G Kumaresan Institute for Energy Studies ANNA UNIVERSITY

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Fluid Power - Definition

Fluid power is the technology that deals with the generation, control, and transmission of power-using pressurized fluids. Fluid power is the use of a confined fluid flowing under pressure to transmit power from one location to another. It is one of three commonly used methods of transmitting power in an industrial setting; the others are electrical and mechanical power transmission.
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Fluid System Classification

Fluid system is divided into two areas: 1. Fluid transport
Fluid transport systems have as their sole objective the delivery of a fluid from one location to another to accomplish some useful purpose.

2. Fluid Power
Fluid power systems are designed specifically to perform work. The work is accomplished by a pressurized fluid bearing directly on an operating fluid cylinder or fluid motor. Fluid power system broadly classified as Hydraulics and Pneumatics.
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Application Area
In general, hydraulic systems are usually preferred for applications that require:

High power / large load capacity, Precise positioning and Smooth movement
Pneumatics is well suited for applications that require:

Low power / light to moderate load capacity Low to moderate precision and Quick response

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Comparison of Hydraulic and Pneumatic system Hydraulic System

Incompressible medium used Used for Heavy loads Very expensive to operate and build Medium is recirculated within the system Hydraulic system provide a very rigid motion

Pneumatic System
Compressible medium used Used for medium loads Less expensive Medium is exhausted into the atmosphere Pneumatic system behave in a springy fashion

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Advantages of Fluid Power

The secret of fluid powers success and widespread use is its versatility and manageability. Fluid power is the muscle of automation because of advantages in the following 4 major categories.

Ease and accuracy of control 2. Multiplication of force 3. Constant force or torque 4. Simplicity, safety, economy
1.
Additional benefits of fluid power systems include instantly reversible motion, automatic protection against overloads and infinitely variable speed control and also highest power-per-weight ratio.
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Hydraulic fluid has 4 primary functions:

i. Power transmission or Energy transfer ii. Lubrication iii. Sealing iv. Cooling

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Basic Principle of Hydraulics

Hydraulics is the science of transmitting force and/or motion through the medium of a confined liquid. In a hydraulic device, power is transmitted by pushing on a confined liquid. The transfer of energy takes place because a quantity of liquid is subject to pressure.

Pascal's Law (also called Pascal's Principle) says that

"changes in pressure at any point in an enclosed fluid at rest are transmitted undiminished to all points in the fluid and act in all directions."

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Hydraulic Jack

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Machine of Multiplying Force

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Friction losses

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Friction losses

cont

Frictional Losses in Laminar Flow Friction Factor f = 64/(Reynolds Number)

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vThe max. recommended velocity for pressure lines is 6.1 m/s in order to prevent turbulent flow and the corresponding losses
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Fast Moving Oil May Become Turbulent

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Slow Moving Oil

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Fluid Power Symbols

long chain thin Enclosure of two or more functions contained in one unit.

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Reading Symbols For Pumps And Motors

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Fluid Power Symbols

Variable displacement pump Fixed displacement pump

Cont..

An arrow through a symbol at approximately 45 degrees indicates that the component can be adjust or varied

Hydraulic Flow direction of Pneumatic

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Reading Symbols For Cylinders

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Physical differences between Liquids and Gases

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Hydraulic mediums used in Industry (i) Mineral oil (ii) Synthetic oil (iii) Water oil emulsion (iv)Glycol in water (v) Chlorinated synthetic fluid (vi)Phosphate ester fluid

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Properties of Fluids

A fluid is defined as any matter that flows when force is applied. Liquids like water or silver are kinds of fluid.

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Forces in fluids
Forces in fluids are more complicated than forces in solids because fluids can change shape.

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Pressure
A force applied to a fluid createspressure. Pressure acts in all directions, not just the direction of the applied force.

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least one of the other two must decrease. For example, if speed goes up, pressure goes down.
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If one variable increases along a streamline,at

Strong intermolecular forces

High viscosity

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Surface tension
Surface tension is the amount of energy required to stretch or increase the surface of a liquid by a unit area.

Strong intermolecular forces

High surface tension

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Cohesion is the intermolecular attraction between like molecules Adhesion is an attraction between unlike molecules

Adhesion

Cohesion

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Hydraulic fluids should have the following properties: Good lubricity:

Stable in viscosity:

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System compatibility:

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Pour point:

Oxidation resistant:

Rust and Corrosion:

The rust will have its effect on all the internal parts of the system. The hydraulic fluid chosen should be a medium having a minimum of this effect. Corrosion happens when acid reacts with the metal. Considering all aspects, a suitable hydraulic oil is chosen

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High Bulk Modulus:

Good Heat Dissipation:

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Adequate low temperature properties:

Flash Point:

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Low foaming tendency:

Fire resistant:

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Low in volatility:

Good Demulsibility:

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Low coefficient of expansion:

Low specific gravity:

Non toxic, Easy to handle and available:

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Conclusion on Properties of hydraulic fluid

Good lubricity 2. Ideal viscosity 3. Chemical and environmental stability 4. Compatibility with system materials 5. High degree of incompressibility 6. Fire resistance 7. Good heat-transfer capability 8. Low density 9. Foam resistance 10. Non toxicity 11. Low volatility 12. Inexpensive and 13. Ready availability
1.

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Components of a Hydraulic Power System

Tank / Reservoir Pump

Gear pump Vane pump Piston pump

Input segment

Electric motor Actuator

Distribution line or Piping system

Valve Directional Control Valve (DCV) Pressure Control Valve (PCV) Flow Control Valve (FCV)

Cylinder (for linear motion) Motor (for rotary motion)

Output segment

Control segment

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Work & Power

Work is done (or energy is transferred) when an object is moved against a force, and is defined as: Work = force (N) x distance moved (m) ; unit Nm=Joule

Power is the rate at which work is performed: Power = work (J)/time (s) ; unit J/s=Watt

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Torque
The term torque is used to define a rotary force, and is simply the product of the force and the effective radius as shown in Figure

T= F (N) x d (m); unit Nm= Joule where, d - distance

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Robert Boyle (1627-1691)

Boyle was born into an

aristocratic Irish family Became interested in medicine and the new science of Galileo and studied chemistry. A founder and an influential fellow of the Royal Society of London Wrote extensively on science, philosophy, and theology.

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Boyles Law - 1662

Gas pressure is inversely proportional to the volume, when temperature is held constant.
Pressure x Volume = a constant Equation: P1V1 = P2V2 (T = constant)

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Graph of Boyles Law

Boyles Law says the pressure is inverse to the volume. Note that when the volume goes up, the pressure goes down
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Charless Law
The volume of a fixed mass of gas is directly proportional to the Kelvin temperature, when pressure is held constant. This extrapolates to zero volume at a temperature of zero Kelvin.

V1 V2 = T1 T2
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( P = constant)

Joseph Louis Gay-Lussac (1778 1850)

French chemist and physicist v Known for his studies on the physical properties of gases. v In 1804 he made balloon ascensions to study magnetic forces and to observe the composition and temperature of the air at different altitudes.
v
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Gay-Lussacs Law - 1802

The pressure and Kelvin temperature of a gas are directly proportional, provided that the volume remains constant.

P P2 1 = T1 T2
How does a pressure cooker affect the time needed to cook food? (Note page 422) Sample Problem 14.3, page 423
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The Combined Gas Law

The combined gas law expresses the relationship between pressure, volume and temperature of a fixed amount of gas.

PV1 P2V2 1 = T1 T2
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 The combined gas law contains all the other gas laws! If the temperature remains constant...

P1 x V1 T1

T2 Boyles Law

P2 x V2

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 The combined gas law contains all the other gas laws! If the pressure remains constant...

P1 x V1 T1

P2 x V2 T2

Charless Law

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The combined gas law contains all the other gas laws! If the volume remains constant...

P1 x V1 T1

P2 x V2 T2

Gay-Lussacs Law

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Hydraulic Pump Classification

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. 1. Pumps that discharge liquid in a continuous flow are nonpositivedisplacement type. 2. Pumps that discharge volumes of liquid separated by periods of no discharge are positive-displacement type.

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Pump

Non Positive displacement

Positive displacement

Centrifugal

Jet pump

Axial type

Gear pump External Gear Internal Gear

Vane pump

Piston pump

Unbalanced

Balanced Bent axis Swash plate

Axial pump

Radial pump Rotary ram

Lobe pump Screw pump

Rotary cylinder

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Nonpositive displacement pump

This type is generally used for low-pressure, high-volume flow applications. Normally their maximum pressure capacity is limited to 250-300 psi.
Pressure (P)

Pmax

Pmin

Q0

Qmax
Flow (Q)

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Gear Pump - External

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Gear Pump
Q

Cont

Qactual

Qtheoretical

vol

QA = 100 QT

Q T (m 3 / min) = VD (m 3 / rev) N(rev / min) 2 VD = Do Di2 L 4

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Gear Pump External (Helical Gear)

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Gear Pump
Advantages:

Cont

Simplicity and compact Low cost Less sensitive to contamination High operating speeds External gear pumps may use spur, herringbone, or helical gear sets to move the fluid. Herringbone pump gives steadier flow than the spur gear pump Helical gears can be designed with a small number of large teeth, thus allowing an increase in capacity without sacrificing smooth flow

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Internal Gear Pump (Off-centered)

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Lobe Pump
Flow at deliver side is not smooth (Pulsation delivery) Volumetric efficiency is higher than gear pumps.

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Screw Pump

Used in submarines Suitable for high pressure applications (up to 3500 psi (241 bar)) Advantage Deliver non pulsating flow Disadvantage Expensive Low in efficiency The rolling action obtained with the thread design of the rotors is responsible for the very quiet pump operation. The symmetrical pressure loading around the power rotor eliminates the need for radial bearings because there are no radial loads

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Gerotor Pump (Centered Internal gear type)

The inner gear has one tooth less than the outer gear, and the volumetric displacement is determined by the space formed by the extra tooth in the outer rotor.
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Gerotor Pump

Cont..

The tooth form of each gear is related to that of the other in such a way that each tooth of the inner gear is always in sliding contact with the surface of the outer gear. Each tooth of the inner gear meshes with the outer gear at just one point during each revolution. In the illustration, this point is at the X.

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Vane Pump
Unbalanced and Fixed displacement type

The rotor, which contains radial slots, is splined to the drive shaft and rotates inside a cam ring. Each slot contains a vane designed to mate with the surface of the cam ring as the rotor turns. Centrifugal force keeps the vanes out against the surface of the cam ring.
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Analysis of Volumetric Displacement

DC diameter of cam ring (m) DR diameter of rotor (m) L - width of rotor (m) N - rotor speed (rpm) e - eccentricity (m) emax - max. possible eccentricity (m) VDmax - max. possible volumetric displacement (m 3 / rev)

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Cont..

Some vane pumps have provisions for mechanically varying the eccentricity. Such a design is called a variable displacement pump

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Vane Pump Unbalanced type

Variable displacement, pressure-compensated vane pump

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Vane Pump Fixed displacement, balanced type

Complete hydraulic balance is achieved Low cost with respect to power output Less noisy Long service life It delivers pressure up to 170 kg/cm2
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Piston Pump- bent axis type

A piston pump works on the principle that a reciprocating piston can draw in fluid when it retracts in a cylinder bore and discharge it when it extends. The pistons are forced in and out of their bores as the distance between the drive shaft flange and cylinder block changes
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cont

S tan() = S = Dtan( ) D VD = YAS Q T = VD N = NYAD tan( )

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Piston Pump Swash plate type

qAs the cylinder rotates, the pistons reciprocate because the piston shoes follow the angled surface of the swash plate qThe inlet and outlet ports are located in the valve plate so that the pistons pass the inlet as they are being pulled out and pass the outlet as they are being forced back in.

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Radial Piston pump

The pistons remain in constant contact with the reaction ring due to centrifugal force and back pressure on the pistons. As the cylinder barrel rotates, the pistons on one side travel outward Suction When a piston passes the point of max.`e, its forced inward by the reaction ring - Delivery
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Cont

Piston pump with stationary cam and rotating block

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Comparison of hydraulic pump types

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Combination pumps
For a clamping cylinder, a large flow, but low pressure, is needed during extension and retraction, but zero flow and high pressure are needed during clamping

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Pump performance
The performance of a pump is mainly a function of the precision of its manufacture. Components must be made to close tolerances. (i) Volumetric efficiency

Gear pump 80 to 90 % Vane pump 82 to 92 % Piston pump 90 to 98 % (ii) Mechanical efficiency (90 to 95 %)

P delivery pressure (Pa) ; QT Theoretical flow rate (m3/s) TA Actual input torque (N-m) ; N Pump speed (rps)

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TT m = 100 TA

Cont

(i) Overall efficiency

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Understanding Atmospheric Pressure

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