Hydraulics

INDUSTRIAL HYDRAULICS
An Introduction to
RAKESH KUMAR I N A TRAINERS
9/11/2013
The Professional Trainers
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Filter
Regulator
Lubricator
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Pressure Gauge
Parts:
1. Frame 2. Borden tube 3. Lever 4. Toothed segments 9/11/2013 5.Pinion 6. Indicator 7.Graduated disc or dial 8. Throttle opening The Professional Trainers
Solenoid Operated Valve
Solenoid Armature
Sub Valve
Main Valve
P
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1 kg/cm2 or 1 bar 2 kg/cm2 or 2 bar

Volume 1 Volume 0.5
4 kg/cm2 or 4 bar
Volume 0.25
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Less than 3000 kgf or 30000 N
More than 3000 kgf or 30000 N
Accurate & consistent 9/11/2013 The Professional Trainers 7
Advantages of Hydraulics
Transmission of high forces by using small equipment (COMPACT) High efficiency Infinite variable speeds from still to maximum Smooth movement- quiet The system can be stalled Control and regulation is simple Controls can be activated directly/ remotely Easy and quick reversal Oil has lubricating property means higher life of equipment.
Hydrostatic Pressure
Hydrostatic Pressure = p = h x x g Pascals Law
(French Physicist Blaise Pascal 1623-16620
Liquids exert equal pressure in
all directions
Any increase in the pressure on fluid in a closed container will be transmitted
throughout the container.

The Principle of a Hydraulic Press
The hydrostatically connected container behaves like mechanical lever. In both cases mechanical advantages is gained in the form of force or pressure but distance is lost. This proves the important principle of conservation of energy which tells that the energy can neither be created nor be destroyed. The above illustration is made the weight of lever, piston and frictional losses are negligible.
Hydrodynamics
Bernoullis Principle
(Swiss physicist, Daniel Bernoulli 1700-1782)
qV = v1 x A1 = v2 x A2
In the regions where the velocity of fluid smaller, the pressure is higher and vice versa.
Note: This principle forms basic function of many hydraulic valves where the hydraulic engineers calls the smaller area as orifice and makes it to function to suit variable sequence and pressure according to his requirement.
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Applications of hydraulics
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Function of Hydraulic system

Hydro motor
Cylinder Throttle valve Check Valve
Direction Control Valve Pressure relief Valve
Pump Filter Tank 9/11/2013 The Professional Trainers 13
Hydraulic fluids
Hydraulic oils should fulfill the following requirement: Viscosity (in mm2/s) Viscosity Index Lubricity Resistance to ageing and oxidation Others Water & Air separation
Corrosion prevention Compatibility with seals, hoses and non ferrous metallic Filterability Pour point Boiling point Flash point etc.,
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Hydraulic Reservoir
Function:
Storage of Hydraulic oil volume Dissipate heat Separate for dirt and oil Support for drive motor, pump, filter, valves etc.,
Reservoir size 3 to 5 times pump delivery Provision for drain, level indicator, filler spout, air breather, baffle plate, top cover etc., Shape of reservoir and ground clearance Pump inlet lines and return lines immersed in oil (1 2 times pipe
dia.)
Hydraulic Reservoir
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Reservoir
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Filters
Return line filter For inline mounting
Return line filter For mounting in tank cover
10= 75 means, that there are 75 times as many particles > 10 m in the filter inlet than there are in the filter outlet
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Filter Circuits
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Pumps
Dynamic Pumps Positive Displacement pumps
Centrifugal pumps
Reciprocating Pumps
Rotary pumps
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PUMPS
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Gear Pumps
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Gear Pump Internal Cross section - I
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Exploded View of a Gear Pump
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Gear Pump Internal Cross section - II
Axial Sealing
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Radial Sealing
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Internal Gear Pump
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Gerotor Pump
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Lobe Pump
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Screw Pump
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Vane Pump
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Vane Pump
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Vane Pump Cross section
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Axial Piston Pump - Principle
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Axial Piston Pump Swash Plate Type
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Axial Piston Pump Swash Plate Type (Bent Axis)
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Swash Plate Pump/ Motor
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Axial Piston Pump
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Type Axial Piston Pump Wobble Plate
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Axial Piston Pump
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Axial Piston Valve Opening
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Radial Piston Pump
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Pressure Control valves

Regulating Pressure Valves
Pressure Relief valve-Direct Op. Pressure Relief valve-Pilot Op. -External drain -internal drain
Switching Pressure Valves

Sequence valve-Internal signal -External signal Unloading Valve Charge Valve for Accumulator Brake valve Counter Pressure valve
Pressure Regulating valve or Pressure Reducing Valve - Direct

Pressure Regulating valve-Pilot
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Pressure Control Valves
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Pressure Relief Valves
Metering Notch
Dampening plunger
Poppet type
Short stroke rapid response Leak proof Damping plunger avoids fluttering
Spool type
Precision control Control edges with metering notch comes into effect first when valve is opened. Improvement of control quality & stability 46
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Pilot operated Pressure Relief Valve
Pilot Valve
Orifice
Main valve
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Graphical symbols Pilot operated Relief Valve
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Pressure Reducing Valve Direct Operated
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Pressure reducing valve - pilot operated
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Pressure Regulating valve - Circuit
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Sequence Valve
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Sequence Valve Circuits
Internal signal input

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External signal input

The Professional Trainers 53
Sequence valve Circuit 2
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Unloading Valve - Circuits
LD,HP
HD,LP
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Accumulator charge valve
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Application of Brake Valve
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Application of Counter Pressure Valve
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Check Valve
Directed operated
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Pilot operated
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Check Valve Circuit
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Directional Control Valves

The D.C. valves are broadly classified as follows: According to the no. of ports and positions According to the construction According to its overlap According to the nominal size According to the mode of operation
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D.C. Valves General Description
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D.C Valve Zero Position Configurations - I

Symbol Details
All ports blocked
Application
Normally used To stop cylinder in any position No unnecessary load on pump Cylinder can be stayed in any position To facilitate hand movement of a single end piston rod
A & B blocked P is open to T
A & B connected to T P blocked
A connected to B P connected to T A connected to T P & B blocked
To facilitate hand movement of a double ended piston rod. Eg. Cylindrical grinder To avoid cylinder coming down when cylinder mounted in vertically
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D. C. Valve Zero configurations - II

Symbol Details
B connected to T P & A blocked
Application
To avoid cylinder coming down under load when mounted vertically
P & A connected to T B blocked

P & B connected to T A blocked All ports connected to T
Similar to the above situation Pump is not unnecessarily loaded
Avoids pressure surge smooth changeover
A connected to T with built in throttle
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D.C Valves Mfg. of Zero Position
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D.C Valve Manually operated
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4/3 Solenoid Operated D.C Valve
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Solenoid operated D.C. Valve
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D.C. Valve Spool Overlap
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D.C. Valve - Pilot & Solenoid Operated
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D.C. Valves Port sizes

D.C.valves are available in sizes of NG 6, NG10, NG16, NG25, NG32, NG 40, & NG50
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Types of Throttle Valves
Long nose type Construction Details
Aperture type
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Positions of Throttle valves
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Principle of flow control valve
qv2= p
Construction Flow control valve
F1 = p1 x A = p2 x A + Fspr p = FsprA p = constant
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Construction Flow control valve
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Hydraulic circuits - I
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Hydraulic circuits - II
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Hydraulic circuits - III
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Hydraulic circuits - IV
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Hydraulic circuit - V
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Hydraulic circuit - VI
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Temp. compensated flow control valve
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Introduction to Proportional control valves
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Function Of Accumulator
Energy storage for economizing the drive power Emergency power source Compensation for leakage losses Dampening of shocks and vibrations Volume compensation In case of pressure variation Suspension element in vehicles
Types of Accumulators
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Compensation for large flow variation
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Maintaining constant pressure
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Accumulator Pressure Calculations

P1= Gas pre charge pressure P2 =Min. pressure when discharges
P3 = Max. pressure when fully charged
P1= 0.9 P2
P3 = 3P2
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- Most Hydraulic systems sequenced electrically and adjusted manually ( flow rate, pressure etc.) - Controlling different flow rate/pressures may not result in smooth transition - To accelerate/decelerate an actuator- vary the pressure means adding extra valves (complexity of circuit) PROPORTIONAL Valves converts continuously variable electrical input
Advantages: - Electrical and remote controls for continuous and smooth variation of pressure and flow. - A large number of fixed programme pressure and flow control valves can be replaced by a single proportional valve - Acceleration and deceleration of cylinders and motors is to be fully controlled
PROPORTIONAL VALVES - TYPES
Proportional pressure control\ valves
Proportional Flow control valves
Proportional Throttle valves
Proportional Direction control valves
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PROPORTIONAL VALVES - CHARECTERISTICS
Hysteresis
Reversal Error
Response sensitivity
These three values are closely interrelated on electro magnetic signal converter, mechanical friction, the play/clearance in transfer elements
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PROPORTIONAL VALVES - TYPES
Hysteresis will be 3 to 5%
Without position control
Hysteresis will be <1%
With position control

PROPORTIONAL SOLENOID
The solenoids are generally powered either by 12 V or 24 V D.C W=VxI V cannot be altered as the supply voltage is 24V/12V D.C I cannot be altered unless the resistance is altered Secondly, proportional valve solenoid has to drop the power supply voltage down, also full coil current may be several amps to pass through the output transistor. Heat is created in the transistor due to high voltage and calls for large heat sink to dissipate heat. Hence to alter the supply level of energy and thereby control the movement of armature infinitely, without increasing the size of heat sink, pulsated supply of voltage is given with the amplifier. So, PULSE WIDTH MODULATION (PWM)
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PULSE WIDTH MODULATION

The amplifier has an out put transistor which gives out on/off pulses to solenoid coil at constant frequency (typically 1 kHz). The signal level is altered by varying the duration of each on pulse relative to each off pulse and the average out the signal as can be seen from figure shown below.
Also very little heat is generated during on pulses. So the size of heat sink required will be smaller than that required for a conventional signal. Pulse width modulation is therefore becoming standard to all valve amplifiers and reduces size and power wastage
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(a) Without position control
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POSITION SENSOR Non contact LVDT

The LVDT consists of a primary and two secondary coils connected to solenoid push pin. The primary coil fed with high frequency AC supply which creates a varying magnetic field and induces voltages in the two secondary coils by transformer action. The core pin remains stationary if two secondary coils are connected in opposition. As the core is moved away from the centre, the voltage induced in one secondary will increase and that in the other reduce. This produces a net output voltage. The magnitude of which is proportional to the amount of movement and the phase shift indicate the direction of movement. The output can then be fed to a phase sensitive rectifier which will produce a D.C signal Proportional to movement and polarity dependant upon direction
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(b) With Position Control
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ELECTRONIC PROPORTIONAL VALVE AMPLIFIER

The specific features of control valve will be, POWER SUPPLY: Generally power supply will be D.C. voltage
ENABLE/DISABLE:
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Electronic Proportional valve Amplifier
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Adjustments
Zero point
Gain
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INDUSTRIAL HYDRAULICS

RAKESH KUMAR I N A TRAINERS

The Professional Trainers

The Professional Trainers

The Professional Trainers

Solenoid Operated Valve

1 kg/cm2 or 1 bar 2 kg/cm2 or 2 bar

The Professional Trainers

Less than 3000 kgf or 30000 N

More than 3000 kgf or 30000 N

Accurate & consistent 9/11/2013 The Professional Trainers 7

Liquids exert equal pressure in

throughout the container.

The Principle of a Hydraulic Press

The Professional Trainers

The Professional Trainers

Function of Hydraulic system

Cylinder Throttle valve Check Valve

Direction Control Valve Pressure relief Valve

Pump Filter Tank 9/11/2013 The Professional Trainers 13

The Professional Trainers

The Professional Trainers

The Professional Trainers

Return line filter For inline mounting

Return line filter For mounting in tank cover

The Professional Trainers

The Professional Trainers

The Professional Trainers

The Professional Trainers

The Professional Trainers

The Professional Trainers

Gear Pump Internal Cross section - I

The Professional Trainers

Exploded View of a Gear Pump

The Professional Trainers

Gear Pump Internal Cross section - II

Internal Gear Pump

The Professional Trainers

The Professional Trainers

The Professional Trainers

The Professional Trainers

The Professional Trainers

The Professional Trainers

Vane Pump Cross section

The Professional Trainers

Axial Piston Pump - Principle

The Professional Trainers

Axial Piston Pump Swash Plate Type

The Professional Trainers

Axial Piston Pump Swash Plate Type (Bent Axis)

The Professional Trainers

Swash Plate Pump/ Motor

The Professional Trainers

Axial Piston Pump

The Professional Trainers

Type Axial Piston Pump Wobble Plate

The Professional Trainers

Axial Piston Pump

The Professional Trainers

Axial Piston Valve Opening

The Professional Trainers

Radial Piston Pump

The Professional Trainers

The Professional Trainers