Hydraulic and Pneumatic Control

Engineering

Pro. Dr. Ahmed Maged

1- Introduction
Some advantages a hydraulic transmission has over
a mechanical transmission is that it has-
•Quick, easy speed adjustment over a wide range
while the power source is operating at constant
(most efficient) speed.
•Rapid, smooth acceleration or deceleration.
•Control over maximum torque and power.
•A cushioning effect to reduce shock loads.
•A smooth reversal of motion.
Pascal law
2- Pumps
 Hydraulic Pumps
Hydraulic pumps convert mechanical energy from a prime mover (engine or electric
motor) into hydraulic (pressure) energy. The pressure energy is used then to operate
an actuator. Pumps push on a hydraulic fluid and create flow

3-1. Pump Classifications

All pumps create flow. They operate on the displacement principle. Fluid is taken in
and displaced to another point. Pumps that discharge liquid in a continuous flow are
nonpositive-displacement type. Pumps that discharge volumes of liquid separated by
periods of no discharge are positive-displacement type.

a. Nonpositive-Displacement Pumps.

b. Positive-Displacement Pumps
a. Nonpositive-Displacement Pumps.
(1) Volute Pump
a. Centrifugal Pump
(

(2) Diffuser Pump (Figure 3-5). Similar to a volute type, a

diffuser pump has a series of stationary blades (the
diffuser) that curve in the opposite direction from
whirling impeller blades. A diffuser reduces the velocity
of a liquid, decreases slippage, and increases a pump's
ability to develop flow against resistance.
b. Positive-Displacement Pumps
 Gear Pumps
Gear pumps are external, internal, or lobe types.

a. External
b. Internal
c. Lobe. Figure 3-8 shows a lobe pump. It differs from other gear pumps
because it uses lobed elements instead of gears. The element drive also
differs in a lobe pump. In a gear pump, one gear drives the other. In a lobe
pump, both elements are driven through suitable external gearing.
Piston Pumps
Piston pumps are either radial or axial
a. Axial Piston Pumps.
In axial piston pumps, the pistons stroke in the same direction on a
cylinder block's centerline (axially). Axial piston pumps may be an in-line
or angle design. (1) In-Line Pump.
2) Bent-Axis Axial Piston Pump.
(
(3) Wobble-Plate In-Line Pump. This is a variation of an in-line piston
pump. In this design, a cylinder barrel does not turn; a plate wobbles
as it turns, and the wobbling pushes the pistons in and out of the
pumping chambers in a stationary cylinder barrel. In a wobble-plate
pump, separate inlet and outlet check valves are required for each
piston, since the pistons do not move past a port.
b. Radial. In a radial piston pump (Figure 3-14), the pistons are arranged
like wheel spokes in a short cylindrical block.
3-7. Vane Pumps
In a vane-type pump, a slotted rotor splined to a drive shaft rotates between
closely fitted side plates that are inside of an elliptical- or circular-shaped
ring. Polished, hardened vanes slide in and out of the rotor slots and follow
the ring contour by centrifugal force
Unbalanced Vane Pumps.
Balanced Vane Pumps
 3- Actuators
1- Linear actuators
Hydraulic Motors
1.Gear-Type Motors. Figure 4-10 shows a gear-type motor. Both gears are
driven gears, but only one is connected to the output shaft.
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2. Vane-Type Motors. Figure 4-11 shows a vane-type motor. Flow from
the pump enters the inlet, forces the rotor and vanes to rotate, and
passes out through the outlet. Motor rotation causes the output shaft
to rotate
c. Piston-Type Motors. Piston-type motors can be in-line-axis or bent-axis
types.
(1) In-Line-Axis, Piston-Type Motors. These motors (Figure 4-15) are almost
identical to the pumps. They are built-in, fixed- and variable-displacement
models in several sizes. Torque is developed by a pressure drop through a
motor.
(2) Bent-Axis, Piston-Type Motors. These motors are almost identical to the
pumps. They are
4- Hydraulic Control
Valves
 a- Direction Control Valves
Valves are used in hydraulic systems to control the operation of the actuators.
Valves regulate pressure by creating special pressure conditions and by
controlling how much oil will flow in portions of a circuit and where it will go. The
three categories of hydraulic valves are pressure-control, flow- (volume-) control,
and directional-control (see Figure 5-1).
Directional-Control Valves
Directional-control valves also control flow direction.
However, they vary considerably in physical
characteristics and operation. The valves may be a-
•Poppet type, in which a piston or ball moves on and off
a seat.
•Rotary-spool type, in which a spool rotates about its
axis.
•Sliding-spool type, in which a spool slides axially in a
bore. In this type, a spool is often classified according
to the flow conditions created when
Two-Way Valve.
Four-Way Valves. Four-way, directional-control valves are used to
control the direction of fluid flow in a hydraulic circuit, which controls the
direction of movement of a work cylinder or the rotation of a fluid motor.
These valves are usually the sliding-spool type. A typical four-way,
directional-control valve has four ports:
•One pressure port is connected to a pressure line.
•One return or exhaust port is connected to a reservoir.
•Two working ports are connected, by lines, to an actuating unit.
Figure 5-22 shows how the spool position determines the possible flow
conditions in the circuit. The four ports are marked P, T, A, and B: P is
connected to the flow source; T to the tank; and A and B to the respective
ports of the work cylinder, hydraulic motor, or some other valve in the
circuit.
Table 1 lists some of the classifications of directional-
control valves. These valves could be identified according
to the-
•Number of spool positions.
•Number of flow paths in the extreme positions.
•Flow pattern in the center or crossover position.
•Method of shifting a spool.
•Method of providing spool return.
 Hydraulic systems and troubleshooting

(2) Sliding-Spool Valve.

.Open-center valves are used when a work cylinder

does not have to be held in position by pressure and
where power is used to perform a single operation.
These valves also avoid shock to a system when a
valve spool is moved from one position to another,
since in the intermediate position, pressure is
temporarily relieved by liquid passing from a pump
directly to the reservoir.
check valve.
 Hydraulic systems and troubleshooting

(5) Solenoid-Operated, Two- and Four-Way Valves. These valves are used to control the direction of
hydraulic flow by electrical means. A spool is shifted by energizing a solenoid that is located at one or both
ends of the spool. When a solenoid is energized,

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 Hydraulic systems and troubleshooting

(3). Manually Operated Four-Way Valve. This valve is used to control the flow direction manually. A spool is
shifted by operating a hand lever (Figure 5-27).

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 Check Valves. Check valves are the most commonly used in fluid-powered
systems. They allow flow in one direction and prevent flow in the other direction.
(2) Pilot-Operated Type (Figure 5-19). In diagram A, the valve has poppet 1
seated on stationary sleeve 2 by spring 3. This valve opens the same as a
conventional check valve. Pressure at the inlet ports must be sufficient to
overcome the combined forces of any pressure at the outlet port and the light
thrust of spring 3 so that poppet 1 raises and allows flow from the inlet ports
through the outlet port. In this situation, there is no pressure required at the
pilot port.
 Pressure-Control Valves
a. Relief Valves. Relief valves are the most common type of pressure-control
valves. The relief valves' function may vary, depending on a system's needs.
They can provide overload protection for circuit components or limit the force
or torque exerted by a linear actuator or rotary motor.
(1) Simple Type. Figure 5-2 shows a simple-type relief valve. This valve is
installed so that one port is connected to the pressure line or the inlet and the
other port to the reservoir. The ball is held on its seat by thrust of the spring,
which can be changed by turning the adjusting screw.
 (2) Compound Type. Figure 5-3 shows a compound-type relief valve.
Passage C is used to keep the piston in hydraulic balance when the
valve's inlet pressure is less than its setting (diagram A). The valve
setting is determined by an adjusted thrust of spring 3 against poppet 4.
When pressure at the valve's inlet reaches the valve's setting, pressure
in passage D also rises to overcome the thrust of spring 3. When flow
through passage C creates a sufficient pressure drop to overcome the
thrust of spring 2, the piston is raised off its seat (diagram B).
b. Pressure-Reducing Valves.
These valves limit pressure on a branch circuit to a lesser
amount than required in a main circuit. For example, in a
system, a branch-circuit pressure is limited to 300 psi, but a
main circuit must operate at 800 psi. A relief valve in a main
circuit is adjusted to a setting above 800 psi to meet a main
circuit's requirements. However, it would surpass a branch-
circuit pressure of 300 psi.
1 X-Series Type. Figure 5-5 shows the internal construction of an X-series pressure-
reducing valve. The two major assemblies are an adjustable pilot-valve assembly in the
cover, which determines the operating pressure of the valve, and a spool assembly in
the body, which responds to the action of the pilot valve to limit maximum pressure at
the outlet port
c. Sequence Valves. Sequence valves control the operating sequence
between two branches of a circuit. The valves are commonly used to
regulate an operating sequence of two separate work cylinders so that one
cylinder begins stroking when the other completes stroking. Sequence
valves used in this manner ensure that there is minimum pressure equal to
its setting on the first cylinder during the subsequent operations at a lower
pressure.
Figure 5-7, diagram A, shows how to obtain the operation of a sequencing
pressure by adjusting a spring's compression, which holds piston 1 in the
closed position. Liquid enters the valve at inlet port C, flows freely past
piston 1, and enters the primary circuit through port D. When pressure of
the liquid flowing through the valve is below the valve's setting, the force
acting upward on piston 1 is less than the downward force of the spring 2.
The piston is held down and the valve is in the closed position.
d. Counterbalance Valves. A counterbalance valve allows
free flow of fluid in one direction and maintains a resistance to flow in
another direction until a certain pressure is reached. A valve is
normally located in a line between a directional-control valve and an
outlet of a vertically mounted actuating cylinder, which supports weight
or must be held in position for a period of time. A counterbalance valve
serves as a hydraulic resistance to an actuating cylinder. For example,
a counterbalance valve is used in some hydraulically operated fork
lifts. It offers a resistance to the flow from an actuating cylinder when a
fork is lowered. It also helps support a fork in the up position.
Figure 5-9 shows a counterbalance valve.
 Hydraulic systems and troubleshooting

5-3. Flow-Control Valves

Flow-control valves are used to control an actuator's speed by metering flow. Metering is measuring or
regulating the flow rate to or from an actuator. The three basic types of flow-control-valve installations are
the meter-in, meter-out, and bleed-off circuits.
a. Meter-In Circuit (Figure 5-37). With this circuit, a flow-control valve is installed in a pressure line that
leads to a work cylinder. All flow entering a work cylinder is first metered through a flow-control valve. Since
this metering action involves reducing flow from a pump to a work cylinder, a pump must deliver more fluid
than is required to actuate a cylinder at the desired speed. Excess fluid returns to a tank through a relief
valve.

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 Hydraulic systems and troubleshooting

b. Meter-Out Circuit (Figure 5-38). With a meter-out circuit, a flow-control valve is installed on the return
side of a cylinder so that it controls a cylinder's actuation by metering its discharge flow. A relief valve is set
slightly above the operating pressure that is required by the type of work.

This type of circuit is ideal for overhauling load

applications.

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 Hydraulic systems and troubleshooting

c. Bleed-Off Circuit. A typical bleed-off circuit is not installed directly in a

feed line. It is Td into this line with its outlet connected to a return line. A
valve regulates flow to a cylinder by diverting an adjustable portion of a
pump's flow to a tank. Since fluid delivered to a work cylinder does not
have to pass through a flow-control valve, excess fluid does not have to be
dumped through a relief valve.

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d. Compensated Flow. The flow-control valves previously discussed do not
compensate for changes in fluid temperature or pressure and are considered
non-compensating valves. Flow rate through these valves can vary at a fixed
setting if either the pressure or the fluid's temperature changes. Viscosity is the
internal resistance of a fluid that can stop it from flowing. A liquid that flows
easily has a high viscosity. Viscosity changes, which can result from
temperature changes, can cause low variations through a valve. Such a valve
can be used in liquid-powered systems where slight flow variations are not
critical consideration factors.
Thank you