APPLIED HYDRAULICS AND

PNEUMATICS
U5MEA23






Prepared by
Mr. Jayavelu.S & Mr. Shri Harish
Assistant Professor, Mechanical Department
VelTech Dr.RR & Dr.SR Technical University

UNIT I : FLUID POWER
SYSTEMS AND
FUNDAMENTALS
Introduction to fluid power
Advantages of fluid power
Application of fluid power system
Types of fluid power systems,
General types of fluids
Properties of hydraulic fluids
Fluid power symbols
Basics of Hydraulics
Applications of Pascals Law
Laminar and Turbulent flow
Reynoldss number
Darcys equation
Losses in pipe, valves and fittings
Introduction to fluid power
Fluid power is a term
describing hydraulics and pneumatics tech
nologies.
Both technologies use a fluid (liquid or gas) to
transmit power from one location to another.
hydraulics, the fluid is a liquid (usually oil),
pneumatics uses a gas (usually compressed
air).
Both are forms of power transmission, which
is the technology of converting power to a
more useable form and distributing it to
where it is needed.
The common methods of power transmission
are electrical, mechanical, and fluid power.
Advantages of fluid power
high horsepower-to-weight ratio You could probably hold a 5-
hp hydraulic motor in the palm of your hand, but a 5-hp electric
motor might weight 40 lb or more.
safety in hazardous environments because they are inherently
spark-free and can tolerate high temperatures.
force or torque can be held constant this is unique to fluid
power transmission
high torque at low speed unlike electric motors, pneumatic and
hydraulic motors can produce high torque while operating at low
rotational speeds. Some fluid power motors can even maintain
torque at zero speed without overheating
pressurized fluids can be transmitted over long distances and
through complex machine configurations with only a small loss in
power
multi-functional control a single hydraulic pump or air
compressor can provide power to many cylinders, motors, or other
actuators
elimination of complicated mechanical trains of gears, chains,
belts, cams, and linkages
motion can be almost instantly reversed

Application of fluid power system

Construction
Mining
Agriculture
Waste Reduction
Utility Equipment
Marine
Offshore
Energy
Metal Forming
Machine Tools
Military & Aerospace
Other Applications

Types of fluid power systems
Fluid transport system
Transport of water from reservoir using
pipe lines
Transport of oil in pipe to two countries.
Fluid power system
Oil used in equipments to acquire desire
movement.
Compressed air in pneumatics for crane
movements
Properties of hydraulic fluids
Density
The density of a fluid is its mass per unit v
olume:
Liquids are essentially incompressible
Density is highly variable in gases nearly
proportional to the pressure.
Note: specific volume is defined as:
Viscosity
Viscosity is a measure of a fluids resistance t
o flow. It determines the fluid strain rate that i
s generated by a given applied shear stress.
Cohesion
Intermolecular attraction between molecules
of same liquid
Adhesion
Attraction between molecules of liquid and
molecules of solid boundary in contact with
liquid.

Cavitation
Cloud of vapour bubble will form when
liquid pressure drops below vapour
pressure due to flow phenomenon
Capillarity
Liquid rises into a thin glass tube above or
below its general level.
Vapour pressure
Pressure exerted by vapour which is in
equilibrium with liquid
Compatibility
Ability of hydraulic fluid to be compatible
with the system.
Volatility
The degree and rate at which it will
vapourize under given conditions of
temperature and pressure.
Corrosiveness
Tendency to promote corrosion in
hydraulic system.

Application of pascals law
Hydraulic press
Hydraulic jack
Laminar and Turbulent flow
Laminar
Turbulent

Reynolds number
Darcys equation

Losses in pipes, valves and
fittings

UNIT 2: HYDRAULIC SYSTEM
COMPONENTS
Sources of Hydraulic Power
construction and working of pumps Variable
displacement pumps
Actuators: Linear hydraulic actuators
Single acting and Double acting cylinders
Fluid motors.

Control Components:
Direction control valve
Flow control valves
Electrical control -- solenoid valves. Relays,
Accumulators and Intensifiers.


Basic Pump Classifications
Hydraulic pumps can be classified
using three basic aspects:
Displacement
Pumping motion
Fluid delivery characteristics
Basic Pump Classifications
Displacement relates to how the output of
the pump reacts to system loads
Positive-displacement pumps produce a
constant output per cycle
Non-positive-displacement pumps produce flow
variations due to internal slippage
Basic Pump Classifications
A non-positive-displacement pump
has large internal clearances
Allows fluid slippage in the pump
Results in varying flow output as system
load varies
Basic Pump Classifications
Non-positive-displacement pump
Basic Pump Classifications
The basic pumping motions used in
hydraulic pumps are:
Rotary
Reciprocating
Basic Pump Classifications
Gear pumps are rotary pumps
Sauer-Danfoss, Ames, IA
Basic Pump Classifications
Piston pumps are reciprocating pumps
Reciprocating piston movement
Basic Pump Classifications
In a rotary pump, the pumping action is
produced by revolving components
In a reciprocating pump, the rotating
motion of the pump input shaft is
changed to reciprocating motion, which
then produces the pumping action
Basic Pump Classifications
Hydraulic pumps are classified as
either fixed or variable delivery
Fixed-delivery pumps have pumping
chambers with a volume that cannot be
changed; the output is the same during
each cycle
In variable-delivery designs, chamber
geometry may be changed to allow
varying flow from the pump
Basic Pump Classifications
Gear pumps are fixed-delivery pumps
Basic Pump Classifications
Piston pumps may be designed as
variable-delivery pumps
Basic Pump Classifications
When selecting a pump for a circuit,
factors that must be considered are:
System operating pressure
Flow rate
Cycle rate
Expected length of service
Environmental conditions
Cost
Pump Design, Operation,
and Application
Gear pumps are positive-
displacement, fixed-delivery, rotary
units
Gear pumps are produced with either
external or internal gear teeth
configurations
Pump Design, Operation,
and Application
Gear pumps are commonly used
Pump Design, Operation,
and Application
Pumping action of gear pumps results
from unmeshing and meshing of the
gears
As the gears unmesh in the inlet area, low
pressure causes fluid to enter the pump
As the pump rotates, fluid is carried to the
pump discharge area
When the gears mesh in the discharge
area, fluid is forced out of the pump into
the system
Pump Design, Operation,
and Application
Gear pumps are available in a wide
variety of sizes
Flow outputs from below 1 gpm to 150
gpm
Pressure rating range up to 3000 psi
Pump Design, Operation,
and Application
The gerotor pump design is an
internal-gear pump
Uses two rotating, gear-shaped elements
that form sealed chambers
The chambers vary in volume as the
elements rotate
Fluid comes into the chambers as they
are enlarging and is forced out as they
decrease in size
Pump Design, Operation,
and Application
The gerotor is a common internal-gear
design
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Gerotor operation
Pump Design, Operation,
and Application
Vane pumps are positive-
displacement, fixed or variable
delivery, rotary units.
Design is commonly used in industrial
applications
Delivery can range up to 75 gpm
Maximum pressure of about 2000 psi
Pump Design, Operation,
and Application
Vane pump consists of a slotted rotor,
fitted with moveable vanes, that rotates
within a cam ring in the pump housing
Rotor is off center in the ring, which creates
pumping chambers that vary in volume as
the pump rotates
As chamber volume increases, pressure
decreases, bringing fluid into the pump
As volume decreases, fluid is forced out
into the system
Pump Design, Operation,
and Application
Operation of a typical vane pump
Pump Design, Operation,
and Application
Parts of a typical vane pump
Pump Design, Operation,
and Application
Vane pump may be pressure
unbalanced or pressure balanced
Unbalanced has only one inlet and one
discharge, which places a side load on
the shaft
Balanced has two inlets and two
discharges opposite each other, creating
a pressure balance and, therefore, no
load on the shaft
Pump Design, Operation,
and Application
Piston pumps are positive-
displacement, fixed- or variable-
delivery, reciprocating units
Several variations
Many provide high volumetric efficiency
(90%), high operating pressure (10,000
psi or higher), and high-speed operation
Pump Design, Operation,
and Application
A basic piston pump consists of a
housing that supports a pumping
mechanism and a motion-converting
mechanism
Pumping mechanism is a block containing
cylinders fitted with pistons and valves
Motion converter changes rotary to
reciprocating motion via cams, eccentric
ring, swash plate, or bent-axis designs
Rotating the pump shaft causes piston
movement that pumps the fluid
Pump Design, Operation,
and Application
Piston pump classification is based on
the relationship between the axes of
the power input shaft and piston
motion
Axial
Radial
Reciprocating
Pump Design, Operation,
and Application
Axial piston pumps use two design
variations:
Inline
Bent axis
Pump Design, Operation,
and Application
Inline has the cylinder block and
pistons located on the same axis as
the pump input shaft
Pistons reciprocate against a swash plate
Very popular design used in many
applications
Pump Design, Operation,
and Application
An inline axial-piston pump
Pump Design, Operation,
and Application
Bent axis has the cylinder block and
pistons set at an angle to the input shaft
Geometry of the axis angle creates piston
movement
Considered a more rugged pump than inline
Manufactured in high flow rates and maximum
operating pressures
Pump Design, Operation,
and Application
A bent-axis axial-piston pump
Pump Design, Operation,
and Application
Radial piston pumps have the highest
continuous operating pressure
capability of any of the pumps
regularly used in hydraulic systems
Models are available with operating
pressure ratings in the 10,000 psi
range
Pump Design, Operation,
and Application
Two variations of radial piston pumps:
Stationary-cylinder design uses springs to
hold pistons against a cam that rotates with
the main shaft of the pump
Rotating-cylinder design uses centrifugal
force to hold pistons against a reaction ring
When the main shaft is rotated, each
piston reciprocates, causing fluid to
move through the pump
Pump Design, Operation,
and Application
A stationary-cylinder radial-piston
pump
Pump Design, Operation,
and Application
Large, reciprocating-plunger pump
designs were widely used when
factories had a central hydraulic power
source
Today, plunger pumps are typically
found in special applications requiring
high-pressure performance
Pump Design, Operation,
and Application
Screw pumps have pumping elements
that consist of one, two, or three
rotating screws
As the screws rotate, fluid is trapped
and carried along to the discharge of
the pump
The design of screw pumps allows
them to operate at a very low noise
level
Pump Design, Operation,
and Application
A typical screw pump
Pump Design, Operation,
and Application
The lobe pump is a close relative of the
gear pump
Two three-lobed, gear-shaped units are
often used to form the pumping element
Output flow is larger than a gear pump of
comparable physical size because of
pumping chamber geometry
Lower pressure rating than gear pumps
Tend to have a pulsating output flow
Pump Design, Operation,
and Application
Operation of a lobe pump
Pump Design, Operation,
and Application
Centrifugal pumps are non-positive-
displacement units
Use centrifugal force generated by a
rotating impeller to move fluid
Large clearances between the impeller and
the pump housing allow internal pump
slippage when resistance to fluid flow is
encountered in the system
Typically used in hydraulic systems as
auxiliary fluid transfer pumps
Pump Design, Operation,
and Application
Operation of a centrifugal pump
Pump Design, Operation,
and Application
Propeller and jet pumps are non-
positive-displacement pumps
Sometimes used to transfer fluid within
hydraulic systems
Propeller pump consists of a rotating
propeller-shaped pumping element
Jet pump creates flow by pumping fluid
through a nozzle concentrically located
within a venturi
Pump Design, Operation,
and Application
Construction of a propeller pump
Pump Design, Operation,
and Application
Construction of a jet pump
Directional control valves
Check valve
Pilot operated check valve
Three-way and four-way valves
Manually-actuated valve
Pilot actuated valve
Solenoid actuated valve
Center flow path configuration
Shuttle valve
Directional control valves
Pilot operated check valve
Three-way valves
Four-way valves
Manually-actuated valve
Pilot actuated valve
Solenoid actuated valve
Pressure control valves
Pressure relief valve
Compound pressure relief valve
Pressure-reducing valve

Pressure relief valve
Compound pressure relief
valve
Pressure-reducing valve
Flow control valve/ Needle
valve
Restrictor needle
valve
Weight loaded accumulator

Spring loaded accumulator

Diaphragm type accumulator

Bladder type accumulator

Intensifier

UNIT 3: PNEUMATIC SYSTEM COMPONENTS
Pneumatic Components:
Properties of air. Compressors.
FRL Unit
Air control valves,
Quick exhaust valves
pneumatic actuators- cylinders, air
motors.

Compressor construction

Types of compressor

Fig shows single-acting piston actions in the cylinder of a
reciprocating compressor.
The piston is driven by a crank shaft via a connecting rod.
At the top of the cylinder are a suction valve and a discharge valve.
A reciprocating compressor usually has two, three, four, or six
cylinders in it.
Piston type reciprocating
compressor
Screw compressor
Screw compressors are also belong to the
positive displacement compressor family.
In screw compressors, the compression is
accomplished by the enmeshing of two
mating helically grooved rotors suitably
housed in a cylinder equipped with
appropriated inlet and discharge ports
Rotary vane compressor
The rotor shaft is mounted eccentrically in a steel
cylinder so that the rotor nearly touches the cylinder
wall on one side, the two being separated only by an oil
film at this point.
Directly opposite this point the clearance between the
rotor and the cylinder wall is maximum.
Heads or end-plates are installed on the ends of the
cylinder and to hold the rotor shaft.

The vanes move back and forth radially in
the rotor slots as they follow the contour of
the cylinder wall when the rotor is turning.
The vanes are held firmly against the
cylinder wall by action of the centrifugal
force developed by the rotating rotor.
In some instances, the blades are spring-
loaded to obtain a more positive seal against
the cylinder wall.
Air In Air Out
Louver
Bowl
Filter Element
Sight Gauge
Drain Cock
Filter
Air In Air Out
Adjustable
Locking Knob
Main Spring
Diaphragm
Assembly
Valve Assembly
Valve Spring
Regulator
Lubricator
Quick Exhaust Valve
1
2
Port 2 is connected directly
to the end cover of a cylinder
Port 1 receives air from the
control valve
Air flows past the lips of the
seal to drive the cylinder
When the control valve is
exhausted, the seal flips to
the right opening the large
direct flow path
Air is exhausted very rapidly
from the cylinder for
increased speed
1
2
1
2
Unit 4: FLUIDICS & PNEUMATIC CIRCUIT DESIGN
Fluidics Introduction to fluidic devices,
simple circuits Introduction to Electro
Hydraulic Pneumatic logic circuits, PLC
applications in fluid power control,
ladder diagrams
Fluid Power Circuit Design:
Sequential circuit design for simple
applications using classic, cascade,
step counter, logic with Karnaugh-
Veitch Mapping and combinational
circuit design methods.

Fluidics

Bistable flip flop

SRT flip flop

OR/NOR & AND/NAND

Fluidic control of pneumatic
cylinders

PLC

Ladder diagram

PLC control of hydraulic
circuit

Cascading circuit

UNIT 5: FLUID POWER CIRCUITS

Speed control circuits, synchronizing
circuit, Pneumo hydraulic circuit,
Accumulator circuits, Intensifier circuits.
Servo systems Hydro Mechanical
servo systems, Electro hydraulic servo
systems and proportional valves.
Deceleration circuit, hydrostatics
transmission circuits, control circuits for
reciprocating drives in machine tools,
Material handling equipments. Fluid
power circuits; failure and
troubleshooting.

Speed control circuit

Regenerative circuit

Pressure intensifier circuit

Accumulator circuit

Pneumatic motor circuit

Regenerative drilling machine

Hydraulic fault diagnosis

Pneumatics fault diagnosis

Thank you.