ME3020

FLUID POWER SYSTEMS AND

MACHINERY
Level 3 Semester 1
Department of Mechanical Engineering
University of Moratuwa
Thusitha Sugathapala
Thermo-Fluids & Energy Group
Department of Mechanical Engineering
University of Moratuwa
September 2009
COURSE STRUCTURE
Module Code: ME 3020
Module Title: Fluid Power Systems and
Machinery
No of Credits: 04
Hrs per Week: Lectures 3.5
Practical / Tutorials 3/2
Pre-requisites: ME 2110 - Fluid Dynamics
Method of Assessment
Continuous Assessment 30% + Final Exam 70%
Recommended Texts
(1) Fundamentals of Fluid Power Wolansky WD, Nagohosian J, Henke RW
(2) Fluid Mechanics Douglas JF, Gasiorek JM, Swaffield JP
(3) Fundamentals of Fluid Film Lubrication Hamrock BJ
SYLLABUS
1. Hydrostatics Power Transmission Systems - 10 hrs
2. Lubrication - 06 hrs
3. Boundary Layer Theory - 04 hrs
4. Particle Mechanics - 06 hrs
5. Fluid Machinery - 07 hrs
6. Design of Industrial Flow Systems - 06 hrs
Lecturers
AGT Sugathapala
KKCK Perera
WK Wimalasiri
SECTION 1
POWER HYDRAULICS
INTRODUCTION
Definition
Power hydraulics (or fluid power) deals with generation,
control and transmission of power using pressurised fluids
Includes hydraulics, which involves liquids, and pneumatics,
which involves gases
Applications
(A) Industrial Hydraulics
- Plastic Machines (eg. injection moulding)
- Presses (eg. drawing, forming, forging)
- Heavy Machinery
- Machine tools (eg. lathe, milling)
(B) Mobile Hydraulics
- Excavators
- Cranes
- Constructional and Agricultural Machinery
INTRODUCTION
Applications
(C) Hydraulics in Steelworks, Civil Engineering and
Generating Stations
- Lock gates and Dams
- Mining Machinery
- Turbines
- Nuclear Power Plants
- Bridge Operating Equipment
(D) Hydraulics in Special Technical Applications
- Telescope and Antenna Operations
- Landing Gear and Rudder Control of Aircraft
INTRODUCTION
Advantages of Fluid Power Systems
- Simple and accurate control
- Multiplication of forces
- Instantly reversible motion
- Step-less change of speed, torque/force etc
- Capable of providing constant force or torque regardless of
speed changes
- Simple automatic overload protection
- High forces/torque with compact size (ie. high power density)
- Simple operation and maintenance
INTRODUCTION
Disadvantages of Fluid Power Systems
- Hydraulic oils are messy
- Leakage cannot be eliminated completely
- Hydraulic lines can burst
- May cause fire near oil leakage with hot temperatures
INTRODUCTION
Hydraulics or Pneumatic ?
Many factors are considered by the manufacturer and/or the
user when determining which type to use in a specific
application
If the application:
Requires speed, a medium amount of pressure,
and only fairly accurate control
Pneumatic
Requires only a medium
amount of pressure and a
more accurate control
Combination of hydraulics
and pneumatics
Requires a great amount of pressure and/or
extremely accurate control
Hydraulics
INTRODUCTION
Advantages of Pneumatic over Hydraulic Systems
- Fire resistance
- Freely available
- Can be exhausted back to atmosphere
- Not messy
Disadvantages of Pneumatic over Hydraulic Systems
- Cannot be used where accurate positioning or rigid
holding is needed
- Sluggish (slow) response
- Poor lubricant
- Air can be corrosive since it contains oxygen and water
HYDRAULIC FLUIDS
Primary functions of a hydraulic fluid
- Transmit power
- Lubricate moving parts
- Dissipate heat
- Seal clearances between moving parts
Properties needed to perform above functions safely
and economically
- Good lubricity
- Chemical and environmental stability
- Low density
- Ideal viscosity
HYDRAULIC FLUIDS
- Compatibility with system materials
- Foam resistance
- Fire resistance
- Good heat transfer capacity
- Low volatility
- Minimum toxicity
- Very high bulk modulus
- Low pour point
- High flash point
Properties needed
- In addition to the above, the fluid should be inexpensive and
readily available
HYDRAULIC FLUIDS
- Mineral (Petroleum-based) oils
Types
Most widely used fluid in
Industrial Hydraulics
- Synthetic oils (Phosphate or Silicate Esters )
Characterized by excellent lubricity
and good fire resistance.
Particularly use in aircraft installations
- Water
Still in limited use in heavy presses, benders, etc.
Least expensive, Ideal fire resistance
But has corrosive & erosive action on metal parts
and low lubrication properties
HYDRAULIC FLUIDS
Types
- Water based fluids
- Water-glycol (35-50% water and mix of various glycols,
polyglycols and additives)
- Water-in-oil emulsions (40% water and mix of oil, emulsifiers and
chemical additives)
- Oil-in-water emulsions (95% water and 5% soluble oil and
additives)
- Synthetic Solutions (95% water and 5% soluble salts and other
chemicals)
Water based fluids are of great interest today
because of the need for lower-cost, safer and
environmentally purer product.
Performance is not good as that for conventional
hydraulic fluids
HYDRAULIC FLUIDS
Ideal fluid medium for a pneumatic system is a readily
available gas that is
- Nontoxic
- Chemically stable
- Free from any acids that cause corrosion of system components
Pneumatic Gases
Most common are compressed air and nitrogen
Compressed Air
Most widely used fluid for pneumatic systems
- Unlimited supply
- Ease of compression
- Has most of the desired properties and characteristics
HYDRAULIC FLUIDS
Requires cleaning
- Moisture separators and air dryers (dehydrators) to minimize or
eliminate moisture
- Particulate filter to remove solid particles
Compressed Air
Compressed Air System Categories
Based on the working pressure
- High-pressure (HP) air (1000 to 5000 psi )
- Medium-pressure (MP) air (150 to 1000 psi )
- Low-pressure (LP) air (<150 psi )
HYDRAULIC FLUIDS
- Inert gas
- Nonflammable
- Does not cause rust or decay
Nitrogen
Therefore its use is preferred over compressed air in many
pneumatic systems
- especially aircraft and missile systems
BASIC COMPONENTS OF A HYDRAULIC
POWER TRANSMISSION SYSTEM
Main Components
Drive
Elect. Motor
IC Engine
Hydraulic
Pump
Hydraulic Control
&
Regulating Units
User
Hydraulic Cylinder
Hydraulic Motor
Operating
elements to be
actuated
Electric
or
Thermal
Energy
Mechanical
Energy
Hydraulic
Energy
Hydraulic
Energy
Mechanical
Energy
Energy Conversion Process
Controllers Energy Converters Energy Converters
BASIC COMPONENTS
Energy Converters
Power Source
- Convert primary energy to mechanical energy to drive pumps
- Electric motor or Internal combustion engine
Pumps / Compressors
- Convert mechanical energy to fluid energy
Actuators
- Convert hydraulic energy to useful mechanical energy
- Cylinders (linear motion) & Motors(rotary motion)
BASIC COMPONENTS
Controllers
To vary the magnitude and direction of flow and/or pressure
to a hydraulic actuator
There are three categories of valves
- Directional Control Valves
- Flow Control Valves
- Pressure Control Valves
Other Main Components
- Tank or Reservoir
- Pipes
- Filters
- Heat Exchangers
- Accumulators
BASIC COMPONENTS
Tank or Reservoir
Used to store and handle the fluid
Other functions:
- dissipation of heat
- trapping of foreign matter
- separation of air bubbles from the fluid
Types:
- Open
- Closed
- Pressurized
(make use of a gas to maintain pressure and provide elastic cushion
for thermal expansion or pressure surge)
BASIC COMPONENTS OF A HYDRAULIC
POWER TRANSMISSION SYSTEM
Pipes
To contain and conduct fluid from one part of the circuit to
another
Copper or Steel
Filters
To reduce the level of dirt in the fluid
Types:
- Pressure filters
- Return filters
- Suction filters
Heat Exchangers
To control the temperature of the working fluid
BASIC COMPONENTS OF A HYDRAULIC
POWER TRANSMISSION SYSTEM
Accumulators
As fluid reserve
-where a large quantity of fluid may be required at short notice
-helps to avoid the use of a large pump with high drive power
-suitable for short-term high power requirement
As an emergency unit
-to stop an operation which has already started without any damage to
the pump or its drive
As leakage compensation
-to make up leakage losses and thus maintain pressure over a long
period
BASIC COMPONENTS OF A HYDRAULIC
POWER TRANSMISSION SYSTEM
Accumulators
To balance out the volume at temperature changes
-for a closed system
To break down pressure peaks
-during switching processes
To cushion vibrations
-decrease of pressure amplitudes on pumps
-cushion shock waves in pipes
For the recovery of break energy
BASIC COMPONENTS OF A HYDRAULIC
POWER TRANSMISSION SYSTEM
Accumulators
Types
-Weight
-Spring loaded
-Piston type
-Bladder
-Membrane

N
2
N
2
N
2
(i) Weight (ii) Spring Loaded (iii) Piston (iv) Bladder (v) Membrane
HYDRAULIC PUMPS
Rotor-dynamic pumps
- Centrifugal or axial -propeller
- High flow rate but low pressure
- Provide smooth continuous flow but the flow rate depends on the
load
- Limited use in power hydraulics
- Principal use in hydraulic systems as circulating or supercharging
pumps
Classifications
Positive displacement pumps
- Widely used in power hydraulics
- Ejects a fixed volume of fluid into the system per revolution of the
pump shaft
HYDRAULIC PUMPS
Advantages
- High pressure capabilities
- High pressure capabilities
- High volumetric efficiency
- Small changes in volumetric efficiency throughout the design
pressure range
- Greater flexibility of performance (ie. wide range of pressure and
speeds)
Positive Displacement Pumps
Fundamental Characteristics
- Produce fluid flow but not the pressure
- Pressure is determined by the load
- Can be fixed or variable displacement (capacity)
- In variable capacity pumps, flow rates can be changed with constant
pump speed
Types
- Gear (Internal or External)
- Vane
- Piston (Axial or Radial)
- Other: Screw / Diaphragm / etc.
HYDRAULIC PUMPS
Positive Displacement Pumps
Most common in power
hydraulics
HYDRAULIC ACTUATORS
- Linear Actuators (Hydraulic Cylinders)
- Rotary Actuators (Hydraulic Motors)
Types
Single Acting Cylinders
- Apply force only in one direction by pressurized fluid
- Retracting force can be gravity or mechanical spring
Double Acting Cylinders
- Both strokes of force are produced by pressurized fluid
Telescoping-Type Cylinders
- Consist of series of rams nested in a telescoping assembly
- Provide relatively long strokes with good mechanical strength
Linear Actuators
HYDRAULIC ACTUATORS
Rotary Actuators
Produce power output to turn a shaft
Categories
- Limited rotation (Oscillatory hydraulic motors)
- Continuous rotation
Types
- Gear
- Vane
- Piston
Fixed or variable capacity
HYDRAULIC CIRCUIT SYMBOLS
- Symbols are used to represent the hydraulic circuit
- DIN-ISO 1219 Standard
International Standards
Common Symbols
- Working Line
- Pilot Line
- Drain Line
- Crossing Lines
or
- Flexible Lines
or - Joint Lines
- Reservoir
- Line to Reservoir
- Energy Flow
- Fixed Restrictor
- Flow Control Valve
HYDRAULIC CIRCUIT SYMBOLS
Common Symbols
- Electric Motor
- Fixed Capacity
Pump
- Variable Capacity
Pump
- Fixed Capacity
Motor
- Accumulator
- Variable Capacity
Motor
- Filter
- Separator
- Cooler
- Single Acting
Cylinder
- Double Acting
Cylinder
M
- Heat Exchanger
Pres. Gauge Temp. Gauge Flow Meter
Represented primarily by a square box
Shows inlet / outlet service ports and flow path(s) though the
valve
Indicates the valve actuation / operating mechanism
Manual: Push button Lever Pedal
Mechanical: Cam Spring
Pilot:
Solenoid:
A direction control valve includes more than one box,
representing its switching positions.
HYDRAULIC CIRCUIT SYMBOLS
Valves
HYDRAULIC CIRCUIT SYMBOLS
Circuit Diagram

M
- Shows the components symbolically
- Describes the operations
A Simple Hydraulic Circuit
HYDRAULIC VALVES
Directional Control Valves
Designated by the number of service ports (control ports not
included) and number of switching positions
A valve with mservice ports and nswitching positions is thus designated
as m/nway valve
Directional Control Valve Symbol

2/2 way valve



P Pressure port
A User port

3/2 way valve
(Direct electrically operated 3/2 way
poppet valve)

P Pressure port
A User port
T Tank

4/3 way valve
(Manually operated 4/3 way
spool valve)

P Pressure port
A, B User port
T Tank

A
P
A
P
T
A
P T
B
HYDRAULIC VALVES
Pressure Control Valves
Pressure relief valve
Used to set the maximum working
pressure of a particular operation
Sequence valve
Used to provide an ordered series of
operations
Pressure reducing valve
Used to supply a constant lower regulated
pressure from a higher pressure source
Unloading valve
Use to bypass the flow as long as a remote
source maintains the preset pressure on
the pilot line
HYDRAULIC VALVES
Pressure Control Valves
Counterbalance valve / Backpressure valve
Used to balance or hold a static load by a hydraulic resistance or to
control the effects of dynamic load momentum by maintaining back
pressure against the load
M
V
3
V
2
V
1
HYDRAULIC VALVES
Flow Control Valves
Meter-In
M
Meter-Out Bleed-Off
M
M
Fundamental Hydraulic Circuits
POWER HYDRAULICS
Applications
ILLUSTRATIONS
INDUSTRIAL HYDRAULICS
- Injection Moulding Machines
INDUSTRIAL HYDRAULICS
- Extrusion Machines
INDUSTRIAL HYDRAULICS
- Hydraulic Presses
INDUSTRIAL HYDRAULICS
- Shearing Machines - Scrap Processing Machines
INDUSTRIAL HYDRAULICS
- Swaging Machines
- Vertical Honing Machines
MOBILE HYDRAULICS
- Hydraulic Excavators
MOBILE HYDRAULICS
- Wheeled Hydraulic Excavators - Mini Hydraulic Excavators
MOBILE HYDRAULICS
- Motor Grader
MOBILE HYDRAULICS
- Mobile Crushers
MOBILE HYDRAULICS
- Bulldozers
MOBILE HYDRAULICS
- Bulldozers
MOBILE HYDRAULICS
- Wheel Loaders
MOBILE HYDRAULICS
- Dump Trucks
MOBILE HYDRAULICS
- Rollers
- Cranes
MOBILE HYDRAULICS
- Reach Tower Cranes
- Forklift

OTHER APPLICATIONS
- Exercise Equipments
- Car Lift
Pumps and Actuators
ILLUSTRATIONS
PUMPS
Gear Pumps
- External Gear Pumps
PUMPS
Gear Pumps
- Internal Gear Pumps
PUMPS
Piston Pumps
- Variable Capacity Axial Piston Pumps
PUMPS
Other Pumps
- Lobe Pumps
PUMPS
Other Pumps
- Diaphragm Pumps
HYDRAULIC CYLINDERS
Double Acting Cylinders
Piston
Piston Rod
Cylinder Housing
Fluid Ports
Differential Cylinder Non-differential Cylinder
HYDRAULIC CYLINDERS
Single Acting Cylinders
- Gravity Return - Spring Return
Piston
Cylinder
Housing
Fluid Port
Air Vents
Rod End
Load
Piston
Rod
Piston
Fluid
Port
Air Vents
Spring
Piston Rod

HYDRAULIC CYLINDERS
Telescopic Cylinders
- Ram Type
Ram 3
Fluid
Port
Fluid
Port
Ram 1
Ram 2
Cylinder
Housing
Oil Reserviour
2/2 Way Directional Control Valve
Pressure Reducing Valve Circuit
A B
T
One Way Flow Control
Hydraulic Valves
- 4/3-way DCV
Hydraulic Valves
- 2/2-way DCV, poppet design
Hydraulic Valves
- 3/2-way DCV, spool design
Hydraulic Valves
- 4/3-way solenoid valve
Hydraulic Valves
- Piloted non return valve
Hydraulic Cylinders
- Double acting cylinder
- Cylinder with end position cushioning