Professional Documents
Culture Documents
By M. R. Doddamani
CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Introduction to Hydraulic power The Source of Hydraulic power Hydraulic Actuators & Motors Control components in Hydraulic systems Hydraulic Circuit Design & Analysis Maintenance of Hydraulic Systems Introduction to Pneumatic control Pneumatic Actuators Directional control valves Simple Pneumatic control Signal processing elements Multi-cylinder applications Electro-Pneumatic control Compressed air
BOOKS
Text Books 1. Fluid power with applications by Anthony Espocito 2. Pneumatics & Hydraulics by Andrew Parr Reference Books 1. Oil hydraulic systems by S. R. Majumdar 2. Pneumatics basic level TP 101 by FESTO 3. Fundamentals of pneumatic control engineering by FESTO 4. Hydraulics basic level TP 501 by FESTO 5. Pneumatic Systems by S. R. Majumdar 6. Power Hydraulics by Ashby 7. Fluid power for Technicians by Donald Newton
INTRODUCTION
Requirement of Industrial processes Device to perform activities PRIME MOVER Prime movers are mechanical devices, which convert one form of energy into another
SOURCES OF POWER
1. Basic sources (prime movers) of power in Industries Electrical Electrical motors Power transmission through cables Mechanical I.C.Engines Power transmission through gears, shafts etc. FLUID POWER Common source Widely used in modern industries Power transmission through high pressure fluids (liquid & gases)
2.
3.
ADVANTAGES OF FP
1. Ease & accuracy of control - Usage of simple levers & push buttons
ADVANTAGES OF FP
2. Multiplication of force
ADVANTAGES OF FP
3. Constant force or torque
FP application in Oceanography
ADVANTAGES OF FP
4. Simplicity, Safety & Economy
ADVANTAGES OF FP
5. 6. Removal of heat generated FP devices are highly responsive because of weight to power ratio
ADVANTAGES OF FP
7. 8. FP devices are much easier to install than mechanical system FP devices are readily reversible and may be operated at either constant or variable torque in either direction
DISADVANTAGES OF FP
1. 2. 3. 4. 5. Hydraulic fluids are messy Susceptible to damage by dirt or contamination Physical injury from high speed particles Fire or explosion hazard Prolonged exposure to loud noise
We may summarize by saying that fluid power is not always best for all requirements, but it should always be considered because of its obvious advantages under certain circumstances
APPLICATIONS
Overhead tram
APPLICATIONS
Harvesting corn
APPLICATIONS
Brush drives
APPLICATIONS
Industrial lift trucks
APPLICATIONS
Excavators
APPLICATIONS
Robotic dexterous arm
APPLICATIONS
Use of variable displacement vane pump Directional control valve is provided for pressure unloading The pressure relief valve is limiting the maximum pressure Infinite pressure displacement is achieved with the use of proportional relief valve For the speed control of the hydraulic motor a flow control valve is employed
APPLICATIONS
Variable displacement, pressure compensated vane pumps are normally used for energy saving and smooth control of each machine heat generation is kept to minimum with variable displacement pumps.
APPLICATIONS
APPLICATIONS
APPLICATIONS
PRINCIPLES OF HYDRAULICS
Language of physical science for FLUID Current focus Oil as a medium Law of Hydrostatics
Potential head
PRINCIPLES OF HYDRAULICS
PRINCIPLES OF HYDRAULICS
Pressure applied to a confined fluid is transmitted undiminished in all directions throughout the fluid & acts perpendicular to the surfaces in contact with the fluid
By applying a smaller force F1 on the smaller piston, a bigger force F2 can be generated in the bigger piston
MECHANICAL LEVER
AE/page-102/Ex-3.15&3.16
COMPARISION
COMPARISION
COMPARISION
COMPARISION
3.
END OF CHAPTER 1
PUMPS
HYDRAULIC PUMP
HYDRAULIC PUMP
AP/35/FIG. 2.1
WHAT IS A PUMP?
Device for converting mechanical energy into hydraulic energy Heart of the hydraulic system as it generates the force necessary to move the load Main purpose is to create the flow of oil through the system which in turn assists transfer of power & motion Does not develop pressure Generally driven at constant speed by 3 phase AC induction motor Mechanical action creates partial vacuum at pump inlet Atmospheric pressure forces the fluid through the inlet line into the pump Pump pushes the fluid into the hydraulic system
PUMPING THEORY
PUMP CLASSIFICATION
PUMP CLASSIFICATION
AP/35/Fig. 2.2
PUMP CLASSIFICATION
POSITIVE or HYDROSTATIC PUMPS Pumping volume changes from maximum to minimum during each pumping cycle Used where pressure is the primary consideration Separation between high & low pressure areas or zones Pumping action is caused by varying the physical size of the sealed pumping chamber Ejects a fixed amount of fluid per rev. of pump shaft rotation Flow enters & leaves the unit at same velocity Capable of overcoming the pressure resulting from the mechanical loads as well as the resistance to flow due to friction
PUMP CLASSIFICATION
Examples include Gear, vane, piston screw pumps Advantages - High pressure capability - Small, compact size - High volumetric efficiency - Small change of efficiency throughout the pressure range - Greater flexibility of performance - Widely used in hydraulic system Variations in design - Fixed displacement (constant pump flow output) - Variable displacement (change in pump flow due to change in displacement output keeping speed constant) - Variable displacement, pressure compensation capability ( less flow as the system pressure builds up, no need of pressure relief valve)
PUMP CLASSIFICATION
NONPOSITIVE or HYDRODYNAMIC PUMPS Fluids are displaced & transferred using the inertia of fluid in motion Uses Newtons 1st law of motion to move the fluid against the system resistance Used for low pressure (up to 40 bar), high volume flow applications Little use in fluid power field Primarily used for transporting fluids from one location to another Examples include centrifugal (rotational inertia) & axial flow propeller pumps (transnational inertia) Advantages - Fewer moving parts - Low initial cost - Minimum maintenance cost - Quieter operation - Capable of handling any type of fluid - Simplicity of operation - High reliability
HOME WORK
1. Distinguish between positive & non-positive displacement pumps 2. Justify the names Hydrodynamic & hydrostatic for positive & non-positive displacement pumps
CENTRIFUGAL PUMPS
CENTRIFUGAL PUMP
Provides smooth continuous flow Fluid enters at the center of impeller, picked up by rotating impeller, centrifugal force causes fluid to move radially outwards Behaves interestingly in case of no demand of fluid No positive internal seal against leakage Highly desirable for pumping stations Easily handles large change in demand Reduction in output flow rate with increase in resistance to flow Need of priming
CENTRIFUGAL PUMP
Impeller imparts kinetic energy to the fluid hence the name Hydrodynamic or Hydrokinetic
GEAR PUMPS
AP/42/Fig. 2.7
Internet source
AE/152/Fig. 5-7
AE/150/Fig. 5-6
SRM/99/Fig. 4.5
Center gear is connected to motor shaft Two independent outputs Short sealing range limits the system pressure
SRM/99/Fig. 4.6
Internet
AE/153/Fig. 5-8
AE/153/Fig. 5-9
GEROTOR PUMP
AP/44/Fig. 2.9 (b)
AE/154/Fig. 5-11
Internet
AE/155/Fig. 5-12
GEROTOR PUMP
GEROTOR GENERATED ROTOR Operates much like the internal gear pump Inner gear rotor (Gerotor element) is power driven which draws outer gear rotor Centers of the gears are offset by approximately one-half the tooth depth Inner gear has one tooth less than the outer one Formation of inlet & discharge pumping chambers between the rotor blades Sealing the pumping chamber because of meshing teeth More compact than the external gear pump Gears must be made to high precision Ratings: - Continuous pressure 125 bar - Max. speed 2000 to 3600 rpm - Max. delivery 200 l/min
LOBE PUMP
LOBE PUMP
AP/43/Fig. 2.8
LOBE PUMP
Operates in a fashion similar to that of external gear pump Both blades are driven externally (one directly by the source of power & other through timing gears) Physically blades doesnt come in contact with each other Quieter than other types of gear pumps Greater amount of pulsation in pump output Used for pumping gas, air, liquid with low pressures with higher flow rate
SCREW PUMP
SCREW PUMP
2 Element rotary type
SRM/103/Fig. 4.10
SCREW PUMP
SCREW PUMP
SCREW PUMP
Axial flow positive displacement unit Three precision ground screws deliver non pulsating flow quietly & efficiently Two symmetrically opposed idler rotors acts as a rotating seals Idler rotors are in rolling contact with the central power rotor which are driven by the pressure of the liquid Operate up to 250 bar pressure at 1000 cm3 per min. Advantages 1. Most reliable 2. Oil supply is pulsation free, continuous 3. No oil churning, pump turbulence etc. 4. Very quiet in operation
SCREW PUMP
Disadvantages - Manufacturing of a screw pump poses difficulty in case of close tolerance requirement - Viscosity dependant pressure rating - Decrease in pump efficiency with increase in fluid viscosity - Overall volumetric & mechanical efficiency is low
VANE PUMP
AE/157/Fig. 5-15
AP/47/Fig. 2.11
PISTON PUMP
DELIVERY PATTERN
DELIVERY PATTERN
DELIVERY PATTERN
Exploded View
Different designs of axial piston pumps can be seen in previous two slides Cylinder body containing the axially placed pistons, is made to rotate against a cam plate (tilting plate or swash plate) Cam plate is kept fixed & positioned at an angle with the axis of the cylinder block Rotating group includes shoe plate, shoes, piston, cylinder block & drive shaft As the cylinder barrel is rotated, the piston shoe follows the surface of swash plate Piston reciprocates inside the cylinder barrel as swash plate is at an angle resulting in suction & discharge of oil
SRM/120/Fig. 4.24
AP/49/Fig. 2.15
AE/170/Fig. 5-29
PUMP COMPARISION
AE/176/Fig. 5-32
AE/177/Fig. 5-33
AE/178/Fig. 5-34
Noise is a sound that people undesirable Sound come as a pressure wave through the surrounding air medium. Pressure waves are generated by a vibrating object (pump. Motor etc.) Human ear converts sound wave into electrical signals that are transmitted to brain.Brain translates electrical signal into sensation of sound. Common sound levels (dB) are presented in following slide Intensity is defined as the rate at which sound energy is transmitted through a unit area The letter A following the symbol dB signifies that the sound level measuring equipment uses a filtering system that more closely simulates a human ear. I (B) = log { I / I (hear. thrsh.)} I = intensity of sound under consideration (W/m2) I (hear. thrsh.)= intensity of sound at the threshold of hearing (W/m2) I (B) = intensity of sound under consideration in units of bels (1 bel=10 dB)
NOISE
AE/179/Fig. 5-35
PUMP NOISE
Generated noise levels vary with - pump component materials - pump mountings - methods applied to eliminate vibration - rigidity - manufacturing & fitting accuracies of pump elements - speed of rotation - pressure pulsation & other components connected in the circuit External gear & the piston pumps are nosiest while screw pumps are very quiet with vane & internal gear pumps somewhere between Any pump which generates noise above 90dB (A) is a loud pump & those around 60 dB (A) or less are considered quiet Noise developed in typical pumps is shown in following slide.
PUMP NOISE
PUMP NOISE
Comparative noise behavior of two pumps with 32 l/min (PR 32 H) & 20 l/min (PR 20 H) capacity respectively working at 1500 rpm with oil viscosity of 32 cSt is shown in the following slide The noise level of a pump kept in a noise isolating room is found to be less by almost 18 dB (A) compared to the noise level at site for a pump installed on a C.I. Oil reservoir. Pattern of rise of noise level depends on the pump construction, flow rate, speed, pressure etc.
PUMP NOISE
SRM/136/Fig. 4.31 (b) Noise intensity in protected room &near pump installation measured at 1 m away
PUMP NOISE
PUMP NOISE
PUMP NOISE
WITH REFERENCE TO PREVIOUS SLIDE Rise in noise level is considerable influenced by the rotational speed (n), operating pressure (P) & volume of oil per revolution of the pump (v) Rise in noise level is observed with increase in n, P & v on case of both the axial piston pump & vane pump [Fig. 4.32 (a) & Fig. 4.32 (b)] In comparison to an axial piston pump, a vane pump produces less noise when n, p and v are increased by same amount under similar working parameters [Fig. 4.32 (b)]
PUMP NOISE
Noise level increases with the increase in power rating of pump Dependence of power & noise intensity SRM/137/Fig. 4.33
SRM/138/Fig. 4.5
PUMP NOISE
WITH REFERENCE TO PREVIOUS SLIDE Rise in noise intercity generated in a positive displacement pump with an increase in pump speed is higher than with an increase in pressure or displacement as seen from Table. Variable axial piston pump is found to generate more noise level at higher power rating compared to low power rating A fixed displacement pump generates less noise intensity than a variable displacement pump under similar working parameters & size Rise in noise intensity by a positive displacement pump with increase of pump speed, is higher than that with increase of pressure or displacement volume. [SRM/138/Fig. 4.5]
SBM5 MAT
SA25FF/B/6
PUMP CAVITATION
Cavitation occurs due to entrained air bubbles in the hydraulic fluid or vaporization of the hydraulic fluid. Occurs when pump suction lift is excessive & the pump inlet pressure falls below the vapor pressure of fluid. Air or vapor bubbles which form in the low pressure inlet region of pump are collapsed when they reach high pressure discharge region. This produces high fluid velocity & impact forces, which erodes metallic components subsequently shortening pump life. Cavitation has been described as: A reduction in pump capacity. - Happens because bubbles take up space and one cannot have bubbles and liquid in the same place at the same time - If the bubble gets big enough at the eye of the impeller, the pump will lose its suction and will require priming A reduction in the head of the pump - Bubbles, unlike liquid, are compressible. It is this compression that can change the head
PUMP CAVITATION
Formation of bubbles in a low pressure area of the pump volute. A noise that can be heard when the pump is running. - Any time a fluid moves faster than the speed of sound in the medium you are pumping, a sonic boom will be heard. (speed of sound in water is 1480 meters/sec). Damage on the pump impeller and volute. TYPES OF CAVITATION 1. Vaporization cavitation A fluid vaporizes when its pressure gets too low, or its temperature too high 2. Air ingestion cavitation The bubbles collapse as they pass from the eye of the pump to the higher pressure side of the impeller. Air ingestion seldom causes damage to the impeller or casing. The main effect of air ingestion is loss of capacity.
PUMP CAVITATION
3. Internal recirculation cavitation Fluid recirculates increasing its velocity until it vaporizes and then collapses in the surrounding higher pressure. Flow turbulence cavitation Vane passing syndrome cavitation Impeller tip gets damaged due to its passing too close to the pump cutwater. The velocity of the liquid increases if the clearance is too small lowering the pressure and causing local vaporization. The bubbles collapse just beyond the cutwater and there is where you should look for volute damage
4. 5.
PUMP RIPPLE
Small variations of flow that take place during pumping are called ripple
2.
4.
5.
8.
END OF CHAPTER 2