifications of Hydraulic cylinders

      7.2.4 Symbols of Hydraulic cylinders for hydraulic circuit drawing

      7.2.5 Cushioned and non-cushioned cylinders

      7.2.6 Ram Cylinder

      7.2.7 Telescopic cylinder

      7.3 POINTS TO RECALL

      8.HYDRAULUC ACTUATORS-2

      8.1 LEARNING OUTCOMES

      8.2 HYDRAULIC MOTORS

      8.3 HYDRAULIC MOTOR COMPARISON WITH ELECTRIC AND PNEUMATIC MOTORS

      8.4 TYPES OF HYDRAULIC MOTORS AND SELECTION OF MOTORS

      8.5 POPULAR TYPES OF HYDRAULIC MOTORS

      8.51 Gear Motor

      8.5.2 Vane Motor

      8.5.3 Piston motors

      8.6 DISADVANTAGES OF HYDRAULIC MOTORS

      8.7 HYDRAULIC CIRCUIT SYMBOLS FOR HYDRAULIC MOTORS

      8.8 POINTS TO RECALL

      9.HYDRAULIC ELEMENTS

      9.1LEARNING OUTCOMES

      9.2 HYDRAULIC ELEMENTS AND ACCESSORIES

      9.2.1 Hydraulic Control elements

      9.2.2 Hydraulic accessories

      9.3 POINTS TO RECALL

      10.UNDERSTANDING HYDRAULIC CIRCUITS

      10.1 LEARNING OUTCOMES

      10.2 FIRST STEP IN THE PROCESS OF BUILDING A HYDRAULIC CIRCUIT

      10.2.1 System pressure relief Valve

      10.2.2 Pressure Reducing valve

      10.2.3 Pressure sequence valve

      10.3 POINTS TO RECALL

      11. UNDERSTANDING HYDRAULIC CIRCUITS-2

      11.1 LEARNING OUTCOMES

      11.2 SIZING OF HYDRAULIC CYLINDER, PUMP AND THE MOTOR FOR HYDRAULIC CIRCUIT.

      11.3 FUNCTION OF DIRECTION CONTROL VALVE

      11.4 A SIMPLE HYDRAULIC CIRCUIT -CONNECTING DIRECTION CONTROL VALVE TO THE CYLINDER

      11.5 POINTS TO RECALL

      12.TYPES OF DIRECTION CONTROLVALVES AND THEIR ACTUATION

      12.1 LEARNING OUT COMES

      12.2 DIRECTION CONTROL VALVE CLASSIFICATIONS

      12.3 PILOT OPERATED DC VALVE

      12.4 CHECK VALVE

      12.5 PILOT OPERATED CHECK VALVE

      12.6 POINTS TO RECALL

      13. UNDERSTANDING HYDRAULIC CIRCUITS-3

      13.1LEARNING OUTCOMES

      13.2 PRESSURE REDUCING VALVE & PRESSURE REDUCING VALVES IN A HYDRAULIC CIRCUIT

      13.3PRESSURE SEQUENCE VALVE IN A HYDRAULIC CIRCUIT

      13.4HYDRAULIC MOTORS IN CIRCUITS

      13.4.1Over center valve with a hydraulic motor

      13.5HYDRAULIC REGENERATIVE CIRCUIT

      13.6POINTS TO RECALL

      14. FLOW CONTROL VALVES

      14.1 LEARNING OUTCOMES

      14.2 FUNCTION OF FLOW CONTROL VALVES

      14.3 TYPES OF FLOW CONTROL VALVES

      14.4 POINTS TO RECALL

      15. UNDERSTANDING HYDRAULIC CIRCUITS-4

      15.1 LEARNING OUTCOMES

      15.2 FLOW CONTROL VALVE USING METER IN METHOD.

      15.3 METER OUT CIRCUIT

      15.4 BLEED OFF CIRCUITS

      15.5 SPEED AND FEED CONTROL IN ONE DIRECTION- MACHINE TOOL APPLICATIONS

      15.5.1 Speed and feed control – Meter in circuit

      15.5.2 Speed and feed control – Meter out circuit

      15.5.3 Speed and feed control in both directions of piston movement

      15.5.4 Standard manifold for dual speed

      15.6 HYDRAULIC CIRCUIT FOR PRESS APPLICATION USING DOUBLE PUMP

      15.7 POINTS TO RECALL

      16. ACCUMULATOR APPLICATIONS

      16.1 LEARNING OUTCOMES

      16.2 FUNCTIONS, TYPES AND SYMBOLS OF HYDRAULIC ACCUMULATORS

      16.3 BLADDER TYPE ACCUMULATORS

      16.4SIZING -ACCUMULATORS

      16.5 ACCUMULATOR CIRCUITS

      16.6 LARGE FLOW RATE REQUIRED FOR SHORT PERIODS – APPLICATION IN PLASTIC INJECTION MACHINES

      16.6.1 Accumulator unloading valve

      16.7 FEW OTHER APPLICATIONS OF ACCUMULATOR

      16.8 POINTS TO RECALL

      17.HYDRAULIC CIRCUITS IN STACKABLE FORM

      17.1 LEARNING OUTCOMES

      17.2 STACKABLE VALVES.

      17.3 POINTS TO RECALL

      18. INTRODUCTION TO PROPORTIONAL VALVES

      18.1LEARNING OUTCOMES

      18.2PROPORTIONAL CONTROL VALVES

      18.4PROPORTIONAL SOLENOIDS

      18.5PROPORTIONAL CONTROL VALVES

      18.6POINTS TO RECALL

      19. SERVO HYDRAULICS

      19.1 LEARNING OUTCOMES

      19.2 WHAT IS SERVO HYDRAULICS

      19.3 COMPARISON OF PROPORTIONAL HYDRAULICS WITH SERVO HYDRAULICS

      19.4 ELECTRO HYDRAULIC SERVO VALVES

      19.4.1 Servo Valves construction

      19.5 POINTS TO RECALL

      20. LOGIC OR CARTRIDGE VALVES

      20.1 LEARNING OUTCOMES

      20.2 WHAT IS A LOGIC/CARTRIDGE VALVE?

      20.3 ADVANTAGES OF CARTRIDGE VALVES

      20.4 CONSTRUCTIONAL FEATURES OF POPPET TYPE SLIP IN CARTRIDGE VALVES

      20.5 POINTS TO RECALL

      21.APPENDIX 1 -HYDRAULIC TERMINOLOGY

      22. APPENDIX2-USEFUL FORMULAE(FPS)

      1.Flow velocity

      2.Hydraulic motors

      23. APPENDIX3-BIBILIOGRAPHY

      HYDRAULICS AND HYDRAULIC CIRCUITS

      Dr.ILANGO SIVARAMAN

      (Acting Deputy Dean, Global College of Engineering and Technology,

      Sultanate of Oman)

      COPYRIGHTS

      All rights for this book are with the author Dr. Ilango Sivaraman.

      © Dr. ilango Sivaraman 2016.

      Book by the same author:

      Pneumatics and Pneumatic circuits available on smashwords platform

      1.FLUID POWER SYSTEMS

      1.1LEARNING OUTCOMES

      On completion of this chapter the student will understand:

      1.The meaning of the term Fluid and its applications.

      2.The types of fluid power systems.

      1.2 TERMINOLOGY OF FLUIDS

      The state of the matter is divided into Solids and fluids. The easiest way to remember the meaning of ‘fluid’ is that it ‘flows’ and has no shape unlike Solids. It generally assumes the shape of its container.

      Fluids are further divided into liquids and gases (including air). If we take compressed air, it is a fluid and dealt under the name ‘Pneumatics.’ Liquids like water and oil are dealt under the caption of ‘Hydraulics. However, the term Hydra refers mainly to water and hence to add clarity to the subject where mineral oil is used in machines, it is not uncommon to refer the application as ‘Oil hydraulics.’

      We should now look at the term Fluid power. Most of us are clear about electrical power (Household applications like lighting/air conditioning and other household applications.). Many of us are also clear about mechanical power – Engines, Gear boxes etc.,

      Fluid power - Fluid power is the use of fluids under pressure to generate, control, and transmit power. The fluid can be compressed air- Pneumatics. (there are ever so many industrial applications of compressed air – the one most common application that we come across every day in city life is the air brake applications in commercial vehicles like buses and lorries. - if you ever changed your car tire in a well-equipped shop, you would have seen a car tire changer entirely using Pneumatics.

      Fluid power can be also be done by using water or mineral oil. There are many advantages of using mineral oil over any other liquid and we shall see these details in the following pages.

      It should be remembered that fluid power does not mean that it is exclusively fluid power– Generally it is a mix of all the three forms of power (Electrical, Mechanical and Fluid power), so that over all we optimize on the efficiency of the machine used.

      The above statement can be supported by citing the example of off highway vehicles like tippers/dumpers and shovels etc., where, we use electrical batteries and starters for getting electrical power, Engines, transmission systems for Mechanical and the operation of tipping/dumping mechanism using hydraulic power.

      1.3COMPARISON OF SYSTEMS

      The three systems – Hydraulics, Pneumatics and Electrical systems are compared in table 1 given below.

      Comparison of Electrical/ Pneumatic and Hydraulic systems

      It is possible to ask a question – What are the advantages of a hydraulic systems?.

      The answer is that each system has their own merits and demerits. Only based on the application, we can make our choice for an appropriate system.

      1.4TYPES OF HYDRAULIC SYSTEMS

      Hydraulic systems are categorized in to two types. They are hydro static systems and Hydro dynamic systems.

      In hydro static systems – The fluid is kept in a confined space. The fluid is then pumped to move in the confined space. As the fluid is moving in its restricted confined pipes, it encounters a load (say, a load is to be pushed). The liquid is constrained to move against the load and the fluid does this by exerting pressure on the load. Hence the fluid pushes to move against the load pressure. The following illustration, for added clarity.

      In this figure 1.1, Oil is pumped in to a pipe which is connected to a hydraulic motor. The hydraulic motor is rotating a heavy load. As the fluid encounters the vanes of the hydraulic motor, it has no other alternative but to push the vane against its load.

      Why?

      Because, more oil is being pumped into the pipe line. The hydraulic oil has a property of non-compressibility cannot be compressed. The only way is that as it is being pressurized to move, it transfers this pressure energy to the vanes of the motor and pushes it away. Subsequent vanes attached to the motor also get pushed by the oil and the motor starts rotating.

      Figure 1 1 Hydrostatic application- application of Pressure energy on the motor vanes

      In hydro dynamic systems, the power of transmission by the oil is by kinetic energy.The differences compared to hydrostatic system are:

      1.The fluid is in motion.

      2.The fluid is not pressurized

      3.It is the kinetic energy of the flow that is transferred for tackling the load.

      Figure1.2, shows the example application of hydro dynamic system.

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