Industrial prime movers

• Most industrial processes require objects or

substances to be moved from one location to
another.
• Or a force to be applied to hold, shape or
compress a product.
• Such activities are performed by Prime Movers.
• Workhorses of manufacturing industries .

1
• In many locations all prime movers are electrical.
• Rotary motions can be provided by simple motors.
• Linear motion can be obtained from rotary motion
by devices such as screw jacks or rack and pinions.

• If a pure force or a short linear stroke is required

then a solenoid is an option . 2
• Although there are limits to force that can be
obtained by electrical means.
• Enclosed fluids (both liquids and gases) can also
be used to convey energy from one location to
another and consequently, to produce rotary or
linear motion or apply a force.
• Fluid based systems using liquids as transmission
media are called Hydraulic systems.
• Oils are most commonly used fluids.
• Gas-based systems are called Pneumatic systems.
• Most common gas is simply compressed air,
although nitrogen is occasionally used . 3
• Main advantages and disadvantages of PS or HS
both arise out of different characteristics of low
density compressible gases and (relatively) high
density incompressible liquids.
• PS - Tends to have a ‘softer’ action than a HS,
which can be prone to producing noisy and wear
inducing shocks in piping.
• HS - Can operate at far higher pressures than a PS
& consequently can be used to provide very large
forces.
• To compare ES, PS & HS.
• Will consider simple lifting task handled by each .
4
• Task considered is how to lift a load by a distance
of about 500 mm.
• Electrical System -
• Choices - solenoid, DC or AC induction motor.
• Solenoid produces a linear stroke directly but
limited to a max. distance of around 100 mm
• Both DC and AC motors are rotary devices and
their outputs need to be converted to linear
motion by mechanical devices such as screw jacks
or rack and pinions.
• Choice of motor depends largely on speed control
requirements . 5
• DC motor fitted with a tacho and driven by a
thyristor drive can give excellent speed control, but
has high maintenance requirements for brushes &
commutator.
• AC motor is virtually maintenance free, but is
essentially a fixed speed device.
(determined by no. of poles & supply frequency).
• Fixed speed raise/lower is required.
• So AC motor driving a screw jack - logical choice
• Neither type of motor can be allowed to stall
against an end of travel stop.
• End of travel limits are needed to stop drive 6 .
Electric circuit

7
Physical layout

8
Hydraulic System

9
Hydraulic System

10
1. Speed control is easily achieved by regulating
volume flow rate to cylinder.
Precise control at low speeds is one of main
advantages of HS.
2. Travel limits are determined by cylinder stroke &
cylinders can be allowed to stall at ends of travel
so no over travel protection is required.
3. Pump needs to be turned on by an external
power source; almost certainly an AC induction
motor which, in turn, requires a motor starter
and overload protection .

11
4. Hydraulic fluid needs to be very clean, hence a
filter is needed to remove dirt, particles before
fluid passes from tank to pump.
5. A leaks of fluid from system are unsightly,
slippery (hence hazardous) and environmentally
very undesirable.
A major failure can be catastrophic .

12
Pneumatic System

13
1. Operating pressures in PS are generally much
lower than those in HS.
2. PS require larger actuators than HS for same load.
3. HS require a pressure regulator to spill excess
fluid back to tank, but pressure control in a HS is
much simpler.
4. A pressure switch, fitted to air reservoir, starts
compressor motor when pressure falls and stops
it again when pressure reaches required level .

14
A comparison

15
A comparison

16
• HS works on principle of Pascal’s law which says
that pressure in an enclosed fluid is uniform in all
directions.
• Pascal’s law is illustrated in fig .

17
• Force given by fluid is given by multiplication of
pressure and area of cross section.
• As pressure is same in all direction, smaller piston
feels a smaller force and a large piston feels a
large force.
• Therefore, a large force can be generated with
smaller force input by using HS .

18
• Schematic of a simple HS is shown in fig

19
• Liquid used is generally high density
incompressible oil.
• Capacity of pump depends on HS design.
• These pumps generally deliver constant volume
in each revolution of pump shaft.
• Therefore, fluid pressure can increase indefinitely
at dead end of piston until system fails.
• Pressure regulator is used to avoid such
circumstances.
• Leak proof piping is also imp. due to safety,
environmental hazards and economical aspects .
20
 Applications of HS
• Industrial:
– Plastic processing machineries, steel making and
primary metal extraction applications, automated
production lines, machine tool industries, paper
industries, loaders, crushes, textile machineries, R & D
equipment and robotic systems etc.
• Mobile hydraulics:
– Tractors, irrigation system, earthmoving equipment,
material handling equipment, commercial vehicles,
tunnel boring equipment, rail equipment, building
and construction machineries and drilling rigs etc .

21
• Automobiles:
– It is used in systems like breaks, shock absorbers,
steering system, wind shield, lift and cleaning etc.
• Marine applications:
– It mostly covers ocean going vessels, fishing boats and
navel equipment.
• Aerospace equipment:
– There are equipment and systems used for rudder
control, landing gear, breaks, flight control and
transmission etc. which are used in airplanes, rockets
and spaceships .

22
 Hydraulic Pump
• Combined pumping and driving motor unit is
known as hydraulic pump.
• It takes fluid (mostly some oil) from storage tank
and delivers it to rest of circuit.
• Speed of pump is constant and pump delivers an
equal volume of oil in each revolution.
• Amount and direction of fluid flow is controlled
by some external mechanisms.
• In some cases, pump itself is operated by a servo
controlled motor but it makes system complex .
23
• Pumps are characterized by its flow rate capacity,
power consumption, drive speed, pressure
delivered at outlet and efficiency of pump.
• Pumps are not 100% efficient.
• Efficiency of a pump can be specified by two
ways.
1. Volumetric efficiency which is ratio of actual
volume of fluid delivered to max. theoretical
volume possible.
2. Power efficiency which is ratio of output
hydraulic power to input mechanical/electrical
power.
• Typ. efficiency of pumps varies from 90-98%.
24
• Hydraulic pumps can be of two types:
i. Centrifugal pump
ii. Reciprocating pump
• Centrifugal pump
• As shown
• Uses rotational kinetic
energy to deliver fluid.
• Rotational energy typ. comes from an engine or
electric motor.
• Fluid enters pump impeller along or near to
rotating axis, accelerates in propeller and flung
out to periphery by centrifugal force. 25
• Delivery is not constant and varies according to
outlet pressure.
• These pumps are not suitable for high pressure
applications and are generally used for low-
pressure and high-volume flow applications.
• Max. pressure capacity is limited to 20-30 bars
and specific speed ranges from 500 to 10000.
• Most of pumps are not self-priming and casing
needs to be filled with liquid before it is started .

26
• Reciprocating pump is a positive plunger pump.
• It is also known as positive displacement pump or
piston pump.

• It is often used where

relatively small quantity
is to be handled and
delivery pressure is quite
large.
• Construction of these
pumps is similar to four
stroke engine as shown . 27
• Crank is driven by some external rotating motor.
• Piston of pump reciprocates due to crank rotation.
• Piston moves down in one half of crank rotation,
inlet valve opens and fluid enters into cylinder.
• In second half crank rotation, piston moves up,
outlet valve opens and fluid moves out from
outlet.
• At a time, only one valve is opened and another is
closed so there is no fluid leakage.
• Depending on area of cylinder, pump delivers
constant volume of fluid in each cycle
independent of pressure at output port. 28
 Pump Lift
• It is placed over fluid storage tank as shown.

• It creates a negative pressure at inlet which

causes fluid to be pushed up in inlet pipe by
atmospheric pressure . 29
• It results in fluid lift in pump suction.
• Max. pump lift can be determined by
atmospheric pressure .
• Theoretically, a pump lift of 8 m is possible but it
is always lesser due to undesirable effects such as
cavitation.
• Cavitation is formation of vapor cavities in a
liquid.
• Cavities can be small liquid-free zones ("bubbles"
or "voids") formed due to partial vaporization of
fluid (liquid) .
30
• These are usually generated when a liquid is
subjected to rapid changes of pressure and
pressure is relatively low.
• At higher pressure, voids implode and can
generate an intense shockwave.
• Therefore, cavitation should always be avoided.
• Cavitation can be reduced by maintaining lower
flow velocity at inlet and therefore inlet pipes
have larger diameter than outlet pipes in a pump.
• Pump lift should be as small as possible to
decrease cavitation and to increase efficiency of
pump .
31
 Pressure Regulation
• It is process of reduction of high source pressure
to a lower working pressure suitable for
application.
• It is an attempt to maintain outlet pressure within
acceptable limits.
• It is performed by using pressure regulator.
• Primary function is to match fluid flow with
demand.
• At same time, regulator must maintain outlet
pressure within certain acceptable limits .
32
• Schematic of pressure regulator and various
valves placement as shown

33
• When valve V1 is closed and V2 is opened then
load moves down and fluid returns to tank but
pump is dead ended and it leads to a continuous
increase in pressure at pump delivery.
• Finally, it may lead to permanent failure of pump.
• Therefore some method is needed to keep
delivery pressure P1 within safe level.
• It can be achieved by placing pressure regulating
valve V3 as shown in fig.
• This valve is closed in normal conditions and
when pressure exceeds a certain limit, it opens
and fluid from pump outlet returns to tank via
pressure regulating valve V3 . 34
• As pressure falls in a limiting range, valve V3
closes again.
• When valve V1 is closed, whole fluid is dumped
back to tank through pressure regulating valve.
• This leads to substantial loss of power because
fluid is circulating from tank to pump and then
pump to tank without performing any useful
work.
• This may lead to increase in fluid temperature
because energy input into fluid leads to increase
in fluid temperature.
• This may need to installation of heat exchanger in
to storage tank to extract excess heat . 35
• Interestingly, motor power consumption is more
in such condition because outlet pressure is
higher than working pressure .

36
 Advantages of Hydraulic system
• HS uses high density incompressible fluid which
results in higher efficiency.
• It delivers consistent power O/P which is difficult
in pneumatic or mechanical drive systems.
• Possibility of leakage is less in HS as compared to
that in pneumatic system.
• Maintenance cost is less.
• These systems perform well in hot environment
conditions .

37
 Disadvantages of Hydraulic system
• Material of storage tank, piping, cylinder and
piston can be corroded with hydraulic fluid.
• Therefore one must be careful while selecting
materials and hydraulic fluid.
• Structural weight and size of system is more
which makes it unsuitable for smaller
instruments.
• Small impurities in hydraulic fluid can
permanently damage complete system, therefore
one should be careful and suitable filter must be
installed .
38
• Leakage of hydraulic fluid is also a critical issue
and suitable prevention method and seals must
be adopted.
• Hydraulic fluids, if not disposed properly, can be
harmful to environment .

39
 Hydraulic Pumps
• Classification of Hydraulic Pumps
i. Non-positive displacement pumps
ii. Positive displacement pumps
• Non-Positive Displacement Pumps
• These pumps are also known as hydro-dynamic
pumps.
• In these pumps fluid is pressurized by rotation of
propeller and fluid pressure is proportional to
rotor speed.
• These pumps can not withstanding high pressures
and generally used for low-pressure and high-
volume flow applications . 40
• Fluid pressure and flow generated due to inertia
effect of fluid.
• These pumps provide a smooth and continuous
flow but flow O/P decreases with increase in
system resistance (load).
• Flow output decreases because some of fluid slip
back at higher resistance.
• Fluid flow is completely stopped at very large
system resistance and thus volumetric efficiency
will become zero.
• Therefore, flow rate not only depends on
rotational speed but also on resistance provided
by system. 41
• Imp. Advantages are lower initial cost, less
operating maintenance because of less moving
parts, simplicity of operation, higher reliability
and suitability with wide range of fluid etc.
• These pumps are primarily used for transporting
fluids and find little use in hydraulic or fluid
power industries.
• Example - Centrifugal pump .

42
 Positive Displacement Pump
• These pumps deliver a constant volume of fluid in
a cycle.
• Discharge quantity per revolution is fixed in these
pumps and they produce fluid flow proportional
to their displacement and rotor speed.
• These pumps are used in most of industrial fluid
power applications.
• O/P fluid flow is constant and is independent of
system pressure (load) .

43
• Advantages:
• High-pressure and low-pressure areas (means I/P
and O/P region) are separated and hence fluid
cannot leak back due to higher pressure at
outlets.
• Capability to generate high pressures, high
volumetric efficiency, high power to weight ratio,
change in efficiency throughout pressure range is
small and wider operating range pressure and
speed .

44
• Fluid flow rate of these pumps ranges from 0.1
and 15,000 gpm, pressure head ranges between
10 and 100,000 psi and specific speed is less than
500.
• Pumps do not produce pressure but they only
produce fluid flow.
• Resistance to output fluid flow generates
pressure.
• It means that if discharge port (O/P) of a positive
displacement pump is opened to atmosphere,
then fluid flow will not generate any output
pressure above atmospheric pressure .
45
• But, if discharge port is partially blocked, then
pressure will rise due to increase in fluid flow
resistance.
• If discharge port of pump is completely blocked,
then an infinite resistance will be generated.
• This will result in breakage of weakest component
in circuit.
• Therefore, safety valves are provided in hydraulic
circuits along with these pumps.
• Imp. positive displacement pumps are gears
pumps, vane pumps and piston pumps .
46
 Gear Pumps
• It is a robust and simple positive displacement
pump.
• It has two meshed gears revolving about their
respective axes.
• These gears are only moving parts in pump.
• They are compact, relatively inexpensive and
have few moving parts.
• Rigid design of gears and houses allow for very
high pressures and ability to pump highly viscous
fluids.
• They are suitable for a wide range of fluids and
offer self-priming performance .
47
• Sometimes gear pumps are designed to function
as either a motor or a pump.
• These pump includes helical and herringbone
gear sets (instead of spur gears), lobe shaped
rotors similar to Roots blowers (commonly used
as superchargers), and mechanical designs that
allow stacking of pumps.
• Based upon design, gear pumps are classified as:
• External Gear Pumps
• Lobe Pumps
• Internal Gear Pumps
• Gerotor Pumps . 48
Generally gear pumps are used to pump:
• Petrochemicals: Pure or filled bitumen, pitch,
diesel oil, crude oil, lube oil etc.
• Chemicals: Sodium silicate, acids, plastics, mixed
chemicals, isocyanates etc.
• Paint and ink
• Resins and adhesives
• Pulp and paper: acid, soap, lye, black liquor,
kaolin, lime, latex, sludge etc.
• Food: Chocolate, cocoa butter, fillers, sugar,
vegetable fats and oils, molasses, animal food etc.
49
 External gear pump
• It consists of externally meshed two gears housed
in a pump case as shown in fig .

50
• One of gears is coupled with a prime mover and
is called as driving gear and another is called as
driven gear.
• Rotating gear carries fluid from tank to outlet
pipe.
• Suction side is towards portion whereas gear
teeth come out of mesh.
• When gears rotate, volume of chamber expands
leading to pressure drop below atmospheric
value.
• Therefore vacuum is created and fluid is pushed
into void due to atmospheric pressure .
51
• Fluid is trapped between housing and rotating
teeth of gears.
• Discharge side of pump is towards portion where
gear teeth run into mesh and volume decreases
between meshing teeth.
• Pump has a positive internal seal against leakage;
therefore, fluid is forced into outlet port.
• Gear pumps are often equipped with side wear
plate to avoid leakage.
• Clearance between gear teeth and housing and
between side plate and gear face is very
important and plays an important role in
preventing leakage .
52
• In general, gap distance is less than 10 um.
• Amount of fluid discharge is determined by no. of
gear teeth, volume of fluid between each pair of
teeth and speed of rotation.
• Imp. drawback is unbalanced side load on its
bearings.
• It is caused due to high pressure at outlet and low
pressure at inlet which results in slower speeds and
lower pressure ratings in addition to reducing
bearing life.
• They are most commonly used for hydraulic fluid
power applications and are widely used in chemical
installations to pump fluid with a certain viscosity .
53
 Lobe Pump
• Working principle of this
is same as that of
external gear pumps.
• Lobes do not make any
contact like external
gear pump as shown.
• Lobe contact is
prevented by external
timing gears located in
gearbox .

54
• Lobes rotate to create expanding volume at inlet.
• Fluid flows into cavity and is trapped by lobes.
• Fluid travels around interior of casing in pockets
between lobes and casing.
• Finally, meshing of lobes forces liquid to pass
through outlet port.
• Bearings are placed out of pumped liquid.
• Therefore pressure is limited by bearing location
and shaft deflection.
• They have superb sanitary qualities, high efficiency,
reliability, corrosion resistance and good clean-in-
place and steam-in-place (CIP/SIP) characteristics .
55
• Widely used in industries such as pulp and paper,
chemical, food, beverage, pharmaceutical and
biotechnology etc.
• These pumps can handle solids (e.g., cherries and
olives), slurries, pastes, and a variety of liquids.
• A gentle pumping action minimizes product
degradation.
• They also offer continuous and intermittent
reversible flows.
• Frequently used in food applications because
they handle solids without damaging product .
56
• Large sized particles can be pumped effectively than
in other positive displacement types.
• As lobes do not make any direct contact therefore,
clearance is not as close as in other pumps.
• This specific design of pump makes it suitable to
handle low viscosity fluids with diminished
performance.
• Loading characteristics are not as good as other
designs, and suction ability is low.
• High-viscosity liquids require reduced speeds to
achieve satisfactory performance.
• Reduction in speed can be 25% or more in case of
high viscosity fluid . 57
 Internal Gear Pump
• Internal gear pumps are exceptionally versatile.
• They are often used for low or medium viscosity
fluids such as solvents and fuel oil and wide range
of temperature.
• This is non-pulsing, self-priming and can run dry
for short periods.
• It is a variation of basic gear pump .

58
• Schematic of internal
gear pump is shown in
fig.
• It comprises of an
internal gear, a regular
spur gear, a crescent-
shaped seal and an
external housing.
• Liquid enters suction port between rotor (large
exterior gear) and idler (small interior gear) teeth.
• Liquid travels through pump between teeth and
crescent .
59
• Crescent divides liquid and acts as a seal between
suction and discharge ports.
• When teeth mesh on side opposite to crescent
seal, fluid is forced out through discharge port of
pump.
• This clearance between gears can be adjusted to
accommodate high temperature, to handle high
viscosity fluids and to accommodate wear.
• These pumps are bi-rotational so that they can be
used to load and unload vessels .

60
• They have only two moving parts and one stuffing
box, therefore they are reliable, simple to operate
and easy to maintain.
• However, these pumps are not suitable for high
speed and high pressure applications.
• Only one bearing is used in pump therefore
overhung load on shaft bearing reduces life of
bearing .

61
 Applications
• All varieties of fuel oil and lube oil
• Resins and Polymers
• Alcohols and solvents
• Asphalt, Bitumen, and Tar
• Polyurethane foam (Isocyanate and polyol)
• Food products such as corn syrup, chocolate, and
peanut butter
• Paint, inks, and pigments
• Soaps and surfactants
• Glycol .
62
 Gerotor Pump
• Gerotor is a positive displacement pump.
• Name Gerotor is derived from "Generated Rotor".
• At most basic level, a Gerotor is essentially one
that is moved via fluid power.
• Originally this fluid
was water, today
wider use is in
hydraulic devices.
• Schematic as
shown .
63
• It is an internal gear pump without crescent.
• It consists of two rotors viz. inner and outer rotor.
• Inner rotor has N teeth, and outer rotor has N+1
teeth.
• Inner rotor is located off-center and both rotors
rotate.
• Geometry of two rotors partitions volume
between them into N different dynamically-
changing volumes.
• During rotation, volume of each partition changes
continuously .
64
• Therefore, any given volume first increases, and
then decreases.
• An increase in volume creates vacuum.
• This vacuum creates suction, and thus, this part
of cycle sucks fluid.
• As volume decreases, compression occurs.
• During this compression period, fluids can be
pumped, or compressed (if they are gaseous
fluids).
• Close tolerance between gears acts as a seal
between suction and discharge ports.
• Rotor and idler teeth mesh completely to form a
seal equidistant from discharge and suction ports.
65
• This seal forces liquid out of discharge port.
• Flow output is uniform and constant at outlets.
• Imp. advantages of pumps are high speed
operation, constant discharge in all pressure
conditions, bidirectional operation, less sound in
running condition and less maintenance due to
only two moving parts and one stuffing box etc.
• However, pump is having some limitations such
as medium pressure operating range, clearance is
fixed, solids can’t be pumped and overhung load
on shaft bearing etc .

66
 Applications
• Widely used in industries and are produced in
variety of shapes and sizes by a no. of different
methods.
• Primarily suitable for low pressure applications
such as lubrication systems or hot oil filtration
systems, but can also be found in low to moderate
pressure hydraulic applications.
• However common applications are as follows:
Light fuel oils, Lube oil, Cooking oils, Hydraulic
fluid .
67
 Vane Pumps
• Gear pumps have a disadvantage of small leakage
due to gap between gear teeth and pump
housing.
• This limitation is overcome in vane pumps.
• Leakage is reduced by using spring or
hydraulically loaded vanes placed in slots of
driven rotor.
• Capacity and pressure ratings of a vane pump are
generally lower than gear pumps, but reduced
leakage gives an improved volumetric efficiency
of around 95% .
68
• Available in a no. of vane configurations including
sliding vane, flexible vane, swinging vane, rolling
vane, and external vane etc.
• Each type of vane pump has its own advantages.
• E. g. external vane pumps can handle large solids.
• Flexible vane pumps can handle only small solids
but create good vacuum.
• Sliding vane pumps can run dry for short periods
of time and can handle small amounts of vapor.
• Vane pumps are known for their dry priming,
ease of maintenance, and good suction
characteristics . 69
• Operating range of these pumps varies from -32
°C to 260 °C.
• Schematic of as shown .

70
• Generate a pumping action by tracking of vanes
along casing wall.
• Generally consist of a rotor, vanes, ring and a port
plate with inlet and outlet ports.
• Rotor is connected to prime mover through a
shaft.
• Vanes are located on slotted rotor.
• Rotor is eccentrically placed inside a cam ring.
• Rotor is sealed into cam by two side plates.
• When prime mover rotates rotor, vanes are
thrown outward due to centrifugal force.
• Vanes track along ring . 71
• It provides a tight hydraulic seal to fluid which is
more at higher rotation speed due to higher
centrifugal force.
• This produces a suction cavity in ring as rotor
rotates.
• It creates vacuum at inlet and therefore, fluid is
pushed into pump through inlet.
• Fluid is carried around to outlet by vanes whose
retraction causes fluid to be expelled.
• Capacity of pump depends upon eccentricity,
expansion of vanes, width of vanes and speed of
rotor .
72
• It can be noted that fluid flow will not occur when
eccentricity is zero.
• These pumps can handle thin liquids (low viscosity)
at relatively higher pressure.
• These pumps can be run dry for a small duration
without any failure.
• These pumps develop good vacuum due to
negligible leakage.
• However, these pumps are not suitable for high
speed applications and for high viscosity fluids or
fluids carrying some abrasive particles.
• Maintenance cost is also higher due to many
moving parts . 73
• These pumps have various applications for
pumping of following fluids:
• Aerosol and Propellants
• Aviation Service - Fuel Transfer, Deicing
• Auto Industry - Fuels, Lubes, Refrigeration
Coolants
• Bulk Transfer of LPG and NH3
• LPG Cylinder Filling
• Alcohols
• Refrigeration - Freons, Ammonia
• Solvents
• Aqueous solutions .
74
 Unbalanced Vane pump
• In practice, vane pumps have more than one vane
as shown in fig

75
• Rotor is offset within housing, and vanes are
constrained by a cam ring as they cross inlet and
outlet ports.
• Although vane tips are held against housing, still
a small amount of leakage exists between rotor
faces and body sides.
• Also, vanes compensate to a large degree for
wear at vane tips or in housing itself.
• Pressure difference between outlet and inlet
ports creates a large amount of load on vanes
and a significant amount of side load on rotor
shaft which can lead to bearing failure.
76
 Balanced vane pump
• As shown

77
• This pump has an elliptical cam ring with two
inlet and two outlet ports.
• Pressure loading still occurs in vanes but two
identical pump halves create equal but opposite
forces on rotor.
• It leads to zero net force on shaft and bearings.
• Thus, lives of pump and bearing increase
significantly.
• Also sounds and vibrations decrease in running
mode of pump.

78
 Adjustable vane pump
• Proper design of pump is imp. & a challenging
task
• In ideal condition, capacity of a pump should be
exactly same to load requirements.
• A pump with larger capacity wastes energy as
excess fluid will pass through pressure relief
valve.
• It also leads to a rise in fluid temperature due to
energy conversion to heat instead of useful work
and therefore it needs some external cooling
arrangement.
79
• Therefore, higher capacity pump increases
power consumption and makes system bulky and
costly.
• Pumps are generally available with certain
standard capacities and user has to choose next
available capacity of pump.
• Also, flow rate from pump in most hydraulic
applications needs to be varying as per
requirements.
• Therefore, some vane pumps are also available
with adjustable capacity as shown in fig.

80
• This can be achieved by adjusting a positional
relationship between rotor and inner casing by
help of an external controlling screw.

81
• These pumps basically consist of a rotor, vanes,
cam ring, port plate, thrust bearing for guiding
cam ring and a discharge control screw by which
position of cam ring relative to rotor can be
varied.
• In general, adjustable vane pumps are
unbalanced pump type.
• Amount of fluid that is displaced by a vane pump
running at a constant speed is determined by
maximum extension of vanes and vanes width.
• However, for a pump running in operation, width
of vanes cannot be changed but distance by
which vanes are extended can be varied. 82
• This is possible by making a provision for
changing position of cam ring (adjustable inner
casing) relative to rotor as shown in fig.
• Eccentricity of rotor with respect to cam ring is
adjusted by movement of screw.
• Delivery volume increases with increase in
eccentricity.
• This kind of arrangement can be used to achieve
a variable volume from pump and is known as
variable displacement vane pump.
• In general, adjusted vane pumps are pressure
compensated.
83
• It means that discharge is controlled by pre-
adjusted value and when discharge pressure
reaches a certain (adjusted) value; pumping action
ceases.
• This mechanism is accomplished by using a
compensating spring to offset cam ring.
• Initially, eccentricity is maximum because discharge
pressure is zero and spring force keeps cam ring at
extreme right position.
• As discharge pressure increases, it acts on inner
contour of cam ring.
• It pushes cam ring towards left against spring force
and hence eccentricity reduces and hence
discharge through pump reduces. 84
• When discharge pressure becomes high enough to
overcome entire spring force; compensator spring
will compress until zero eccentricity is achieved.
• In this condition, pumping action ceases and fluid
flow (except small leakages) does not occur.
• Therefore, system pressure can be adjusted by
setting compensator spring.
• These pumps ensure their own protection against
excessive system pressure and do not rely on safety
control devices of hydraulic system.
• These pumps are used as energy savings devices
and have been used in many applications, including
automotive transmissions. 85
 Piston pumps
• Meant for high-pressure applications.
• These pumps have high-efficiency and simple
design and needs lower maintenance.
• These pumps convert rotary motion of input
shaft to reciprocating motion of piston.
• These pumps work similar to four stroke engines.
• They work on principle that a reciprocating piston
draws fluid inside cylinder when piston retracts in
a cylinder bore and discharge fluid when it
extends.
• Can be used for both liquids and gases . 86
• Piston pumps are basically of two types:
i. Axial piston pumps
ii. Radial piston pumps
• Axial Piston Pump
• These are positive displacement pumps which
converts rotary motion of input shaft into an axial
reciprocating motion of pistons.
• These pumps have a no. of pistons (usually an
odd no.) in a circular array within a housing which
is commonly referred to as a cylinder block, rotor
or barrel.
• These pumps are used in jet aircraft . 87
• They are also used in small earthmoving plants such
as skid loader machines.
• Another use is to drive screws of torpedoes.
• Max. operating temp. of about 120 °C.
• So, leakage between cylinder housing and body
block is used for cooling and lubrication of rotating
parts.
• This cylinder block rotates by an integral shaft
aligned with pistons.
• These pumps have sub-types as:
I. Bent axis piston pumps
II. Swash plate axial piston pump . 88
• Schematic of bent axis piston pump .

89
• Reciprocating action of pistons is obtained by
bending axis of cylinder block (CB).
• CB rotates at angle which is inclined to drive
shaft.
• CB is turned by drive shaft through a universal
link.
• CB is set at an offset angle with drive shaft.
• CB contains a no. of pistons along its periphery.
• These piston rods are connected with drive shaft
flange by ball-and-socket joints .

90
• These pistons are forced in and out of their bores
as distance between drive shaft flange & CB
changes.
• A universal link connects block to drive shaft, to
provide alignment and a positive drive.
• Volumetric displacement (discharge) of pump is
controlled by changing offset angle.
• It makes system simple and inexpensive.
• Discharge does not occur when cylinder block is
parallel to drive shaft .

91
• Offset angle can vary from 0° to 40°.
• Fixed displacement units are usually provided with
23° or 30° offset angles while variable
displacement units are provided with a yoke and
an external control mechanism to change offset
angle.
• Some designs have arrangement of moving yoke
over center position to reverse fluid flow direction.
• Flow rate of pump varies with offset angle.
• There is no flow when cylinder block centerline is
parallel to drive shaft centerline (offset angle is 0°).
92
 Swash Plate Axial Piston Pump
• It is a device that translates rotary motion of a
shaft into reciprocating motion.
• It consists of a disk attached to a shaft as shown.

93
• If disk is aligned perpendicular to shaft; disk will
turn along with rotating shaft without any
reciprocating effect.
• Similarly, edge of inclined shaft will appear to
oscillate along shaft's length.
• This apparent linear motion increases with
increase in angle between disk and shaft (offset
angle).
• Apparent linear motion can be converted into an
actual reciprocating motion by means of a
follower that does not turn with swash plate.
• Series of pistons are aligned coaxially with a shaft
through a swash plate to pump a fluid . 94
• Axial reciprocating motion of pistons is obtained
by a swash plate that is either fixed or has
variable degree of angle.
• As piston barrel assembly rotates, piston rotates
around shaft with piston shoes in contact with
swash plate.
• Piston shoes follow angled surface of swash plate
and rotational motion of shaft is converted into
reciprocating motion of pistons.
• When swash plate is perpendicular to shaft;
reciprocating motion to piston does not occur .

95
• As swash plate angle increases, piston follows
angle of swash plate surface and hence it moves
in and out of barrel.
• Piston moves out of cylinder barrel during one
half of cycle of rotation thereby generating an
increasing volume, while during other half of
rotating cycle, pistons move into cylinder barrel
generating a decreasing volume.
• This reciprocating motion of piston results in
drawing in and pumping out of fluid.
• Pump capacity can be controlled by varying
swash plate angle with help of a separate
hydraulic cylinder . 96
• Pump capacity (discharge) increases with
increase in swash plate angle and vice-versa.
• Cylinder block and drive shaft in this pump are
located on same centerline.
• Pistons are connected through shoes and a shoe
plate that bears against swash plate.
• These pumps can be designed to have a variable
displacement capability.
• It can be done by mounting swash plate in a
movable yoke.
• Swash plate angle can be changed by pivoting
yoke on pintles . 97
 Radial Piston Pump
• Typical construction as shown.

98
• Piston pump has pistons aligned radially in a CB.
• It consists of a pintle, a cylinder barrel with
pistons and a rotor containing a reaction ring.
• Pintle directs fluid in and out of cylinder.
• Pistons are placed in radial bores around rotor.
• Piston shoes ride on an eccentric ring which
causes them to reciprocate as they rotate.
• Eccentricity determines stroke of pumping piston.
• Each piston is connected to inlet port when it
starts extending while it is connected to outlet
port when start retracting.
99
• This connection to inlet and outlet port is
performed by timed porting arrangement in
pintle.
• For initiating a pumping action, reaction ring is
moved eccentrically with respect to pintle or
shaft axis.
• As cylinder barrel rotates, pistons on one side
travel outward.
• This draws fluid in as cylinder passes suction port
of pintle.
• It is continued till max. eccentricity is reached.
100
• When piston passes max. eccentricity, pintle is
forced inwards by reaction ring.
• This forces fluid to flow out of cylinder and enter
in discharge (outlet) port of pintle.
• Radial piston pump works on high pressure (up to
1000 bar).
• It is possible to use pump with various hydraulic
fluids like mineral oil, biodegradable oil, HFA (oil
in water), HFC (water-glycol), HFD (synthetic
ester) or cutting emulsion.
• This is because parts are hydrostatically balanced.
101
• It makes pump suitable for many applications
such as :
• Machine tools (displace of cutting emulsion,
supply for hydraulic equipment like cylinders),
• High pressure units (overload protection of
presses),
• Test rigs,
• Automotive sector (automatic transmission,
hydraulic suspension control in upper-class cars),
• Plastic (powder injection molding)
• Wind energy etc.
102
 Combination Pump
• There are two basic requirements for load lifting
or load applying by a hydraulic ram.
1. Large volume of fluid at a low pressure when
cylinder extends or retracts.
• Low pressure is required to overcome frictional
resistance.
2. High pressure is needed, when load is gripped .

103
• For to fulfill this an arrangement as shown in fig .

104
• Two separate pumps are driven by a common
electrical motor.
• P1 is a high volume low pressure pump and P2 is
a high pressure low volume pump.
• HS is associated with relief valves RV1 and RV2
and a one-way check valve CV1.
• This kind of arrangement allows fluid flow from
left to right, but blocks in reverse direction .

105
• RV1 is a normal high pressure valve.
• RV2 is not operated by pressure at point A,
however, it is remotely operated by pressure at
point B.
• This can be achieved with balanced piston valve.
• In low pressure mode both relief valves are
closed and both pumps P1 and P2 deliver fluid to
load but majority comes from pump P1 as its
capacity is higher .

106
• When load is in holding mode, pressure at B rises
and relief valve RV2 opens.
• It results in all fluid from pump P1 to return
straight to tank directly and pressure at A to fall
to a low value.
• Check valve CV1 stops fluid from pump P2 pass it
back to tank via relief valve RV2, consequently
pressure at B rises to level set by relief valve RV1.
• This kind of arrangement saves energy as large
volume of fluid from pump P1 is returned to tank
at a very low pressure, and only a small volume of
fluid from pump P2 is returned at a high pressure.
107