HYDRAULICS AND PNEUMATICS

INTRODUCTION, APPLICATION AND SCOPE

by
Varun Pratap Singh
 LEARNING OBJECTIVES
• Explain the meaning of fluid power.
• List the various applications of fluid power.
• Differentiate between fluid power and transport systems.
• List the advantages and disadvantages of fluid power.
• Explain the industrial applications of fluid power.
• List the basic components of the fluid power.
• List the basic components of the pneumatic systems.
• Differentiate between electrical, pneumatic and fluid power
systems.
• Appreciate the future of fluid power in India.
 INTRODUCTION
• In the industry we use three methods for transmitting
power from one point to another.
• Mechanical transmission is through shafts, gears, chains,
belts, etc.
• Electrical transmission is through wires, transformers, etc.
• Fluid power is through liquids or gas in a confined
space.
• In this PPT, we shall discuss a structure of hydraulic
systems and pneumatic systems.
 HYDRAULIC FLUID
TRANSMISSION
• Let : F = Force (N)
• P = Pressure (N/m2)
• A = Area (m2)
HYDRAULIC FLUID COMPENSATION

• Let : S = Displacement(m)
• A = Area (m2)
HYDRAULIC SYSTEM
A TYPICAL HYDRAULIC SYSTEM

1 – pump
2 – oil tank
3 – flow control valve
4 – pressure relief valve
5 – hydraulic cylinder
6 – directional control valve
7 – throttle valve
 STRUCTURE OF A HYDROSTATIC DRIVE

Control
Aggregate Actuator
elements

Pump, motor Valves, determining Elements doing work

Fluid reservoir the path, pressure, • Linear
Pressure relief valve flow rate of the • Rotational
working fluid
Filter • Swinging
Piping

These components and their interaction is the subject of this

semester
 Fluid Power and Its Scope
• Fluid power is the technology that deals with the generation, control
and transmission of forces and movement of mechanical element or
system with the use of pressurized fluids in a confined system. Both
liquids and gases are considered fluids. Fluid power system includes
a hydraulic system (hydra meaning water in Greek) and a pneumatic
system (pneuma meaning air in Greek). Oil hydraulic employs
pressurized liquid petroleum oils and synthetic oils, and pneumatic
employs compressed air that is released to the atmosphere after
performing the work.
• the term “fluid” we refer to air or oil, for it has been
shown that water has certain drawbacks in the transmission of
hydraulic power in machine operation and control.
• The application of fluid power is limited only by the ingenuity of the
• designer, production engineer or plant engineer. If the application
pertains to lifting, pushing, pulling, clamping, tilting, forcing,
pressing or any other straight line (and many rotary)
• motions, it is possible that fluid power will meet the requirement.
 Fluid power applications
• Stationary hydraulics (remain firmly fixed
in one position.)
• Machine tools and transfer lines.
• Lifting and conveying devices.
• Metal-forming presses.
• Plastic machinery such as injection-molding machines.
• Rolling machines.
• Lifts.
• Food processing machinery.
• Automatic handling equipment and robots.
 Fluid power applications Cont.
• Mobile hydraulics (move on wheels or
tracks )
• Automobiles, tractors, aeroplanes, missile, boats, etc.
• Construction machinery.
• Tippers, excavators and elevating platforms.
• Lifting and conveying devices.
• Agricultural machinery.
Industries base Application
Industries base Application
Industries base Application
 CLASSIFICATION OF FLUID
POWER SYSTEMS
1. Based on the control system
a) Open-loop system: no feedback
b) Closed-loop system: uses feedback
2. Based on the type of control (AND, NAND, OR, NOR)
a) Moving part logic (MPL)-
diaphragms, disks and poppets
Fluidics:- no moving parts and depend solely on interacting fluid jets
b) Electrical control (controlled by electrical devices.)
programmable logic control (PLC) or microprocessor
 POWER TRAIN
Prime mover
AC Motor Machine
Mi, ωi Power M0, ω0
DC Motor (linear or
transmission
Diesel Engine system rotational
F0, v0
Otto Engine
motion)

• Mechanical power transmission:

– Gears
– Belt drive
– Friction drive Properties:
– Rigid couplings
– Clutches • Continuously variable drive is difficult
• The relative spatial position of prime mover is fixed
• If the motor is electrical (DC motor or AC motor with
variable frequency), then the rotational speed can be
continuously changed but they are expensive
 HYDROSTATIC & HYDRODYNAMIC
SYSTEMS
• A hydrostatic system uses fluid pressure to transmit power. Hydrostatics
deals with the mechanics of still fluids and uses the theory of equilibrium
conditions in fluid. The system creates high pressure, and through a
transmission line and a control element, this pressure drives an actuator
(linear or rotational). The pump used in hydrostatic systems is a positive
displacement pump. The relative spatial position of this pump is arbitrary but
should not be very large due to losses (must be less than 50 m). An
example of pure hydrostatics is the transfer of force in hydraulics.
• Hydrodynamic systems use fluid motion to transmit power. Power is
transmitted by the kinetic energy of the fluid. Hydrodynamics deals with the
mechanics of moving fluid and uses flow theory. The pump used in
hydrodynamic systems is a non-positive displacement pump. The relative
spatial position of the prime mover (e.g., turbine) is fixed. An example of
pure hydrodynamics is the conversion of flow energy in turbines in hydroelectric
power plants.
HYDRAULIC POWER TRANSMISSION
• Hydraulic power transmission:
Hydro = water, aulos = pipe
The means of power transmission is a liquid (pneumatic  gas)
Hydrostatic power transmission:
• Positive displacement pump
Hydrodynamic power transmission:
• Creates high pressure and
• Turbo pump and turbine
through a transmission line and
• Power transmission by kinetic control elements this pressure
energy of the fluid drives an actuator (linear or
rotational)
• Still the relative spatial position
is fixed •
The relative spatial position is
arbitrary but should not be very
• Compact units
large because of losses (< 50 m)
 A continuously variable transmission is possible
Most of this lecture will be about hydrostatic systems (in common language it is
also called simply hydraulics)
 HYDROSTATIC VS HYDRODYNAMIC SYSTEMS

 kg  Power density Hydrostat.

Roughly speaking:  kW 
P = Dp·Q
Large Q, small Dp 
hydrodynamic transmission
Large Dp, small Q 
hydrostatic transmission. Hydrodyn.
But there is no general rule, P [kW]
depends on the task. 100 200 300 400

o Generally larger than 300 kW power hydrodynamic is more favourable.

o But for soft operation (starting of large masses) hydrodynamic is used for
smaller powers either.
 Linear movement against large forces: hydrostatic
 Linear movement and stopping in exact position: also hydrostatic
 ADVANTAGES
FLUID POWER SYSTEM
1. Fluid power systems are simple, easy to operate and
can be controlled accurately
2. Multiplication and variation of forces
3. Multifunction control:
4. Low-speed torque
5. Constant force or torque
6. Economical
7. Low weight to power ratio
8. Fluid power systems can be used where safety is of
vital importance
 ADVANTAGES OF HYDROSTATIC DRIVES

 Simple method to create linear movements

 Creation of large forces and torques, high energy density
 Continuously variable movement of the actuator
 Simple turnaround of the direction of the movement, starting
possible under full load from rest
 Low delay, small time constant because of low inertia
 Simple overload protection (no damage in case of overload)
 Simple monitoring of load by measuring pressure
 Arbitrary positioning of prime mover and actuator
 Large power density (relatively small mass for a given power
compared to electrical and mechanical drives)
 Robust (insensitive against environmental influences)
 DISADVANTAGES OF HYDROSTATIC
DRIVES
 Working fluid is necessary (leakage problems, filtering, etc.)
 It is not economic for large distances
 Basic Components of a Hydraulic
System
• Hydraulic systems are power-transmitting assemblies employing pressurized
liquid as a fluid for transmitting energy from an energy-generating
source to an energy-using point to accomplish useful work. Figure 1.1
shows a simple circuit of a hydraulic system with basic components.
 HYDRAULIC FLUIDS - TASKS
Primary tasks:
o Power transmission (pressure and motion
transmission)
o Signal transmission for control
Secondary tasks:
o Lubrication of rotating and translating components
to avoid friction and wear
o Heat transport, away from the location of heat
generation, usually into the reservoir
o Transport of particles to the filter
o Protection of surfaces from chemical attack,
especially corrosion
 HYDRAULIC FLUIDS - REQUIREMENTS
 Functional
o Good lubrication characteristics
o Viscosity should not depend strongly on
temperature and pressure
o Good heat conductivity
o Low heat expansion coefficient
o Large elasticity modulus
 Economic
o Low price
o Slow aging and thermal and chemical stability 
long life cycle
 HYDRAULIC FLUIDS -
REQUIREMENTS (CONTD.)
 Safety
o High flash point or in certain cases not
inflammable at all
o Chemically neutral (not aggressive at all
against all materials it touches)
o Low air dissolving capability, not inclined to
foam formation

 Environmental friendliness
o No environmental harm
o No toxic effect
HYDRAULIC FLUID TYPES

1. Water (3%)
2. Mineral oils (75%)
3. Not inflammable fluids (9%)
4. Biologically degradable fluids
(13%)
5. Electro rheological fluids (in
development)
 HYDRAULIC FLUID TYPES (CONTD.)
1. Water:
- Clear water
- Water with additives

o Oldest fluid but nowadays there is a renaissance

o Used where there is an explosion or fire danger or hygienic problem:
Food and pharmaceutical industry, textile industry, mining

Advantages:
 No environmental pollution
 No disposal effort
 Cheap
 No fire or explosion danger
 Available everywhere
 4 times larger heat conduction coefficient than mineral oils
 2 times higher compression module than mineral oils
 Viscosity does not depend strongly on temperature
 HYDRAULIC FLUID TYPES (CONTD.)
1. Water:
• Disadvantages:
 Bad lubrication characteristics
 Low viscosity (problem of sealing, but has good sides: low
energy losses)
 Corrosion danger
 Cavitation danger (relatively high vapour pressure)
 Limited temperature interval of applicability (freezing,
evaporating)

Consequences: needs low tolerances and very good materials (plastics,

ceramics, stainless steel)  components are expensive
 HYDRAULIC FLUID TYPES (CONTD.)
2. Mineral oil:
- Without additives
- With additives
o „Conventional” use, stationary hydraulics
o Always mixtures of different oils, often with additives
Additives:
- decrease corrosion
- increase life duration
- improve temperature dependence of viscosity
- improve particle transport

Advantages: Disadvantages:
 Good lubrication  Inflammable
 High viscosity (good for sealing,  Environmental pollution
bad for losses)
 Cheap
 HYDRAULIC FLUID TYPES (CONTD.)
3. Not inflammable fluids:
• - Contains water
– - Does not contain water
o mines, airplane production, casting, rolling, where there
is explosion and fire danger
o Water-oil emulsions (oil synthetic) or water-free synthetic
liquids

Disadvantages:
 Higher density, higher losses, more inclination to cavitation
 Limited operational temperature < 55 °C
 Worse lubrication characteristics, reduction of maximum load
 Worse de-aeration characteristics
 Sometimes chemically aggressive against sealing materials
 HYDRAULIC FLUID TYPES (CONTD.)

4. Biologically degradable fluids:

- Natural
- Synthetic
o Environmental protection, water protection
o Agricultural machines
o Mobile hydraulics
- Characteristics similar to mineral oils but much more
expensive.
- If the trend continues its usage expands, price will drop.
 BASIC COMPONENTS OF A PNEUMATIC
SYSTEM
• A pneumatic system carries power by employing compressed gas,
generally air, as a fluid for transmitting energy from an energy-
generating source to an energy-using point to accomplish useful
work. Figure 1.3 shows a simple circuit of a pneumatic system with
basic components.
• Air is drawn from the atmosphere through an air filter and raised to
required pressure by an air compressor. As the pressure rises, the
temperature also rises; hence, an air cooler is provided to cool
the air with some preliminary treatment to remove the moisture. The
treated pressurized air then needs to get stored to maintain the pressure.
With the storage reservoir, a pressure switch is fitted to start and stop
the electric motor when pressure falls and reaches the required level,
respectively.
 COMPARISON
HYDRAULIC & PNEUMATIC SYSTEMS
S. No. Hydraulic System Pneumatic System

1. It employs a pressurized liquid It employs a compressed gas, usually

as a fluid air, as a fluid
2. An oil hydraulic system operates at A pneumatic system usually operates
pressures up to 700 bar at 5–10 bar

3. Generally designed as closed system Usually designed as open system

4. The system slows down when leakage Leakage does not affect the system
occurs much

5. Valve operations are difficult Valve operations are easy

6. Heavier in weight Lighter in weight

7. Pumps are used to provide Compressors are used to provide

pressurized liquids compressed gases

8. Automatic lubrication is provided Special arrangements for lubrication

are needed
 COMPARISON OF DIFFERENT POWER
SYSTEMS
Property Mechanical Electrical Pneumatic Hydraulic
Input energy I C engines I C engines I C engines I C engines
source Electric motor Water/gas turbines Pressure tank Electric motor
Air turbine
Energy transfer Levers, gears, Electrical cables Pipes and hoses Pipes and hoses
element shafts and magnetic
field
Energy carrier Rigid and Flow of Air Hydraulic
elastic electrons liquids
objects
Power-to-weight Poor Fair Best Best
ratio
Torque/inertia Poor Fair Good Best
Stiffness Good Poor Fair Best
Response speed Fair Best Fair Good
Relative cost Best Best Good Fair
Control Fair Best Good Good
Motion type Mainly rotary Mainly rotary Linear or rotary Linear or rotary
 COMPARISION
PNEUMATIC &ELECTRIC SYSTEM
 Future of Fluid Power Industry in India
• The automation market in India is estimated to be 1/10ththat of China. If India has to become
one of the leading economies in the world, based on manufacturing, it will have to attain higher
technological standards and higher level of automation in manufacturing.
• In the past 30 years, fluid power technology rose as an important industry. With increasing emphasis
on automation, quality control, safety and more efficient and green energy systems, fluid power
technology should continue to expand in India.
• Fluid power industry is gaining a lot of importance in Indian industry. According to a recent survey, it
has shown a growth of 20% over the last 10 years and the size of market is estimated to be
close to 5000 crores per annum. This makes it a sizable industry segment in India. The growth rate
of this industry in India is typically about twice the growth of economy.
• The reasons for this are three-fold:
• 1. As the economy grows, this industry grows.
• 2. There is a lot of automation and conversion into more sophisticated manufacturing methods which
increases the rate.
• 3. One of the interesting things happening in this industry is that India i s becoming an attractive
destination for manufacturing and outsourcing of some of the products.
• So these three aspects together create a situation where the growth of this industry is twi ce the
growth of GDP in India.

• The fluid power sector in India consists of many sophisticated Indian industries and
partnership with number of global fluid power technology leaders that include Festo, Rexroth,
Vickers, Eaton, Parker Hannifin, Norgen, , Saucer Donfos, Yuken, Siemens, Shamban, Pall and
Gates, , Rotex, , Janatics, Maxwell, Wipro Dynamatic Technologies and many more.
Future of Fluid Power Industry in India
• One of the major segments for hydraulic industry in India is mobile
hydraulics. Because of massive programs on road construction, there is a major
expansion of construction machinery industry as well. In addition to this, a
trend toward the usage of more sophisticated hydraulics in tractors and farm
equipment is witnessed. The manufacturing industry in India is working toward
higher automation and quality of output. As Indian industry moves toward
modernization to meet the productivity and to compete in the global market,
an excellent potential for the pneumatic industry is expected in India Another area
of interest for fluid power industry would be the opportunities in defence
equipment. Defence is a major market segment in Indian fluid power industry
and contributes to over 40% of the market demand. There is also a move
toward products with miniature pneumatics, process valves, servo drives,
hydraulic power steering with new controls and sophisticated PLC,
microprocessor controls.
• However, the key input required for the effective utilization of fluid power is
education and training of users. So there is a big need for education and
training in design application and maintenance of fluid power systems. Rexroth
recently opened many competence centres in India to train the manpower and
to create awareness about the use of fluid power in Indian industry.