Lecture 1

INTRODUCTION TO HYDRAULICS AND PNEUMATICS

Learning Objectives

Upon completion of this chapter, the student should be able to:

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.

1.1 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 chapter, we shall discuss a structure of hydraulic systems and pneumatic systems. We
will also discuss the advantages and disadvantages and compare hydraulic, pneumatic,
electrical and mechanical systems.

1.2 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.
 Perhaps it would be in order that we clarify our thinking on one point. By 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. Commercially, pure water
contains various chemicals (some deliberately included) and also foreign matter, and unless
special precautions are taken when it is used, it is nearly impossible to maintain valves and
working surfaces in satisfactory condition. In the cases where the hydraulic system is closed
(i.e., the one with a self-contained unit that serves one machine or one small group of
machines), oil is commonly used, thus providing, in addition to power transmission, benefits of
lubrication not afforded by water as well as increased life and efficiency of packings and
valves. It should be mentioned that in some special cases, soluble oil diluted with water is
used for safety reasons. 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 can be classified into two major segments:

Stationary hydraulics: Stationary hydraulic systems remain firmly fixed in one position.
The characteristic feature of stationary hydraulics is that valves are mainly solenoid operated.
The applications of stationary hydraulics are as follows:

Production and assembly of vehicles of all types.

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.

Mobile hydraulics: Mobile hydraulic systems move on wheels or tracks such as a tower crane or
excavator truck to operate in many different locations or while moving. A characteristic feature of
mobile hydraulics is that the valves are frequently manually operated. The applications of
mobile hydraulics are as follows:
 Automobiles, tractors, aeroplanes, missile, boats, etc.
Construction machinery.
Tippers, excavators and elevating platforms.
Lifting and conveying devices.
Agricultural machinery.

Hydraulics and pneumatics have almost unlimited application in the production of goods and
services in nearly all sectors of the country. Several industries are dependent on the
capabilities that fluid power affords. Table 1.1 summarizes few applications of fluid power.

Table 1.1 More applications of fluid power

Agriculture Tractors; farm equipment such as mowers, ploughs,

chemical and water sprayers, fertilizer spreaders, harvesters

Automation Automated transfer lines, robotics

Automobiles Power steering, power brakes, suspension systems,

hydrostatic transmission

Aviation Fluid power equipment such as landing wheels in aircraft.

Helicopters, aircraft trolleys, aircraft test beds, luggage
loading and unloading systems, ailerons, aircraft servicing,
flight simulators

Construction For metering and mixing of concrete rudders, excavators,

industry/equipment lifts, bucket loaders, crawlers, post-hole diggers, road
graders, road cleaners, road maintenance vehicles, tippers
Defense Missile-launching systems, navigation controls
Entertainment Amusement park entertainment rides such as roller coasters

Fabrication industry Hand tools such as pneumatic drills, grinders, borers,

riveting machines, nut runners
Food and beverage All types of food processing equipment, wrapping, bottling,
Foundry Full and semi-automatic molding machines, tilting of
furnaces, die-casting machines
Glass industry Vacuum suction cups for handling
Hazardous gaseous areas Hydraulic fracturing technologies: It involves pumping
large volumes of water and sand into a well at high pressure
to fracture shale and other tight formations, allowing
hazardous oil and gas to flow into the well. However,
hydraulic fracturing has serious environmental and water
pollution related issues.

Instrumentation Used to create/operate complex instruments in space

rockets, gas turbines, nuclear power plants, industrial labs
Jigs and fixtures Work holding devices, clamps, stoppers, indexers

Machine tools Automated machine tools, numerically controlled(NC)

machine tools
Materials handling Jacks, hoists, cranes, forklifts, conveyor systems

Medical Medical equipment such as breathing assistors, heart assist

devices, cardiac compression machines, dental drives and
human patient simulator
Movies Special-effect equipment use fluid power; movies such as
Jurassic park, Jaws, Anaconda, Titanic
Mining Rock drills, excavating equipment, ore conveyors, loaders

Newspapers and periodicals Edge trimming, stapling, pressing, bundle wrapping

Oil industry Off-shore oil rigs

Paper and packaging Process control systems, special-purpose machines for
rolling and packing
Pharmaceuticals Process control systems such as bottle filling, tablet
placement, packaging
Plastic industry Automatic injection molding machines, raw material
feeding, jaw closing, movement of slides of blow molder
Press tools Heavy duty presses for bulk metal formation such as sheet
metal, forging, bending, punching, etc.
Printing industry For paper feeding, packaging

Robots Fluid power operated robots, pneumatic systems

Ships Stabilizing systems, unloading and loading unit, gyroscopic

instruments, movement of flat forms, lifters, subsea
inspection equipment
Textiles Web tensioning devices, trolleys, process controllers

Transportation Hydraulic elevators, winches, overhead trams

Under sea Submarines, under sea research vehicles, marine drives and
control of ships
Wood working Tree shearers, handling huge logs, feeding clamping and
saw operations

The following are the two types of hydraulic systems:

1. Fluid transport systems: Their sole objective is the delivery of a fluid from one
location to another to accomplish some useful purpose. Examples include pumping
stations for pumping water to homes, cross-country gas lines, etc.
2. Fluid power systems: These are designed to perform work. In fluid power systems,
work is obtained by pressurized fluid acting directly on a fluid cylinder or a fluid
motor. A cylinder produces a force resulting in linear motion, whereas a fluid motor
produces a torque resulting in rotary motion.

1.3 Classification of Fluid Power Systems

The fluid power system can be categorized as follows:
1. Based on the control system

Open-loop system: There is no feedback in the open system and performance is

based on the characteristics of the individual components of the system. The open-
 loop system is not accurate and error can be reduced by proper calibration and
control.
Closed-loop system: This system uses feedback. The output of the system is fed back
to a comparator by a measuring element. The comparator compares the actual output to
the desired output and gives an error signal to the control element. The error is used
to change the actual output and bring it closer to the desired value. A simple closed-
loop system uses servo valves and an advanced system uses digital electronics.
2. Based on the type of control

Fluid logic control: This type of system is controlled by hydraulic oil or air. The
system employs fluid logic devices such as AND, NAND, OR, NOR, etc. Two types
of fluid logic systems are available:
(a) Moving part logic (MPL): These devices are miniature fluid elements using
moving parts such as diaphragms, disks and poppets to implement various logic
gates.
(b) Fluidics: Fluid devices contain no moving parts and depend solely on interacting
fluid jets to implement various logic gates.
Electrical control: This type of system is controlled by electrical devices. Four basic
electrical devices are used for controlling the fluid power systems: switches, relays,
timers and solenoids. These devices help to control the starting, stopping, sequencing,
speed, positioning, timing and reversing of actuating cylinders and fluid motors.
Electrical control and fluid power work well together where remote control is
essential.
Electronic control: This type of system is controlled by microelectronic devices. The
electronic brain is used to control the fluid power muscles for doing work. This
system uses the most advanced type of electronic hardware including programmable
logic control (PLC) or microprocessor ( P). In the electrical control, a change in
system operation results in a cumbersome process of redoing hardware connections.
The difficulty is overcome by programmable electronic control. The program can be
modified or a new program can be fed to meet the change of operations. A number of
such programs can be stored in these devices, which makes the systems more flexible.
1.4 Hydrostatic and 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.

In oil hydraulics, we deal mostly with the fluid working in a confined system, that is, a
hydrostatic system.
1.5 History of Fluid Power

Fluid power is as old as our civilization itself. Water was used for centuries to produce
power by means of water wheels and air was used to turn windmills and to propel ships.
Chinese used wooden valves to control water flow through bamboo pipes in 4000 BC.
Ancient Egyptians have built a masonry dam across Nile, 14 miles south to present Cairo, for
the control of irrigation water by canals, sluices, brick conduits and ceramic pipes. During the
Roman empire, extensive water systems using aqueducts, reservoirs and valves were
constructed to carry water to cities. However, these early uses of fluid power required the
movement of huge quantities of fluid because of the relatively low pressures provided by
nature.

Fluid power technology actually began in 1650 with the discovery of Pascal’s law. Simply
stated, this law says that pressure in a fluid at rest is transmitted undiminished equally in all
directions in a confined body of fluid. Pascal found that when he rammed a cork down into a
jug completely full of wine, the bottom of the jug broke and fell out. However, in order for
Pascal’s law to be made effective for practical use, it was necessary to make a piston that
would fit exactly. Not until over 100 years later was this accomplished. It was in 1795 that
Joseph Brahmah invented the cup packing that led to the development of a workable
hydraulic press. Brahmah’s hydraulic press consisted of a plunger pump piped to a large
cylinder and a ram. This new hydraulic press found wide use in England because it provided a
more effective and economical means of applying large force to industrial applications.

In 1750, Bernoulli developed his law of conservation of energy for a fluid flowing in a
pipeline. Both Pascal’s and Bernoulli’s laws operate at the heart of all fluid power
applications and are used for analytical purposes. However, it was not until the Industrial
Revolution of 1850 in Great Britain that these laws were actually applied to the industry.

The first use of a large hydraulic press for foregoing work was made in 1860 by Whitworth.
In the next 20 years, many attempts were made to reduce the waste and excessive
maintenance costs of the original type of accumulator. In 1872, Rigg patented a three-cylinder
hydraulic engine in which provision was made to change the stroke of plungers to vary its
displacement without a throttle valve. In 1873, the Brotherhood three-cylinder, constant-
stroke hydraulic engine was patented and was widely used for cranes, winches, etc. Both the
above-mentioned engines were driven by fluid from an accumulator.

Up to this time, electrical energy was not developed to power the machines of industry.
Instead, fluid power was being used to drive hydraulic equipment such as cranes, presses,
shearing machines, etc. With electricity emerging dominantly in the 19th century, it was soon
found superior to fluid power for transmitting power over great distances.

The modern era in fluid power began around the turn of the century. Fluid applications were
made to such installations as the main armament system of USS Virginia in 1906. In these
applications, a variable-speed hydrostatic transmission was installed to drive the main guns.
Since that time, marine industry has applied fluid power to cargo-handling systems,
controllable pitch controllers, submarine control system, aircraft elevators, aircraft- and
missile-launching system and radar/sonar-driven systems. In 1926, the United States
developed the first unitized, packaged hydraulic system consisting of a pump, controls and an
actuator.

Today fluid power is used extensively in practically every branch of industry. The
innovative use of modern technology such as electrohydraulic closed loops, microprocessors
and improved materials for component construction continues to advance the performance of
fluid power systems. The military requirements kept fluid power applications and
developments going at a good pace. Aviation and aerospace industry provided the impetus for
many advances in fluid power technology.
 1.6 Advantages of a Fluid Power System

Oil hydraulics stands out as the prime moving force in machinery and equipment designed to
handle medium to heavy loads. In the early stages of industrial development, mechanical
linkages were used along with prime movers such as electrical motors and engines for
handling loads. But the mechanical efficiency of linkages was very low and the linkages often
failed under critical loading conditions. With the advent of fluid power technology and
associated electronics and control, it is used in every industry now.

The advantages of a fluid power system are as follows:

1. Fluid power systems are simple, easy to operate and can be controlled accurately:
Fluid power gives flexibility to equipment without requiring a complex mechanism.
Using fluid power, we can start, stop, accelerate, decelerate, reverse or position large
forces/components with great accuracy using simple levers and push buttons. For
example, in Earth-moving equipment, bucket carrying load can be raised or lowered by
an operator using a lever. The landing gear of an aircraft can be retrieved to home
position by the push button.

2. Multiplication and variation of forces: Linear or rotary force can be multiplied by a

fraction of a kilogram to several hundreds of tons.
3. Multifunction control: A single hydraulic pump or air compressor can provide power
and control for numerous machines using valve manifolds and distribution systems. The
fluid power controls can be placed at a central station so that the operator has, at all times, a
complete control of the entire production line, whether it be a multiple operation
machine or a group of machines. Such a setup is more or less standard in the steel mill
industry.
4. Low-speed torque: Unlike electric motors, air or hydraulic motors can produce a large
amount of torque while operating at low speeds. Some hydraulic and pneumatic motors
can even maintain torque at a very slow speed without overheating.
5. Constant force or torque: Fluid power systems can deliver constant torque or force
regardless of speed changes.

6. Economical: Not only reduction in required manpower but also the production or
elimination of operator fatigue, as a production factor, is an important element in the use
of fluid power.
7. Low weight to power ratio: The hydraulic system has a low weight to power ratio
compared to electromechanical systems. Fluid power systems are compact.
8. Fluid power systems can be used where safety is of vital importance: Safety is of
vital importance in air and space travel, in the production and operation of motor vehicles, in
mining and manufacture of delicate products. For example, hydraulic systems are
responsible for the safety of takeoff, landing and flight of aeroplanes and space craft.
Rapid advances in mining and tunneling are the results of the application of modern
hydraulic and pneumatic systems.

1.7 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.

Load
Motor 1 – Off 2 – Forward 3– Return

1
3 2
Pressure
Filter regulator

Pump

Direction
control
valve
Actuator
Oil tank

Figure 1.1 Components of a hydraulic system

Functions of the components shown in Fig. 1.1 are as follows:

1. The hydraulic actuator is a device used to convert the fluid power into mechanical
power to do useful work. The actuator may be of the linear type (e.g., hydraulic
cylinder) or rotary type(e.g., hydraulic motor) to provide linear or rotary motion,
respectively.
2. The hydraulic pump is used to force the fluid from the reservoir to rest of the
hydraulic circuit by converting mechanical energy into hydraulic energy.
3. Valves are used to control the direction, pressure and flow rate of a fluid flowing
through the circuit.
 4. External power supply (motor) is required to drive the pump.
5. Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.
6. Piping system carries the hydraulic oil from one place to another.
7. Filters are used to remove any foreign particles so as keep the fluid system clean and
efficient, as well as avoid damage to the actuator and valves.
8. Pressure regulator regulates (i.e., maintains) the required level of pressure in the
hydraulic fluid.

The piping shown in Fig. 1.1 is of closed-loop type with fluid transferred from the storage
tank to one side of the piston and returned back from the other side of the piston to the tank.
Fluid is drawn from the tank by a pump that produces fluid flow at the required level of
pressure. If the fluid pressure exceeds the required level, then the excess fluid returns back to
the reservoir and remains there until the pressure acquires the required level.

Cylinder movement is controlled by a three-position change over a control valve.

1. When the piston of the valve is changed to upper position, the pipe pressure line is
connected to port A and thus the load is raised.

2. When the position of the valve is changed to lower position, the pipe pressure line is
connected to port B and thus the load is lowered.

3. When the valve is at center position, it locks the fluid into the cylinder(thereby holding it in
position) and dead-ends the fluid line (causing all the pump output fluid to return to tank via
the pressure relief).

In industry, a machine designer conveys the design of hydraulic systems using a circuit
diagram. Figure 1.2 shows the components of the hydraulic system using symbols. The
working fluid, which is the hydraulic oil, is stored in a reservoir. When the electric motor is
switched ON, it runs a positive displacement pump that draws hydraulic oil through a filter
and delivers at high pressure. The pressurized oil passes through the regulating valve and does
work on actuator. Oil from the other end of the actuator goes back to the tank via return
line. To and fro motion of the cylinder is controlled using directional control valve.
 Cylinder
Extended

Retract

Motor Directional control valve

Pump

Pressure regulator
Filter

Breather

Reservoir

Figure 1.2 Components of a hydraulic system (shown using symbols).

The hydraulic system discussed above can be broken down into four main divisions that are
analogous to the four main divisions in an electrical system.

1. The power device parallels the electrical generating station.

2. The control valves parallel the switches, resistors, timers, pressure switches, relays, etc.

3. The lines in which the fluid power flows parallel the electrical lines.

4. The fluid power motor (whether it is a rotating or a non rotating cylinder or a fluid power
motor) parallels the solenoids and electrical motors.

1.8 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.
 Power Opens when set
supply pressure is reached
Load

Pressure 1 – Off 2 – Forward 3- Return

switch 1
Motor 3 2
Storage
Air cooler reservoir
Air filter

Air compressor

Direction
control
Air from
valve
atmosphere
Air actuator
Air to atmosphere

Figure 1.3 Components of a pneumatic system.

The functions of various components shown in Fig. 1.3 are as follows:

1. The pneumatic actuator converts the fluid power into mechanical power to perform
useful work.
2. The compressor is used to compress the fresh air drawn from the atmosphere.
3. The storage reservoir is used to store a given volume of compressed air.
4. The valves are used to control the direction, flow rate and pressure of compressed air.
5. External power supply (motor) is used to drive the compressor.
6. The piping system carries the pressurized air from one location to another.

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.

The three-position change over the valve delivering air to the cylinder operates in a way
similar to its hydraulic circuit.
1.9 Comparison between Hydraulic and Pneumatic Systems
Usually hydraulic and pneumatic systems and equipment do not compete. They are so dissimilar
that there are few problems in selecting any of them that cannot be readily resolved.
Certainly, availability is one of the important factors of selection but this may be outweighed
by other factors. In numerous instances, for example, air is preferred to meet certain
unalterable conditions, that is, in“hot spots” where there is an open furnace or other potential
ignition hazard or in operations where motion is required at extremely high speeds. It is often
found more efficient to use a combined circuit in which oil is used in one part and air in
another on the same machine or process. Table 1.2 shows a brief comparison of hydraulic and
pneumatic systems.

Table 1.2 Comparison between a hydraulic and a pneumatic system</table>

S. No. Hydraulic System Pneumatic System

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

1. air, as a fluid
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

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

5. Valve operations are difficult Valve operations are easy

6. Heavier in weight Lighter in weight

Pumps are used to provide Compressors are used to provide

7. compressed gases
pressurized liquids

8. The system is unsafe to fire hazards The system is free from fire hazards

Automatic lubrication is provided Special arrangements for lubrication

9.
are needed
 1.10 Comparison of Different Power Systems

There are three basic methods of transmitting power: electrical, mechanical and fluid
power. Most applications actually use a combination of the three methods to obtain the most
efficient overall system. To properly determine which method to use, it is important to
know the salient features of each type. For example, fluid systems can transmit power
more economically over greater distances than mechanical types. However, fluid
systems are restricted to shorter distances compared to electrical systems. Table 1.3
lists the salient features of each type.

Table 1.3 Comparison of different power systems</table>

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 elastic Flow of Air Hydraulic
objects electrons liquids
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
Dirt sensitivity Best Best Fair Fair
Relative cost Best Best Good Fair

Control Fair Best Good Good

Motion type Mainly rotary Mainly rotary Linear or rotary Linear or rotary
 1.11 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 is 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 twice 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.

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 defense
equipment. Defense 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 centers in
India to train the manpower and to create awareness about the use of fluid power in Indian
industry.
Objective Type Questions

Fill in the Blanks

1. Fluid power is the technology that deals with the generation, and transmission of
forces and movement of mechanical elements or systems.

2. The main objective of fluid transport systems is to deliver a fluid from one location to
another, whereas fluid power systems are designed to perform .

3. There are three basic methods of transmitting power: Electrical, mechanical and .

4. Only are capable of providing constant force or torque regardless of speed

changes.

5. The weight-to-power ratio of a hydraulic system is comparatively than that of an

electromechanical system.

State True or False

1. Hydraulic lines can burst and pose serious problems.

2. Power losses and leakages are less in pneumatic systems.

3. Pneumatic system is not free from fire hazards.

4. Hydraulic power is especially useful when performing heavy work.

5. Water is a good functional hydraulic fluid.

Review Questions
1. Define the term fluid power.
2. Differentiate between fluid transport and fluid power systems.
3. Differentiate between hydraulics and pneumatics.
4. List the six basic components used in a hydraulic system.
5. List the six basic components used in a pneumatic system.
6. List 10 applications of fluid power in the automotive industry.
7. Name 10 hydraulic applications and 10 pneumatic applications.
8. List five advantages and five disadvantages of hydraulics.
9. List five advantages and five disadvantages of pneumatics.
10. List the main components of a fluid power system and their functions.
11. Discuss in detail the future of fluid power industry in India.
12. Compare different power systems used in industries.
13. What is the main difference between an open-loop and a closed-loop fluid power
system?
14. List five major manufactures of fluid power equipment and systems in India.
15. List five major manufactures of fluid power equipment and systems in the world.
16. Visit any industry nearby and list the hydraulic/pneumatic parts or systems used and
their purposes.
17. Why is the hydraulic power especially useful when performing heavy work?
18. Differentiate between oil hydraulics and pneumatics.
19. List any five applications of fluid power systems.
20 List the main components of a fluid power system and their functions.
 Answers

Fill in the Blanks

1. Control

2. Work

3. Fluid power

4. Fluid power systems

5. Less

State True or False

1. True

2. True

3. False

4. True

5. False
 Lecture 2
PROPERTIES OF FLUID
Learning Objectives

Upon completion of this chapter, the student should be able to:

 Define three states of matter: Solid, liquid and gas.

 Define mass density, specific weight and weight density.
 Understand the meaning of the term pressure.
 Explain the difference between gauge and absolute pressures.
 Understand the difference between kinematic and absolute viscosities.
 Differentiate between the ideal and real fluids.
 Define bulk modulus
 Explain the dependence of viscosity on temperature.

1.1 Introduction

Fluids, both liquids and gases, are characterized by their continuous deformation when a shear
force, however small, is applied. Liquids and gases may be distinguished by their relative
incompressibilities and the fact that liquid may have a free surface while a gas expands to fill
its confining container. Because the liquid is the medium of transmission of power in
hydraulic system, knowledge of its characteristics is essential. The purpose of this chapter is
to define certain fundamental properties of fluids which will be useful to apply the basic
principles of fluid mechanics to the solution of practical problems on fluid power.

1.2 Solids and Fluids (Liquids and Gases)

1.2.1 Distinction between a Solid and a Fluid

The molecules of a solid are usually closer to each other than those of a fluid. The attractive
forces between the molecules of a solid are so large that a solid tends to retain its shape. This
is not the case with a fluid where the attractive forces between the molecules are smaller. An
ideal elastic solid deforms under load, and once the load is removed, it returns to its original
state.

1.2.2 Distinction between a Gas and a Liquid

A fluid may be either a gas or a liquid. The molecules of a gas are much farther apart than
those of a liquid. Hence, a gas is very compressible, and when all external pressure is
removed, it tends to expand indefinitely. A liquid is relatively incompressible, and if all
pressure, except its own vapor pressure, is removed, the cohesion between molecules holds
them together, so that the liquid does not expand indefinitely. Therefore, a liquid may have a
free surface, that is, a surface from which all pressure is removed, except its own vapor
pressure.
1.3 Density, Specific Weight, Specific Volume and Specific Gravity

1.3.1 Density

Density (ρ) is defined as mass per unit volume, that is,

Mass m  kg 
   3 (1.1)
Volume V  m 

The density characteristics of typical hydraulic fluids are given in Table 1.1.

Table 1.1 Density characteristics of hydraulic fluids

Density
Fluid (kg/m3)
Shell Tellus ISO 32 mineral oil 875
Shell HFB 60%oil,40%oil 933
Shell HFC 60%glycol,40%water 1084
Shell HFD phosphate ester 1125
Shell Naturelle HFE 32 918

It is well known that density increases with pressure and decreases with temperature. Figure
1.1shows such a characteristic for an ISO 32 mineral oil.

Figure 1.1 Characteristics of ISO 32 mineral oil.

1.3.2Specific Weight

Specific weight () is defined as weight per unit volume, that is,

Weight  N 
   (1.2)
Volume  m3 
Density and specific weight are related by


    g
g

where g is acceleration due to gravity. Now

Dimension of  N / m3 (kgm / s 2 ) / m3 kg
Dimension of      3
Dimension of g m / s 2 m / s2 m

Note that the density () is absolute, since it depends on mass, which is independent of
location. The specific weight (), on the other hand, is not absolute, since it depends on the
value of gravitational acceleration (g), which varies with location, primarily latitude and
elevation above mean sea level. The densities and specific weights of fluids vary with
temperature. Table 1.2 gives specific weight of common fluids. The specific weight of a liquid
varies only slightly with pressure, depending on the bulk modulus of the liquid; it also
depends on temperature and the variation may be considerable. Since the specific weight () is
equal to g, the specific weight of a fluid depends on the local value of the acceleration due to
gravity in addition to the variation in temperature and pressure.

Table 1.2 Specific weight(inkN/m3) of common liquids at 20°C, 1013 millibar abs with g =
9.81 m/s2

Carbon tetrachloride 15.6

Ethyl alcohol 7.76

Gasoline 6.6

Glycerin 12.3

Kerosene 7.9

Motor oil 8.5

Seawater 10.03

Water 9.79

1.3.3Specific Volume

Specific volume (SV) is the volume occupied by a unit mass of fluid. We commonly apply it
to gases and usually express it in m3/kg. Specific volume is the reciprocal of density. Thus,

1
SV  (1.3)

1.3.4Specific Gravity

Specific gravity (SG) of a given fluid is defined as the specific weight of the fluid divided by
the specific weight of water, that is

 oil
SG oil 
 water

 oil
 SG oil  (1.4)
 water at standard temperature
SG of a liquid is a dimensionless ratio. Physicists use 4°C as the standard temperature, but
engineers often use 15.56°C. In the metric system, the density of water at 4°C is 1.00 g/cm3,
equivalent to 1000 kg/m3, and hence the SG (which is dimensionless) of a liquid has the same
numerical value as its density expressed in g/mL or mg/m3.

The SG of a gas is the ratio of its density to that of either hydrogen or air at some specified
temperature and pressure, but there is no general agreement on these standards, and so we
must explicitly state them in any given case. Since the density of a fluid varies with
temperature, we must determine and specify specific gravities at a particular temperature.

Example 1.1
Air at 20°C and atmospheric pressure has a density of 1.23 kg/m3. Find its specific gravity.
What is the ratio of the specific gravity of water to the specific gravity of air at 20°C and
atmospheric pressure? What is the significance of the ratio?
Solution: GivenT = 20°C, air density ( air ) 1.23 kg / m3 , water density
( water )  1000 kg / m3 . Specific gravity of air is given by
air
 1.23103
 water

We know that specific gravity of water = 1. So

Specific gravity of air 1

  813
Specific gravity of water 1.23 103

Therefore, water is 813 times heavier than air.

Example1.2
The specific weight of oil mixture at ordinary pressure and temperature is 9.81 kN/m3. The
specific gravity of mercury is 13.56. Compute the density of oil mixture and the specific
weight and density of mercury.

Solution: Given specific weight of oil mixture  oil = 9.81. The density of oil is
  oil 9.81
oil    1.00 mg/m3  1.00 g / mL
g 9.81

The specific weight and density of mercury are, respectively,

 mercury  Smercury oil  13.56(9.81)  133.0 kN / m3

mercury  Smercury oil  13.56(1.00)  13.56 kN / m3

Example 1.3
A cylinder container has a diameter of 0.5 m and a height of 1 m. If it is to be filled with a
liquid having a specific weight of 2000 N/m3, how many kg of this liquid must be added?

Solution: Given diameter (d )  0.5 m, height (h)  1 m . The volume is given by

 d 2h
Volume (V )   0.19635 m3
4

Also it is given that specific weight () is 2000 N/m3. Now

Weight  V   0.19635 2000  392.7 N

The mass is given by

W
Mass   40 kg
g

Example 1.4

One liter of SAE30 oil weighs 8.70 N. Calculate its specific weight, density and specific
gravity.

Solution: Given volume (V )  1 liter  103 m3 , weight (W )  8.7 N . The specific weight is

W 8.7
   8700 N / m3
V 103

and mass density is


oil   887.755 kg / m3
g

Therefore,

oil 8878.75
SG oil    0.889
water at standard temperature 1000
1.4 Pressure

Pressure is defined as force per unit area. It is the amount of force acting over a unit area, that
is

Force F
P  (1.5)
Area A

The pressure developed at the bottom of a column of any liquid is called hydrostatic pressure
and is given by

P   gh (1.6)

where P is the hydrostatic pressure or the pressure at the bottom of liquid column in Pascal or
N/m2,  is the density of liquid in kg/m , g is the acceleration due to gravity in m/s and h is
3 2

the level of the column of liquid in meters.

Since

mgh Wh
P   gh  
V V
and P  h

where  is the specific weight of liquid in N/m3, we have P (N/m2 )   (N/m3 ) h (m) .

1.4.1 Pressure at the Bottom of a Column of Liquid

Let us now refer to Fig. 1.2, which shows the pressure head developed at the bottom due to
the column of liquid. Let h be the height of the liquid column and W be the weight of the
liquid. Let the liquid have a specific weight  and volume V:

F W W V W V
P     
A A A V V A

(  V ) (  A  H )
 
A A

 P  H (1.7)
 Figure 1.2 Pressure developed by a column of fluid.

Observing the equation, it can be concluded that pressure does not depend on the cross-
sectional area of the liquid column but only on the column height and specific weight of the
liquid. Changing the cross-sectional area of the liquid column changes the weight of the liquid
by a proportional amount. Hence, F/A (pressure) remains constant.

1.4.2 Atmospheric Pressure and Absolute Pressure

Atmospheric pressure is the force per unit area exerted against a surface by the weight of air
above that surface in the Earth’s atmosphere. In most circumstances, atmospheric pressure is
closely approximated by the hydrostatic pressure caused by the weight of air above the
measurement point. Low-pressure areas have less atmospheric mass above their location,
whereas high-pressure areas have more atmospheric mass above their location. Similarly, as
elevation increases, there is less overlying atmospheric mass, such that the pressure decreases
with increasing elevation. The standard atmosphere is a unit of pressure that is equal to
101325 Pa or 101.325 kPa. The following units are equivalent, but only to the number of
decimal places displayed: 760 mmHg (torr), 29.92 in Hg, 14.696 psi, 1013.25 mbar/hPa. One
standard atmosphere is the standard pressure used for pneumatic fluid power (ISO R554) and
in the aerospace (ISO 2533) and petroleum (ISO 5024) industries. Absolute pressure is
measured relative to a perfect vacuum such as that existing in outer space.

1.4.3 Gauge pressure and absolute pressure

Gauge pressure is measured relative to the atmosphere, whereas absolute pressure is measured
relative to a perfect vacuum such as that existing in outer space.

A chart showing the difference between gauge and absolute pressure is given in Fig. 1.3. Let
us examine the two pressure levels P1 and P2.

1. Relative to a prefect vacuum, they are:

 P1 = 0.7 bar (absolute), that is, a pressure less than an atmospheric pressure.
 P2 = 2 bar (absolute), that is, a pressure greater than an atmospheric pressure.
2. Relative to atmosphere, they are:
 P1 = −0.3 bar (gauge, suction or vacuum).
 P2 = 1 bar (gauge).

As can be seen from Fig. 1.3, the following rule can be used in pressure conversion
calculations:

Absolute pressure = Gauge pressure + Atmospheric pressure

It should be noted that vacuum or suction pressures exist in a certain location of fluid power
systems (e.g., in the inlet or suction lines of pumps). Therefore, it is important to understand
the meaning of pressures below atmospheric pressure. One way to generate a suction pressure
is to remove some of the fluid from a closed vessel initially containing fluid at atmospheric
pressure.
 1 bar gaugepressure

Atmospheric pressure Zero gauge pressure

0.3 bar gaugepressure

2bar absolute
pressure

1 bar absolute
0.7 bar absolute
pressure
pressure Absolute zero pressure (complete
vacuum)

Figure 1.3 Difference between absolute and gauge pressure.

Example 1.5

For the fluid power automobile lift system of Fig. 1.4, the hydraulic piston has a 250-mm
diameter. How much of oil pressure (kPa) is required to lift a 13300 N automobile?

Control valve

Air from
compressor
Piston
AIR

OIL

Figure 1.4
Solution: Given force F = 13300 N, diameter (d) = 0.25 m, area (A) = 0.0491 m2.The gauge
pressure is

F 13300
Pressure ( P)    270.876 kPa
A 250

Example 1.6

For the fluid power automobile lift system of Fig. 1.5, the air pressure equals 550 kPagauge. If
the hydraulic piston has a diameter of 250 mm, what is the maximum weight of an automobile
that can be lifted? The specific gravity of oil is 0.9. What percentage error in the answer to
this problem occurs by ignoring the 1-m head of oil to between the air and interface surface
and bottom surface of the piston? Density (  )  900 kg / m3 .

Control valve

Air from
compressor
1m Piston
AIR
Diameter (d )  250 mm
Oil

Sp. gravity  0.9

Figure 1.5

Solution: Given pressure of

air ( Pair )  550 kPa . We know that

Pair  Pressure at piston ( Ppiston )  Pressure due to1 m oil head

 550103  Ppiston   gh

 Ppiston  550 103  900  9.811  541.18 kPa

If we ignore 1-m oil head, then Ppiston  550 kPa. Then, error in solution is calculated as

550  541.18
%error  100  1.63%
541.18
1.5 Compressible and Incompressible Fluids

Fluid power deals with both incompressible and compressible fluids, that is, with oil and air of
either constant or variable density. Although there is no such thing in reality as an
incompressible fluid, we use this term where the change in density with pressure is so small as
to be negligible. This is usually the case with liquids. We may also consider gases to be
incompressible when the pressure variation is small compared with the absolute pressure.

Ordinarily, we consider liquids to be incompressible fluids; yet sound waves, which are really
pressure waves, travel through them. This provides the evidence of the elasticity of liquids.

The flow of air in a ventilating system is a case where we may treat a gas as incompressible,
for the pressure variation is so small that the change in density is of no importance. However,
for a gas or steam flowing at a high velocity through a long pipeline, the decrease in pressure
may be so high that we cannot ignore the change in density. For an airplane flying at a speed
below 100 m/s, we may consider the air to be of constant density. But as an object moving
through air approaches the velocity of sound, which is of the order of 1200 km/h depending
on temperature, the pressure and density of the air adjacent to the body become materially
different from those of the air at some distance away.

1.6 Bulk Modulus (Volume Modulus of Elasticity)

Bulk modulus is a measure of the compressibility of a liquid and is required when it is desired
to calculate oil volume changes for high pressure and large system volumes such as forging
pressures or natural frequencies generally caused by the interaction of fluid compressibility
and moving mass. Bulk modulus is analogous to the modulus of elasticity for solids; however,
for fluids, it is defined on a volume basis rather than in terms of the familiar one-dimension
stress–strain relation. The compressibility (a change in volume due to a change in pressure) of
liquid is inversely proportional to its bulk modulus. For liquids, the value of bulk modulus is
1.72 × 106kPa. The volume modulus of mild steel is about 170000 MPa. Taking a typical
value for the volume modulus of cold water to be 2200 MPa, we see that water is about 80
times as compressible as steel. The compressibility of liquids covers a wide range. Mercury,
for example, is approximately 8% as compressible as water, whereas the compressibility of
nitric acid is nearly six times that of water.

Example 1.7

A 500 cm3 sample of oil is to be compressed in a cylinder until its pressure is increased from 1
to 50 atm. If the bulk modulus of oil equals 1750 MPa, find the percentage change in its
volume.

Solution: Given volume (V) = 500 cm3, P1 1 atm, P2  50 atm and B  1750 MPa . We
know that
P
B
V / V
V P 49 1.0131000000
  
V B 1750000000

Reduction in volume = −0.2836 %, which implies that oil is incompressible.

Example 1.8

A positive displacement pump with a delivery of 1 L/min is fed into a pipe with a total volume
of 1 L. If the end of the pipe is suddenly blocked, calculate the rise in pressure after 1 s. (The
bulk modulus of the fluid being pumped may be taken as 2000 MPa; neglect any change in the
volume of the pipe.)

Solution: Bulk modulus is given as

P
B
V / V

where ΔP is the change in pressure, ΔV is the change in volume and V is the original volume.
Now

1
V  Pump flow in 1 s  L
60

Hence,

 V  2000
P  B    33.3 MPa
 V  60

This rapid rise in pressure illustrates the necessity of having some form of control to limit the
rise in pressure in a system should a pump be deadheaded. The control may be built into the
pump or may be an external pressure-limiting device such as a relief valve.

Example 1.9

An 8 L sample of oil is compressed in a cylinder until pressure increases from 0.7 to 2.7 MPa.
If the bulk modulus equals 80 MPa, find the change in the volume of oil.

Solution: Given initial volume V = 8 L = 0.008 m3 and change in pressure ∆P =2.7 − 0.7 = 2
MPa. Bulk modulus is given by

P
B
V / V
So, change in volume

 P   2
∆V = −V   = −0.008   = −0.002 m
3

 B   80 

1.7 Reynolds Number

It is a dimensionless number referred to as a compressible or incompressible fluid flow. It was

postulated by a British engineer Osborne Reynolds. The Reynolds number set criteria by
which the fluid flow regime may be distinguished:
 v D
Re 


where is the density (kg/m3), v is the velocity of fluid (m/s), D is the diameter of the pipe (m)
and µ is the absolute or dynamic viscosity (Pa s or ms/m2).

1.8 Types of Fluid Flow

Based on the range of Reynolds number, the flow of fluid is classified as laminar flow,
transition flow and turbulent flow.

1. Laminar flow: In the laminar flow region, the flow is characterized by the smooth motion
of the laminae or layers. When there is no macroscopic mixing of adjacent fluid layers for the
flow in the laminar regimes, the Reynolds number is less than 2000.

2. Turbulent flow: In the turbulent flow region, the flow is characterized by the random
motion of the fluid particles in three dimensions in addition to mean motion. There is
considerable macroscopic mixing of adjacent fluid layers and significant velocity fluctuations.
For the turbulent flow, the Reynolds number is greater than 4000.

3. Transition flow: In the transition flow region, the flow is in transition between laminar and
turbulent flows. The Reynolds number lies between 2000 and 4000.

1.9 Ideal Fluid

An ideal fluid is usually defined as a fluid in which there is no friction; it is inviscid (its
viscosity is zero). Thus, the internal forces at any section within it are always normal to the
section, even during motion. So these forces are purely pressure forces. Although such a fluid
does not exist in reality, many fluids approximate frictionless flow at a sufficient distance
from solid boundaries, and so we can often conveniently analyze their behaviors by assuming
an ideal fluid.

In a real fluid, either liquid or gas, tangential or shearing forces always develop whenever
there is a motion relative to body, thus creating fluid friction, because these forces oppose the
motion of one particle past another. These friction forces give rise to a fluid property called
viscosity.

1.10 Viscosity

The viscosity of a fluid is a measure of its resistance to shear or angular deformation. Motor
oil, for example, has a high viscosity and resistance to shear; it is cohesive and feels “sticky,”
whereas gasoline has a low viscosity. The friction forces in a flowing fluid result from the
cohesion and momentum which are interchangeable between molecules. The viscosity of
typical fluids depends on temperature. Figure 1.7 indicates how the viscosities of typical
fluids depend on temperature. As the temperature increases, the viscosities of all liquids
decrease, whereas the viscosities of all gases increase. This is because of the force of
cohesion, which diminishes with temperature, predominates with liquids, whereas with gases,
the predominating factor is the interchange of molecules between the layers of different
velocities. Thus, a rapidly moving gas molecule shifting into a slower moving layer tends to
speed up the latter, and a slow-moving molecule entering a faster moving layer tends to slow
down the faster moving layer. This molecular interchange sets up a shear or produces a
friction force between adjacent layers. At higher temperatures, molecular activity increases,
thereby causing the viscosity of gases to increase with temperature.

Gases
Viscosity

Liquids

Temperature

Figure 1.7Trends in viscosity variation with temperature.

Consider a classic case of two parallel plates (Fig. 1.8), sufficiently large that we can neglect
edge conditions, a small distance Y apart, with fluid filling the space in between. The lower
plate is stationary whereas the upper one moves parallel to it with a velocity U due to a force
F corresponding to some area A of the moving plate.

F,U
Upper Boundary
dy Velocity
Y
profile Lower Boundary
y

u du

(a)
 U

F, U

u Velocity Profile
Y profile
y Slope = dy/dx

(b)

Figure 1.8Velocity profiles across parallel plates: (a) Linear (no bulk flow) and (b)
linear (bulk flow to right).

At the boundaries, the particles of a fluid adhere to the walls, so their velocities are zero
relative to the walls. This is the so-called no-slip condition that occurs in all viscous fluids.
Thus, in Fig. 1.8, the fluid velocities must be U when in contact with the plate at the upper
boundary and zero at the lower boundary. We call the form of velocity variation with distance
between these two extremes, as depicted in Fig. 1.8, a velocity profile. If the separation
distance Y is not too large, the velocity profile is linear, as shown in Fig. 1.8(a). If, in addition,
there is a small amount of bulk fluid transport between the plates, which could result from
pressure-fed lubrication, for example, the velocity profile becomes the sum of the previous
linear profile and a parabolic profile as shown in Fig. 1.8(b); the parabolic additions to the
linear profile are zero at the walls and maximum at the centerline. The behavior of the fluid is
much as if it is consisted of a series of thin layers, each of which slips a little relative to the
next.

For a large class of fluids under the conditions of Fig. 1.8(a), experiments have shown that

AU
F
Y
We see from similar triangles that we can replace U/Y by the velocity gradient du/dy. If we
now introduce a constant of proportionality µ, we can express the shearing stress τ between
any two thin sheets of fluid by

F U du
 µ µ (1.8)
A Y dy

This equation is called Newton’s equation of viscosity, since Sir Isaac Newton (1642–1727)
first suggested it. Although better known for this formulation of the fundamental laws of
motion and gravity for the development of differential calculus, Newton, an English
mathematician and natural philosopher, also performed many pioneering studies in fluid
mechanics. In transposed form, Eq. (1.8) defines the proportionality constant

τ
µ
du / dy
where µ is known as the coefficient of viscosity, the dynamic viscosity or simply the
viscosity of the fluid. “Absolute viscosity” shall be used to help differentiate it from another
viscosity that will be discussed shortly.

In the beginning of this chapter, we noted that the distinction between a solid and a fluid lies
in the manner in which each can resist shearing stress. A further distinction among various
kinds of fluids and solids will be clarified by referring to Fig. 1.9. In the case of a solid, shear
stress depends on the magnitude of the deformation, but Eq. (1.8) shows that in many fluids,
shear stress is proportional to the time rate of deformation.

Elastic solid
Shear stress ()

Newtonian fluid

Non-Newtonian fluid
Ideal plastic
Ideal fluid

du/dy

Figure 1.9Velocity profiles – linear (bulk flow to right).

A fluid for which the constant of proportionality does not change with the rate of deformation
is called a Newtonian fluid, and this is plotted as a straight line in Fig. 1.9. The slope of this
line is the absolute viscosity µ. The ideal fluid with no viscosity falls on the horizontal axis,
whereas a true elastic solid is plotted on the vertical axis. A plastic that sustains a certain
amount of stress before suffering a plastic flow corresponds to a straight line intersecting the
vertical axis at the yield stress. There are certain non-Newtonian fluids in which µ varies with
the rate of deformation. These are relatively uncommon in engineering usage, so we restrict
the remainder of this text to the common fluids that under normal conditions obey Newton’s
equation of viscosity. Note that

Dimension of τ (N / m2 ) N s
Dimension of µ    2
Dimension of (du / dy ) s1 m

A widely used unit of viscosity in the metric system is the poise (P) named after Jean Louis
Poiseuille (1799–1869). Poiseuille, a French anatomist, was one of the first investigators of
viscosity. A poise = 0.10 Ns/m2. A centipoise (=0.01 P) is frequently a more convenient unit.
It has a further advantage in that the viscosity of water at 20.2°C is 1 cP. Thus, the value of
viscosity in centipoise is an indication of the viscosity of a fluid relative to that of water at
20.2°C.
In many problems involving viscosity, the absolute viscosity is divided by density. This ratio
defines the kinematic viscosity,  <COMP: Greek letter nu>, so called because force is not
involved, the only dimensions being length and time, as in kinematics. Thus,


 (1.9)


Usually, the kinematic viscosity (  ) is measured in m2/s. Previously, in the metric system, the
common units were cm2/s, also called the stoke (St), after Sir George Stokes (1819–1903), an
English physicist and pioneering investigator of viscosity. Many physicists found centistoke
(cSt) a more convenient unit to work with.

A comparison of kinematic viscosities of fluids is shown in Fig. 1.10(a) for low operating
pressures. A more detailed characteristic of an ISO 32 mineral oil is shown in Fig. 1.10(b),
illustrating the important effect of both temperature and pressure. The data shown in Fig. 1.10
make it clear that experimental testing must specify both pressure and temperature so that
related studies may be compared with at least a minimum of confidence. It is common that
computer dynamic simulations of hydraulic systems usually assume a mean temperature in a
sense that the temperature does not vary significantly during the milliseconds to second of
transient behavior. However, it may be necessary to model the effect of pressure on viscosity
if large fluctuations in pressure are expected, although its effect may well be of secondary
significance.

(b)
300

250 700 bar

200 350 bar

Viscosity (cSt)

Atmos
150

100

50

0
0 50 100 150

Temperature (oC)
Figure 1.10Typical kinematic viscosities for a range of fluids. (a) Some fire-resistant fluids.
(b) An ISO 32 mineral oil.
Example 1.11

A 4.5 N force moves a piston inside a cylinder at a velocity of 3 m/s as shown in Fig. 1.11.
The piston of 10.16 cm diameter is centrally located in the cylinder having an internal
diameter of 10.17 cm. An oil film separates the piston from the cylinder. Find the absolute
viscosity of the oil.

50 mm

F = 4.5 N Piston v = 3 m/s

Figure 1.11

Solution: Given force on the piston = 4.5 N, piston diameter (d) =10.16 cm, velocity (v) = 3
m/s, cylinder diameter (D) = 10.17 cm and length (L) = 5 cm. Using Newton’s law of
viscosity we have

du
F
dy

For small gaps,

Av
F  (1.10)
y

Now we have

A   DL =  10.16 5  159.6 cm 2

v  3m/s  300 cm / s

D  d 10.17  10.16
y   0.005 cm
2 2

Substituting in Eq. (1.10) we get

 159.6  300
4.5 
0.005
 4.7 107 N s 4.7 107 N s
   4.7 103 N s / m2
cm2 104 m2

Since 1 N = 105 dynes, we get

4.7 107 N s 4.7 107 105 dynes s

 
cm2 cm2
 0.047 poise  4.7 centipoise

Now

Absolute viscosity (µ) in cP = Specific gravity (0.89) × Kinetic viscosity () in cS

  = 4.7/0.89 = 5.28 cS

Example 1.12

In Fig. 1.12, oil of the absolute viscosity µ fills the small gap of thickness Y.

(a) Neglecting fluid stress exerted on the circular underside, obtain an expression for the
torque T required to rotate the cone at a constant speed ω.

(b) What is the rate of heat generation, in J/s, if the absolute viscosity of oil is 0.20 Ns/m2, 
= 45º, a = 45 mm, b = 60 mm, Y = 0.2 mm and the speed of rotation is 90 rpm?

Figure 1.12

Solution: We have

(a) We have U = r. For small gap Y we have

 du U  r
 
dy Y Y

µdu µ r
 
dy Y

2 rdy
dA  2 rds 
cos 

 r (2 rdy)
dF  dA  
Y (cos  )

2 3
dT  r dF  r dy (where r  tan )
Y cos 

2 tan 3  3
 dT  y dy
Y cos 

Integrating we get

a b
2 tan 3 
T  y dy
3

Y cos  a

2 tan 3 
T  [(a  b)4  a 4 ]
4Y cos 

(b) We have

[(a  b)4  a4 ]  (0.105 m)4  (0.045 m)4  0.0001175 m4

ω = (90 rev/min)(2π radians/rev)(1min/60s) = 3π rad/s

Heat generation rate = Power =T
2  2 tan 3 
P [(a  b) 4  a 4 ]
4Y cos 
2 (0.20 Ns/m 2 )(3 s 1 ) 2 (1)3 (0.0001175 m 4 )

4(2 104 m) cos 45

= 23.2 Nm/s = 23 .2 J/s

1.11 Viscosity Index

The viscosity of hydraulic oils decreases with increase in temperature. Hence, the viscosity of
the given oil must be represented at a special temperature. The variation of viscosity with
respect to temperature is different for different oils.

The viscosity index (VI) is a relative measure of the change in the viscosity of an oil with
respect to a change in temperature. An oil having a low VI is one that exhibits a large change
in viscosity with a small change in temperature. A high VI oil does not change appreciably
with a change in temperature.
The VI of any hydraulic oil can be calculated as follows:

L U
VI  100 (1.11)
LH
where L is the viscosity in SUS (Saybolt universal viscosity)of a 0 VI oil at 100°F, U is the
viscosity in SUS of an unknown VI oil at 100°F and H is the viscosity in SUS of a 100 VI oil
at 100 °F. The VI of an unknown oil is determined from tests. A reference oil of 0 VI and a
reference oil of 100 VI are selected. The viscosities of three oils (L, U and H) are then
measured at 100°F.This is shown schematically in Fig. 1.13.

A high VI oil is a good all-weather-type oil for use in outdoor machines operating in extreme
temperature swings. For a hydraulic system, the oil temperature does not change appreciably;
hence, the VI of the oil is not crucial.

Zero VI oil

L
Unknown VI oil
Viscosity (SUS)

100 VI oil

100 210
Temperature (

Figure 1.13Viscosity index.

Example 1.13

A sample of oil with viscosity index of 70 is tested with a 0 VI oil and a 100 VI oil whose
viscosity values at 100°F are 375 and 125 SUS, respectively. What is the viscosity of the
sample oil at 100°F in units of SUS?

Solution: We know that

L U
VI  100
LH

where L is the viscosity of 0 VI oil at 100F, H is the viscosity of 100 VI oil at 100F, and U
is the required viscosity in SUS So,

375  U
70  100
375  125

U  200 SUS

Example 1.14

A sample oil is tested with a 0 VI oil and a 100 VI oil whose viscosity values at 38°C are 400
and 150 SUS, respectively. If the viscosity of the sample oil at 38°C is 200 SSU, what is the
viscosity index of the sample oil?

Solution: We know that

L U 400  200
VI of the sample oil = × 100 = × 100
LH 400  150

200
= × 100 = 80 VI
250
Objective Type Questions

Fill in the Blanks

1. The molecules of a solid are usually ______ to each other than those of a fluid.

2. The molecules of a gas are much ______ than those of a liquid.

3. Absolute pressures are measured relative to ______ such as that existing in outer space.

4. An ideal fluid is usually defined as a fluid in which there is ______.

5. The viscosity of a fluid is a measure of its resistance to ______.

State True or False

1. Gauge pressures are measured relative to atmosphere.

2. The bulk modulus is analogous to the modulus of elasticity for solids.

3. At any given temperature, the bulk modulus of water does vary a great deal for a moderate
range in pressure.

4.Hydraulic power is especially useful when performing a heavy work.

5. The viscosity of hydraulic oils increases with increase in temperature.

6. Mineral oil has a high bulk modulus compared to phosphate esters and water glycol fluids.
Review Questions

1. What are the differences between a liquid and a gas?

2. Define the terms specific density, specific weight and specific gravity.

3. Differentiate between absolute and gauge pressures.

4. What is meant by bulk modulus? Give its typical value for liquid and gas.

5. Differentiate between viscosity and viscosity index.

6. Define viscosity index and also suggest an optimum range.

7. Name two undesirable results when using an oil with a viscosity that is too high.

8. Name two undesirable results when using an oil with a viscosity that is too low.

9.What is meant by the term pressure head?

10.Under what conditions is viscosity index important?

11.It is desired to select an oil of a viscosity index suitable for a hydraulic powered front-end
loader what will operate a year round. What viscosity index characteristics should be
specified? Why?
Answers

Fill in the Blanks

1. Closer

2. Farther apart

3. Perfect vacuum

4. No friction

5. Shear or angular deformation

State True or False

1. True

2. True

3. True

4. True

5. False

6.False
 Lecture 3

FLUIDS FOR HYDRAULIC SYSTEMS

Learning Objectives

Upon completion of this chapter, the student should be able to:

List the various functions of hydraulic fluid.

Explain the desirable properties of fluid.
Differentiate between thick and boundary lubrication.
Define neutralization number and demulsibility.
Define fire point and flash point.
Explain the various hydraulic fluids.
Explain the various fire-resistant fluids.

1.1 Introduction

Although mineral oils were readily available in the beginning of 20th century, they were not
practically used in hydraulic system until the 1920. In 1940s, additives were first used to
improve the physical and chemical properties of hydraulic mineral oils. The first additives
were developed to counter rust and oxidation. However, mineral oils are highly flammable,
and fire risk increases when operating at high temperatures. This led to the development of
fire-resistant fluids that are mainly water based, with limitations on the operating conditions.
The need for extremes of operating temperatures and pressures led to the development of
synthetic fluids. Personnel who operate, service, or design fluid power should have knowledge
of the individual characteristics of hydraulic fluid and this chapter deals with functions of
hydraulic fluid and their effect on system’s performance.

1.2 Functions of Hydraulic Fluids

A hydraulic fluid is the transmitting medium of a hydraulic system. It is, therefore, an

essential part of the system and we must know enough about it to ensure that the hydraulic
system works efficiently. The most common liquid that is used as a medium in fluid power
systems is petroleum-based mineral oil.
In fluid power systems, a hydraulic fluid has to perform various functions such as the
following:

1. Power transmission: To transmit power, which is the primary function.

2. Lubrication: To lubricate various parts, so as to avoid metal-to-metal contact and
reduce friction, wear and heat generation.
3. Sealing: To seal the moving elements to avoid leakage.
4. Cooling: To carry away the heat generated in the system and to dissipate the heat
through a reservoir or a heat exchanger.
5. Contaminant removal: To carry along the contaminations to the tank, where they
can be removed through filters.
For a fluid to perform efficiently, it must possess certain properties. The various properties
required for an ideal hydraulic fluid are as follows:
1. Ideal viscosity.
2. Good lubrication capability.
3. Demulsibility.
4. Good chemical and environmental stability.
5. Incompressibility.
6. Fire resistance.
7. Low flammability.
8. Foam resistance.
9. Low volatility.
10. Good heat dissipation.
11. Low density.
12. System compatibility.
It is almost impossible to achieve all these properties in a hydraulic fluid. Although we can
select a good fluid with desirable properties, some of the characteristics of a fluid change with
usage. For example, it is common for the temperature of a fluid to rise due to friction in the
system, which reduces the viscosity of the fluid, which in turn increases leakage and reduces
lubrication ability. A fluid gets oxidized and becomes acidic with usage. Certain additives are
added to preserve the desirable properties and to make the fluid more stable. Some of the
desirable properties and their influence on a hydraulic fluid are discussed briefly in the
following sub-sections.

1.2.1 Ideal Viscosity

The most basic desirable property of a hydraulic fluid is optimum viscosity. It is a measure of
a fluid’s resistance to flow. When viscosity is low, the fluid flows easily. On the other hand,
when viscosity is high, the fluid flows with difficulty. A low viscous fluid is thin and can flow
easily, whereas a high viscous fluid is thick and cannot flow easily. The viscosity of a fluid
should be high enough to seal the working gap between the parts and prevent leakage but
should be low enough to cause easy flow throughout the system. A high-viscosity fluid
requires high energy to overcome the internal friction, resulting in excess heat generation. On
the other hand, a low-viscosity fluid flows easily but causes leakages and reduces the
volumetric and overall efficiency. Therefore the hydraulic fluid should have an optimum
viscosity.

1. High viscosity:
High resistance to flow.
Increased power consumption due to frictional loss.
High temperature caused by friction.
Increased pressure drop because of the resistance.
Possibility of sluggish or slow operation.
Difficulty in separating air from oil in a reservoir.
Greater vacuum at the pump inlet, causing cavitation.
Higher system noise level.
 2. Low viscosity:
Increased internal leakage.
Excessive water.
Possibility of decreased pump efficiency, causing slower operation of the
actuator.
Increased temperature resulting from leakage losses.

There are two basic methods of specifying the viscosity of fluids: absolute and kinematic
viscosity. Viscosity index is an arbitrary measure of a fluid resistance to viscosity change with
temperature changes. Thus, viscosity is affected by temperature changes. As temperature
increases, the viscosity of a fluid decreases. A fluid that has a relatively stable viscosity at
temperature extremes has a high viscosity index. A fluid that is very thick while cold and
very thin while hot has a low viscosity index.

1.2.1.1 Specification of Oil as Per ISO

Standardization of hydraulic oils has been done by the International Organization for
Standardization. Table 1.1 lists ISO VG for engine oils and Table 1.2 lists ISO VG for
industrial oil. Indian Oil Corporation markets oil as per ISO designation.

Table 1.1 ISO VG for engine oils

ISO Viscosity Grade Kinematic Viscosity (cS @ 40 C)
Minimum Maximum
ISO VG 2 1.98 2.42
ISO VG 3 2.88 3.52
ISO VG 5 4.14 5.06
ISO VG 7 6.12 7.48
ISO VG 10 9 11.0
ISO VG 15 13.5 16.5
ISO VG 22 19.8 24.2
ISO VG 32 28.8 35.2
ISO VG 46 41.4 50.6
ISO VG 68 61.2 74.8
ISO VG 100 90 110
ISO VG 150 135 165
ISO VG 220 198 242
ISO VG 320 288 352
ISO VG 460 414 506
ISO VG 680 612 748
ISO VG 1000 900 1100
ISO VG 1500 1350 1650
Table 1.2 ISO VG for industrial oil

Old Designation New Designation

Servo system 311 Servo system 32
Servo system 314 Servo system 46
Servo system 317 Servo system 57a
Servo system 68
Servo system 321 Servo system 81a
Servo system 100
Servo system 526 Servo system 121
Servo system 150
Servo system 533 Servo system 176
Servo system 220
Servo system 563 Servo system 320
Servo system 460
Servo system 711 Servo system A 32
Servo system 733 Servo system A 176a
Servocirol 11 Servocirol 32
Servocirol 14 Servocirol 46
Servocirol 17 Servocirol 57a
Servocirol 68
Servocirol 21 Servocirol 81a
Servocirol 100
Servocirol 26 Servocirol 121a
Servocirol 100
Servohydex 14 Servohydex 32
Servohydex 21 Servohydex 57a
a
Non-standard ISO VG.

1.2.2Lubrication Capability
Hydraulic fluids must have good lubricity to prevent friction and wear between the closely
fitted working parts such as vanes of pumps, valve spools, piston rings and bearings. Wear is
the removal of surface material due to the frictional force between two metal-to-metal contact
of surfaces. This can result in a change in dimensional tolerances, which can lead to improper
functioning and failure of the components. Hydraulic oil should have a good lubricating
property. That is, the film so formed should be strong enough that it is not wiped out by the
moving parts.
There are two main kinds of lubrication mechanisms: thick film and boundary film. In low-
pressure hydraulic systems such as hand-operated pumps and cylinders, a fluid providing
thick-film lubrication is sufficient. A thick film is about 10 times the surface roughness. Under
such conditions, there is no metal-to-metal contact as shown in Fig. 1.1, and therefore there is
no wear (the coefficient of friction is as low as 0.01–0.02).
 Figure 1.2 Thick film lubrication

However as the speed of the moving part increases like in high speed motor, actuators, valves
the film thickness reduces to about three to five times the surface roughness. This increases
metal-to-metal contact as shown in Fig. 1.2 and also increases the coefficient friction
and wear rate. In such situations, additives are added to the fluid to increase the load- carrying
capacity of the film. In this case, the coefficient of friction is quite high and the wear rates are
higher than the thick-film lubrication condition.

Figure 1.2 Boundary film lubrication

The friction force (F) is the force parallel to the two mating surfaces that slide relative to each
other. This friction force actually opposes the sliding movement between the two surfaces.
The greater the frictional force, the greater the wear and heat generated. This, in turn, results
in power losses and reduced life, which, in turn, increases maintenance cost.

It has been determined that the frictional force (F) is proportional to the normal force N that
forces the two surfaces together. The proportionality constant is called the coefficient of
friction (µ)
F=µN (1.1)
Thus, the greater the values of the coefficient of friction and normal force, the greater the
frictional force and hence wear. The magnitude of the normal force depends upon the amount
of power and forces being transmitted and thus is independent of hydraulic fluid properties.
However, the coefficient of friction depends on the ability of the fluid to prevent metal –metal
contact of the closely fitting mating parts.

Equation (1.1) can be rewritten to solve for the coefficient of friction, which is a
dimensionless parameter:

µ (1.2)

F
N
It can be seen now that µcan be experimentally determined to give an indication of the anti-
wear properties of a fluid F and N can be measured.

1.2.3 Demulsibility
The ability of a hydraulic fluid to separate rapidly from moisture and successfully resist
emulsification is known as “demulsibility.” If an oil emulsifies with water, the emulsion
promotes the destruction of lubricating and sealant properties. Highly refined oils are basically
water resistant by nature.

1.2.4 Good Chemical and Environmental Stability (Oxidation and Corrosion Resistance)
For a good hydraulic fluid, a good chemical and environmental stability is desirable. Most
fluids are vulnerable to oxidation, as they come in contact with oxygen in air. Mineral oils or
petroleum-based oils (widely used in hydraulic systems) contain carbon and hydrogen
molecules, which easily react with oxygen. The oxidation products are highly soluble in oil
and being acidic in nature they can easily corrode metallic parts. The soluble acidic products
cause corrosion, whereas insoluble products make the operation sluggish. Oxidation leads to
deterioration in the chemical nature of fluid, which may form some chemical sledges, gum or
varnish at low velocity or stagnation points in the system.

Many factors influence the rate of oxidation, such as temperature, pressure, moisture and so
on. Temperature is the most affecting one, as the rate of oxidation increases severely with rise
in temperature.

The moisture entering the hydraulic system with air causes the parts made of ferrous materials
to rust. Rust is a chemical reaction between iron or steel and oxygen. Corrosion, on the other
hand, is the chemical reaction between a metal and an acid. The result of rusting and corrosion
is the “eating away” of the metal surfaces of the hydraulic components. Rust and corrosion
cause excessive leakage between moving parts. Rust and corrosion can be prevented by
incorporating additives that plate on the metal surface to prevent chemical reaction.
1.2.5 Neutralization Numbers

Neutralization number is a measure of the acidity or alkalinity of hydraulic oil. This is referred
to as the pH value of the oil. High acidity causes the oxidation rate in oil to increase rapidly.

1.2.6 Incompressibility
Though we consider hydraulic fluids as incompressible, in practice, they are relati vely
compressible. Most mineral oils undergo reduction in the volume of about 0.7% for every 100
bar rise in pressure. In fact, the compressibility of a fluid is greatly influenced by temperature
and pressure.

The incompressibility of a fluid is a measure of its stiffness and is given by its bulk modulus.
The bulk modulus (B) of a fluid is the ratio of volumetric stress to volumetric strain and is
given by the relation
B
Δ
P
ΔV / V
where B is the bulk modulus (Pa), ΔP is the change in pressure (Pa), ΔV is the change in
volume (m3) and V is the original volume.The compressibility of a fluid has an influence on
the system response and makes it susceptible to shock waves. In normal hydraulic systems, its
effect on system response is not considered, whereas decompression valves are used to avoid
shock wave problems.

1.2.7 FireResistance
There are many hazardous applications where human safety requires the use of a fire-resistant
fluid. Examples include coal mines, hot metal processing equipment, aircraft and marine fluid
power systems. A fire-resisting fluid is one that can be ignited but does not support
combustion when the ignition source is removed. Flammability is defined as the ease of
ignition and ability to propagate the flame. The following are the usual characteristics tested
in order to determine the flammability of hydraulic fluids:
1. Flash point: The temperature at which an oil surface gives off sufficient vapors to
ignite when a flame is passed over the surface.
2. Fire point: The temperature at which an oil releases sufficient vapors to support
combustion continuously for 5 s when a flame is passed over the surface.
3. Autogenously ignition temperature: The temperature at which ignition occurs
spontaneously.
The fire-resistant fluids are designated as follows:
1. HFA: A high-water-content fluid or HWCF (80% or more), for example, water–oil
emulsions.
2. HFB: This is water–oil emulsion containing petroleum oil and water.
3. HFC: This is a solution of water and glycol.
4. HFD: This is a synthetic fluid, for example, phosphates or phosphate–petroleum
blends.
The commonly used hydraulic liquids are petroleum derivatives; consequently, they burn
vigorously once they reach a fire point. For critical applications, artificial or synthetic
hydraulic fluids are used that have fire resistance.
Fire-resistant fluids have been developed to reduce fire hazards. There are basically four
different types of fire-resistant hydraulic fluids in common use:
1. Water–glycol solution: This type consists of an actual solution of 40% water and
60% glycol. These solutions have high-viscosity-index values, but as the viscosity
rises, the water evaporates. The operating temperature ranges run from −20°C to
about 85°C.
2. Water-in-oil emulsions: This type consists of about 40% water completely dispersed
in a special oil base. It is characterized by small droplets of water completely
surrounded by oil. The operating temperature range runs from −30°C to about 80°C.
As is the case with water–glycol solutions, it is necessary to replenish evaporated
water to maintain proper viscosity.
3. Straight synthetics: This type is chemically formulated to inhibit combustion and in
general has the highest fire-resistant temperature. The disadvantages of straight
synthetics include low viscosity index, incompatibility with most natural or synthetic
rubber seals and high cost.
4. High-water-content fluids (HWCFs): This type consists of about 90% water and
10% concentrate (designated as 90/10). The concentrate consists of fluid additives
that improve viscosity, lubrication, rust protection and protection against bacteria
growth.The maximum operating temperature should be held to 50°C to minimize
evaporation.
The advantages of HWCF are as follows:
1. Fire resistance due to a high flash point of about 150°C.
2. Lower system operating temperature due to good heat dissipation.
3. Biodegradable and environmental-friendly additives.
4. High viscosity index.
5. Cleaner operation of the system.
6. Low cost of concentrate and storage.
The disadvantages of HWCF are as follows:
1. Greater contamination due to higher densities of fluids.
2. High evaporation loss.
3. Faster corrosion due to oxidation.
4. pH value to be maintained between 7.5 and 9.0.
5. Promotion of bacterial growth and filtration difficulties due to the acidic
nature of fluids.
Performance of HWCFs can be improved using additives such as
1. Anti-wear additives.
2. Anti-foaming additives.
3. Corrosion inhibitors.
4. Biocides to kill water-borne bacteria.
5. Emulsifying agents.
6. Flocculation promoters.
7. Deionization agents.
8. Oxidation inhibitors.
9. Anti-vaporizing agents.

1.2.8Low Flammability
A fire-resistant fluid is one that can get ignited in the presence of an ignition source but does
not support combustion when the source is removed. This characteristic is defined as
flammability. It refers to the ease with which a fluid gets ignited and propagates the flame.
Hence, it is desirable to have a low flammability for a hydraulic fluid.

1.2.9 Foam Resistance

Air can be present in a hydraulic fluid in two forms: dissolved and entrained. For example, if
the return line to the reservoir is not submerged, the jet of oil entering the liquid surface will
carry air with it. This causes air bubbles to form in the oil. If these bubbles rise to the surface
too slowly, they will be drawn into the pump intake. This can cause pump damage due to
cavitation. Another adverse effect of entrained and dissolve air is a great reduction in the bulk
modulus of the hydraulic fluid.

1.2.10 Low Volatility

A fluid should possess low vapor pressure or high boiling point. The vapor pressure of a fluid
varies with temperature and hence the operating temperature range of the system is important
in determining the stability of the fluid.

1.2.11 Good Heat Dissipation

A hydraulic fluid should have a high heat dissipation capability. The temperature of a fluid
shoots up if its heat dissipation characteristics are poor. Too high fluid temperature can cause
a system to malfunction. If the fluid overheats, it may cause the following:
1. Give off vapor and cause cavitation of the pump.
2. Increase the rate of oxidation causing its rapid deterioration by producing sledges,
varnishes, etc., thus shortening its useful life.
3. Reduce viscosity of the fluid resulting in increased leakage, both internal and external.
4. Cause thermal distortion in components.
5. Damage seals and packaging owing to embrittlement.
Hydraulic systems should be designed so that a heat balance occurs at a satisfactory operating
temperature.

1.2.12 Low Density

The relative density of a mineral oil is 0.9 (the exact value depends on the base oil and the
additive used). Synthetic fluids can have a relative density greater than 1. The relative density
is important when designing the layout of pumps and reservoir.

1.2.13 System Compatibility

A hydraulic fluid should be inert to materials used in or near the hydraulicequipment. If the
fluid in anyway attacks, destroys, dissolves or changes the parts of hydraulic system, the
system may lose its functional efficiency and may start malfunction.
1.3 Additives in Hydraulic Fluids
Some of the commonly used additives and their purposes are as follows:
1. Pour point depressant: A pour point is the temperature at which a fluid ceases to flow.
The minimum operating temperature in a hydraulic system should be at least 10°C above the
pour point. Pour point depressants inhibit the formation of wax crystals in the mineral oils and
hence enhance the pour points.There is a range of pour point depressant additives of
different chemical species, important ones are polymethacrylates, polyacrylates and
alkalated naphthalene.
2. Viscosity index improvers: These additives are long-chain polymers that stay in a coiled
form in the hydraulic fluid. At a low operating temperature, they have no effect on viscosity.
But when the temperature rises, these polymers uncoil and intermesh causing a thickness
effect in the fluid, thereby not allowing the viscosity to drop down.
3. Defoamers(anti-foam additives): Certain additives, such as silicon polymer, act as
defoamers. They cause a rapid breakdown of the foam by removing the entrained air bubbles.
Foaming occurs in oil as a surface phenomenon. Bubbles of air are encircled by an oil film
and cannot escape. These bubbles under pressure become very hot and can be the cause of
system overheating.Foam usually forms in the reservoir and, if drawn into the pump suction,
can cause noisy pump operation and may even damage pump parts. Control response is
spongy and unreliable.Although all fluids are susceptible to foaming, the amount of foam in a
system can be reduced to a minimum by the addition of chemical depressants.
4. Oxidation inhibitors: Oxidation causes the chemical reaction and formation of acidic
products that leads to corrosion problems. The oxidation rate increases with temperature.
Certain additives having greater affinity for oxygen are added so that they easily react with
them than with oil.
5. Corrosion inhibitors: These additives form a thin film on the metal surface and shield it
from coming in direct contact with the chemicals/acids in the fluid, thereby preventing
corrosion problems.
6. Anti-wear additives: These are either long-chain polymer or extreme pressure (EP)
additives. The long-chain polymers are adsorbed on the metal surfaces, causing a high local
temperature and polish the surface. This helps in reducing the surface roughness, hence the
wear problem.
7. Load-carrying capacity: The load-carrying capacity of a hydraulic fluid is a measure of
the oil’s capability to maintain a film of lubricant between two metal surfaces under extremes
of load or pressure. All hydraulic oils have a natural load-carrying capacity that can be
enhanced by special additives known as EP additives. These additives help reduce wear
especially in hydraulic pumps and motors by providing lubrication when almost all the oil
film has been squeezed out under heavy load conditions.

1.4 Types of Hydraulic Fluids

There are different types of hydraulic fluids that have the required properties. In general,
while selecting a suitable oil, a few important factors are considered. First, its compatibility
with seals, bearing and components is seen; second, its viscosity and other parameters such as
fix resistance and environmental stability are also considered. There are five major types of
hydraulic flow fluids which meet various needs of the system. These are briefly discussed as
follows:
1. Petroleum-based fluids: Mineral oils are the petroleum-based oils that are the most
commonly used hydraulic fluids. Basically, they possess most of the desirable characteristics:
they are easily available and are economical. In addition, they offer the best lubrication
ability, least corrosion problems and are compatible with most seal materials. The only major
disadvantage of these fluids is their flammability. They pose fire hazards, mainly from the
leakages, in high-temperature environments such as steel industries, etc.
Mineral oils are good for operating temperatures below 50°C, At higher temperatures, these
oils lose their chemical stability and form acids, varnishes, etc. All these lead to the loss of
lubrication characteristics, increased wear and tear, corrosion and related problems.
Fortunately, additives are available that improve chemical stability, reduce oxidation, foam
formation and other problems.

A petroleum oil is still by far the most highly used base for hydraulic fluids. In general,
petroleum oil has the following properties:
Excellent lubricity.
Higher demulsibility.
More oxidation resistance.
Higher viscosity index.
Protection against rust.
Good sealing characteristics.
Easy dissipation of heat.
Easy cleaning by filtration.
Most of the desirable properties of the fluid, if not already present in the crude oil, can
be incorporated through refining or adding additives.
A principal disadvantage of petroleum oil is that it burns easily. For applications where fire
could be a hazard, such as heat treating, hydroelectric welding, die casting, forging and many
others, there are several types of fire-resistant fluids available.

2. Emulsions: Emulsions are a mixture of two fluids that do not chemically react with
others. Emulsions of petroleum-based oil and water are commonly used. An emulsifier is
normally added to the emulsion, which keeps liquid as small droplets and remains suspended
in the other liquid. Two types of emulsions are in use:
Oil-in-water emulsions: This emulsion has water as the main phase, while small
droplets of oil are dispersed in it. Generally, the oil dilution is limited, about 5%;
hence, it exhibits the characteristics of water. Its limitations are poor viscosity,
leading to leakage problems, loss in volumetric efficiency and poor lubrication
properties. These problems can be overcome to a greater extent by using certain
additives. Such emulsions are used in high-displacement, low-speed pumps (such as
in mining applications).
Water-in-oil emulsions: Water-in-oil emulsions, also called inverse emulsions, are
basically oil based in which small droplets of water are dispersed throughout the oil
phase. They are most popular fire-resistant hydraulic fluids. They exhibit more of an
oil-like characteristic; hence, they have good viscosity and lubrication properties. The
commonly used emulsion has a dilution of 60% oil and 40% water. These emulsions
are good for operations at 25°C, as at a higher temperature, water evaporates and
leads to the loss of fire-resistant properties.
3. Water glycol: Water glycol is another nonflammable fluid commonly used in aircraft
hydraulic systems. It generally has a low lubrication ability as compared to mineral oils and is
not suitable for high-temperature applications. It has water and glycol in the ratio of 1:1.
Because of its aqueous nature and presence of air, it is prone to oxidation and related
problems. It needs to be added with oxidation inhibitors. Enough care is essential in using this
fluid as it is toxic and corrosive toward certain metals such as zinc, magnesium and
aluminum. Again, it is not suitable for high-temperature operations as the water may
evaporate. However, it is very good for low-temperature applications as it possesses high
antifreeze characteristics.
4. Synthetic fluids: Synthetic fluid, based on phosphate ester, is another popular fire-resistant
fluid. It is suitable for high-temperature applications, since it exhibits good viscosity and
lubrication characteristics. It is not suitable for low-temperature applications. It is not
compatible with common sealing materials such as nitrile. Basically being expensive, it
requires expensive sealing materials (viton). In addition, phosphate ester is not an
environmental-friendly fluid. It also attacks aluminum and paints.
5. Vegetable oils: The increase in the global pollution has led to the use of more
environmental-friendly fluids. Vegetable-based oils are biodegradable and are environmental
safe. They have good lubrication properties, moderate viscosity and are less expensive. They
can be formulated to have good fire resistance characteristics with certain additives. Vegetable
oils have a tendency to easily oxidize and absorb moisture. The acidity, sludge formation and
corrosion problems are more severe in vegetable oils than in mineral oils. Hence, vegetable
oils need good inhibitors to minimize oxidation problems.
6. Biodegradable hydraulic fluids: As more and more organizations are understanding their
social responsibility and are turning toward eco-friendly machinery and work regime, a
biodegradable hydraulic fluid is too becoming a sought after product in the dawn of an
environmentalist era. Biodegradable hydraulic fluids, alternatively known as bio-based
hydraulic fluids, Bio-based hydraulic fluids use sunflower, rapeseed, soybean, etc., as the base
oil and hence cause less pollution in the case of oil leaks or hydraulic hose failures. These
fluids carry similar properties as that of a mineral oil–based anti-wear hydraulic fluid,
Hypothetically, if a company plans to introduce bio-based fluids into the hydraulic
components of the machinery and the permissible operating pressure of hydraulic components
is reduced to 80%, then it would inversely lead to a 20% reduction in breaking-out force
owing to the 20% reduction in excavator’s operating pressure. It is so because a reduction in
the operating pressure of a system leads to a reduction in actuator force.
Besides, the transformation would not only include the cost of fluid and flushing of machinery
to transcend from a mineral oil to vegetable oil repeatedly but also include the derating costs
of machinery.
1.5 Factors Influencing the Selection of a Fluid
The selection of a hydraulic fluid for a given system is governed by the following factors:
1. Operating pressure of the system.
2. Operating temperature of the system and its variation.
3. Material of the system and its compatibility with oil used.
4. Speed of operation.
5. Availability of replacement fluid.
6. Cost of transmission lines.
7. Contamination possibilities.
8. Environmental condition (fire proneness, extreme atmosphere like in mining, etc.).
9. Lubricity.
10. Safety to operator.
11. Expected service life.
Objective-Type Questions
Fill in the Blanks
1. The ability of a hydraulic fluid to separate rapidly from moisture and successfully resist
emulsification is known as .
2. The neutralization number is a measure of the of hydraulic oil.
3. Emulsions are a mixture of two fluids which chemically react with others.
4. Rust is a chemical reaction between iron or steel and .
5. The incompressibility of a fluid is a measure of its .

State True or False

1. Synthetic fluids can have a relative density greater than 1.
2. Viscosity index improvers are short–chain polymers.
3. Viscosity index is the arbitrary measure of a fluid resistance to viscosity change with
temperature changes.
4. Mineral oils or petroleum-based oils easily react with oxygen.
5. Rust is a chemical reaction between a metal and an acid.
Review Questions
1. What is a fluid? What are the functions and characteristics of hydraulic fluids?
2. List 10 properties that a hydraulic oil should possess.
3. Discuss the role of additives used in fluid power systems.
4. Differentiate between absolute and kinematic viscosities. Also write their units in CGS and
SI systems of units.
5. List some fire-resistant fluids used in hydraulic industry.
6. Why is water not used as a medium in fluid power systems?
7. What are the advantages of high-water-based fluids?
8. How are fire-resistant fluids designated?
9. What is the neutralization number of a hydraulic fluid?Give its importance.
10. What are the functions of a hydraulic fluid?
11. What are the types of liquids used in a hydraulic system?
12. List the types of additives used in a hydraulic fluid.
13. Give the specification of two typical mineral-based hydraulic oils as per ISO.
14. What are the main disadvantages of biodegradable oils?

Answers
Fill in the Blanks
1.Demulsibility
2. Acidity or alkalinity
3. Does not
4. Oxygen
5. Stiffness
State True or False
1. True
2. False
3. True
4. True
5. False
 Lecture 4
GOVERNING PRINCIPLES AND LAWS
Learning Objectives

Upon completion of this chapter, the student should be able to:

 State Pascal’s law.
 Write force power and force displacement relations.
 State practical applications of Pascal’s law and evaluate the parameters.
 Explain the wworking of pressure booster and evaluate the parameters.
 Explain law of conservation of energy.
 Derive ccontinuity and Bernoulli’s equation.
 Modify Bernoulli’s equation to energy equation.
 State Torricelli’s theorem and workout related problems.
 State siphon principleand workout problems.

1.1 Introduction

Fluid power systems are designed using all the principles learned in fluid mechanics. It is appropriate
to briefly review these principles before proceeding with our study of the applications. One of
underlying postulates of fluid mechanics is that, for a particular position within a fluid at rest, the
pressure is the same in all directions. This follows directly from Pascal’s Law. A second postulate
states that fluids can support shear forces only when in motion. These two postulates define the
characteristics of fluid media used to transmit power and control motion. This chapter deals with
fundamental laws and equations which govern the fluid flow which is essential for the rational design
of fluid power components and systems. Traditional concept such as continuity, Bernoulli’s equation
and Torricelli’s theorem are presented after a brief review on mechanics.

1.2 Brief review of Mechanics

Fluid power deals with conversion Hydraulic power to mechanical power. Therefore it is essential to
understand the concept of energy and power.

1.2.1 Energy

Energy is defined as the ability to perform work. If a force acts on a body and moves the body through
a specified distance in the direction of its application, a work has been done on the body. The amount
of this work equals the product of the force and distance where both the force and distance are
measured in the same direction. Mathematically we can write

WD = Fd
where is the force (N), d is the distance (m) and WD is the work done (J or Nm).In the SI system, a
joule (J) is the work done when a force of 1 N acts through a distance of 1 m. Since work equals force
times distance, we have
1 J = 1 N 1 m = 1 Nm
Thus, we have
Energy (J) = F (N) × d (m)
The transfer of energy is an important consideration in the operation of fluid power systems. Energy
from a prime mover is transferred to a pump via a rotating motor shaft and couplings. The pump
converts this mechanical energy into hydraulic energy by increasing the fluid pressure. The
pressurized fluid does work on hydraulic actuators. An actuator converts the hydraulic energy into
mechanical energy and moves the external load. Not all the input mechanical energy is converted into
useful work. There are frictional losses through valves, fittings and other system control components.

1
These losses show up as heat loss that is lost to the atmosphere with the increase in the fluid
temperature.

1.2.2 Power
Itis defined as the rate of doing work. Thus, the power input to the hydraulic system is the rate at
which an actuator delivers energy to the external load. Similarly, the rate at which an actuator delivers
energy to the external load is equal to the power output of a hydraulic system. The power output is
determined by the requirements of the external load.

A hydraulic system is used because of its versatility in transferring power. The versatility includes the
advantages of variable speed, reversibility, overload protection, high power-to-weight ratio and
immunity to damage under a stalled condition:
Fd
Power  P 
t
or P  Fv
where is the force (N), v is the velocity (m/s) and P is the power (N m/s or W). In the SI system, 1
watt (W) of power is the rate at which 1 J of work is done per second:
Work
Power =
Time
In SI units we have
1Joule
1W   1N m / s
s
Thus, we have
Work (N m)
Power (W) 
Time (s)
Balancing the units, we can write
Hydraulic power (W ) = Pressure × Flow
= p (N / m2 )  Q (m3 / s)
= p  Q (N m / s)  p  Q (W)

It is usual to express flow rate in liters/minute (LPM) and pressure in bars. To calculate hydraulic
power using these units, a conversion has to be made. Thus,
Q (L/min) = Q/60 (L/s)
 L  Q L Q  m3 
 Q      3  
 min  60  s  60  10  s 
N
 p (bar)  p 105
m2
Hydraulic power is
 l  1  105  m3 N 
Q   p (bar)    
 min  60  103  s m2 
1  103 Q (LPM)  p (bar)
 Q  p (bar)  (W)  (kW)
600 600

Thus, hydraulic power (kW) is

Flow (LPM) × Pressure (bar)
600
In the SI metric system, all forms of power are expressed in watt. The pump head Hp in units of
meters can be related to pump power in units of watt by using p   h . So

2
 Pump hydraulic power (W)
Hp 
 N  m3 
  3   Q 
m   s 
The above equation can also be used to find a motor head where Hp is replaced by Hm. The hydraulic
power is replaced by the motor hydraulic power and Q represents the motor flow rate.
The mechanical power output (brake power or torque power) delivered by a hydraulic motor can be
found by the following equation
T (N m)   (rad/s) T (N m)  N (rpm)
Power (kW)  
1000 9550
WhereT is the torque and or N is the angular speed.

1.3 Pascal’s Law

Pascal’s law states that the pressure exerted on a confined fluid is transmitted undiminished in all
directions and acts with equal force on equal areas and at right angles to the containing surfaces. In
Fig. 1.1, a force is being applied to a piston, which in turn exerts a pressure on the confined fluid. The
pressure is equal everywhere and acts at right angles to the containing surfaces. Pressure is defined as
the force acting per unit area and is expressed as
F
Pressure 
A
where F is the force acting on the piston, A is the area of the piston and p is the pressure on the fluid.
F

Confined fluid

Figure 1.1 Illustration of Pascal’s law

1.3.1 Multiplication of Force

The most useful feature of fluid power is the ease with which it is able to multiply force. This is
accomplished by using an output piston that is larger than the input piston. Such a system is shown in
Fig. 1.2.

3
 Fin
Fout

Input piston Output piston SoutVoutXout

Ain Aout

SinVinXin

Figure 1.2 Multiplication of force

This system consists of an input cylinder on the left and an output cylinder on the right that is filled
with oil. When the input force is Fin on the input piston, the pressure in the system is given by
F
P  out
Aout
F A
 Fout  PAout  in Aout  out Fin
Ain Ain
Here to obtain the output force, the input force is multiplied by a factor that is equal to the ratio of the
output piston area to the input piston area. If the output piston area is x times the input piston area,
then the output force is x times the input force. Generally, the cross-sectional area of the piston is
circular. The area is given by
A  d 2 / 4
Hence, the above equation can be written as
2
dout
Fout  Fin
din2
2
Fout dout
  2
Fin din
The conservation of energy is very fundamental principle. Itstates that energy can neither be created
nor destroyed. At first sight, multiplication of force as depicted in Fig.1.2 may give the impression
that something small is turned into something big. But this is wrong, since the large piston on the right
is only moved by the fluid displaced by the small piston on left. Therefore, what has been gained in
force must be sacrificed in piston travel displacement. Now we shall mathematically derive force
displacement relation and force power relation.

1. Force displacement relation: A hydraulic oil is assumed to be incompressible; hence, the

volume displaced by the piston is equal to the volume displaced at the output piston:
Vin  Vout
Since the volume of a cylinder equals the product of its cross-sectional area and its height, we
have
Ain Sin  Aout Sout

whereSin is the downward displacement of the input piston and Soutis the upward displacement
of the output piston:
Sin A
 out
Sout Ain
Comparing

4
 Fout Aout Sin
  (1.1)
Fin Ain Sout

2. Force power relation: A hydraulic oil is assumed to be incompressible; hence, the quantity of oil
displaced by the input piston is equal to the quantity of oil gained and displaced at the output
piston:
Flow rate is the product of area and volume of fluid displaced in a specified time

Qin  Qout
 AinVin  AoutVout
Aout Vin (1.2)
 
Ain Vout

Comparing Equations. (1.1) and (1.2) we get

Aout Vin F S
  out  in
Ain Vout Fin Sout
From the above equation, we get
Fin Sin  Fout Sout
or (Work done)in = (Work done)out
We know that
Power = Force x Velocity
 Fin vin  Fout vout
or (Power)in = (Power)out

Example 1.1

An input cylinder with a diameter of 30 mm is connected to an output cylinder with a diameter of 80

mm (Fig. 1.3). A force of 1000 N is applied to the input cylinder.

(a) What is the output force?

(b) How far do we need to move the input cylinder to move the output cylinder 100 mm?

Fin
Fout

SoutVoutXout
Input piston
Output piston
Vout,Xout

Ain Aout

Sin VinXin

Figure 1.3

Solution: Since the volume of a cylinder equals the product of its cross-sectional area and its height,
we have

5
 Ain X in  Aout X out

whereXin is the downward movement of the input piston and Xout is the upward movement of the
output piston. Hence we get
X out Ain

X in Aout
The piston stroke ratio X out / X in equals the piston area ratio Ain / Aout . For a piston area of 10, the
output force Fout increases by a factor of 10, but the output motion decreases by a factor of 10.

Thus, the output force is greater than the input force, but the output movement is less than the input
force and the output movement is less than the input movement. Hence, we can write by combining
equations
X A
Ain X in  Aout X out and out  in
X in Aout
that
Fout X in

Fin X out
 Win  Wout
Hence, the input work equals the output work.
Given Fin = 1000 N, A1 = 0.7854 × 302 mm2 and A2 = 0.7854 × 802 mm2, Sout = 1000 mm.
To calculate SinandF2.
(a) Force on the large piston F2:By Pascal’s law, we have
F1 A1

F2 A2
A F 1000 N
 F2  2 1   0.7854  802
A1 0.7854  302
 F2  7111.1 N

(b) Distance moved by the large piston Sout:We also know by the conversation of
energy that
F1 Sout

F2 Sin
S  F2 1000  7111.1
 Sin  out 
F1 1000
 Sin  7111.11 mm

Example 1.2

A force of P = 850 N is applied to the smaller cylinder of a hydraulic jack (Fig.1.4). The area a of the
small piston is 15 cm2 and the area A of the larger piston is 150 cm2. What load W can be lifted on the
larger piston (a) if the pistons are at the same level, (b) if the large piston is 0.75 m below the smaller
one? The mass density ρ of the liquid in the jack is 103 kg /m3.

Solution: A diagram of a hydraulic jack is shown in Fig. 1.4.A force F is applied to the piston of the
small cylinder which forces oil or water into the large cylinder thus raising the piston supporting the
load W. The force F acting on the area a produces a pressure p1 that is transmitted equally in all
directions through the liquid. If the pistons are at the same level, the pressure p2 acting on the larger
piston must equal p1as per Pascal’s law

6
 W

Small piston Large piston

VoutXout d2
VoutXout

Area, a Area, A
d1

(a)

W
Small piston
Vout, Xout

Area, a
0.75 d2
m d1 Area, A

Large piston
Vout, Xout

Figure 1.4 (a) Pistons are at same level. (b) Pistons are at different level.
We know that
F W
p1  and p2 
a A

If p1  p2 , a small force can raise a larger load W. The jack has a mechanical advantage of A/a.

(a) Now P  850 N, a 15 /1000 m2 , A 150 /10000 m2 . Using Pascal’s law we can write

p1  p2
F W
 
a A
F  A 850  1.5
W    8500 N
a 0.15
Now
W 8500
Mass lifted    868 kg
g 9.81
(b) If the larger piston is a distance h below the smaller, the pressure p2 is greater than p1, due to
the head h, by an amount g where is the mass density of the liquid:

7
 p2  p1   gh
Now
F 850
p1    56.7 104 N / m 2
a 15  104
 103 kg / m3
h 0.75 m
So
p2  56.7 104  (103  9.81)  0.75
 57.44 104 N / m2
Now
W  p2 A  57.44104150 104 8650 N
Therefore
W
Mass lifted   883 kg
g

Example 1.3

Two hydraulic cylinders are connected at their piston ends (cap ends rather than rod ends) by a single
pipe (Fig. 1.5). Cylinder A has a diameter of 50 mm and cylinder B has a diameter of 100 mm. A
retraction force of 2222 N is applied to the piston rod of cylinder A. Determine the following:

(a) Pressure at cylinder A.

(b) Pressure at cylinder B.
(c) Pressure in the connection pipe.
(d) Output force of cylinder B.

F1 = 2222 N F2

Cylinder A, Cylinder B, VoutXout

VoutXout d2

A1 A2
d1

Figure 1.5

Area of the piston of cylinder A is


(50)2  1963.5 mm2
4
Area of the piston of cylinder B is

(100)2  7853.8 mm2
4

(a) Pressure in cylinder A is given by

8
 Force 2222 N
  1.132  1.132 MPa
Area 1963.5 mm2
(b) By Pascal’s law, pressure in cylinder A = pressure in cylinder B = 1.132 MPa
(c) By Pascal’s law, pressure in cylinder A = pressure in cylinder B = pressure in the pipe line
= 1.132 MPa

(d) Force on the large piston (cylinder B) F2: By Pascal’s law, we have
F1 A1

F2 A2
A F 2222 N
 F2  2 1   7853.8 mm2  8888 N
A1 1963.5 mm2

Example 1.4

A pump delivers oil to a cylindrical storage tank, as shown in Fig. 1.6. A faulty pressure switch,
which controls the electric motor driving the pump, allows the pump to fill the tank completely. This
causes the pressure p1 near the base of the tank to build to 103.4 kPa.

(a) What force is exerted on the top of the tank?

(b) What does the pressure difference between the tank top and point 1 say about Pascal’s law?

(c) What must be true about the magnitude of system pressure if the changes in pressure due to
elevation changes can be ignored in a fluid power system (assume the specific gravity of oil to be
0.9).
3048

p1

6096

9144

Pump

All dimensions in mm

Figure 1.6

(a) We know that

p   (H )
N
 900  9.81  (6.096 m)
m3
 53821.6 Pa
 53.822 kPa

Thus,
Ftop of tank  103.4  53.82  49.58 kPa

9
(b) Now
F = Pressure × Area

 49.58  1000  (3.048) 2
4
 361755 N
=361.76 kN

Pascal’s law states that pressure in a static body of fluid is transmitted equally only at the same
elevation level. Pressure increases with depth and vice versa in accordance with the following
equation: p   (H ) .

(c) Changes in pressure due to elevation changes can be ignored in a fluid power system as long as
they are small compared to the magnitude of the system pressure produced at the pump discharge
port.

Example 1.5

The hydraulic jack, shown in Fig. 1.7, is filled with oil. The large and small pistons have diameters of
75 and 25 mm, respectively. What force on the handle is required to support a load of 8896 N? If the
force moves down by 125 mm, how far is the weight lifted?

Load

25 mm 375 mm

Figure 1.7

Solution: The relation for the lever force system gives

F  400  F1  25
F
F 1
16
Now since the oil pressure must remain the same everywhere, we have p1  p2 . Therefore

F1 F2

A1 A2

10
 F1 8896
 
  0.025 / 4   0.0752 / 4
2

 F1  988.44 N
From the relation obtained above, we get
F1 988.44
F   61.78 N
16 16
The force moves by 125 mm. The force displacement diagram is shown in Fig. 1.8

Load
25 mm 375 mm

25 mm 375 mm
Q
P R
S1
T

Figure 1.8Force displacement diagram

From Fig. 1.8 we have

RS RP

QT PQ
RS RP
 
S1 PQ
RS  PQ 150  25
 S1    9.375 mm
RP 400
Now
A1S1  A2 S2
252 752
   9.375     S2
4 4
1
 S2   9.375  1mm
9

Hence, 150 mm stroke length of lever moves the load of 8896 N by only 1 mm. In other words,
mechanical advantage is obtained at the expense of distance traveled by the load.

11
Example 1.6

In the hydraulic device shown in Fig.1.9, calculate the output torque T2, if the input torque T1 =10 N-
cm. Use the following data: radius R1 = 2 cm, diameter d1 = 8 cm, radius R2 = 4 cm, diameter d2 = 24
cm.

d2

Figure 1.9

Solution: We can use Pascal’s law and write

p1  p2
F1 A1
 
F2 A2
F F
 12  22
d1 d 2

Since torque T  F  R which implies F  T / R, we can also write

T1 T
2
 22
R1d1 R2 d 2

T1  R2 d 22
 T2 
R1d12
10  4  242
 T2   180 N cm
2  82
Alternate method: We know that
Torque T  Force  Radius of the gear
Consider gear 1. We have
T1  F1 R1
T1 10
 F1   5N
R1 2
Now
F1
p1 
A1
whereA1 is the area of the horizontal piston given by

12
  
(d 2 )  (82 )  49.84 cm2
4 4
So
5
p1   0.100 N / cm2
49.84

According to Pascal’s law, p1  p2  0.100 N / cm2 . Here

F
p2  2
A2
whereA2 is the area of the horizontal piston given by
 2 
(d ) 
2
(24 )  452.16 cm2
4 4
So
F2
p2 
A2
F2
 0.100 
452.16
 F2  45.216 N
Now
T2  F2 R2  45.216  4  180.8 N cm

Example 1.7
A hydraulic system has 380 L reservoir mounted above the pump to produce a positive pressure
(above atmospheric) at the pump inlet, as shown in Fig. 1.10. The purpose of the positive pressure is
to prevent the pump from cavitating, when operating, especially at start up. If the pressure at the pump
inlet is to be 0.35 bar prior to turning the pump ON and the oil has a specific gravity of 0.9, what
should the oil level be above the pump inlet?
Vent

h 0.36 bar

Filter

Pump

Figure 1.10

We know that
poil   oil H oil
poil 0.35  105 N/m2
 H oil    3.96 m
 oil 0.90  9797 N/m3
Thus, oil level should be 3.96 m above the pump inlet.

Example 1.8

13
For the hydraulic pressure shown in Fig. 1.11, what would be the pressure at the pump inlet if the
reservoir were located below the pump so that the oil level would be 1.22 m below the pump inlet?
The specific gravity of oil is 0.90. Ignore frictional losses and changes in kinetic energy on the
pressure at the pump inlet. Would this increase or decrease the chances for having pump cavitation? If
yes, why?
p
Pump

Vent
Q

Filter

Figure 1.11

Solution: We know that

poil   oil H oil
N
 0.90  9797  1.22 m  10757 Pa
m3
= −0.10757 bar (gauge)
Frictional losses and changes in kinetic energy would cause the pressure at the pump inlet to increase
negatively (greater suction pressure) because pressure energy decreases as per Bernoulli’s equation.
This would increase the chances for having the pump cavitation because the pump inlet pressure more
closely approaches the vapor pressure of the fluid (usually about 0.34 bar suction) or −0.34 bar
(gauge), allowing for the formation and collapse of vapor bubbles

Example 1.9
A hydraulic cylinder is to compress a body down to bale size in 10 s. The operation requires a 3 m
stroke and a 40000 N force. If a 10 MPa pump has been selected, assuming the cylinder to be 100%
efficient, find
(a) The required piston area.
(b) The necessary pump flow rate.
(c) The hydraulic power delivered to the cylinder.
(d) The output power delivered to the load.
(e) Also solve parts (a)–(d) assuming a 400 N friction force and a leakage of 1 LPM. What is the
efficiency of the cylinder with the given friction force and leakage?

Solution:

(a) Since the fluid pressure is undiminished, we have p1  p2  10 MPa . Now

F2 F 40000
p2   A2  2   0.004 m2
A2 p2 10 10 6

which is the required piston area.

(b) Stroke length l  3 m , time for stroke t  10 s , piston area A2  0.004 m . Flow rate is
2

14
 A2l 0.004  3
Q   12  104 (m3 /s)  72 LPM
t 10

(c) Power delivered to the cylinder

Power  Pressure  Flow rate
 (10 106 )  (12 104 )
 12000 W  12 kW
(d) Power delivered to load is

F  l 40000  3
Power    12000 W  12 kW
t 10
Since efficiency is assumed to be 100%, both powers are the same.

(e) With a friction force of f  400 N and 1LPM leakage, piston area is

F2  f 40000  400
A2    0.00404 m2
p2 10 106
Now pump flow rate is
A2l 0.00404  3
Q  
t 10
4
 12.12  10 m3 / s  72.72 LPM
So

Total flow  Q  Leakage

 72.72  1
 73.72 LPM
 12.287  104 m3 / s

Power delivered to the cylinder is given by

p  Q = (10 106 )  (12.287 104 )
12287 W  12.287 kW
Power delivered to the load is
F  l 40000  3
Power    12000 W  12 kW
t 10

It will remain the same as without losses. The efficiency of the cylinder
Power delivered to load

Power delivered to cylinder
12
  100  97.66%
12.287
Example 1.10
An automobile lift raises a 15600 N car 2.13 m above the ground floor level. If the hydraulic cylinder
contains a piston of diameter 20.32 cm and a rod of diameter 10.16 cm, determine the
(a) Work necessary to lift the car.
(b) Required pressure.
(c) Power if the lift raises the car in 10 s.
(d) Descending speed of the lift for 0.000629 m3/s flow rate.
(f) Flow rate for the auto to descend in 10 s.

15
Solution:
(a) We have

Work necessary to lift the car = Force × Distance

= 15600 × 2.13 m = 33200 N m

(b) We have
 (0.2032)2 m2
Piston area   0.0324 m 2
4
So required pressure is
Force 15600
Pressure  
Area 0.0324
 481000N / m2  481 kPa

(c) We have
Work done 33200
Power  
Time 10
 3320N m / s  3320 W  3.32 kW

(d) Q = 0.000629 m3/s.

 (0.2032)2   (0.1016)2
Annulus area   0.0243 m2
4
So
Flow rate 0.000629
Decending speed of the lift    0.0259 m / s
Annulus area 0.0243

(e) Flow rate for the auto to descend in 10 s is

Distance
Flow rate  Annulus area 
Time
2.13
 0.0243   0.00518 m3 / s
10
1.3.2 Practical Applications of Pascal’s Law

The practical applications of Pascal’s law are numerous. In this section, two applications of Pascal’s
law are presented: (a) The hand-operated hydraulic jack and (b) the air-to-hydraulic pressure booster.

1.3.2.1 Hand-Operated Hydraulic Jack

This system uses a piston-type hand pump to power a hydraulic load cylinder for lifting loads, as
illustrated in Fig. 1.12. The operation is as follows:

1. A hand force is applied at point A of handle ABC which is pivoted at point C. The piston rod
of the pump cylinder is pinned to the input handle of the pump piston at point B.
2. The pump cylinder contains a small-diameter piston that is free to move up and down. The
piston and rod are rigidly connected together. When the handle is pulled up, the piston rises
and creates a vacuum in the space below it. As a result, the atmospheric pressure forces the oil
to leave the oil tank and flow through check valve 1 to fill the void created below the pump
piston. This is the suction process.
3. A check valve allows flow to pass in only one direction, as indicated by the arrow. When the
handle is pushed down, oil is ejected from the small-diameter pump cylinder and it flows
through check valve 2 and enters the bottom end of the large-diameter load cylinder.

16
 4. The load cylinder is similar in construction to the pump cylinder and contains a piston
connected to a rod. Pressure builds up below the load piston and equals the pressure generated
by the pump piston. The pressure generated by the pump piston equals the force applied to the
pump piston rod divided by the area of the pump piston.
5. The load that can be lifted equals the product of the pressure and the area of the load piston.
Also, each time when the input handle is cycled up and down, a specified volume of oil is
ejected from the pump to raise the load cylinder a given distance.
6. The bleed valve is a hand-operated valve, which, when opened, allows the load to be lowered
by bleeding oil from the load cylinder back to the oil tank.

Hand force

150 mm 50 mm
Load

C
A B

Handle

Pump piston Check valve 2

Check valve 1

Atmospheric Load cylinder

pressure

Bleed valve

Oil tank

Figure 1.12 Application of Pascal’s law: Hand-operated hydraulic jack

1.3.2.2 Air-to-Hydraulic Pressure Booster

This device is used for converting shop air into higher hydraulic pressure needed for operating
hydraulic cylinders requiring small to medium volumes of higher pressure oil. It consists of a cylinder
containing a large-diameter air piston driving a small-diameter hydraulic piston that is actually a long
rod connected to the piston. Any shop equipped with an airline can obtain smooth, efficient hydraulic
power from an air-to-hydraulic pressure booster hooked into the air line. The alternative would be a
complete hydraulic system including expensive pumps and high-pressure valves. Other benefits
include space savings and low operating and maintenance costs.

Figure 1.13 shows an application where an air-to-hydraulic pressure booster supplies high-pressure oil
to a hydraulic cylinder whose short stroke piston is used to clamp a workpiece to a machine tool table.
Since shop air pressure normally operates at 100 psi, a pneumatically operated clamp would require
an excessively large cylinder to rigidly hold the workpiece while it is being machined.

17
 Inlet air supply

Air valve

Air

Air piston

Clamp
Retractable shortstroke piston

Oil
Work
piece

Machine tool table

Figure 1.13Application of Pascal’s law: Air-to-hydraulic pressure booster

The air-to-hydraulic pressure booster operates as follows. Let us assume that the air piston has 10 cm2
area and is subjected to a 10 bar air pressure. This produces a 1000 N force on the booster’s hydraulic
piston. Thus, if the area of the booster’s hydraulic piston is 1 cm2, the hydraulic oil pressure is 100
bar. As per Pascal’s law, this produces 100 bar oil at the short stroke piston of the hydraulic clamping
cylinder mounted on the machine tool table.

The pressure ratio of an air-to-hydraulic pressure booster can be found by using the following
equation:
Output oil pressure
Pressure ratio 
Input oil pressure
Area of air piston

Area of hydraulic piston

Substituting into the above equation for the earlier mentioned pressure booster, we have
10000 kPa 10 cm2
Pressure ratio  
1000 kPa 1 cm2
For a clamping cylinder piston area of 0.5 cm2, the clamping force equals 1000 N/cm2 × 0.5 cm2 or
500 N. To provide the same clamping force of 500 N without booster requires a clamping cylinder
piston area of 5 cm2, assuming 10 bar air pressure. Air-to-hydraulic pressure boosters are available in
a wide range of pressure ratios and can provide hydraulic pressures up to 1000 bar using
approximately 7 bar shop air.

Example 1.11
An operator makes 15 complete cycles in 15 s interval using the hand pump shown in Fig. 1.14. Each
complete cycle consists of two pump strokes (intake and power). The pump has a piston of diameter
30 mm and the load cylinder has a piston of diameter 150 mm. The average hand force is 100 N
during each power stroke.

18
(a) How much load can be lifted?

(b) How many cycles are required to lift the load by 500 mm, assuming no oil leakage? The pump
piston has 20 mm stroke.

(c) What is the output power assuming 80% efficiency?

Hand force

500 50 mm
mm Load

C
A B

Handle

Pump
piston Check valve 2

Check valve 1

Load
cylinder
Bleed valve

Oil
tankTan
k
Figure 1.14

Solution:Given:pump diameter d  30 mm , load cylinder diameter D150 mm , hand force

f 100 N , number of cycles n 15 strokes/s, pump piston force
100  550
F1   1100 N
50
(a) Load capacity: Now since the pressure remains undiminished throughout, we have p1  p2 .
Therefore,
F1 F2

A1 A2
 D2 / 4 1502
 F2  F  1100  27500 N  27.5 kN
d2 / 4
1
302

(b) Number of cycles:Stroke length l = 20 mm. Let the number of strokes be N.Then assuming no
leakage, we get
Q1  Q2
where

= Total volume of fluid displaced by pump piston

= (Area Stroke) Number of strokes =
= Flow rate of load cylinder= (Area Stroke of load cylinder)
=
So we get
N  A1l  A2  500
1502
N 500  625
20  302
Hence, the number of cycles required is 625.

19
(c) Output power:
Input power = F1  l n
Output power =   F1  l n  0.8 1100  0.02 15  264 W

Example 1.12
For the pressure booster of Fig. 1.15, the following data are given:
Inlet oil pressure (p1) = 1 MPa
Air piston area (A1) = 0.02 m2
Oil piston area (A2) = 0.001 m2
Load carrying capacity = 300000 N
Find the load required on load piston area A3.

Inlet air supply

Air valve

Air (p1 = air intake pressure)

F = Load
Air piston

Hydraulic
cylinder

Load piston

Oil

p3

p2 = Oil pressure

Figure 1.15

Solution:We know that

p1 A1 1MPa  0.02 m2
p2    20 MPa
A2 0.001m2
Also p3  p2  20 MPa . So
F 300000 N
A3    0.015 m2
p3 20  10 N / m
6 2

1.4 Conservation of Energy

The first law of thermodynamics states that energy can neither be created nor be destroyed. Moreover,
all forms of energy are equivalent. The various forms of energy present in fluid flow are briefly
discussed. The total energy includes potential energy due to elevation and pressure and also kinetic
energy due to velocity. Let us discuss all these in detail.

1. Kinetic energy of a flowing fluid:A body of mass m moving with velocity vpossesses a kinetic
energy (KE), that is,

20
 mv 2
KE 
2

Thus, if a fluid were flowing with all particles moving at the same velocity, its kinetic energy would
also be (1/ 2)(m) v2 ; this can be written as
1 2 1
mv [( )Volume]v 2
KE 2 2 v2
  
Weight ( )Volume ( )Volume 2g

whereg is the acceleration due to gravity. In SI units,v2/2g is expressed as Nm/N = m..

2. Potential energy due to elevation (z): Consider a unit weight of fluid as shown in Fig. 1.16.The
potential energy of a particle of a fluid depends on its elevation above any arbitrary plane. We are
usually interested only in the differences of elevation, and therefore the location of the datum plane is
determined solely by consideration of convenience. A fluid particle of weight W situated at a distance
Z above datum possesses a potential energy Wz. Thus, in SI units, its potential energy per unit weight
is expressed asNm/N = m.

p W = unit weight of fluid

p p

z
p
Datum

Figure 1.16Potential energy due to elevation

3. Potential energy due to pressure (PE): This term represents the energy possessed by a fluid per
unit weight of fluid by virtue of the pressure under which the fluid exists:

p
PE 

where is the specific weight of the fluid. PE has the unit of meter. The total energy possessed by the
weight of fluid remains constant (unless energy is added to the fluid via pumps or removed from the
fluid via hydraulic motors or friction) as the weight W flows through a pipeline of a hydraulic system.
Mathematically, we have
p v2
ETotal  z  
 2g
Energy can be changed from one form to another. For example, the chunk of fluid may lose elevation
as it flows through a hydraulic system and thus has less potential energy. This, however, would result
in an equal increase in either the fluid’s pressure energy or its kinetic energy. The energy equation
takes into account the fact that energy is added to the fluid via pumps and that energy is removed from
the fluid via hydraulic motors and friction as the fluid flows through actual hydraulic systems.

21
Example 1.13
Oil with specific gravity 0.9 enters a tee, as shown in Fig. 1.18, with velocity v1 =5 m/s. The diameter
at section 1 is 10 cm, the diameter at section 2 is 7 cm and the diameter at section 3 is 6 cm. If equal
flow rates are to occur at sections 2 and 3, find the velocities v2 and v3.

2
Q Tee
1
3

Figure 1.18

Solution: Assuming no leakage

Q1  Q2  Q3
Also,
1 1
Q2  Q3  Q1  A1v1
2 2
1  d12 1   0.12
   v1    5  19.63  103 m3 /s
2 4 2 4
Therefore,
Q2 19.63  103
v2    5.1 m / s
A2   0.072 / 4
Q3 19.63 103
v3    6.942 m / s
A3   0.062 / 4

Example 1.14
A double-rod cylinder is one in which a rod extends out of the cylinder at both ends (Fig. 1.19). Such
a cylinder with a piston of diameter 75 mm and a rod of diameter 50 mm cycles through 254 mm
stroke at 60 cycles/min. What LPM size pump is required?

Barrel
Piston
Extension stroke

Rod Retractionstroke

Port Port
Figure 1.19

Solution: The annulus area is

22
  (752  502 )
AAnnulus   2454 mm2
4
Volume of oil displaced per minute (m3/s) is
Area × Stroke length × No. of cycles per second
Now
 (752  502 ) mm2  254  60
Q  106 m2    2 (m)  (s)
4 1000  60
 0.001296 m /s  77.8 LPM
3

We can select 80 LPM pump.

Example 1.15
A cylinder with a piston of diameter 8 cm and a rod of diameter 3 cm receives fluid at 30 LPM. If the
cylinder has a stroke of 35 cm, what is the maximum cycle rate that can be accomplished?

Solution:We know that

Volume of oil displaced per minute (m3/min) = Area × Stroke length × No. of cycles per
minute
So

 (0.082 ) m2  35   (0.082  0.032 ) m2  35 

Q   (m)  N (cycles / min)    (m)  N (cycles / min)
4 100  4 100 
 0.03m3 / min
 0.030  0.00176  0.0015  N
 N  9.2 cycles/min

Example 1.16
A hydraulic pump delivers a fluid at 50 LPM and 10000 kPa. How much hydraulic power does the
pump produce?

Solution: We have
50
Q  50 LPM   0.833  103 m3 /s
60  103
Now
1 L = 1000 cc = 1000 × 106 m3 = 103 m3
So
Power (kW) = p (kPa) ×Q (m3/s)
= 10000 × 0.833  103
= 8.33 kW = 8330 W

23
1.7 The Energy Equation
The Bernoulli equation discussed above can be modified to account for fractional losses (HL) between
stations 1 and 2. Here HLrepresents the energy loss due to friction of 1 kg of fluid moving from
station 1 to station 2. As discussed earlier, represents the energy head put into the flow by the
pump. If there exists a hydraulic motor or turbine between stations 1 and 2, then it removes energy
from the fluid. If Hm (motor head) represents the energy per kg of fluid removed by a hydraulic motor,
the modified Bernoulli equation (also called the energy equation) is stated as follows for a fluid
flowing in a pipeline from station 1 to station 2: The total energy possessed by 1 kg of fluid at station
1 plus the energy added to it by a pump minus the energy removed from it by a hydraulic motor minus
the energy it loses due to friction equals the total energy possessed by 1 kg of fluid when it arrives at
station 2. The energy equation is as follows, where each term represents a head and thus has the unit
of length:

p1 v12 p v2
z1    H p  H m  H L  z2  2  2
 2g  2g

1.9 Elements of Hydraulic Systems and the Corresponding Bernoulli’s Equation

The main elements of hydraulic systems are pump, motor, pipes, valves and fittings. Let us write the
energy flow from point1 to point 2 as shown in Fig. 1.22.After the fluid leaves point 1, it enters the
pump where energy is added. A prime mover, such as an electric motor, drives the pump and the
impeller of the pump transfers the energy to the fluid. Then the fluid flows through a piping system
composed of a valve, elbows and the lengths of pipe in which energy is dissipated from the fluid and
is lost. Before reaching point 2, the fluid flows through a fluid motor that removes some of the energy
to drive an external device. The general energy equation accounts for all these energies.
In a particular problem, it is possible that not all of the terms in the general energy equation are
required. For example, if there is no mechanical device between the sections of interest, the terms Hp
and Hmwill be zero and can be left out of the equation. If energy losses are so small that they can be
neglected, the term HL can be left out. If both these conditions exist, it can be seen that the energy
equation reduces to Bernoulli’s equation.

Hydraulic motor

Frictional
(Energy
losses delivered)
Fitting Hm

Valve Flow out

Pump
Fitting
1
Flow
Hp (Energy received)
in

Figure1.22Elements of a hydraulic system

24
Example 1.17
(a) Calculate the work required for a pump to pump water from a well to ground level 125 m above
the bottom of the well (see Fig.1.23). At the inlet to the pump, the pressure is 96.5 kPa, and at the
system outlet, it is 103.4 kPa. Assume the constant pipe diameter. Use  = 9810 N/m3, and assume it
to be constant. Neglect any flow losses in the system.

2
p2 =103.4 kPa z2

125 m
p1 =96.5 kPa

1
z1 =0

Figure 1.23

Given z1  0, z2  125 m, p1  96.5kPa, p2  103.4kPa, H L  0, D1  D2 . FindHp.

Assumptions: Steady incompressible flow, no losses
Basic equations:
Continuity: A1v1 = A2v2
p1 v12 p v2
Energy equation:   z1  H p  2  2  z2  H L
 2g  2g

(b) Solve the above problem if there is friction in the system whose total head loss equals 12.5 m.
Given z1  0, z2  125 m, p1  96.5kPa, p2  103.4kPa, H L  12.5m, D1  D2 . FindHp.
Assumptions: Steady incompressible flow, no losses
Basic equations:
Continuity: A1v1 = A2v2
p1 v12 p v2
Energy equation:   z1  H p  2  2  z2  H L
 2g  2g

Solution:

(a) Write the energy equation

p1 v12 p v2
  z1  H p  2  2  z2  H L
 2g  2g
Note that v1 =v2 and HL = 0.Thus,
p2 p1
Hp    z2  z1
 
With z1 = 0we get
103.4 kPa 96.5 kPa
Hp    125  125.7 m
9.81kN / m 9.81kN / m3
3

(b) Write the energy equation

p1 v12 p v2
  z1  H p  2  2  z2  H L
 2g  2g

25
As before, v1 =v2 but HL = 12.5 m.Therefore,
p2 p1
Hp    z2  z1  H L
 
With z1 = 0 we get
103.4 kPa 96.5 kPa
Hp    137.5  138.2 m
9.81kN / m 9.81kN / m3
3

Note that the pump is required to overcome the additional friction head loss, and for the same flow,
this requires more pump work. The additional pump work is equal to the head loss.

Example 1.18
A hydraulic turbine is connected as shown in Fig. 1.24. How much power will it develop? Use 1000
kg/ m3 for the density of water. Neglect the flow losses in the system.

1 (p1 =1000 kPa)

Q = 0.01 m3/s

30 m Pipe 100mm
throughout

2
(p2 =500 kPa)

Datum

Figure 1.24
Given z1  30m, z2  0, p1  1000kPa, p2  500kPa, H L  0, D1  D2  100mm, Q =0.01m3 / s.
Find turbine power.
Assumptions: Steady incompressible flow, no losses
Basic equations:
Continuity: A1v1 = A2v2
p1 v12 p v2
Energy:   z1  H p  2  2  z2  H L
 2g  2g
Power: P  H T  Q  
Solution: Again let us write the energy equation, but this time for a turbine:
p1 v12 p v2
  z1  H p  2  2  z2  H L
 2g  2g
Since there are no losses in the pipe and the pipe diameter is constant, v1  v2 , z2  0, z1  30 m.
Therefore, H T is found as
p1  p2
HT   ( z1  z2 )

Using the data given we get

26
 (1000  500)1000
HT   (30  0)  80.97 m
1000  9.81
Horsepower is given by
Horsepower  H T  Q  
 80.97  0.011000  9.81
 7941 W  7.941 kW

Example 1.19
For the hydraulic system shown in Fig.1.25, the following data are given:
The pump is adding 4 kW to the fluid (i.e., the hydraulic power of the pump).
The pump flow is 0.002 m3/s.
The pipe has an inside diameter of 25 mm.
The specific gravity of oil is 0.9.
Point 2 is at an elevation of 0.6 m above the oil level, that is, point 1.
The head loss due to friction in the line between points 1 and 2 is 10.
Determine the fluid pressure at point 2, the inlet to the hydraulic motor. Neglect the pressure drop at
the strainer. The oil tank is vented to atmosphere.

Hydraulic motor
2

0.6 m Breather Pump Electric motor

Strainer

Figure 1.25

Solution:Givenp1 = 0 (as the tank is vented to the atmosphere)

P (kW) = 4 (kW) = 4 × 103 W
Q = 0.002 m3/s
Dp= 25 mm = 0.025 m
SG = 0.9
z 2 – z 1= 6 m
HL = 10 m
Hm = 0 (there is no motor between 1 and 2)

The problem can be solved by using the energy equation (Bernoulli’s equation):
p1 v12 p v2
z1    H p  H m  H L  z2  2  2
 2g  2g
We can take v1 = 0 since the tank cross-section is large. Let us compute some of the unknown terms
in the equation. The pump head is given by

27
 P (W)
Hp 
 (N/m3 )  Q (m3 /s)
4  103
  226.7 m
0.9  9800  0.002
The velocity head is
Q (m3 /s) 0.002
v2    4.07 m/s
2
A (m ) 
(0.0252 )
4

The velocity head is

v22 4.072
  0.85 m
2 g 2  9.81

Substituting the values into the energy equation and rearranging, we can write
p
z1  0  0  266.7  0  10  z2  2  0.85

p
 2  ( z1  z2 )  266.7  10  0.85  6  266.7  10  0.85

p
 2  209.85 m

 p2  209.85  0.9  9800  1850877 Pa  1850.9 kPa

Example 1.20
The oil tank for the hydraulic system shown in Fig.1.26is pressurized at 68 kPa gauge pressure. The
inlet to the pump is 3 m below the oil level. The pump flow rate is 0.001896 m3/s. Find the pressure at
station 2. The specific gravity of oil is 0.9 and kinematic viscosity of oil is 100 cS. Assume the
pressure drop across the strainer to be 6.9 kPa. Also given the pipe diameter is 38 mm and the total
length of the pipe is 6 m.
Total pipe length = 6m

Breather 38 mm dia
pipe

z1

3m

z2 Electric
motor
Pump

Figure 1.26

Solution: We have p1 = 68 kPa, z1− z2 = 3 m, Q = 0.001896 m3/s, ps= 6.9 kPa, SG = 0.9, Dp= 38 mm,
v= 100 cS, Lp= 6 m. To calculate p2 .
By the application of Bernoulli’s (energy) equation, we can write
p1 v12 p v2
z1    H p  H m  H L  z2  2  2
 2g  2g

28
Now z1  z2  3 m , H m  0 (because there is no fluid motor between points 1 and 2), v1  0 (assuming
the oil tank area to be large).The velocity at point 2, v2, is
Q (m3 /s) 0.001896
v2    1.67 m / s
A (m )  (0.0382 ) / 4
2

Equivalent velocity head is

v22 1.672
  0.142 m
2 g 2  9.81
The head loss is
f  Lp v2
HL  
Dp 2g
Here
Lp  Total length of pipe  6 m
Dp  Diameter of pipe  0.38 m
Value of f (friction factor) depends on the value of Reynolds number.
vDp1.67  0.038
Re  
 100  106
 634.6  2000, flow is laminar
Now
64 64
f    0.1
Re 634.6
So head loss due to friction is
0.1  6
HL   0.142  2.24 m
0.038

Case 1: Point 2 is before the pump

When point 2 is before the pump, the pump head is zero, that is, H p  0. Rearranging the energy
equation to solve for the present head, we can write
p2 p1 v22
 ( z1  z2 )   Hp  HL 
  2g
68000
 3  0  2.24  0.142  8.33 m
0.9  9800

 p2  8.33  0.9  9800  73470 Pa  73.5 kPa

This valve ofp2 is without considering the pressure drop across the strainer. The pressure drop is 6.9
kPa across the strainer. Therefore, the pressure at point 2 is
p2actual  73.5  6.9 kPa  66.6 kPa
Which is less than 1 atmospheric pressure (101 kPa)?

Case 2: Point 2 is after the pump

When point 2 is after the pump, the pump head must be taken into account
P(W)
Hp 
 (N/m3 )  Q (m3 /s)

Now
  SG   water  0.9  9800 N / m3
Also

29
 Power  p1  Q
 kN   m3 
P  68  3   0.001896    0.13 kW
m   s 
So
0.13 103 W
Hp   7.7 m
 N   m3 
0.9  9800  3   0.001896  
m   s 

Rearranging the energy equation to solve for the present head, we can write
p2 p v2
 ( z1  z2 )  1  H p  2
  2g
68000
 3  7.7  2.24  0.142
0.9  9800
 16.028 m

This valve of p2 is without considering the pressure drop across the strainer. The pressure drop is 6.9
kPa across the strainer. Therefore, the pressure at point 2 is
p2-actual  p2  6.9 kPa  141.4  6  134.5 kPa
which isgreater than 1 atmospheric pressure (101 kPa).

Example 1.21
The volume flow rate through the pump shown in Fig.1.27is 7.8 m3/s. The fluid being pumped is oil
with specific gravity 0.86. Calculate the energy delivered by the pump to the oil per unit weight of oil
flowing in the system. Energy losses in the system are caused by the check valve and friction losses as
the fluid flows through the piping. The magnitude of such losses has been determined to be 1.86 N
m/N.

B
=296 kPa

25 mm pipe
=28 kPa
1m
Flow

Hydraulic pump
75 mm dia pipe

Figure 1.27

Solution: Using the section where pressure gauges are located as the section of interest, write the
energy equation for the system, including only the necessary terms:

30
 pA v2 p v2
 zA  A  H Added  H Removed  H Losses  B  zB  B
γ 2g  2g
p  pA v v
2 2
or H Added  B  zB  zA  B A  H Losses
 2g
In this case, the specific gravity of oil is
γ  (SG)(γwater )  (0.86)(9.81)  8.44 kN/m3
Since pB  296 kPa and pA  28 kPa we get
pB  pA [296  (28)] kN m3
   38.4 m
 m2 8.44 kN
Now zB  zA  1 m as B is at a higher elevation than A.The volume flow rate and continuity
equation are used to determine the velocity. Now
Q  Av  AAvA  ABvB
Q  0.014 m3  3
 vA    (4.768 10 )m  2.94 m/s
2

AA  s 
Q  0.014 m 
3
3
and vB    (2.168 10 )m  6.46 m/s
2

AB  s 
So,
vB2  vA2 (6.462  2.942 ) m 2 / s 2
  1.69 m
2g  9.81 m 
2 
 s 
2

Given H Losses  1.86 m . Therefore,

H Added  38.4 m  1.0 m  1.69 m  1.86 m  42.9 m or 42.9 N m/N
That is, the pump delivers 42.9 N m of energy to each newton of oil flowing through it.

Example 1.22
For the hydraulic system of Fig.1.28, the following data are given:
1. Pump flow is 0.001896 m3/s.
2. The air pressure at station 1 in the hydraulic tank is 68.97 kPa gauge pressure.
3. The inlet line to the pump is 3.048 m below the oil level.
4. The pipe has an inside diameter of 0.0381 m.

Find the pressure at station 2 if

(a) There is no head loss between stations 1 and 2.
(b) There is 7.622 m head loss between stations 1 and 2.

31
 Breather
0.0381 m (ID)

3.048 m

Pump

Figure 1.28

Solution: We use Bernoulli’s equation

p1 v12 p v2
z1    H p  H m  H L  z2  2  2
 2g  2g

Case (a): There is no head loss between stations 1 and 2

Here z1  z2  3.0489 m, H L  0, p1 =68.97 kPa. Now

Flow 0.001896
v2    1.66 m/s
Area  (0.03812 )
4
H
Since there is no pump between 1 and 2, p  0.
Since there is no motor between 1 and 2, H m  0.
Assume v1 = 0 (assuming that area of cross-section is large).
Simplification gives for no head loss,
p1 p2 v2
  z2  z1  2
g g 2g
Assuming  g  8817 N/m3 we get

68970 N/m2 p2 (1.66 m/s)2

 0  z1  0  0  0   z
8817 N/m3  g 2  9.81 m/s 2 2
Knowing that z1  z2  3.048 m we get
p2 68970 (1.66)2
 3.048    3.048  7.82  0.142  10.73 m
g 8817 2  9.81

p2  10.73 (m)  8817 (N/m3 )  94610 Pa

 94.6 kPa

32
Case (b): There is 7.622 m head loss between stations 1 and 2

p2
 10.73 m  7.622  3.11 m
g
So
p2  3.11 (m)  8817 (N/m3 )  27400 Pa
 27.4 kPa

Example 1.23
For the pump in Fig.1.29, Qout =0.00190 m3/s of oil having a specific gravity of 0.9. What is Qin? Find
the pressure difference between A and B if
(a) The pump is turned OFF.
(b) The input power to the pump is 1494 W.

0.0254 m dia pipe

B
0.0508 m dia pipe
Qout
A
Pump
Qin

Figure 1.29

Solution:
(a) The pump is turned OFF:

As per Bernoulli’s equation, pB  pA  0

(b) The input power to the pump is 1494 W

We use Bernoulli’s equation:

pA vA2 p v2
  zA  H p  H m  H L  B  B  zB
 g 2g  g 2g
Here
Pump power (W)
Hp 
 (N/m3 )  Q(m3 /s)
1494
  89.2 m
0.9  9800  0.00190

Flow 0.00190
vA    0.937 m/s
Area  (0.05082 )
4

33
 Flow 0.00190
vB    3.75 m/s
Area  (0.02542 )
4
Substituting values, we have

( pA  pB ) (vB2  vA2 )
 Hp 
 2g
(3.752  0.937 2 )
 89.2 
2  9.81
 88.5 m
So
pB  88.5 (m)  9800 (N/m3 )  0.9
 781000 Pa
 781kPa

1.10 Torricelli’s Theorem

Torricelli’s theorem is Bernoulli’s equation with certain assumptions made. Torricelli’s theorem states
that the velocity of the water jet of liquid is directly proportional to the square root of the head of the
liquid producing it. This deals with the setup where there is a large tank with a narrow opening
allowing the liquid to flow out (Fig. 1.30). Both the tank and the narrow opening (nozzle) are open to
the atmosphere:
p1 v12 p v2
z1    H p  H m  H L  z2  2  2
 2g  2g

Figure 1.30Tank with a narrow opening (nozzle)

In this setup, certain assumptions are made:

34
 1. Pressure is the same because the tank and the nozzle are open to the atmosphere, that
is, .

2. Also, let z2  z1  h.
3. The fluid velocity of the tank (water level) is very much slower than the fluid velocity of the nozzle
as the area of the liquid surface is much larger than that of the cross section of nozzle, that is, v2 v1.
4. There is no pump or motor, that is, H p  H m  0.
5. There are no frictional losses, that is, H L  0.

Keeping all these assumptions in mind, Bernoulli’s equation gets reduced to

v2  2 gh

wherev2 is the jet velocity (m/s), g is the acceleration due to gravity (m/s2) and h is the pressure head
(m). Now if we do not consider an ideal fluid, then the friction head will be present (HL). In that case
v2  2 g (h  H L )
This shows that the velocity of jet decreases if the friction losses are taken into account.

1.11 Siphon
U tube

2
Z
1

Zero elevation reference

Z
2

Figure 1.31The siphon principle

A siphon is a familiar hydraulic device (Fig. 1.31). It is commonly used to cause a liquid to flow from
one container in an upward direction over an obstacle to a second lower container in a downward
direction. As shown in Fig. 1.31, a siphon consists of a U-tube with one end submerged below the
level of the liquid surface, and the free end lying below it on the outside of the container. For the fluid
to flow out of the free end, two conditions must be met:

1. The elevation of the free end must be lower than the elevation of the liquid surface inside the
container.
2. The fluid must initially be forced to flow up from the container into the center portion of the
U-tube. This is normally done by temporarily providing a suction pressure at the free end of
the siphon. For example, when siphoning gasoline from an automobile gas tank, a person can
develop this suction by momentarily sucking the free end of the hose. This allows
atmospheric pressure in the tank to push the gasoline up the U-tube hose, as required. For
continuous flow operation, the free end of the U-tube hose must lie below the gasoline level
in the tank.

35
We can analyze the flow through a siphon by applying the energy equation between points 1 and 2 as
shown in Fig. 1.31:
p1 v12 p v2
  z1  H p  H m  H L  2  2  z2
 2g  2g

The following conditions apply for a siphon:

1. = = atmospheric pressure.
2. The area of the surface of the liquid in the container is large so that the velocity equals
essentially 0.

Example 1.24
For the siphon system shown in Fig.1.32, the following data are given:z1= 4 m, z2 = 0.2 m, HL = 0.5 m.
If the inside diameter of the siphon pipe is 30 mm, determine the velocity of the fluid and the flow
rate (in LPM) through the siphon. Apply the energy equation and solve the problem.

U tube

Zero elevation reference

Figure 1.32

Solution: Given z1 =4 m,z2= 0.2 m, HL = 0.5m, D = 30 mm = 30×103 m. To calculate v2 and Q2.This

problem can be solved by using the energy equation (modified Bernoulli’s theorem) to points (1) and
(2) as below:

p1 v12 p v2
z1    H p  H m  H L  z2  2  2
 2g  2g
wherep1 = p2 = 0 (atmospheric pressure), v1 = 0 (as the tank is quite large, the velocity is negligible),
Hp = 0 (no pump), Hm=0 (no motor), z1 − z2 = h (the head). Substituting these values in the above
equation we obtain
v22
h  0  0  0  0  HL  0 
2g
v22
 h  HL 
2g
 v2  2 g (h  H L )
2

 v2  2 g (h  H L )  2  9.81(3.8  0.5)  8.05 m/s

36
 The flow rate is given by

Q2  A2v2  (30  103 ) 2  8.05
4
 Q2  5.7 103 m3 /s
 Q2  5.7 103 103  60
 Q2  342 LPM

Example 1.25
A siphon is made of a pipe whose inside diameter is 25.4 mm and is used to maintain a constant level
in a 6.0975 m deep tank (Fig. 1.33). If the siphon discharge is 9.144 m below the top of tank, what
will be the flow rate if the fluid level is 1.524 m below the top of tank?
U tube

Figure 1.33

Solution: From Fig.1.33, h = (9.144−1.524) = 7.62 m. From the previous problem, we can write using
the modified Bernoulli’s theorem
v22  2 gh
 v2  2 gh = 2  9.81 7.62 = 12.2 m/s
Now
 
Q  v2  A2  12.2   0.02542 
4 
 0.00618 m /s  6.18 LPS
3

37
Objective-Type Questions

Fill in the Blanks

1. Pascal’s law states that the pressure exerted on a _______ is transmitted undiminished in _______
and acts with equal force on equal areas and at _______to the surface of the container.

2. The total energy includes potential energy due to elevation and pressure and also _______.

3. The _______ energy of a particle of a fluid depends on its elevation above any arbitrary plane.

4. Pressure energy is possessed by the fluid per unit _______ of fluid virtue of the pressure under
which the fluid exists.

5. Torricelli’s theorem states that the velocity of the water jet of liquid is _______ proportional to the
_______ of the head of the liquid producing it.

State True or False

1. Continuity equation states that the weight flow rate is the same for all cross sections of a pipe.

2. Hydraulic power is equal to the product of pressure and volume flow rate.

3. A pump converts mechanical energy into hydraulic energy by increasing the fluid flow.

4. It is easy to achieve overload protection using hydraulic systems.

Flow (LPM)×Pressure (bar)

5. Hydraulic power in kW  .
320

38
Review Questions

1. Define hydraulic power. Derive an expression for hydraulic power if the flow is in LPS and
pressure in kPa.
2. How will you explain Pascal’s law with reference to working of a hydraulic cylinder?
3. State Bernoulli’s theorem.
4. What is a continuity equation and what are its implications relative to fluid power?
5. What is the significance of each term in the energy equation?
6. Define pressure head, elevation head and kinetic head.
7. State Torricelli’s theorem and mention its significance.
8. Explain how a siphon operates.
9. State Pascal’s law.
10. Explain the meaning of Bernoulli’s equation and how it affects the flow of a fluid in a hydraulic
circuit.
11. Relative to power, there is an analogy among mechanical, electrical and hydraulic systems.
Describe this analogy.

12. What is the significance of each term in the energy equation?

13. State the basic principle laws and equations of hydraulics.

39
Answers

Fill in the Blanks

1. Confined fluid, all directions,right angles

2. Kinetic energy due to velocity

3. Potential

4. Weight

5. Directly, square root

State True or False

1. True

2. True

3. False

4. True

5. False

40
 Lecture 5

DISTRIBUTION OF FLUID POWER

Learning Objectives

Upon completion of this chapter, the student should be able to:

 Write the points to be considered for the selection of hydraulic conductors.

 Differentiatebetween burst pressure and working pressure.
 List commontypes of fittings used in fluid power.
 List common types of screws used in fluid power.
 Explain varioustypes of joints used in fluid power.
 Write guidelinesfor the selection of plastic conductors.
 Explain varioustypes of hoses used in fluid power.
 Explain theuse of rotary joints and quick couplings.

1.1 Introduction
The size of pipe, tubing or hose for plumbing fluid power systems is very important. If the size
with too small an inside cross-sectional area is used, the oil is forced to flow at a high rate of
speed, and this creates excessive power loss and heat generation in the oil. If the size used is larger
than necessary, then the power transfer is good and heat generation is low but the time and cost of
installation are more than they should be. Pressure losses are present only when fluid is moving.
Force can be transmitted from one end of fluid column to other with virtually no loss but when the
fluid starts to move, which is necessary to transmit work or power, then the losses start. This
chapter deals with selection of distribution systems, losses in fluid power transmission lines and its
effect on the performance of fluid system.

1.2 Choice of Distribution

A fluid distribution system is composed of pipes, tubings, hose assemblies, manifolds and fittings
so arranged that the fluid is carried with minimum losses from the reservoir through controls and
working components and is then returned. All materials used to convey fluid power are commonly
classified as conductors and the various fittings for connecting components are classified as
connectors. More than one type of conductors may be used in the same installations. Conductors
are generally steel regardless of conductor material and they may be coated with cadmium or some
other corrosion-resistant material. Stainless steel conductors or fittings may be used if extremely
corrosive environments are anticipated, but the high cost of such conductors and fitting precludes
the general use of this material. Copper can never be used in a hydraulic system because it
catalyzes the oxidation of petroleum fluids, while zinc, magnesium and cadmium cannot be used
because they are rapidly corroded by glycol fluids. A galvanized pipe is unsatisfactory because
galvanization tends to flake off into the system.

The choice of pipe, tube or hose depends on the operating pressures of system and flow. Other
important factors include environmental conditions, type of fluid and operating temperature, shock
loads, relative motion between connected parts, practicality and compliance with certain standards.
The material used must have a continuous operating pressure rating so that it can withstand
working pressures and provide a factor of safety for short-lived pressure peaks resulting from a
hydraulic shock. Hydraulic shocks occur due to sudden stopping or reversing a flow that is backed
by large flow forces, sudden deceleration, stopping or reversing of heavy workloads.

1
The following points must be considered both while designing the system and selecting a
conductor:

 The working strength of conductor must be sufficient to contain fluid under all normal
operating conditions, and there must be sufficient reserve strength to withstand shock
loads due to system operations.
 The mechanical strength of the conductor must be sufficient to span the distance required
by the machine configurations and to withstand mechanical vibrations that may be
encountered.
 The interior surface of the conductor must be as smooth as possible to minimize friction.
 The pipe size must be adequate to permit design flow at a reasonable fluid velocity.
 Conductors should be positioned so that they cannot be damaged by normal operations at
and around the machine.
 Conductors should be supported in such a way that vibrations and shocks to them are
minimized.
 Conductor runs may frequently be reduced by using manifolds or by using machine
structural components as conductors.

1.3 Conductor Sizing

The pressure rating of various conductors depends on the tensile strength of the material used and
the wall thickness of the conductor. The wall thickness and safety factors recommended by the
fluid power industry standards are based on calculations using Barlow’s formula
Maximum wall thickness  OD of conductor
Minimum wall thickness 
2  Tensile strength( σ )

The formula is adequate for practical purposes in selecting conductor wall thickness to withstand
the maximum rate of surge peak pressures at frequencies developed by cycling of the hydraulic
equipment operation. Surge pressures that may be encountered within a system are rarely known
and seldom appreciated in their full potential strength.

In addition to normal working pressure and surge pressure peaks, there may be mechanical stresses
produced by thermal expansion, abuse and environmental factors. Evaluation of all phenomena is
difficult, so a higher factor of safety is used. Table 1.1 shows the typical specification of a
hydraulic pipe.

Table 1.1 Typical specification of a hydraulic pipe

Standard followed DIN 2391

Outer diameter 0.5–12 inch
Thickness 0.039-0.472 inch
Steel grade 16Mn (DIN 2391 ST 35.8 / 37.4)
Composition C(0.13), Si(0.37),Mn(0.65), P(0.035), Cr(0.3)max, Ni(0.25), Cu(0.2)
Manufactured Cold drawn
Surface treatment Copper coated

1.4 Burst Pressure and Working Pressure

When a valve is closed suddenly, high surge pressure can burst pipe lines. The burst pressure is the
pressure of the fluid that causes the pipe to burst. This occurs when the tensile stress developed
due to pressure () equals the tensile strength (S) of the pipe material:
p d
t 
2 

2
We can rewrite this expression in terms of the tensile strength of material:
p d
t 
2 S
If pBP is the burst pressure then we can write
2t S
pBP 
d

The working pressure (WP) is the maximum safe operating fluid pressure and is defined as the
burst pressure divided by an appropriate factor of safety (FOS):

Maximum (Burst) pressure p

Working pressure   BP
Factor of safety FOS

A factor of safety ensures the integrity of the conductor by determining the maximum safe level of
working pressure. Industry standards recommend the following factors of safety based on
corresponding operating pressures:

 FOS = 8 for pressures from 0 to 70 bar

 FOS = 6 for pressures from 70 to 180 bar
 FOS = 4 for pressures above 180 bar

If a fluid system is subjected to high-pressure shocks, then an FOS of 10 is used.

Example 1.1

A pump produces a flow rate of 75 LPM. It has been established that the fluid velocity in a
discharge line should be between 6 and 7.5 m/s. Determine the minimum and maximum pipe
inside diameter that should be used.

Solution:

Flow rate = Discharge= 75 LPM = 0.075/60=1.25  10−3 m3/s

Now

Discharge = Area  Velocity

π 2 Discharge 1.25 103

Amin  (d )    0.0001667 m 2
4 Velocity(maximum) 7.5

Solving we get d  14.5 mm (for the maximum velocity). So

π 2 Discharge 1.25 103

Amax  (d )    0.0002804 m2
4 Velocity (minimum) 6

Solving, we obtain d  16.3 mm (for the minimum velocity).

3
Example 1.2

A steel tubing has an outside diameter of 30 mm and an inside diameter of 24 mm. It is made up of
commercial steel of the tensile strength of 520 MPa. What is the safe working pressure? Assuming
that tubing is subjected to a high-pressure shock, determine the tensile stress for an operating
pressure of 10 MPa.

Solution:

2 t S 2  3  517
Bursting pressure  pBP    129.3 MPa
d 24

Since the tubing is subjected to a high-pressure shock, we can take factor of safety as 10:
Maximum pressure 129.3
Working pressure    12.93 MPa  129.3 bar
Factor of safety 10

The tensile stress is

p  d 10  0.024
   40 MPa
2t 2  0.003

1.5 Steel Pipes

Steel pipes are still extensively used in fluid power systems, although they are rapidly being
supplemented by steel or plastic tubing. The major disadvantages of steel pipes are their weight
and the large number of fitting requirement for connection . Its greatest advantage is its mechanical
strength and particularly its ability to withstand abuse. Steel pipes are sized according to the
nominal diameter that is neither the outside nor the inside diameter, while the wall thickness is
specified by a schedule number. Most of the industries seldom use metric designation while
designing and buying pipes. The prime considerations for selecting conductors for a hydraulic
power system are the type of materials, capacity and pressure rating. Piping has originally been
classified by weight as standard, extra heavy and double extra heavy. This classification has been
superseded by classification according to schedule numbers. A hot- or cold-drawn seamless pipe is
recommended for use in a hydraulic system and must be internally free from rust scale and dirt.
Schedule numbers run from 40 (earlier standard) to 80 (earlier extra duty) and to 160 (earlier
double extra duty). Table 1.2 shows the usage of schedule pipes under fluid power standards.
Industry hydraulic standard recommends a 4:1 factor of safety for systems operating above 180–
200 bar. Steel pipe fittings are most often fabricated from malleable iron that has a sufficient
strength and ductility to withstand forces encountered in a fluid power system.

4
 Table 1.2 The usage of schedule pipes under fluid power standards

Schedule 40 Schedule 80 Schedule 160

Normal Pipe Pipe Outside ID WP ID WP ID WP
Size (in.) Diameter (in.) (in.) (psi) (in.) (psi) (in.) (psi)
1/8 0.405 0.269 590 0.215 2100 – –
1/4 0.540 0.364 1250 0.302 2620 – –
3/8 0.675 0.493 1090 0.423 2300 – –
1/2 0.840 0.622 1350 0.546 2420 0.466 7380
3/4 1.050 0.824 1160 0.742 2080 0.614 6000
1 1.315 1.049 1260 0.957 2070 0.815 5720
1-1/4 1.660 1.380 850 1.278 1550 1.160 4470
1-1/2 1.900 1.610 800 1.500 1450 1.338 4100
2 2.375 2.067 720 1.939 1330 1.689 3580
21/2 2.875 2.469 970 2.323 1550 2.125 3940
3 3.500 3.068 875 2.900 1400 2.624 3520

It is to be noted that for a given nominal size of pipe, the wall thickness increases as the schedule
number increases. Table 1.4 shows the usage of metric pipes. These metric designations are not
common in industry.

Table 1.4 The usage of metric pipes under fluid power standards

Tube Tube Wall Tube Tube Wall Tube Tube Wall

OD ID Thickness OD ID Thickness OD ID Thickness
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
4 3 0.5 14 10 2.0 25 19 3.0
6 4 1.0 15 12 1.5 25 17 4.0
6 3 1.5 15 11 2.0 28 24 2.0
8 6 1.0 16 12 2.0 28 23 2.5
8 5 1.5 16 10 3.0 30 24 3.0
8 4 2.0 18 15 1.5 30 22 4.0
10 8 1.0 20 16 2.0 35 31 2.0
10 7 1.5 20 15 2.5 35 29 3.0
10 6 2.0 20 14 3.0 38 30 4.0
12 10 1.0 22 20 1.0 38 28 5.0
12 9 1.5 22 19 1.5 42 38 2.0
12 8 2.0 22 18 2.0 42 36 3.0

Example 1.3

A steel tube of inner diameter 25 mm has a burst pressure of 50 MPa. If the tensile strength is 380
MPa, find the minimum acceptable OD.

Solution: The bursting pressure is given by

2tS
pBP 
d

5
 2  t  380
 50 
0.025
Solving we obtain t = 1.644 × 103 m = 1.644 mm.Now

OD = ID + 2t = 25 + 2 × 1.644 = 28.3 mm

Example 1.4

What is the minimum size of commercial pipe tubing with a wall thickness of 2 mm required at the
inlet and outlet of a 75 LPM pump? The inlet and outlet velocities are limited to 1.2 and 6.1 m/s,
respectively.

Solution: We have

75 LPM = 0.075/60=1.25  10−3 m3/s

We know that discharge

Q = Area × Velocity

π 2 Discharge 1.25 103

Amin  (d )    0.001042 m2
4 Velocity(max) 6.1

Solving, we obtain d  36.5 mm (for the maximum velocity). Referring to Table 1.4 we select
42(OD)  36(ID) for the pump inlet.

Again

π 2 Discharge 1.25 103

Amax  (d )    0.0002049 m2
4 Velocity (min) 1.2

Solving we obtain d  16.2 mm (for the minimum velocity). Referring to Table1.4, we select
22(OD)  18(ID) for the pump outlet.

Example 1.5

What is the minimum size of commercial pipe tubing with a wall thickness of 2.4 mm required at
the inlet and outlet of a 0.00189 m3/s pump? The inlet and outlet velocities are limited to 1.92 m/s
and 6.08 m/s, respectively.

Solution: This problem has to be solved by the trial-and-error method.

Pump Inlet:

(a) Using Table 1.4, let us selectt = 2.5 mm, OD = 28 mm and ID = 23 mm. Now

Discharge 0.00189
Velocity    4.54 m/s
π 2 π 2
(d ) (0.023 )
4 4

(b) Let us select t = 3 mm, OD = 25 mm and ID = 19 mm. Now

6
 Discharge 0.00189
Velocity    6.67 m/s
π 2 π 2
(d ) (0.019 )
4 4

(c) Let us select t = 3 mm, OD = 42 mm and ID = 36 mm. Now

Discharge 0.00189
Velocity    1.86 m/s
π 2 π 2
(d ) (0.036 )
4 4

Referring to Table 1.4,we can use a 28 × 23 × 2.5 mm3 pipe for the pump outlet and a 42 × 36 × 3
mm3 pipe for the pump inlet.

Example 1.6

The flow rate of certain fluid in a pipe is 0.001 m3/s and an operating pressure is 70 bar. The
maximum recommended velocity is 6.1 m/s and the factor of safety of 8 is allowed. Select a metric
steel tube when

(a) Material is SAE 1010 with a tensile strength of 380 MPa.

(b)Material is AISI 4130 with a tensile strength of 570 MPa.

Solution:

(a) Selection of Pipe for the SAE 1010

π 2 Discharge 0.001
Flow area  (d )    0.0001639 m2
4 Velocity(max) 6.1

Solving we get inside diameter (d )  14.4 mm.

From Table 1.4 we select t = 1.5 mm, ID = 12 mm and OD = 15mm. So bursting pressure is

2 t S 2  0.0015  380
pBP    94.9 MPa
d 0.012
The working pressure is

Maximum pressure 94.9

Working pressure =   11.93 MPa  119.3bar
Factor of safety 8

Working pressure is greater than the operating pressure of 70 bar. So we use a pipe of 15  12 
1.5 mm.

(b) Selection of Pipe for the AISI 4130

2 t S 2  0.0015  517
pBP    129.3 MPa
d 0.012

The working pressure is

7
 Maximum pressure 94.9
Working pressure    16.2 MPa  162 bar
Factor of safety 8

Working pressure is greater than the operating pressure of 70 bar. So we use a pipe of 15  12 
1.5 mm.

1.6 Screwed Connections

Steel piping in fluid power systems is most often joined by threaded connections. Unfortunately,
threading weakens the pipe thereby making it necessary to use heavier walls than would otherwise
be required. This difficulty can be overcome by welding, but welded sections are not desirable in
fluid power systems that require frequent disassembly. Large-diameter piping systems generally
are fabricated with flanged joints.

Taper threads form a seal by an interference fit between a male and a female component when they
are tightened together, and some form of jointing compound or flexible plastic tape is added to
ensure a good joint. Great care must be taken when screwing taper threads into the body of a
component, particularly if it is made of cast iron, otherwise the casting may be cracked.

Parallel threads are easier to manufacture and simpler to use. Joints made with parallel threads
must have a sealing washer between the component body and a suitable shoulder on the pipe
fitting in order to prevent fluid leakage [Fig. 1.1(c)]. Parallel thread fittings should never be used
in taper thread holes or vice versa.

The most commonly used screw thread forms for hydraulic pipe fittings are as follows:

1. British standard pipe threads (BSP).

2. American National pipe threads (NPT).
3. Unified pipe threads (UNF).
4. Metric pipe threads.

1.7 Steel Tubing

Seamless steel tubing is the most widely used material for hydraulic system conductors.One major
reason of its popularity is the fact that it can be easily formed to fit irregular paths so that fewer
fittings are required. The obvious result is a considerably lessened chance of leakage since every
connection is a potential leak point. It is also relatively small and light, thus making it easy to use.

Rigid steel tubing is either drawn or seam welded, the later sometimes used in hydraulic systems
for pipe work but is generally unsuitable for higher pressure and is more difficult to manipulate as
the seam tends to split when the pipe is bent.

When bending steel tubing, it is always important to use proper tube-bending equipment with
fixtures of the correct size, otherwise the pipe is flattened. This reduces its cross-sectional area
and causes a higher resistance to the flow of fluid. It is usual to specify hydraulic tubing by
reference to the outside diameter (OD) and wall thickness. A range of standard tubes are available
in both inch and metric sizes from about 5 mm OD. For most fluid power applications, the tubing
used is SAE 1010 dead soft cold-drawn steel tubing. This material is easily worked and has
strength equal to or greater than the schedule 80 pipe. If a greater strength is required, a similar
tubing fabricated from AISI 4230 steel can be used that can withstand approximately 50% more
working pressure.
Various standard wall thicknesses are available for each size of tubing, and tube manufacturers
supply tables indicating the safe working pressure for each size. A minimum safety factor of 4:1

8
should be used when selecting the wall thickness of a tube. It means the bursting pressure of the
tube must be four times the maximum fluid pressure. Obviously, thicker tubes are more difficult to
manipulate, particularly with a larger diameter.
Flow rates through smooth bore tubes should normally not exceed 5m/s in pressure lines or 1.2 m/s
in suction lines. Tubes used for hydraulic systems must be clean and free from rust; otherwise
particles of grit may find their way into the precision equipment, causing serious damage to pumps
and valves. Tubes in transit or storage should always have their open ends capped to prevent the
ingress of dirt and moisture. Tubes are attached to end fittings using compression joint and flared
tubes. Very large fittings are usually welded.

1.8 Compression Joints

Compression-type fittings comprise a loose ring having a cone-shaped nose that must face the
open end of a tube, a mating tapered barrel and a retaining nut. The end of the tube must always be
cut square and deburred before assembly. When the tube is pushed fully in the fitting and the
retaining nut is tightened, the compressive action forces the nose of the ring into the surface of the
metal tube, creating a permanent and very strong interference fit that is capable of withstanding
pressure in excess of 350 bar.

1.8 Plastic Conductors

Plastic tubing is now available in polyethylene, polypropylene, polyvinyl chloride and nylon. Each
material has specific characteristics that make it more suitable for some services than for others.
The best procedure is to check the manufacturer’s literature against the service conditions
whenever plastic tubing is being considered.. In general, plastic tubing is most often used in
pneumatic systems, primarily because it does not have sufficient strength to be used in most
hydraulic systems. The plastics are compatible with most hydraulic fluids, however, and could
safely be used in low-pressure applications.
Plastic tubing has gained rapid acceptance in the industry because it is inexpensive and extremely
easy to use. It can easily be formed to fit around obstructions without special tools; it is light and
easy to handle. It is also available in colors so the different circuit lines can be color coded,
especially in chemical industries. Because of its resilience, it is highly resistant to damage crushing
although it can be fairly easily cut. It may also be used where flexing or vibration can damage steel
tubing. Plastic tubing fittings vary slightly from steel tubing compression fitting.In fact, most steel
tubing fittings can be used for the same services if a special sleeve is first inserted in the tubing to
give it a crushing resistance at the compression point. Although testing for a specific purpose is
recommended, a 4:1 factor of safety is considered good engineering practice in most of the fluid
power systems.
In general, plastic tubing can be worked and installed with the ordinary tubing tools. It cuts easily
and can be heated and given permanent bends; it can be used with standard metallic compression
and flare fittings designed for metal tubing. Many new developments are being made in the nature
of tools, fittings, quick disconnects and other devices especially for plastic fabrications.

1.9 Flexible Hoses

Hose assemblies are primarily used to connect fluid power systems to actuators that must be
located on movable parts such as a cylinder coupled to a radius arm traversing in an arc, or a motor
driving a machine carriage. A hose is manufactured from natural and synthetic rubbers and several
plastics. This material is supported by fabric or by wire cloth, and wire braid may be used between
plies or as an outside casing for high-pressure applications. Hose assemblies of nearly any length,
complete with end connections, are available from most manufacturers. It is only necessary to
specify the system service pressure and the fluid that is to be used. Extreme caution should be
taken in changing a fluid or replacing hoses, however, to be sure that the hose material and fluid
are compatible. Table 1.6 gives some typical hose sizes for single braid high tensile strength steel
wire reinforcement with an inner tube made of oil-resistant nittrile (BTN) and a cover compound
made up of black neoprene (oil-resistant and abrasion-resistant type).

9
 Table 1.6 Typical hose sizes

Hose ID Wire Hose Working Burst Pressure Minimum Weight

ID OD Pressure Bend
Radius
in. mm mm mm MPa psi MPa psi mm kg/m
3/16 4.8 9.5 11.8 25 3630 100 14280 90 0.190
1/4 6.4 10.8 12.8 22.5 3270 90 12840 100 0.222
5/16 7.9 12.5 14.5 21.5 3120 85 12280 115 0.261
3/8 9.5 14.6 16.8 18 2610 72 10280 130 0.324
1/2 12.7 17.6 19.8 16 2320 64 9180 180 0.418
5/8 15.9 21.1 23.1 13 1890 52 7420 200 0.476
3/4 19 24.7 27 10.5 1530 42 6000 240 0.619
1 25.4 32.5 35 8.8 1280 35 5020 300 0.883
1−1/4 31.8 39.5 43.5 6.3 920 25 3600 420 1.220
1−1/2 38.1 45.8 49.8 5 730 20 2850 500 1.408
2 50.8 59 63 4 580 16 2280 630 1.889

Steel end fittings are attached in various ways by clamping or squeezing the rubber hose between a
serrated inner piece and an outer retaining ring. These end fittings are available for assembly on
site by the user in a variety of designs that may require the use of portable tools, or as readymade
hose assemblies, in which retaining rings are usually machine swaged at the factory.In some self-
assembly versions, the inner end piece is screwed into the hose on a tapered interface to provide a
compressive grip. In others, the outer sleeve is split and is held together on the hose by clamping
screws to provide the same effect. The advantage of self-assembled hoses is that for emergency
repairs, they can be cut to exact length on site, thus reducing the need for large stocks to be
maintained, but they tend to be more costly than pre-assembled hoses.
End fittings used in flexible hoses tend to have a smaller internal diameter than their equivalent
rigid tube fittings, thus creating slightly more resistance to flow. Most suppliers offer straight,
angled and elbow end fittings for flexible hoses, with a variety of male and female threads.

1.9.1 Designation of Hoses

Hoses are fabricated in layers of elastomers and braided fabric or braided wires. The braided fabric
or wires are used to increase the strength of the hoses. The hose may have a minimum of three
layers including one braided layer or can have several layers to sustain the higher operating
pressures. The steel wires have a spiral weave or cross weave. Spiral reinforced hoses have high
strength and require fittings to be supplied by the manufacturer. The cross woven braids are re-
usable and are easy to assemble. The inner tuber material of the hose should be compatible with
the fluid.

Important considerations in the installation of hose assemblies are as follows:

1. Hose assemblies must be of proper overall lengths. Since a hose expands under pressure,
both the hose length and space allowed for it must be adequate.
2. A hose under variations in working pressure must have enough length to expand and
contract.
3. Do not clamp high- and low-pressure hoses together.
4. Never clamp a hose at a bend. Bend radii cannot absorb a change if clamped at the bend.
5. When there is a relative motion between two ends of a hose assembly, always allow the
adequate length of travel.
6. To prevent twisting, a hose should be bent in the same plane as the motion of the part to
which it is attached.

10
 7. To prevent twisting in hose lines bent in two planes, clamp the hose at the change of the
plane.
8. Use the proper hydraulic adaptors to reduce the number of joints and improve performance
as well as appearance.
9. Wherever the radius falls below the required minimum bend, an angle adapter should be
used.
10. Contact with sharp edges and rubbing against any surface should be avoided.
11. Arrange proper positioning of hose and adaptors before tightening to avoid distortion.
12. Apply clamps properly and keep tight to prevent abrasion due to line surge.
13. Be sure to use the proper strength of hose to maintain a good factor of safety.
14. Select the proper size of hose of stay within the recommended velocity range. Consult
velocity-flow nomographs.
15. Prevent dirt, chips or any other foreign materials from entering the system during the
fabrication of system.
16. Be sure that all the material used is compatible with the hydraulic fluid designed for the
system.

1.11 Quick Disconnect Couplings

Another type of hydraulic fitting in regular use is the quick release coupling. This type of coupling
in conjunction with flexible hoses connects movable components together hydraulically. Typical
applications are mobile trailers and agriculture machinery towed behind tractors.
Quick release couplings usually comprise a plug and socket arrangement that provides a leak-proof
joint when two parts are connected together, and that can be released easily without the use of
tools. Each half of the coupling contains a spring-loaded ball or poppet that automatically closes
on disconnection, so that two completely leak-free joints are obtained. Leaking during the process
of disconnecting or connecting coupling is negligible

11
Objective-Type Questions

Fill in the Blanks

1. Stainless steel conductors or fittings may be used if extremely ________ environments are
anticipated.

2. In fluid power installations, a galvanized pipe is unsatisfactory because galvanization tends to

________ into the system.

3. The choice of pipe, tube or hose depends on operating pressures of system and ________.

4. Pressure rating of various conductors depends on ________ of the material used and the wall
thickness of the conductor.

5. Tubes are attached to the end fittings in various ways, some of which use metal-to-metal
________ known as a compression joint.

State True or False

1. Copper and cadmium tubing are most commonly used in a hydraulic system.

2. Steel piping in fluid power is most often jointed by threaded connections.

3. Welded sections are most desirable in fluid power systems.

4. Rigid steel tubing is generally suitable for high pressures.

5. Flow rates through smooth bore tubes should normally not exceed 1.2 m/s in pressure lines or 5
m/s in suction lines.

Review Questions

1. What is the purpose of a fluid distribution system?

2. Why should copper not be used in conductors or fitting?
3. Why can metals not be used with glycol fluid?
4. Why should the conductor have a greater strength than the system working pressure?
5. Why are smooth conductors desired?
6. What are the major disadvantages of steel pipes?
7. What is the recommended factor of safety for a fluid power system design?
8. Why is malleable iron used for steel pipe fittings?
9. What effect do threaded connections have on a fluid power system?
10. Why are unions not required in tubing systems?
11. Why is steel tubing used more often than steel pipe?
12. How do compression fittings prevent the tube from blowing out under pressure?
13. How can steel tube fittings be used with plastic tubings?
14. What major advantages does plastic tubing have over steel tubing?
15. What are the two disadvantages of steel pipes?
16. Define the burst pressure and working pressure of hydraulic pipes.
17. What is the use of quick disconnect coupling?
18. What is the difference between hydraulic tubing and hoses?
19. What is the difference between flared fitting and compression fitting?
20. List the factors influencing the selection of hoses.

12
Answers

Fill in the Blanks

1. Corrosive

2. Flake off

3. Flow

4. Tensile strength

5. Interference fit

State True or False

1. False

2. True

3. False

4. False

5. False

13
 Lecture 6
ENERGY LOSSES IN HYDRAULIC SYSTEMS
Learning Objectives
Upon completion of this chapter, the student should be able to:
 State the differences between laminar and turbulent flows.
 Define Reynolds number and state its importance.
 Explain the Darcy–Weisbach equation.
 Explain the various types of joints used in fluid power.
 Evaluate the head losses for laminar and turbulent flow.
 Explain the various types of losses in fittings and valves.
 Design a system considering all head losses in the system.

1.1 Introduction

Liquids such as water or petrol flow much easily than other liquids such as oil. The resistance to
flow is essentially a measure of the viscosity of a fluid. The greater the viscosity of a fluid, the
less readily it flows and the more is the energy required to move it. This energy is lost because it
is dissipated as heat.

Energy losses occur in valves and fittings. Various types of fittings, such as bends, couplings,
tees, elbows, filters, strainers, etc., are used in hydraulic systems. The nature of path through the
valves and fittings determines the amount of energy losses. The more circuitous is the path, the
greater are the losses. In many fluid power applications, energy losses due to flow in valves and
fittings exceed those due to flow in pipes. Therefore,a proper selection of fitting is essential. In
general, the smaller the size of pipe and fittings, the greater the losses.

The resistance to flow of pipes, valves and fittings can be determined using empirical formulas
that have been developed by experimentation. The energy equation and the continuity equation
can be used to perform a complete analysis of a fluid power system. This includes calculating the
pressure drops, flow rates and power losses for all components of the fluid power system.

The purpose of this chapter is to study the detailed circuit analysis of energy losses in fluid
power systems containing valves, fittings and other power transmission and energy conversion
elements.

1.2 Laminar and Turbulent Flows

When speaking of fluid flow, one refers to the flow of an ideal fluid. Such a fluid is presumed to
have no viscosity. This is an idealized situation that does not exist. When referring to the flow of
a real fluid, the effects of viscosity are introduced into the problem. This results in the
development of shear stresses between neighboring fluid particles when they move at different
velocities. In the case of an ideal fluid flowing in a straight conduit, all the particles move in
parallel lines with equal velocity. In the flow of a real fluid, the velocity adjacent to the wall is
zero; it increases rapidly within a short distance from the wall and produces a velocity profile
such as shown in Figure1.1.
 u

(a) (b)
Figure 1.1 Typical velocity profile: (a) Ideal fluid.(b) Real fluid

There are two types of flow in pipes:

1. Laminar flow:This is also known as streamline or viscous flow and is illustrated in Fig.1.2. In
streamline flow, the fluid appears to move by sliding of laminations of infinitesimal thickness
relative to adjacent layers; that is, the particles move in definite and observable paths or
streamlines. The flow characteristic of a viscous fluid is one in which viscosity plays a
significant part.

F, U

Velocity
Y
profile
y

Figure 1.2 Laminar flow

2.Turbulent flow: It is illustrated in Fig.1.3. It is characterized by a fluid flowing in random
way. The movement of particles fluctuates up and down in a direction perpendicular as well as
parallel to the mean flow direction.
This mixing action generates turbulence due to the colliding fluid particles. This causes a
considerable more resistance to flow and thus greater energy losses than those produced by
laminar flow. A distinguishing characteristic of turbulence is its irregularity, there being no
definite frequency, as in wave motion, and no observable pattern, as in the case of large eddies.

Figure 1.3 Turbulent flow

1.3 Reynolds Number

In the flow of a fluid through a completely filled conduit, gravity does not affect the flow pattern.
It is also obvious that capillarity is of no practical importance, and hence significant forces are
inertial force and fluid friction due to viscosity. The same is true for an airplane traveling at
speed below that at which compressibility of air is appreciable. Also, for a submarine submerged
far enough so as not to produce waves on the surfaces, the only forces involved are those of
friction and inertia.

Considering the ratio of inertial forces to viscous forces, the parameter obtained is called the
Reynolds number, in honor of Osborne Reynolds, who presented this in a publication of his
experimental work in 1882. He conducted a series of experiments to determine the conditions
governing the transition from laminar flow to turbulent flow. Reynolds came to a significant
conclusion that the nature of the flow depends on the dimensionless parameter, that is,
vD 
Re 

Where v is the fluid velocity,D is the inside diameter of the pipe,  is the fluid density and  is
the absolute viscosity of the fluid.

1. If Reis less than 2000, the flow is laminar.

2. If Reis greater than 4000, the flow is turbulent.
3. Reynolds number between 2000 and 4000 covers a critical zone between laminar and
turbulent flow.

It is not possible to predict the type of flow that exists within a critical zone. Thus, if the
Reynolds number lies in the critical zone, turbulent flow should be assumed. If turbulent flow is
allowed to exist, higher fluid temperatures occur due to greater frictional energy losses.
Therefore, turbulent flow systems suffering from excessive fluid temperature can be helped by
increasing the pipe diameter to establish laminar flow.

Example 1.1

The kinematic viscosity of a hydraulic fluid is 0.0001 m2/s. If it is flowing in a 30-mm diameter
pipe at a velocity of 6 m/s, what is the Reynolds number? Is the flow laminar or turbulent?

Solution: From the definition of Reynolds number, we can write

vD vD vD 6  0.03
Re      1800 <COMP: v and nu both being used>
 /  0.0001
SinceRe is less than 2000, the flow is laminar.
1.4 Darcy–Weisbach Equation
If a fluid flows through a length of pipe and pressure is measured at two stations along the pipe,
one finds that the pressure decreases in the direction of flow. This pressure decrease is mainly
due to the friction of the fluid against the pipe wall. Friction is the main cause of energy losses in
fluid power systems. The prediction of this friction loss is one of the important problems in fluid
power. It is a very complicated problem and only in special cases, the friction factor is computed
analytically.

Head losses ina long pipe in which the velocity distribution has become fully established or
uniform along its length can be found by Darcy’s equation as
 L  v 
2
HL  f    
 D   2g 
wherefis the Darcy friction factor, L is the length of pipe (m), D is the inside diameter of the pipe
(m), v is the average velocity (m/s) and g is the acceleration of gravity (m/s2).

Theactual dependence of f on Re has to be determined experimentally. It should be apparent that

friction factors determined do not apply near the entrance portion of a pipe where the flow
changes fairly quickly from one cross-section to the next or to any other flow in which
acceleration terms are not negligible.

1.5 Frictional Losses in Laminar Flow

Darcy’s equation can be used to find head losses in pipes experiencing laminar flow by noting
that for laminar flow, the friction factor equals the constant 64 divided by the Reynolds number:
64
f 
Re
Substituting this into Darcy’s equation gives the Hagen–Poiseuille equation:
64  L   v 2 
HL    
Re  D   2 g 

Example 1.2
The kinematic viscosity of a hydraulic fluid is 0.0001 m2/s. If it is flowing in a 20-mm diameter
commercial steel pipe, find the friction factor in each case:
(a) The velocity is 2 m/s.
(b) The velocity is 10 m/s.

Solution:
a) If the velocity is 2 m/s, then
vD vD vD 2  0.02
Re      400
 /  0.0001
The flow is laminar. Now
64 64
f    0.16
Re 400
(b) If the velocity is 10 m/s, then
 vD vD vD 10  0.02
Re      2000
 /  0.0001
Theflow is laminar. Now
64 64
f    0.032
Re 2000

Example 1.3
The kinematic viscosity of a hydraulic fluid is 0.0001 m2/s. If it is flowing in a 30-mm diameter
pipe at a velocity of 6 m/s, find the head loss due to friction in units of bars for a 100-m smooth
pipe. The oil has a specific gravity of 0.90.

Solution: We have

vD vD vD 6  0.03
Re      1800
 /  0.0001
We can express the head loss in bar as

64  L   v 2 
HL    
Re  D   2 g 
64  100   62 
   
1800  0.030   2  9.81 
 217.5 m
Hence,
p   H L
 1000 kg/m3  0.90  9.81 m/s 2  217.5
 1.92 MN/m 2
 1.92 MPa
 19.2 bar

1.6 Frictional Losses in Turbulent Flow

Darcy’s equation can be used to find head losses in pipes experiencing turbulent flow. However,
the friction factor in turbulent flow is a function of Reynolds number and the relative roughness
of the pipe.
1.6.1 Effect of Pipe Roughness
The relative roughness of pipe is defined as the ratio of inside surface roughness ( )
tothediameter:

Relative roughness 
D
Table 1.1 gives typical values of absolute roughness for various types of pipes.

Table 1.1Typical values of absolute roughness for various types of pipe

Type of Pipe  (mm)
Glass or plastic Smooth
Drawn tube 0.0015
Wrought iron 0.046
Commercial steel 0.046
Asphalted cast iron 0.12
Galvanized iron 0.15
Cast iron 0.26
Riveted steel 1.8

To determine the values of the friction factor for use in Darcy’s equation, we use the Moody
diagram. If we know the relative roughness and Reynolds number, the friction factor can be
determined easily. No curves are drawn in the critical zone,Re lies in between 2000 and
4000because it is not possible to predict whether flow is laminar or turbulent in this region.At the
left end of the chart (Reynolds number less than 2000), the straight line curves give the
relationship for laminar flow:
64
f 
Re

1.7 Frictional Losses in Valves and Fittings

For many fluid power applications, the majority of the energy losses occur in valves and fittings
in which there is a change in the cross-section of flow path and a change in the direction of the
flow. Tests have shown that head losses in valves and fittings are proportional to the square of
the velocity of the fluid:
 v2 
HL  K  
 2g 
WhereK is called the loss coefficient of valve or fittings.K factors for commonly used valves are
given in Table1.2.
Table 1.2 K factors for commonly used valves

Valve or Fitting K Factor

Globe valve Wide open 10
1/2 open 12.5
Gate valve Wide open 0.20
3/4 open 0.90
1/2 open 4.5
1/4 open 24
Return bend 2.2
Standard tee 1.8
Standard elbow 0.90
45 elbow 0.42
90 elbow 0.75
Ball check valve 4
Union socket 0.04

1.8 Equivalent Length Technique

We can find a length of pipe that for the same flow rate would produce the same head loss as a
valve or fitting. This length of pipe, which is called the equivalent length of a valve or fitting,
can be found by equating head losses across the valve or fitting and the pipe:
 v2   L  v 
2
K   f   
 2g   D   2g 
Thisgives
 KD 
Le   
 f 
where Le is the equivalent length of a valve or fitting.

Example 1.4
For the hydraulic system shown in the Fig. 1.4, the following data are given:
(a) A pump adds 2.984 kW to a fluid (pump hydraulic power = 2.984 kW).
(b) The elevation difference between stations 1 and 2 is 6.096 m.
(c) The pump flow rate is 0.00158 m3/s.
(d) The specific gravity of oil is 0.9.
(e) The kinematic viscosity of oil is 75 cS.
(f) The pipe diameter is 19.05 mm.
(g) Pipe lengths are as follows: 0.305, 1.22 and 4.88 m.
Find the pressure available at the inlet to the hydraulic motor. The pressure at the oil top surface
level in the hydraulic tank is atmospheric (0 Pa gauge).
 Load
Coupling

Hydraulic Motor 2

Breather Elevation
Hydraulic pump Prime mover

Figure 1.4

Solution:
Kinematic viscosity = 75 cS = 75 × 10−6 m2/s
We write the energy equation between stations 1 and 2:
p1 v12 p v2
Z1    H p  H m  H L  Z2  2  2
 2g  2g
Since there is no hydraulic motor between stations 1 and 2,
P
H m  0, v1  0 and 1  0

as oil tank is vented to the atmosphere. Now,
Z 2  Z1  6.096 m
The velocity at point 2 is
Q (m3 /s) 0.00158
v2    5.54 m/s
A (m2 )  (0.01905)2
4
The velocity head at point 2 is
v22 5.542
  1.57 m
2 g 2  9.81
Also,
vD vD vD 5.54  0.01905
Re      1400
 /  75 106
So the flow is laminar. The friction is
64 64
f    0.0457
Re 1400
We can now find the head loss due to friction between stations 1 and 2:
fLp v 2
HL  
Dp 2 g
where
 KD 
Lp  4.88  0.305  1.22   
 f std elbow
 0.9  0.01905 
 6.41   
 0.4057 
 6.79 m
0.0457  6.79
and HL  1.57  25.6 m
0.01905
Next use Bernoulli’s equation to solve for P2 /  :
p1v12 p2 v22
Z1    H p  H m  H L  Z2  
 2g  2g
p2 v22 p1
  ( Z1  Z 2 )  H p   HL 
  2g
 6.096  H p  0  25.6  1.57
 H p  33.2
The pump head is given by
P (W)
HP 
γ (N/m3 )  Q (m3 /s)
Now γ  8817 N/m3 and P  2984 W . So
2984 W
HP   214.3 m
8817 (N/m )  0.00158 (m3 /s)
3

Now

p2
 H p  33.2

 214.3  33.2
 181.1m of oil
Finally, we solve for the pressure at station 2:
p2
 181.18817  1600000  1600 kPa


Example 1.5
The oil tank for a hydraulic system (shown in Fig. 1.5) has the following details:
(a) The oil tank is air pressurized at 68.97 kPa gauge pressure.
(b) The inlet to the pump is 3.048 m below the oil level.
(c) The pump flow rate is 0.001896 m3/s.
(d) The specific gravity of oil is 0.9.
(e) The kinematic viscosity of oil is 100 cS.
(f) Assume that the pressure drop across the strainer is 6.897 kPa.
 (g) The pipe diameter is 38.1 mm.
(h) The total length of the pipe is 6.097 m.
Find the pressure at station 2.

Three standard elbows (A, B and C)

A
B

Breather 38 mm (ID)

1
Pipe length = 6m

CC 3m

Pump

Figure 1.5
Solution: Givenp1 = 68.97kPa, ,Z1−Z2 = 3m, Q = 0.001896m3/s, ps = 6.897kPa, SG = 0.9, Dp =
38.1mm,  =100 cS = 100 × 106 m2/s, Lp= 6m. We have to find P2. This problem can be
solved by the application ofmodified Bernoulli’s (energy) equation:
p1 v12 p v2
Z1    H p  H m  H L  Z2  2  2
 2g  2g
Also, given
Z1  Z 2  3 m
We can write H m  0, as there being no motor between points1 and 2, the motor head is zero.
Assuming the oil tank area (cross-section) to be large, the velocity at point 1 is v1  0 (negligible
velocity). To solve forP2, let us compute and substitute different quantities into the energy
equation.
The pressure head at station 1 is
p1 68970
  7.82 m
 8817
The velocity at point 2 is
Q (m3 /s) 0.001896
v2    1.66 m/s
2
A (m )  (0.03812 )
4

The velocity head at point 2 is

 v22 1.662
  0.141 m The Reynolds number is
2 g 2  9.81
vD vD vD 1.66  0.0381
Re      632
 /  100 106
So the flow is laminar.The friction is
64 64
f    0.101
Re 632
Point 2 is before the pump; therefore, H p  0.
We can now find the head loss due to friction between stations 1 and 2
fLp v2
HL    Head loss across the strainer
Dp 2g
Three standard elbows are used:
 KD 
Lp  6.097  3  
 f std elbow
 0.9  0.0381 
 6.097  3    7.12
 0.101 
Pressure drop across the strainer is 6.9 kPa. The head loss across strainer can be calculated as
pstrainer 6900
Head loss across strainer    0.782 m
 8817
Now use Bernoulli’s theorem
p1 v12 p v2
Z1    H p  H m  H L  Z2  2  2
 2g  2g
p2 p1 v22
  (Z1  Z 2 )   HL 
  2g
p2
  3.048  7.82  3.44  0.141

= 7.29m of oil
Finally, we solve for p2 :
p2
 7.29

So p2  7.29  8817  64300 Pa  64.3 kPa
If point 2 is after the pump, the pump head is given by
P (W)
Hp 
γ (N/m3 )  Q (m3 /s)
Here γ  8817 N/m3 . We know that
Power( P)  p1  Q
 P  68.97 (kN/m3 )  0.001896 (m3 /s)  0.13 kW

So, pump head is

 0.13  103 W
Hp   7.7 m
8817 (N/m3 )  0.001896 (m3 /s)
We also know that
p1 v12 p v2
Z1    H p  H m  H L  Z2  2  2
 2g  2g
p2 p1 v22
  (Z1  Z 2 )   HL  Hp 
  2g
p2
  3.048  7.82  3.44  7.7  0.141  15m of oil

Finally, we solve for p2:
p2
 15

 p2  15  8817  132255 Pa  132.26 kPa

Example 1.7
For the system shown in Fig. 1.6, the following new data are applicable:
Pipe 1: length = 8m, ID = 25mm
Pipe 2: length =8m, ID = 25mm
The globe valve is 25mm in size and is wide open.
SG =0.90 kinematic viscosity (  0.0001 m2 /s) and Q =0.0025 m3 /s
Find p2  p1 in units of bars.

Pipe 1 Pipe 2

Qoil =40 GPM

Globe
25 mm dia valve 25 mm dia
8 m long 8 m long

Figure 1.6

Solution: The velocity can be calculated as

Q (m3 /s) 0.0025
v   5.09 m/s
2
A (m )  (0.0252 )
4
We know that
 vD vD vD 5.09  0.025
Re      1272
 /  0.0001
So the flow is laminar. Now friction factor is
64 64
f    0.0503
Re 1272
Also, head loss is
f Lp v2
HL  
Dp 2g
Now

 KD   10  0.025 
Lp  8  8     16     21 m
 f std elbow  0.0503 
K = 10 for globe valve (fully open). So

0.0503  21 5.092
HL   = 55.8 m of oil
0.025 2  9.81
Now
p
 HL

 p   H L
 (1000  0.9  9.81)  55.8
 493000 N/m 2
So

p2  p1  p
 493000 N/m 2
 493 kPa  4.93 bar

Example 1.8
For the system shown in Fig. 1.7, the following data are applicable: P1  7 bar, Q =0.002 m3 /s .
Pipe: total length = 15m and ID = 38mm
Oil: SG =0.90 and kinematic viscosity (  0.0001 m2 /s)
Solve for p2 in units of bars.
 Motor

Pipe length = 3m

Pump 90˚ elbow

Q 38 mm (ID)
Breather

Pipe length = 2m

90˚ elbow
Load force
C
Pipe length = 4 m Pipe length= 6m

Figure 1.7

Solution: The velocity V is

Q (m3 /s) 0.002
v   1.76 m/s
2
A (m )  (0.038)2
4
We know that
vD vD vD 1.76  0.038
Re      669
 /  0.0001
So the flow is laminar. The friction is
64 64
f    0.096
Re 669
Now we can calculate the equivalent length ( Le ) as

 KD   KD 
Le  Lpipe     2 
 f globe valve  f 90 elbow
 10  0.038   0.75  0.038 
 15     2 
 0.096   0.096 
 15  4  0.6  19.6 m
Head loss due to friction is given by

0.096  19.6 1.762

HL    7.82 m of oil
0.038 2  9.81
Now we can express the head loss due to friction in terms as pressure using
 p
 HL

 p   H L  (1000  0.9  9.81)  7.82
 690000 N/m2  0.69 bar
From the pressure drop we can calculated p2 as
p1  p2  p  0.69 bar
 7  p2  0.69 bar
 p2  6.31 bar

Example 1.9
For the fluid power system shown in Fig. 1.8, determine the external load F that a hydraulic
cylinder can sustain while moving in an extending direction. Take frictional pressure losses into
account. The pump produces a pressure increase of 6.9 MPa from the inlet port to the discharge
port and a flow rate of 0.00253 m3/s. The following data are applicable.
Kinematic viscosity 0.0000930 m2 /s
Weight density of oil 7840 N/m3
Cylinder piston diameter 0.203 m
Cylinder rod diameter 0.102 m

All elbows are at 90 with K factor = 0.75. Pipe length and inside diameters are given in Fig. 1.7.

Motor

Check valve k= Cylinder

3 4
Breather
Pump 4 External
13 load
5
9 8
2
12 7
6

Reservoir 1 10
11
Directional
controlvalveK =5

Figure 1.8
Pipe Number Length (m) Diameter Pipe Number Length (m) Diameter
1 0.610 0.0381 8 1.52 0.0254
2 1.83 0.0381 9 1.52 0.0190
3 0.610 0.0381 10 1.52 0.0190
4 15.2 0.0254 11 18.3 0.0190
5 3.05 0.0254 12 3.05 0.0190
6 1.52 0.0254 13 6.10 0.0190
7 1.52 0.0254
(a) Determine the heat generation rate.
(b) Determine the extending and retracting speeds of cylinder.

Solution:We can use the following equations

13  fL  v2
HL    K
p

1  Dp
 2g

Now

Q (m3 /s)
v
A (m2 )
We know that
vD vD vD
Re   
 / 
Also

(0.2032  0.1022 )
Qreturn  0.00253  0.00189 m3 /s
0.203
Velocity calculation:
0.00253 (m3 /s)
v1,2,3   2.22 m/s
 (0.03812 ) 2
m
4
0.00253 (m3 /s)
v4,5, 6   4.99 m/s
 (0.02542 ) 2
m
4
0.00189 (m3 /s)
v7,8   3.73 m/s
 (0.02542 ) 2
m
4
0.00253 (m3 /s)
v9,10   8.92 m/s
 (0.01902 ) 2
m
4
0.00189 (m3 /s)
v11 ,12,13   6.67 m/s
 (0.01902 ) 2
m
4
Reynolds number calculation:
2.22  0.0381
Re(1,2, 3)   909
0.000093
4.99  0.0254
Re(4,5, 6)   1362
0.000093
3.73 0.0254
Re 7,8   1018
0.000093
8.92  0.019
Re(9,10)   1822
0.000093
6.67  0.019
Re(11,12,13)   1363
0.000093

All flows are laminar. Now

64
f 
Re
Now head loss can be calculated for each element:

 64 3.05  2.22
2
H L(1,2,3)    1.5   1.79 m  14000 Pa
 909 0.0381  2  9.81
 64 19.8  4.99
2
H L(4,5,6)    10.5   59.8 m  469000 Pa
 1362 0.0254  2  9.81
 64 3.05  3.73
2
H L(7,8)    0.75   5.89 m  46200 Pa
 1018 0.0254  2  9.81
 64 3.05  8.92
2
H L(9,10)    0.75   25.9 m  203000 Pa
 1822 0.019  2  9.81
 64 27.4  6.67
2
H L(11,12,13)    1.5   157 m  1230000 Pa
 1363 0.019  2  9.81
Nowexternal load F that a hydraulic cylinder can sustain while moving in an extending
directioncan be calculated as

F  Pressure on piston side × Area    Pressure on rod side × Area 

  (0.2032 )    (0.2032  0.1022 ) 

F  [(6900000)  (14000  469000  203000)]  
 (46200  1230000)  
 4   4 

F  (201000)  (30900)  170000 N

(a) Heat generation rate (power loss in watts) = Pressure × Discharge

Power loss = {(14000  469000  20300)  (0.00253)  (46200  1230000)  (0.00189)}
= 1740 + 2410
 = 4150 W = 4.15 kW
(b) Now to calculate forward and retracting speed of the cylinder

Qpump  0.00253 m3 / s
Cylinder piston diameter = 0.2032 m
 (0.2032 2 )
Area of pistonA = m2
4
Knowing the area of piston and discharge we can calculate the forward velocity of piston as

Q (m3 /s) 0.00253

Vextending    0.0780 m/s
2
A (m )  (0.20322 )
4
Now

Cylinder rod diameter = 0.1016 m

 (0.10162 )
Area of rod = m2
4
 (0.20322 )  (0.10162 )
Annulus area = 
4 4
Knowing the annulus area and discharge we can calculate the return velocity of piston as
Q (m3 /s) 0.00253
Vextending    0.104 m/s
A (m2 )  (0.20322 )  (0.10162 )

4 4
Objective-Type Questions
Fill in the Blanks

1. In fluid power systems, energy losses due to flow in valves and fittings may ______ those due
to flow in pipes.
2. Darcy’s equation can be used to find head losses in pipes experiencing ______ flow.
3. In the case of an ideal fluid flowing in a straight conduit, all the particles move in parallel lines
with equal ______.
4. The flow characteristic of a viscous fluid is one in which ______ plays a significant part.
5. Energy loss in turbulent flow is ______ than laminar flow.

State True or False

1. Reynolds number is the ratio of viscous forces to inertial force.

2. In the flow of a fluid through a completely filled conduit, gravity affects the flow pattern.
3. Friction is the main cause of energy losses in fluid power systems.
4. In the flow of a real fluid, the velocity adjacent to the wall is maximum.
5. A distinguishing characteristic of turbulence is its irregularity, no definite and no observable
pattern.

Review Questions

1. Differentiate between laminar flow and turbulent flow.

2. List the main causes of turbulence in fluid flow.
3. Define Reynolds number and list its range for laminar and turbulent flows.
4. Briefly explain the method to calculate the equivalent length of a valve or fitting.
5. Define the relative roughness and K factor of a valve or fitting.
6. Write an expression for pressure drop down a pipe in terms of friction factor.
7. What are the important conclusions of the Reynolds experiment?
8. Name two causes of turbulence in fluid flow.
9. What is meant by the equivalent length of a valve or fitting?
10. Why is it important to select properly the size of pipes, valves and fittings in hydraulic
systems?
Answers
Fill inthe Blanks
1.Exceed
2.Turbulent
3.Velocity
4.Viscosity
5.Less
State True or False

1.False
2.False
3.True
4.False
5.True
 Lecture 7
HYDRAULIC PUMPS
Learning Objectives
Upon completion of this chapter, the student should be able to:
 Classify the hydraulic pumps used in the industry.
 Differentiate between positive displacement and non-positive displacement pumps.
 Explain the working and construction of gear, vane and piston pumps.
 Evaluate the discharge parameters of gear, vane and piston pumps.
 Define mechanical, volumetric and overall efficiency of pumps.
 Evaluate the performance parameters of gear, vane and piston pumps.
 Differentiate between internal and external gear pumps.
 Differentiatebetween a bent-axis piston pump and a swash plate.
 State the advantage of balance vane pumps.
 Explain cavitation and various means to control it.
 Explain the importance of noise control in pumps.
 Write a computer program to evaluate the performance of the system.

1.1Introduction
The function of a pump is to convert mechanical energy into hydraulic energy. It is the heart
of any hydraulic system because it generates the force necessary to move the load.
Mechanical energy is delivered to the pump using a prime mover such as an electric
motor.Partial vacuum is created at the inlet due to the mechanical rotation of pump shaft.
Vacuum permits atmospheric pressure to force the fluid through the inlet line and into the
pump. The pump then pushes the fluid mechanically into the fluid power actuated devices
such as a motor or a cylinder.
Pumps are classified into three different ways and must be considered in any discussion of
fluid power equipment.
1. Classification based on displacement:
 Non-positive displacement pumps (hydrodynamic pumps).
 Positive displacement pumps (hydrostatic pumps).

2. Classification based on delivery:

 Constant delivery pumps.
 Variable delivery pumps.

3. Classification based on motion:

 Rotary pump.
 Reciprocating pump.

1.2 Classification of Pumps

1.2.1Classification Based on Displacement

1.2.1.1 Non-Positive Displacement Pumps

Non-positive displacement pumps are primarily velocity-type units that have a great deal of
clearance between rotating and stationary parts. Non-displacement pumps are characterized
by a high slip that increases as the back pressure increases, so that the outlet may be
completely closed without damage to the pump or system. Non-positive pumps do not
develop a high pressure but move a large volume of fluid at low pressures. They have
essentially no suction lift. Because of large clearance space, these pumps are not self-priming.
In other words, the pumping action has too much clearance space to seal against atmospheric
pressure. The displacement between the inlet and the outlet is not positive. Therefore, the
volume of fluid delivered by a pump depends on the speed at which the pump is operated and
the resistance at the discharge side. As the resistance builds up at the discharge side, the fluid
slips back into the clearance spaces, or in other words, follows the path of least resistance.
When the resistance gets to a certain value, no fluid gets delivered to the system and the
volumetric efficiency of the pump drops to zero for a given speed. These pumps are not used
in fluid power industry as they are not capable of withstanding high pressure. Their
maximum capacity is limited to 17–20 bar.These types of pumpsare primarily used for
transporting fluids such as water, petroleum,etc.,from one location to another considerable
apart location. Performance curves for positive and non-positive displacement pumps are
shown in Fig.1.1.
Thetwo most common types of hydrodynamic pumps are the centrifugal and the axial flow
propeller pumps.

Advantages and disadvantages ofnon-positive displacement pumps

The advantages are as follows:

1.Non-displacement pumps have fewer moving parts.

2.Initial and maintenance cost is low.
3. They give smooth continuous flow.
4. They are suitable for handling almost all types of fluids including slurries and sledges.
5.Their operation is simple and reliable.

The disadvantages are as follows:

1.Non-displacement pumps are not self-priming and hence they must be positioned below the
fluid level.
2. Discharge is a function of output resistance.
3.Low volumetric efficiency.

1.2.1.2Positive Displacement Pumps

Positive displacement pumps, in contrast, have very little slips, are self-priming and pump
against very high pressures, but their volumetric capacity is low. Positive displacement
pumps have a very close clearance between rotating and stationary parts and hence are self-
priming. Positive displacement pumps eject a fixed amount of fluid into the hydraulic system
per revolution of the pump shaft. Such pumps are capable of overcoming the pressure
resulting from mechanical loads on the system as well as the resistance of flow due to
friction. This equipment must always be protected by relief valves to prevent damage to the
pump or system. By far, a majority of fluid power pumps fall in this category, including gear,
vane and piston pumps.Performance curves for positive and non-positive displacement
pumps are shown in Fig. 1.1.
Positive displacement pumps are classified based on the following characteristics:

1. Type of motion of pumping element: Based on the type of motion of pumping

element, positive displacement pumps are classified as follows:
 Rotary pumps, for example, gear pumps and vane pumps.
 Reciprocating pumps, for example, piston pumps.

2. Displacement characteristics: Based on displacement characteristics, positive

displacement pumps are classified as follows:
 Fixed displacement pumps.
 Variable displacement pumps.
3. Type of pumping element.

The advantages of positive displacement pumps over non-positive displacement pumps are as
follows:

1. They can operate at very high pressuresof up to 800 bar (used for lifting oils from very
deep oil wells).
2. They can achieve a high volumetric efficiency of up to 98%.
3. They are highly efficient and almost constant throughout the designed pressure range.
4. They are a compact unit, havinga high power-to-weight ratio.
5. They can obtain a smooth and precisely controlled motion.
6. By proper application and control, they produce only the amount of flow required to
move the load at the desired velocity.
7. They have a great flexibility of performance. They can be made to operate over a wide
range of pressures and speeds.

1.2.2 Classification Based on Delivery

1.2.2.1 Constant Delivery Pumps

Constant volume pumps always deliver the same quantity of fluid in a given time at the
operating speed and temperature. These pumps are generally used with relatively simple
machines, such as saws or drill presses or where a group of machines is operated with no
specific relationship among their relative speeds. Power for reciprocating actuators is most
often provided by constant volume pumps.

1.2.2.2Variable Delivery Pumps

The output of variable volume pumps may be varied either manually or automatically with no
change in the input speed to the pump. Variable volume pumps are frequently used for
rewinds, constant tension devices or where a group of separate drives has an integrated speed
relationship such as a conveyor system or continuous processing equipment.

1.2.3Classification Based on Motion

This classification concerns the motion that may be either rotary or reciprocating. It was of
greater importance when reciprocating pumps consisted only of a single or a few relatively
large cylinders and the discharge had a large undesirable pulsation. Present-day reciprocating
pumps differ very little from rotary pumps in either external appearance or the flow
characteristics.
Differences between positive displacement pumps and non-positive displacement pumps are
enumerated in Table 1.1.

Table 1.1 Differences between positive displacement pumps and non-positive displacement
pumps
Positive Displacement Non-positive Displacement
Pumps Pumps

The flow rate does not The flow rate decreases with
change with head head
The flow rate is not much The flow rate decreases with
affected by the viscosity of the viscosity
fluid
Efficiency is almost constant Efficiency increases with
with head head at first and then
decreases

(a)

(b)

Figure 1.1 Performance curves for positive and non-positive displacement pumps
1.3Pumping Theory
A positive displacement hydraulic pump is a device used for converting mechanical energy
into hydraulic energy.It is driven by a prime mover such as an electric motor.It basically
performs twofunctions.First, it creates a partial vacuum at thepump inlet port.This vacuum
enables atmospheric pressure to force the fluid from the reservoir into the pump.Second,the
mechanical action of the pump traps this fluid within the pumping cavities,transports it
through the pump and forces it into the hydraulic system. It is important to note that pumps
create flow not pressure. Pressure is created by the resistance to flow.

Outlet Outlet
Low pressure Outlet valve is High pressure
closed Outlet valve is
Rod moves outward Rod moves inward open

Inlet
valve is
closed
Breather

Strainer

Suction stroke Delivery stroke

Figure 1.2Illustration of pumping theory

All pumps operate by creating a partial vacuum at the intake, and a mechanical force at the
outlet that induces flow. This action can be best described by reference to a simple piston
pump shown in Fig.1.2.

1. As the piston moves to the left, a partial vacuum is created in the pump chamber
thatholds the outlet valve in place against its seat and induces flow from the reservoir
that is at a higher (atmospheric) pressure.As this flow is produced, the inlet valve is
temporarily displaced by the force of fluid, permitting the flow into the pump
chamber (suction stroke).
2. When the piston moves to the right, the resistance at the valves causes an immediate
increase in the pressure that forces the inlet valve against its seat and opens the outlet
valve thereby permitting the fluid to flow into the system. If the outlet port opens
directly to the atmosphere, the only pressure developed is the one required to open the
outlet valve(delivery stroke).
1.4Gear Pumps

Gear pumps are less expensive but limited to pressures below 140 bar.It is noisy in operation
than either vane or piston pumps. Gear pumps are invariably of fixed displacement type,
which means that the amount of fluid displaced for each revolution of the drive shaft is
theoretically constant.

1.4.1 External Gear Pumps

External gear pumps are the most popular hydraulic pumps in low-pressure ranges due to
their long operating life, high efficiency and low cost. They are generally used ina simple
machineThe most common form of external gear pump is shown in Figs. 1.3and 1.4 It
consist of a pump housing in which a pair of preciselymachined meshing gears runs with
minimal radial and axial clearance.One of the gears, called a driver,is driven by a prime
mover. The driver drives another gear called a follower.As the teeth of the two gears separate,
the fluid from the pump inlet gets trapped between the rotating gear cavities and pump
housing.The trapped fluid is then carried around the periphery of the pump casing and
delivered to outlet port. The teeth of precisely meshed gears provide almost a perfect seal
between the pumpinlet and the pump outlet.When the outlet flow is resisted, pressure in the
pump outlet chamber builds up rapidly and forces the gear diagonally outward against the
pump inlet. When the system pressure increases, imbalance occurs. This imbalance increases
mechanical friction and the bearing load of the two gears.Hence, the gear pumps are operated
to the maximum pressure rating stated by the manufacturer.
It is important to note that the inlet is at the point of separation and the outlet at the point of
mesh. These units are not reversible if the internal bleeds for the bearings are to be drilled to
both the inlet and outlet sides.So that the manufacturer’s literature should be checked before
attempting a reversed installation. If they are not drilled in this manner, the bearing may be
permanently damaged as a result of inadequate lubrications.

Advantages and disadvantages of gear pumps

The advantages are as follows:

1.They are self-priming.

2.They give constant delivery for a given speed.
3. They are compact and light in weight.
4. Volumetric efficiency is high.

The disadvantages are as follows:

1. The liquid to be pumped must be clean, otherwise it will damage pump.

2. Variable speed drives are required to change the delivery.
3. If they run dry, parts can be damaged because the fluid to be pumped is used as lubricant.
Expression for the theoretical flow rate of an external gear pump
Let
Do =the outside diameter of gear teeth
Di= the inside diameter of gear teeth
L =the width of gear teeth
N=the speed of pump in RPM
VD=the displacement of pump in m/rev
M= module of gear
z=number of gear teeth
= pressure angle
Volume displacement is

VD  ( Do 2  Di 2 ) L
4
Di  Do  2(Addendum  Dendendum)
Theoretical discharge is

QT (m3 /min)  VD (m3 /rev)  N (rev/min)

If the gear is specified by its module and number of teeth, then the theoretical discharge can
be found by

   2 cos 2 20   3
QT  2 Lm2 N  z  1    m /min
  12 

Figure 1.3Operation of an external gear pump

1.4.2Internal Gear Pumps

Another form of gear pump is the internal gear pump, which is illustrated in Fig. 1.5. They
consist of two gears:An external gear and an internal gear. The crescent placed in between
these acts as a seal between the suction and discharge.(Fig.1.6) When a pump operates, the
external gear drives the internal gear and both gears rotate in the same direction. The fluid
fills the cavities formed by the rotating teeth and the stationary crescent. Both the gears
transport the fluid through the pump. The crescent seals the low-pressure pump inlet from the
high-pressure pump outlet. The fluid volume is directly proportional to the degree of
separation and these units may be reversed without difficulty. The major use for this type of
pump occurs when a through shaft is necessary, as in an automatic transmission. These
pumps have a higher pressure capability than external gear pumps.

Figure 1.5Operation of an internal gear pump

1.4.3 Gerotor Pumps

Gerotor pumps operate in the same manner as internal gear pumps. The inner gear rotor is
called a gerotor element. The gerotor element is driven by a prime mover and during the
operation drives outer gear rotor around as they mesh together. The gerotor has one tooth less
than the outer internal idler gear. Each tooth of the gerotor is always in sliding contact with
the surface of the outer element. The teeth of the two elements engage at just one place to
seal the pumping chambers from each other. On the right-hand side of the pump, shown in
Fig. 1.7, pockets of increasing size are formed, while on the opposite side, pockets decrease
in size. The pockets of increasing size are suction pockets and those of decreasing size are
discharge pockets. Therefore, the intake side of the pump is on the right and discharge side on
the left.

Pumping chambers are formed by the adjacent pair of teeth, which are constantly in contact
with the outer element, except for clearance. Refer to Fig 1.7,asthe rotor is turned, its gear
tips are accurately machined sothat they precisely follow the inner surface of the outer
element. The expanding chambers are created as the gear teeth withdraw. The chamber
reaches its maximum size when the female tooth of the outer rotor reaches the top dead
center. During the second half of the revolution, the spaces collapse, displacing the fluid to
the outlet port formed at the side plate. The geometric volume of the gerotor pump is given as
VD  b Z ( Amax  Amin )
where b is the tooth height, Z is the number of rotor teeth, Amax is the maximum area between
male and female gears (unmeshed – occurs at inlet) and Amin is the minimum area between
male and female gears (meshed – occurs at outlet).

Figure 1.7Gerotor gear pump

Example 1.1
The inlet to a hydraulic pump is 0.6 m below the top surface of an oil reservoir. If the specific
gravity of the oil used is 0.86, determine the static pressure at the pump inlet.
Solution: We know that
Pressure   gh
The density of water is 1 g/cm or 1000 kg/m3.
3

Therefore, the density of oil is 0.861 g/cm3 or 860 kg/m3 .

Pressure at the pump inlet is
P= 860  0.6 kg/m 2 = 516 kg/m 2 = 0.0516 kg/cm 2  0.0516 0.981bar
 0.0506 bar
(Note: 1kg/cm  0.981bar .)
2

Example 1.2
A hydraulic pump delivers 12 L of fluid per minute against a pressure of 200 bar. (a)
Calculate the hydraulic power. (b) If the overall pump efficiency is 60%, what size of electric
motor would be needed to drive the pump?

Solution:
(a) Hydraulic power is given by

200 (bar)
Hydraulic power (kW) 12 L/min   4 kW
600
(b) We have

Hydraulic power
Electric motor power (power input) =
Overall efficiency
 Substituting we get

4
Electric motor power (power input) =  6.67kW
0.6

4
Electric motor power   6.67 kW
0.6

Example 1.3
A gear pump has an outside diameter of 80mm, inside diameter of 55mm and a width of
25mm. If the actual pump flow is 1600 RPM and the rated pressure is 95 LPM what is the
volumetric displacement and theoretical discharge.

Solution: We have
Outside diameter Do  80 mm
Inside diameter Di  55 mm
Width d  25mm
Speed of pump N = 1600 RPM
Actual flow rate = 95 LPM
Now
QA  95 LPM  95 103 m3 /min

VD   ( Do 2  Di 2 )  L
4

VD   (0.0802  0.0552 )  0.025  6.627 105 m3 / rev
4

Theoretical flow rate


QT   ( Do 2  Di 2 )  L  N
4

=  (0.0802  0.0552 )  0.025 1600
4
= 0.106 m3 /min

Example 1.4
Calculate the theoretical delivery of a gear pump. Module of the gear teeth is 6mm and width
of gear teeth is 25mm. Number of teeth on driver gear is 18 and pressure angle of the gear is
20 . Pump speed is 1000 RPM. Volumetric efficiency is 90%.

Solution: If the gear is specified by its module and number of teeth, then the theoretical
discharge can be found by
    2 cos   3
QT  2 Lm 2 N  z  1    m /min
  12  
   2 cos 2 20   3
 2 (0.025)(6 103 ) 2 1000  18  1    m /min
  12 
 0.1118 m3 /min

Example 1.5
Calculate the theoretical delivery of a gear pump. Module of the gear teeth is 6mm and width
of gear teeth is 65mm. Number of teeth on driver gear is 16 and pressure angle of the gear is
20 . Pump speed is 1600 RPM. Outer diameter of gear is 108 mm and Dedendum circle
diameter is 81 mm. Volumetric efficiency is 88%at 7 MPa.

Solution: If the gear is specified by its module and number of teeth, then the theoretical
discharge can be found by
   2 cos 2 20   3
QT  2 Lm 2 N  z  1    m /min
  12 
   2 0.9392  3
 2 (0.065)(6 103 ) 2 1600  16  1    m /min
  12 
 0.416 m3 /min

Alternatively we can use


VD   ( Do 2  Di 2 )  L
4


QT   (0.1082  0.0812 )  0.065 1600  0.416 m3 /rev
4

1.5Lobe Pumps

The operation of lobe pump shown in Fig.1.9 is similar to that of external gear pump, but
they generally have a higher volumetric capacity per revolution. The output may be slightly
greater pulsation because of the smaller number of meshing elements.

Lobe pumps, unlike external gear pumps,have both elements externally driven and neither
element hasany contact with the other.For this reason, they are quieter when compared to
other types of gear pumps. Lobe contact is prevented by external timing gears located in the
gearbox.Pump shaft support bearings are located in the gearbox, and because the bearings are
out of the pumped liquid, pressure is limited by bearing location and shaft deflection. They
do not lose efficiency with use. They are similar to external gear pumps with respect to the
feature of reversibility.
Stages of operation of Lobe pump

1.As the lobes come out of mesh, they create expanding volume on the inlet side of the
pump.Liquid flows into the cavity and is trapped by the lobes as they rotate.

2.Liquid travels around the interior of the casing in pockets between the lobes and the casing
(it does not pass between the lobes).

3.Finally, the meshing of the lobes forces the liquid through the outlet port under pressure.

Lobe pumps are frequently used in food applications because they are good at handling solids
without inflicting damage to the product. Solid particle size can be much larger in lobe
pumps than in other positive displacement types.Because lobes do not make contact, and
clearances are not as close as in other positive displacement pumps, this design handles low-
viscosity liquids 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.Reductions of 25% of rated speed and lower are common
with high-viscosity liquids.
1.5.1Advantages

The advantages of lobe pumps are as follows:

1. Lobe pumps can handle solids, slurries, pastes and many liquid.
2. No metal-to-metal contact.
3. Superior CIP(Cleaning in Place) /SIP(Sterilization in Place) capabilities.
4. Long-term dry run (with lubrication to seals).
5. Non-pulsating discharge.

1.5.2Disadvantages
The disadvantages of lobe pumps are as follows:

1. Require timing gears.

2. Require two seals.
3. Reduced lift with thin liquids.
1.5.3Applications
Common rotary lobe pump applications include, but are not limited to, the following:

1. Polymers.
2. Paper coatings.
3. Soaps and surfactants.
4. Paints and dyes.
5. Rubber and adhesives.
6. Pharmaceuticals.
7. Food applications.

1.6Screw Pumps

These pumps have two or more gear-driven helical meshing screws in a closefitting caseto
develop the desired pressure. These screws mesh to form a fluid-type seal between the screws
and casing.
A schematic diagram of a screw pump is shown in Fig 1.10. A two-screw pump consists of
two parallel rotors with inter-meshing threads rotating in a closely machined casing. The
driving screw and driven screw are connected by means of timing gears. When the screws
turn, the space between the threads is divided into compartments. As the screws rotate, the
inlet side of the pump is flooded with hydraulic fluid because of partial vacuum.When the
screws turn in normal rotation, the fluid contained in these compartments is pushed uniformly
along the axis toward the center of the pump, where the compartments discharge the fluid.
Here the fluid does not rotate but moves linearly as a nut on threads. Thus, there are no
pulsations at a higher speed; it is a very quiet operating
pump.
3. and carried
4. To the along in these
discharge spaces

1. As this screw
rotates

2. This screw also

rotates and oil is
drawn here

Ina screw pump, a chamber is formed between thread and housing as shown in Fig.1.11. The
following expression gives the volumetric displacement

π 2  α sin 2α 
VD  ( D  d 2 )s  D 2   s
4 2 2 
Dd
Heres is the stroke length and cos(α) 
2D

Figure 1.11Volumetric displacement of a screw pump

Advantages and disadvantages of screw pump

Theadvantages are as follows:

1.They are self-priming and more reliable.

2. They are quiet due to rolling action of screw spindles.
3.They can handle liquids containing gases and vapor.
4. They have long service life.

The disadvantages are as follows:

1.They are bulky and heavy.
2.They are sensitive to viscosity changes of the fluid.
3. They have low volumetric and mechanical efficiencies.
4. Manufacturing cost of precision screw is high.
 Lecture 8
HYDRAULIC PUMPS [CONTINUED]

1.7 Vane Pumps

There are two types of vane pumps:

1. Unbalanced vane pump: Unbalanced vane pumps are of two varieties:

 Unbalanced vane pump with fixed delivery.

 Unbalanced vane pump with pressure-compensated variable delivery.

2. Balanced vane pump.

1.7.1 Unbalanced Vane Pump with Fixed Delivery

A simplified form of unbalanced vane pump with fixed delivery and its operation are shown
in Figs. 1.12 and 1.13. The main components of the pump are the cam surface and the rotor.
The rotor contains radial slots splined to drive shaft. The rotor rotates inside the cam ring.
Each radial slot contains a vane, which is free to slide in or out of the slots due to centrifugal
force. The vane is designed to mate with surface of the cam ring as the rotor turns. The cam
ring axis is offset to the drive shaft axis. When the rotor rotates, the centrifugal force pushes
the vanes out against the surface of the cam ring. The vanes divide the space between the
rotor and the cam ring into a series of small chambers. During the first half of the rotor
rotation, the volume of these chambers increases, thereby causing a reduction of pressure.
This is the suction process, which causes the fluid to flow through the inlet port. During the
second half of rotor rotation, the cam ring pushes the vanes back into the slots and the trapped
volume is reduced. This positively ejects the trapped fluid through the outlet port. In this
pump, all pump action takes place in the chambers located on one side of the rotor and shaft,
and so the pump is of an unbalanced design. The delivery rate of the pump depends on the
eccentricity of the rotor with respect to the cam ring.
 Figure 1.12Simple vane pump

1.7.4 Pressure-Compensated Variable Displacement Vane Pump (an Unbalanced Vane

Pump with Pressure-Compensated Variable Delivery)

Figure 1.14 Operation of a variable displacement vane pump

Schematic diagram of variable displacement vane pump is shown in Fig.1.14.Variable

displacement feature can be brought into vane pumps by varying eccentricity between the
rotor and the cam ring. Here in this pump, the stator ring is held against a spring loaded
piston.The system pressure acts directly through a hydraulic piston on the right side. This
forces the cam ring against a spring-loaded piston on the left side. If the discharge pressure is
large enough, it overcomes the compensated spring force and shifts the cam ring to the left.
This reduces the eccentricity and decreases the flow. If the pressure continues to increase,
there is no eccentricity and pump flow becomes zero.

1.7.5 Balanced Vane Pump with Fixed Delivery

A balanced vane pump is a very versatile design that has found widespread use in both
industrial and mobile applications. The basic design principle is shown in Fig. 1.15. The rotor
and vanes are contained within a double eccentric cam ring and there are two inlet segments
and two outlet segments during each revolution. This double pumping action not only gives a
compact design, but also leads to another important advantage: although pressure forces
acting on the rotor in the outlet area are high, the forces at the two outlet areas are equal and
opposite, completely canceling each other. As a result, there are no net loads on shaft
bearings. Consequently, the life of this type of pump in many applications has been
exceptionally good. Operating times of 24000 h or more in industrial applications are
widespread. In more severe conditions encountered in mobile vehicles, 5000–10000 h of
trouble-free operation is frequently achieved.

Figure 1.15 Operation of a balanced vane pump

1.7.2 Advantages and disadvantages of Vane Pumps

The advantages of vane pumps are as follows:

1. Vane pumps are self-priming, robust and supply constant delivery at a given
speed.
2. They provide uniform discharge with negligible pulsations.
3. Their vanes are self-compensating for wear and vanes can be replaced easily.
4. These pumps do not require check valves.
5. They are light in weight and compact.
6. They can handle liquids containing vapors and gases.
7. Volumetric and overall efficiencies are high.
8. Discharge is less sensitive to changes in viscosity and pressure variations.

The disadvantages of vane pumps are as follows:

 1. Relief valves are required to protect the pump in case of sudden closure of delivery.
2. They are not suitable for abrasive liquids.
3. They require good seals.
4. They require good filtration systems and foreign particle can severely damage pump.

Advantages and disadvantagesofbalancedvane pumps

The advantages of balanced vane pumps are as follows:

1. The balanced pump eliminates the bearing side loads and therefore high operating pressure
can be used.
2.The service life is high compared to unbalanced type due to less wear and tear.

The disadvantages of balanced vane pumps are as follows:

1. They are fixed displacement pumps.

2. Design is more complicated.
3. Manufacturing cost is high compared to unbalanced type.

1.7.4 Expression for the Theoretical Discharge of Vane Pumps

Let DC be the diameter ofa cam ring in m, DRthe diameter of rotor in m, L the width of rotor
in m, e the eccentricity in m, VD the pump volume displacement in m3/rev and emax the
maximum possible eccentricity in m.

From geometry (Fig.1.13) the maximum possible eccentricity,

D  DR
emax  C (1.1)
2
Themaximum value of eccentricity produces the maximum volumetric displacement

VD(max)  ( DC2  DR2 ) L (1.2)
4
Using Equation (1.1), Equation (1.2) can be simplified as

VD(max)  ( Dc  Dg )( Dc  Dg ) L
4


< VD(max) 
( Dc  Dg )(2emax ) L
4
The actual volumetric displacement occurs when emax  e . Hence,

VD(max)  ( DC  DR )e L m3/rev
2
When the pump rotates at N rev/min (RPM),the quality of discharge by the vane pump is
given by
QT  vD  N
Theoretical discharge
 
QT  ( DC  DR )e L m3/min
2

Example 1.6
A vane pump has a rotor diameter of 63.5 mm, a cam ring diameter of 88.9 mm and a vane
width of 50.8 mm. What must be eccentricity for it to have a volumetric displacement of
115cm3?

Solution: Volumetric displacement is

 D  DR 
VD    C  Le
 2 
whereDcis the diameter of the cam ring, DR is the diameter of the rotor, e is the eccentricity
and L is the width of the vane pump. So we have
0.0889  0.0635
115 106     e  0.0508
2
Therefore eccentricity
e  9.456 103 m  9.456 mm

1.8Piston Pumps
Piston pumps are of the following two types:

1. Axial piston pump:These pumps are of two designs:

 Bent-axis-type piston pump.

 Swash-plate-type piston pump.

2. Radial piston pump.

1.8.1Bent-Axis-Type Piston Pump

Schematic diagram and detailed cut section of bent axis type piston pump is shown in
Fig.1.16. It contains a cylinder block rotating with a drive shaft. However,thecenterline of the
cylinder block is set at an offset angle relative to the centerline of the drive shaft.Thecylinder
block contains a number of pistons arranged along a circle.The piston rods are connected to
the drive shaft flange by a ball and socket joints. The pistons are forced in and out of their
bores as the distance between the drive shaft flange and cylinder block changes. A universal
link connects the cylinder block to the drive shaft to provide alignment and positive drive.
The volumetric displacement of the pump depends on the offset angle . No flow is produced
when the cylinder blockis centerline.can vary from 0to a maximum of about 30.For a
fixed displacement, units are usually provided with 23 or 30 offset angles.

1.8.2 Swash-Plate-Type Piston Pump

Schematic diagram of swash plate type piston pump is shown in Fig. 1.17. In this type, the
cylinder block and drive shaft are located on the same centerline. The pistons are connected
to a shoe plate that bears against an angled swash plate. As the cylinderrotates,the pistons
reciprocatebecausethe piston shoesfollow the angled surface of the swash plate. The outlet
andinlet ports are located in the valve plate so that the pistons pass theinlet as they are being
pulledout and pass the outlet as they are being forced back in. This type of pump can also be
designed to have a variable displacementcapability. The maximumswash plate angle is
limited to 17.5° by construction.

Figure 1.17Operation of a swash-plate-type piston pump

1.8.4 Volumetric Displacement and Theoretical Flow Rate of an Axial Piston Pump

Figure 1.19(a) shows in and out position of the pistons of axial piston pump.Figure1.19(b)
gives schematic diagram of stroke change with respect to offset angle.

Letθ be an offset angle, S the piston stroke in m, D the piston circle diameter, Y the number of
pistons, A the piston area inm2, N the piston speed in RPM and QT the theoretical flow rate in
m3/min.
 (Maximum displacement)

(Partial displacement)

(No displacement)
(No stroke)

(b)
Figure 1.19Stroke changes with offset angle

From a right-angled triangle ABC [Fig. 1.19(b)]

BC S
tan   
AB D
 S  D  tan  (1.3)
The displacement volume of one piston = ASm3
Total displacement volume of Ynumber of pistons = YASm3
VD  YAS (1.4)
From Eqs. (1.3) and (1.4), we have
VD  YAD tan  m3 /rev (1.5)
Theoretical flow rate is
QT  DANY tan  m3 /min

Example 1.7
What is the theoretical flow rate from a fixed-displacement axial piston pump with a nine-
bore cylinder operating at 2000 RPM? Each bore has a diameter of 15 mm and stroke is 20
mm.

Solution: Theoretical flow rate is given by

QT  Volume  RPM  Number of pistons

  D2  L  N  n
4
 2000
=  0.0152  0.02  9
4 60
= 10.6 × 103 m3 /s
  1.06 LPS = 63.6 LPM

1.9Comparison of Hydraulic Pumps

Pump design with a wide range of operating characteristics are available. A designer must
select carefully to achieve a circuit design that meets the functional objective while
minimizing total cost which includes both ownership cost and operating cost over the life of
component. Pump selection is important decision in circuit design. Designer must compare
the various options available and then choose the optimum pump. Table 1.2 gives a typical
comparison of all pumps.

The major factor in adopting a pump to a particular system is the system’s overall needs. It
would be wrong to use a pump with high delivery in a system that requires only a
lowdelivery rate. On the contrary, using a pump that must produce at its peak continuously
just to meet the minimum requirements of the system is equally wrong. Making either of
these mistakes produces a poor system due to excessive initial pump costs or maintenance
cost.

One should use a pump that is suited to the system, whether a gear pump which has fewer
moving precision parts or a piston pump whichhas many parts fitted to close tolerance and is
therefore more expensive.

Table 1.2

Pressure Discharge(LPM) MaximumSpeed Overall

(Bar) (RPM) Efficiency
Gear pump 20–175 7–570 1800–7000 75–90
Vane pump 20–175 2–950 2000–4000 75–90
Axial piston pump 70–350 2–1700 600–6000 85–95
Radial piston
pump 50–250 20–700 600–1800 80–92

1.10Pump Performance

The performance of a pump is a function of the precision of its manufacture. An ideal pump
is one having zero clearance between all mating parts. Because this is not possible, working
clearances should be as small as possible while maintaining proper oil films for lubrication
between rubbing parts. The performance of a pump is determined by the following
efficiencies:
1. Volumetric efficiency (  v ):It is the ratio of actual flow rate of the pump to the
theoretical flow rate of the pump. This is expressed as follows:
 Actual flow rate of the pump
Volumetric efficiency (v ) =
Theoretical flow rate of the pump
Q
 A
QT

Volumetric efficiency (  v ) indicates the amount of leakage that takes place within the
pump.This is due to manufacture tolerances and flexing of the pump casing under designed
pressure operating conditions.
For gear pumps,  v = 80%–90%.
For vane pumps,  v = 92%.
For piston pumps,  v = 90%–98%.

2. Mechanical efficiency (  m ): Itis the ratio of the pump output power assuming no leakage
to actual power delivered to the pump:

Pump output power assuming no leakages

Mechanical efficiency (m ) =
Actual power delivered to the pump

Mechanicalefficiency(  m ) indicates the amount of energy losses that occur for reasons other
than leakage. This includes friction in bearings and between mating parts. This includes the
energy losses due to fluid turbulence. Mechanical efficiencies are about 90%–95%. We also
have the relation
p QT
m 
TA N

wherep is the pump discharge pressure in Pa or N/m2, QT is the theoretical flow rate of the
pump in m3/s, TA is the actual torque delivered to the pump in Nm and N is the speed of the
pump in rad/s.
It (  m ) can also be computed in terms of torque as follows:

Theoretical torque required to operate the pump

m =
Actual torque delivered to the pump
T
 T
TA
The theoretical torque ( TT ) required to operate the pump is the torque that would be required
if there were no leakage.
The theoretical torque ( TT ) is determined as follows
VDN  3 N 
TT (N m)  m  2  = N m
2π  m 
The actual torque ( TA ) is determined as follows
 P N m/s
Actual torque TA (N m)   Nm
ω  rad / s 
whereω = 2πN/60. HereNis the speed in RPM.

3. Overall efficiency (o ):It is defined as the ratio of actual power delivered by the pump to
actual power delivered to the pump

Actual power delivered by the pump

Overall efficiency (o ) 
Actual power delivered to the pump
Overall efficiency ( o ) considers all energy losses and can be represented mathematically as
follows:
Overall efficiency (o )  vm
Q pQT
 ηo  A 
QT TA N

Example 1.8
A gear pump has an outside diameter of 82.6 mm, inside diameter of 57.2 mm and a width of
25.4 mm. If the actual pump flow is 1800 RPM and the rated pressure is 0.00183 m3 /s, what
is the volumetric efficiency?

Solution: We have
Outside diameter Do  82.6 mm
Inside diameter Di  57.2 mm
Width d  25.4 mm
Speed of pump N = 1800 RPM
Actual flow rate = 0.00183 m3 /s
Theoretical flow rate
 N
QT   ( Do 2  Di 2 )  d 
4 60
 1800
=  (0.08262  0.05722 )  0.0254 
4 60
= 2.125  10 3
Volumetric efficiency is
0.00183
v = 100  86.11%
2.125 103

Example 1.9
A pump having a volumetric efficiency of 96% delivers 29 LPM of oil at 1000 RPM. What is
the volumetric displacement of the pump?

Solution:
 Volumetric efficiency of the pump  v = 96%
Discharge of the pump = 29 LPM
Speed of pump N  1000 rpm
Now
Actual flow rate of the pump Q
v =  A
Theoritical flow rate of the pump QT
29
 0.96 
QT
 QT  30.208 LPM
Volumetric displacement
Q 30.208 103  60
VD  T 
N 60 1000
 30.208 106 m3 / rev  0.0302 L / rev

Example 1.10
A positive displacement pump has an overall efficiency of 88% and a volumetric efficiency
of 92%. What is the mechanical efficiency?

Solution: Theoverall efficiency is

ηo  η m  η v
η 88
 ηm  o =  100 = 95.7%
η v 92

Example 1.11
Determine the overall efficiency of a pump driven by a 10 HP prime mover if the pump
delivers fluid at 40 LPM at a pressure of 10 MPa.

Solution:

Output power  pQ
m3 /s 1 min
 10 10 N/m  40 L/min 
6 2

1000 L/s 60 s
 6670 W
746 W
Input power  10 HP   7460 W
1 HP
Now

Pump output power

ηo 
Pump input power
6670
  0.894  89.4%
7460
Example 1.12
How much hydraulic power would a pump produce when operating at 140 bar and delivering
0.001 m3/s of oil? What power rated electric motor would be selected to drive this pump if its
overall efficiency is 85%?

Solution:
Operating pressure of the pump = 140 bar
Flow rateQ = 0.001m3/s. Now
Power of pump  Pressure ×Flow rate
 140  105  0.001
 14 kW
Overall efficiency of pump ηo  85%
Power to be supplied is
Power of pump 14 kW
  16.47 kW
ηo 0.85

Example 1.13
A pump has a displacement volume of 98.4 cm3. It delivers 0.0152 m3/s of oil at 1000 RPM
and 70 bar. If the prime mover input torque is 124.3 Nm. What is the overall efficiency of
pump? What is the theoretical torque required to operate the pump?

Solution:
Volumetric discharge  98.4 cm3
Theoretical discharge is
N 1000
QT VD   98.4   1.64 103 m3 /s
60 60
Volumetric efficiency is
1.52 103
ηv  100 = 92.68 %
1.64 103
Overall efficiency is
Q  pressure 1.52 103  70 105  60
ηo  A =  100 = 81.74%
T ω 124.3  2 1000  π
The mechanical efficiency is
η 81.74
ηmechanical  overall   88.2
ηvolumetric 92.78
Now
Theoretical torque = Actual torque × ηmechanical = 124.3 × 0.882 = 109.6 Nm
Note: Mechanical efficiency can also be calculated as
pQT
m 
T
70 105 N/m 2  0.00164 m3 / s

1000
124.3 (N m)   2 rad/s
60
 0.882  88.2%
 Lecture 9
HYDRAULIC PUMPS [CONTINUED]
1.11 Pump Performance Curve

Pump performance characteristics are first analyzed independently of the rest of hydraulic
system and then as a part of the system. Both sets of data are valuable to the designer.
Analyzing the pump by itself gives an indication of its capabilities and performance based on
the speed of rotation, internal geometry, cost factors, etc., whereas analyzing pump
performance in system essentially determines pump system compatibility. In the first case,
the system designer may observe performance curves to see if a specific pump has the
pressure and volume flow rate to operate a given set of actuators. In a second instance, the
system designer may be computing the noise, vibration, cavitation and flow characteristics of
a specific pump before or after installation to determine if the pump and existing system are
compatible. Where the two are necessarily complimentary, in practice much of hands-on
work is completed independently. Pump performance characteristics are interpreted from data
in tabular form and then graphed.

Figure 1.20 shows a graphical representation of a typical positive displacement pump. Figure
1.20(a) represents the relationship between input power and pump output flow of a variable
displacement piston pump as a function of pump speed.Observe the linear relationship
between the discharge flow and pump speed. Figure 1.20(b) gives curves of overall and
volumetric efficiencies as a function of speed. Performance curves of radial piston pump are
given in Fig.1.20(c). Discharge flow of these pumps is nearly constant over a broad pressure
range.Discharge flow can be varied infinitely between the point of inflection on the constant
discharge portion of the curve and zero flow.

Flow

Power

(a)
 (b)

(c)
Figure 1.20Pump performance curves

1.12Pump Noise

Pump noise is an important parameter used to determine the performance. Any increase in
noise indicates increased wear and eventually pump failure. Pumps are good generators but
poor radiators of noise. Noise is not just the sound coming directly from the pump, but also
from the vibration and fluid pulsation produced by the pump. Pumps are small in size and
hence, they are poor radiators of noise. Reservoirs, electric motors and piping being largerin
size are better radiators. Hence,a pump-induced vibration can cause audible noise greater than
that coming from the pump. Fixed displacement pumps are less noisy than variable
displacement pumps because of their rigid construction.
 Figure 1.21 Pumpnoise characteristics
As can be seen from Fig.1.21, the pump speed has a strong effect on noise compared to
displacement and pressure. To reduce the noise levels, electric motors are used and the most
advantageous combination of size and pressure is selected to produce the needed power.

1.13Pump Cavitation
During the working of a positive displacement pump, vacuum is created at the inlet of the
pump. This allows atmospheric pressure to push the fluid in. In some situations, the vacuum
may become excessive, and a phenomenon known as cavitation occurs. When the pressure of
the liquid reaches a low enough level, it vaporizes or boils. Cavitation is the formation of oil
vapor bubbles due to a very low pressure (high vacuum) on the inside of the pump. The low
pressure also causes air, which is dissolved in the oil to come out of the solution and form
bubbles. These air and oil vapor bubbles collapse when they reach the outlet side of the
pump, which is under a high pressure. The collapsing of these vapor bubbles causes
extremely high localized pressure and fluid velocity. These pressures are so high that they
cause pitting of metal and consequently decrease the life and efficiency of the pump.

1.13.1 Factors Causing Cavitation

Cavitation is caused by the following factors:

1. Undersized plumbing.
2. Clogged lines or suction filters.
3. High fluid viscosity.
4. Too much elevation head between the reservoir and the pump inlet.

1.13.2 Rules to Eliminate (Control) Cavitation

Following are the rules to control cavitation:

1. Keep suction line velocities below 1.2 m/s.

2. Keep the pump inlet lines as short as possible.
3. Minimize the number of fittings in the inlet line.
4. Mount the pump as close as possible to the reservoir.
5. Use low-pressure drop inlet filters.
6. Use proper oil as recommended by the pump manufacturer.
Example 1.14
Calculate the pipe bores required for the suction and pressure lines of a pump delivering 40
L/min using a maximum flow velocity in the suction line of 1.2 m/s and a maximum flow
velocity in the pressure line of 3.5 m/s.

Solution:Consider the suction line

Flow = Average velocity × Flow area
Flow through pipe
Area of pipe =
Velocity of flow
Now
Flow = 40 LPM = 40/60 LPS = 40/60 × 103 m3/s
40  103
Area of pipe = = 0.555 × 103 m2
60  1.2
Let the bore of the pipe be of diameter D. Then
3 πD 2
Area of pipe  0.555 10 m  2

4
 D = 0.0266 m
Minimum bore suction pipe = 26.6 mm.
Note: in all calculations great care must be taken to ensure that units are correct.
Alternatively, if a flow velocity of 1m/s is used then suction pipe bore can be of diameter 29
mm. The required diameter of the pressure line can be calculated in a similar manner taking
the flow velocity as 3.5 m/s. Here the minimum bore of pressure pipe is equal to 15.6 mm.
It is unlikely that a pipe having the exact bore is available, in which case select a standard
pipe having a larger bore. Alternatively, a smaller bore pipe may be chosen but it will be
necessary to recheck the calculation to ensure that the flow velocity falls within the
recommended range. That is, a standard pipe with an outside diameter of 20 mm and a wall
thickness of 2.5 mm is available. This gives an internal diameter of 15 mm.
Flow through pipe
Flow velocity =
Area of pipe bore
Now
π
Area of pipe bore = 152 mm2  177 mm2  177  106 m2
4
So
60  103
Flow velocity =  3.77 m / s
60  177  106
This is satisfactory. It is also important to ensure that the wall thickness of pipe is sufficient
to withstand the working pressure of the fluid.

1.14Pump Selection
The main parameters affecting the selection of a particular type of pump are as follows:

1. Maximum operating pressure.

2. Maximum delivery.
3. Type of control.
4. Pump drive speed.
5. Type of fluid.
6. Pump contamination tolerance.
 7. Pump noise.
8. Size and weight of a pump.
9. Pump efficiency.
10. Cost.
11. Availability and interchangeability.
12. Maintenance and spares.

1.14.1 Maximum Operating Pressure

This is determined by the power requirement of the circuit, the particular
application,availability of components, type of fluid and to some extent the environment and
level of labor both using and maintaining the equipment.

In general, the higher the operating pressure, the higher the component cost and the lower the
choice of components. The main advantage of higher working pressures is the reduction in
fluid flow rates for a given system power, resulting in smaller pumps, smaller bore pipes and
smaller components. The disadvantage is that at higher working pressures, the
compressibility of the fluid used can have considerable adverse effects where precision
control is required over a wide range of loads.

The general tendency is toward increased operating pressures. Typical maximum pressures
for fewapplications are given in Table 1.3. The operating pressures of pumps depend to some
extent on the fluid used. A fire-resistant fluid is generally not as good lubricant as a mineral
oil. So to give a reasonable pump life expectancy when using a fire-resistant fluid, the
maximum operating pressure must be reduced and it is advisable to consult the pump
manufacturer.

The maximum operating pressure and range of flow rates for different types of currently
available hydraulic pumps are shown in Table 1.4.The figures given cover a range of sizes
and makes; maximum valuesof delivery and pressure are not applicable to one pump.

Table 1.3System maximum pressure in relation to application

Application Pressure (bar)

Machine tool 200

Mechanical 250
handling
Mobile 300
Press work 800
 Table 1.4Operating pressure and size ranges for hydraulic pump types
Maximum
Maximum Min. Noise
Delivery Speed(RPM)
Pump Type Pressure Filtratio Pulsation Level( η (%)
(L/min)
n(µm) dB)
From To From To From To
External gear 40 300 0.25 760 500 3000 100 High 90 70–90
Internal gear 100 210 0.6 740 3000 4000 100 Low 85 75–90
65–80
Vane 50 140 6 360 500 3000 50 Low 80
Balanced vane 140 175 2 620 500 300 50 Low 85 70–90
Axial piston 80–90
200 350 1 1450 200 2000 25 High 90
(swash plate)
Axial piston 50–90
250 350 17 3500 200 2000 25 High 90
(bent-axis)
Radial piston 350 1720 0.3 1000 200 2000 50 High 90 80–90

1.14.2 Maximum Delivery

The pump system selected must be capable of delivering the maximum flow rate demanded
by the circuit. If the circuit demand is reasonably constant, a fixed displacement pump is
chosen. When the demand is at a series of fixed levels, a multi-pump system is used. For
demands which vary within a relatively narrow band, a variable displacement pump is used.
If there is a wide variance in system demand, an accumulator circuit may best satisfy the
requirements.
Pump capacities are stated by manufactures for a particular viscosity fluid at given operating
temperatures and pressures. Any increase in temperature and hence a reduction in viscosity or
an increase in operating pressure causes more leakage across the pump and consequently
reduces the pump delivery. As the pump wears the leakage will increase.It is usual to select a
pump with a capacity about 10% higher than that required to make an allowance for the
reduction in volumetric efficiency with wear. Pumps are available with flows from a fraction
of 1 LPM to–1000 LPM and above.

1.14.3 Type of Control

Various types of pump controls are available such as manual servo control, pressure
compensated control, constant power control and constant flow control. The choice of control
is dependent upon the circuit requirement such as complexity, accuracy of control, cost, type
of machining operation,etc.The designer has to choose carefully the type of control after a
detailed study of system characteristics.

1.14.4Pump Drive Speed

Amajority of pumps are driven directly from the prime mover – electric motor or internal
combustion engine–so the proposed drive speed is known. The fluid delivery rate is
proportional to the speed of rotation. Each design has a minimum and maximum operating
speed: the faster the pump runs, the shorter its life.

1.14.5Types of Fluid
Pumps are designed to operate within a particular range of fluid viscosity. Mineral oils of the
correct viscosity work satisfactory with most pumps provided the oil is clean. Operating with
synthetic or water-based fluids reduces the working life of a pump that relies on the hydraulic
fluid to lubricate the bearings and moving parts. When any fluid other than a mineral oil is to
be used, it is advisable to seek the pump manufacturer’s advice.
1.14.6Fluid Contamination
Any fluid contamination causes pump damage. Precision pumps with very fine clearances are
more susceptible to damage. If a contaminated fluid has to be pumped, such as in a cleanup
loop, particular attention must be paid to pump selection. Non-precision gear pumps, lobe
pumps and gerotor pumps are the most dirt tolerant.Whichever type is used, a strainer must
be fitted in the suction line. In the case of precision pumps, the manufacturer’s
recommendation on filtration must be followed; otherwise the life of pump will be drastically
reduced and the maker’s warranty voided.

1.14.7Pump Noise
Noise has become increasingly important environmentally. Operating levels vary
considerably between the pumps of the same type but of different makes.The manufacturers
are working on those aspects which most affect the emission of noise– port plate design,
bearings, flow passages, pressure controls, materials and methods of mounting. Generally, the
sound generated increases with speed and pressure. Certain kinds do, however, propagate
lower noise levels, in particular, those with internal gears. A multi-stage internal gear pump is
marketed by one manufacturer under the name Q pump, with Q signifying quiet.

Example 1.15
The intensity (in units of W/m2) of the noise of a pump increases by a factor of 10 due to
cavitation. What is the corresponding increase in noise level in decibels?

Solution:
I (final)
dB increase  10  log  10  log10  10 dB
I (initial)

1.14.8Size and Weight of a Pump

Generally, not only the overall size and weight of a hydraulic system is important in mobile
installations, but also the whole system is important, as the size and weight of a pump is only
part of the whole system. In a mobile hydraulic field, the trend is to reduce the weight of the
hydraulic system by increasing the operating pressure,reducing the size of the reservoir and
using efficient oil coolers.
The best power-to-weight ratios can usually be achieved in the 200–300 bar operating
pressure range. The actual sizeand weight of a pump depend upon the particular
manufacture’s design. Very light compact units have been developed for use in the aerospace
industry but these tend to be extremely expensive.

1.14.9Efficiency
Reciprocating pumps tend to have higher efficiencies than rotary pumps. The actual
efficiency depends on design, operating pressure, speed and fluid viscosity.Table1.5gives an
indication of the range of efficiencies of various types of pumps.
Table 1.5Efficiency ranges of pumps
Pump Type Volumetric Efficiency Overall Efficiency
Piston
Plunger in line  99  95
Radial  95  90
Axial  95  90
Precision gear pumps  95  90
Vane pump  90  80

1.14.10Cost
The initial cost of a pump is usually of secondary importance to running and maintenance
costs.Gear pumps are cheaper, vane and piston pumps are expensive.

1.14.11Availability and Interchangeability

A number of gear pump manufacturers produce units to CETOP and SAE standards so far as
the external dimensions are concerned. This gives direct interchangeability between gear
pumps of different manufacturers. The shafts, mounting flanges and port connections of most
of the other types also comply with various international standards allowing a degree of
interchangeability.

1.14.12Maintenance and Spares

In every type of pump, the components involved in pumping worn out after a time and need
replacing. In gear pumps, it is usual to replace the entire pump. With some types of vane
pumps, the wear parts are grouped together as a cartridge that can easily be replaced without
dismantling the pump drive. In the case of piston pumps, it may be advisable to ensure that
the manufacturer offers a fast overall service for critical applications to carry a spare pump in
stock.

Example 1.16
A pump has a displacement volume of 120 cm3. It delivers 0.0015 m3/s at 1440 RPM and 60
bar. If the prime mover input torque is 130 Nm. What is the overall efficiency of the pump?
What is the theoretical torque required to operate the pump. The pump is driven by an electric
motor having an overall efficiency of 88%. The hydraulic system operates 12 h/d for 250
days per year. The cost of electricity is Rs 8 per kWh. Determine the yearly cost of electricity
to operate the hydraulic system. The amount of the yearly cost of electricity that is due to the
inefficiencies of the electric motor and pump.

Solution: Given volumetric displacement, VD = 120 cm3 , QA  0.0015 m3 /s, N  1440 rpm ,
P  60 bar , input torque TA  130 N m .

Total number of working hours available  250  12  3000 h

Volumetric displacement in m3/rev is

3
120 cm3  1 m 
VD =    0.000120 m /rev
3

rev  100 cm 
Theoretical dischargecan be calculated as

1440
QT  VD N  0.000120 rev/s  0.00288 m3 /s
60

Now we can calculate the volumetric efficiency as

Q 0.0015
v  A   52.08%
QT 0.00288

Mechanical efficiency is given by

pQT 60 105  0.00288 17280
m     88.2%
TA 2 19603
130 1440 
60
Note the product TA gives power in units of Nm/s (W) where TA has a unit of Nm and shaft
speed has units of rad/s.
The overall efficiency is
ηo  m v  0.882  0.5208  0.459  45.9%

Alternativelyoverall efficiency can also be calculated as

pQA 60 105  0.0015 9000
ηo     45.9%
TA 130 1440  2  19603
60
Now since the mechanical efficiency is known, we can calculate the theoretical torque as

TT  TA m  130  .882  114.7 N m

Thus, due to mechanical losses within the pump, 130 Nm of torque are required to drive the
pump instead of 114.7 Nm.

First we calculate the mechanical input power the electric motor delivers to the pump.

Pump input power (kW) isgiven by

2
TA  130 1440   19603 W  19.603 kW
60

Next we calculate the electrical input power.

Electric motor input power is given by

Electric motor output power 19.603
  22.28 kW
Electric motor overall efficiency 0.88
So
Yearly cost = Power rate  Time per year  Unit cost of electricity
= 22.28  12 h/d  250 d/y  8 Rs/kWh
= Rs 534627
The total loss equals kW loss due to electric motor plus the kW loss due to pump. Thus, we
have
Total loss  (1  0.88)  22.28  (1  0.459) 19.603
 2.674  10.61  13.284 kW

Yearly cost due to inefficiencies is

13.284
 534627 Rs/year  318760 Rs / year
22.28
Since
13.284
 59.2
22.28
we conclude that 59.2% of the total cost of electricity is due to inefficiency of the electric
motor and pump. This also means that only 49.8% of the electrical power entering the electric
motor is transferred into hydraulic power at the pump outlet port.

Example 1.17
For the fluid power system of Fig. 1.22, the following data are given:

Cylinder piston diameter 0.203 m

Cylinder rod diameter 0.102 m
Extending speed of cylinder 0.0762 m/s
External load on a cylinder 178000 N
Pump volumetric efficiency 92%
Pump mechanical efficiency 90%
Pump speed 1800 RPM
Pump inlet pressure −27600 Pa

(i)The total pressure drop in the line from the pump discharge port to the blank end of the
cylinder is 517000 Pa.
(ii) The total pressure drop in the return line from the rod end of the cylinder = 345000 Pa.
Determine the
(a) Volumetric displacement of the pump.
(b) Input power required to drive the pump.
(c) Input torque required to drive the pump.
(d) Percentage of pump input power delivered to the load.
 Motor

Check valve Cylinder

F
Breather
Pump External
load

Reservoir
Directional control Valve

Figure 1.22</figure caption>

Solution:
(a) Volumetric displacement of pump.
Qpump-actual  Apiston Vpiston ext

  0.2032  0.0762  0.00247 m3 /s
4
= 2.47 LPS
Qpump-actual 0.00247 m3
Qpump-theoretical    0.00268
Vol 0.92 s

Now
Qpump-theoretical  VD N
1800
 0.00268 VD 
60
 VD  0.0000893 m  0.0893 L
3

(b) Input power required to drive the pump

Pump output power = (p)Qactual
 pblank-end  Apiston  prod-end  ( Apiston  Arod )  Fexternal load on cylinder
 
 pblank-end   0.2032  345000   (0.2032  0.1022 )  178000
4 4
 pblank-end  5758000 Pa  5758 kPa
Pump output power = {(5758  517  27.6)0.00247}  15.6 kW
Pump output power 15.6
Pump input power =   18.8 kW
 v  m 0.92  0.90

(c) Input torque required to drive the pump

Pump input power is
 rev 1min 2 rad
T   T 1800   188 rad/s
min 60 s
Now
18800 W  T 188 rad/s
So torque required to drive pump is T = 100 Nm.
(d) Power delivered to load is
Fexternal load on cylinder Vcyl.ext
= 178000 0.0762 = 13600 W = 13.6 kW
Percent of pump input power delivered to load = 13.6/18.8 100 = 72.3%

Example 1.19
The system of in Example 1.17 contains a fixed displacement pump with a pressure relief
valve set at 6871 kPa. The system operates 20 h/d for 250 days in a year. The cylinder is
stalled in its fully extended position 70% of the time. When the cylinder is fully extended,
0.0633 LPS leaks past its piston.
(a) If the electric motor driving the pump has an efficiency of 85% and the cost of electricity
is Rs 10 per kWh, find the annual cost of electricity for powering the system
(b) It is being considered to replace fixed displacement pump with a pressure-
compensated pump (compensator set at 6871 kPa) that cost Rs 250000
more. How long will it take for the pressure-compensated pump to pay for
itself if its overall efficiency is same as fixed displacement pump?

Solution
(a)Annual cost of electricity for powering the system
pblank-end  5758000 Pa  5758 kPa
The total pressure drop in the line from the pump discharge port to the blank end of the
cylinder is 517000 Pa.
Pump inlet pressure = −27600 Pa
Pump discharge pressure = 5758000 Pa  517000 Pa  27600 Pa  6247.4 kPa
Pump input power = 18.8 kW
Electric motor input power = 18.8/0.85 = 22.1 kW
Thus with the cylinder fully extended (pressure relief valve set at 6871 kPa) we have
6871
Electric motor input power =  22.1  24.3 kW
6247.4
Thus, the yearly cost of electricity is
Yearly cost = Power rate × Time per year × Unit cost of electricity
= 0.30 × 22.1 (kW) 20 h/d  250 d/yr  10/kWh + 0.70 24.3 20 250 10
= Rs 1182000/year
(b) The fixed displacement pump produces 2.47 LPS at 6871 kPa when the cylinder is fully
extended. Leakis 0.0633 LPS through the cylinder plus 2.407 LPS through the relief valve.
Thus, when the cylinder is fully extended, we have power lost with a fixed displacement
pump
pQ = 6871  0.00247 = 16.97 kW
Hence, the electric motor input power is
16.97
 24.1
0.828  0.85
The overall efficiency of the pump 82%.The pressure-compensated pump would produce
only 0.0633 LPS at 6871 kPa when the cylinder is fully extended. For this case we have the
power lost with pressure-compensated pump is
pQ = 6871 × 0.0000633 = 0.44 kW
Hence, the electric motor input power is
0.44
 0.63 kW
0.828  0.85
Thus, the kW power saved while cylinder is fully extended = 24.1−0.63 = 23.47 kW
Savings per year = 23.47 0.70  20 250 10 = Rs 821450 per year
Time to pay for pump = Rs 250000/821450 = 0.3 years
Objective-Type Questions
Fill in the Blanks

1. Non-positive displacement pumps are primarily ______type units that have a

______clearance between rotating and stationary parts.
2. Flow rate of pump does ______ with head in the case of a positive displacement pump,
while it ______ with head in the case of a non-positive displacement pump.
3. In a lobe pump, the output may be slightly ______ because of the smaller number of
______ elements.
4. In a screw pump, there are no pulsations at ______ speed; it is a very quiet operating
pump.
5. In a balanced vane pump, the rotor and vanes are contained within a ______ eccentric cam
ring and there are ______ inlet segments and two outlet segments during each revolution.

State True or False

1. The volumetric capacity of a positive displacement pump is less than that of a non-positive
displacement pump.
2. Too low elevation head between the reservoir and the pump inlet causes cavitation.
3. Efficiency is almost constant with the head in the case of non-positive displacement
pumps.
4. The sole purpose of pumps is to create pressure.
5. Mechanical efficiency indicates the amount of energy losses that occur for reasons other
than leakage.

Review Questions

1. What is a positive displacement pump? In what ways does it differ from a centrifugal
pump?
2. Define the source of hydraulic power (pump).
3. Explain the working principle of a pump.
4. Pumps do not pump pressure. Justify this statement.
5. What is the function of a pump in a hydraulic system?
6. How is the pumping action in positive displacement pumps accomplished?
7. How the volumetric efficiency of a positive displacement pump is determined?
8. List the advantages of hydrostatic pumps over hydrodynamic pumps.
9. Give the classification of hydrostatic pumps used in a fluid power system.
10. What is the difference between a fixed displacement pump and a variable displacement
pump?
11. What types of pumps are available in variable displacement designs?
12. How can the vane pump/piston pumps be made as variable displacement pumps?
13. Name three designs of external gear pumps.
14. Name two designs of internal gear pumps.
15. What are the advantages of screw pumps over other gear pumps?
16. Why is the operation of screw pump quiet?
17. How can the unbalanced vane pump be used as a variable displacement pump?
18. What is a pressure-compensated vane pump and how does it work?
19. What is meant by a balanced design vane pump?
20. Name the important considerations when selecting a pump for a particular application.
21. Why a gear pump cannot be used as a variable displacement pump?
22. How can the displacement of an axial piston pump be varied?
23. What is pump cavitation and what is its cause?
24. How is pressure developed in hydraulics systems?
25. Why centrifugal pumps are rarely used in fluid power systems?
26. Draw the graphical symbols for the fixed displacement and variable displacement pumps.
27. Which parameters affect the noise level of a positive displacement pump?
28. What is meant by the pressure rating of a positive displacement pump?
29. Name the four rules that control or eliminate cavitation of a pump.
30. Comment on the relative comparison in performance among gear, vane and piston pumps.
31. What are the two ways of expressing a pump size?
32. What are pump characteristic curves? Draw the same for the positive displacement
pumps.
33. How is the capability of a variable displacement pump affected by the addition of
pressure compensation?
34. Name the three principal ways in which noise reduction can be accomplished.

35. What are the most common things apart from pressure or speed that can cause a pump to
fail? Explain each.
36. Where are external gear pumps used?

Answers
Fill in the Blanks

1.Velocity, large
2.Not change, decreases
3.Greater pulsation,meshing
4.Higher;
5.Double, two

State True or False

1.True
2.False
3.False
4.False
5.True
 Lecture 10
HYDRAULIC MOTORS

Learning Objectives

Upon completion of this chapter, the student should be able to:

 Differentiatebetween a hydraulic motor and a hydraulic pump.
 List various applications of hydraulic motor in fluid power.
 Discuss variousclassifications of hydraulic motor.
 Explain the construction and working of gear, vane and piston motors.
 Discuss the various types of limited-rotation motors.
 Explain various types of efficiency terms used in hydraulic motors.
 Evaluate the performance parameters of systems using motors.

1.1Introduction

Hydraulic motors are rotary actuators. However, the name rotary actuator is reserved for a particular type
of unit that is limited in rotation to less than 360.A hydraulic motor is a device which converts fluid
power into rotary power or converts fluid pressure into torque. Torque is a function of pressure or, in other
words, the motor input pressure level is determined by the resisting torque at the output shaft. A hydraulic
pump is a device which converts mechanical force and motion into fluid power. A hydraulic motor is not a
hydraulic pump when run backward. A design that is completely acceptable as a motor may operate very
poorly as a pump in a certain applications. Differences between a hydraulic motor and a hydraulic pump
are given in Table 1.1.

Table1.1Differences between a hydraulic motor and a hydraulic pump

Hydraulic Motor Hydraulic Pump
It is a device for delivering torque at a given It is a device for delivering flow at a given
pressure. The main emphasis is on mechanical pressure. The main emphasis is on volumetric
efficiency and torque that can be transmitted. efficiency and flow.
Motors usually operate over a wide range of Pumps usually operate at high RPM.
speed, from a low RPM to high RPM.
Most motors are designed for bidirectional In most situations, pumps usually operate in one
applications such as braking loads, rotary tables. direction.
Motors may be idle for long time (as in index Pumps usually operate continuously.
table).
Motors are subjected to high side loads (from Majority of pumps are not subjected to side loads.
gears, chains, belt-driven pulleys). Usually pumps are pad mounted on power pack
top and shaft is connected to the prime mover
directly.

1.2Applications

Hydraulic motors have becomepopular in industries. Hydraulic motors can be applied directly to the
work.They provide excellent control for acceleration, operating speed, deceleration, smooth reversals and
positioning. They also provide flexibility in design and eliminate much of bulk and weight of mechanical
and electrical power transmission. The applications of hydraulic motors in their various combinations
with pumping units are termed hydrostatic transmission.
A hydrostatic transmission converts mechanical power into fluid power and then reconverts fluid power
into shaft power. The advantages of hydrostatic transmissions include power transmission to remote areas,
infinitely variable speed control, self-overload protection, reverse rotation capability, dynamic braking and
a high power-to-weight ratio. Applications include material-handling equipment, farm tractors, railway
locomotives, buses, lawn mowers and machine tools.

New fields of applications are being discovered constantly for hydrostatic transmissions. Farm
implements, road machinery, material-handling equipment, Numerical Control(NC) machineshigh-
performance aircrafts, military uses and special machinery are only a few of new fields expanding through
the use of fluid power transmission. Many automobiles, railway locomotives and buses usea hydrostatic
transmission.

1.3 Comparison Betweena Hydraulic Motor and an Electric Motor

Table 1.2 gives the comparison between a hydraulic motor and an electric motor.

Table 1.2 Comparison between a hydraulic motor and an electric motor

Electric Motor Hydraulic Motor
Electric motors cannot be stopped instantly. Their Hydraulic motors can be stalled for any length of
direction of rotation cannot be reversed instantly. time. Their direction of rotation can be instantly
This is because of air gap between the rotor and reversed and their rotational speed can be
stator and the weak magnetic field. infinitely varied without affecting their torque.
They can be braked instantly and have immense
torque capacities.
Electric motors are heavy and bulky. Hydraulic motors are very compact compared to
electric motors. For the same power, they occupy
about 25% of the space required by electric
motors and weigh about 10% of electric motors.
Moment of inertia-to-torque ratio is nearly 100. Moment of inertia-to-torque ratio is nearly 1.

1.4Classification of Hydraulic Motors

There are two types of hydraulic motors: (a) High-speed low-torque motors and (b) low–speed high-torque
motors. In high-speed low-torque motors, the shaft is driven directly from either the barrel or the cam
plate, whereas in low-speed high-torque motors, the shaft is driven through a differential gear arrangement
that reduces the speed and increases the torque. Depending upon the mechanism employed to provide shaft
rotation, hydraulic motors can be classified as follows:
1. Gear motors.
2. Vane motors.
3. Piston motors:
 Axialpiston-type motors.
 Radial piston-type motors.

Gear motors are the least efficient, most dirt-tolerant and have the lowest pressure rating of 3. Piston
motors are the most efficient, least dirt-tolerant and have high pressure ratings. Vane and piston motors
can be fixed or variable displacement, but gear motors are available with only fixed displacement.

1.5Gear Motors: A gear motor develops torque due to hydraulic pressure acting against the area of one
tooth. There are two teeth trying to move the rotor in the proper direction, while one net tooth at the center
mesh tries to move it in the opposite direction. In the design of a gear motor, one of the gears is keyed to
an output shaft, while the other is simply an idler gear. Pressurized oil is sent to the inlet port of the motor.
Pressure is then applied to the gear teeth, causing the gears and output shaft to rotate. The pressure builds
until enough torque is generated to rotate the output shaft against the load. The side load on the motor
bearing is quite high, because all the hydraulic pressure is on one side. This limits the bearing life of the
motor. Schematic diagram of gear motor is shown in Fig.1.1.

Most of the gear motors are bidirectional. Reversing the direction of flow can reverse the direction of
rotation.As in the case of gear pumps, volumetric displacement is fixed. Due to the high pressure at the
inlet and low pressure at the outlet, a large side load on the shaft and bearings is produced. Gear motors
are normally limited to 150 bar operating pressures and 2500 RPM operating speed. They are available
with a maximum flow capacity of 600 LPM. The gear motors are simple in construction and have good
dirt tolerance, but their efficienciesare lower than those of vane or piston pumps and they leak more than
the piston units. Generally,they are not used as servo motors.Hydraulic motors can also be of internal gear
design. These types can operate at higher pressures and speeds and also have greater displacements than
external gear motors.

Figure 1.1Gear motor

1.6Vane Motors
Figure 1.2 shows an unbalanced vane motor consisting of a circular chamber in which there is an
eccentric rotor carrying several spring or pressure-loaded vanes. Because the fluid flowing through the
inlet port finds more area of vanes exposed in the upper half of the motor, it exerts more force on the
upper vanes, and the rotor turns counterclockwise. Close tolerances are maintained between the vanes
and ring to provide high efficiencies.

The displacement of a vane hydraulic motor is a function of eccentricity. The radial load on the shaft
bearing of an unbalanced vane motor is also large because all its inlet pressure is on one side of the
rotor.
Figure 1.3 shows the balanced vane motor. The radial bearing load problem is eliminated in this design
by using a double-lobed ring with diametrically opposite ports. Side force on one side of bearing is
canceled by an equal and opposite force from the diametrically opposite pressure port. The like ports are
generally connected internally so that only one inlet and one outlet port are brought outside. The balanced
vane-type motor is reliable open-loop control motor but has more internal leakage than piston-type and
therefore generally not used as a servo motor.

1.7Piston Motors
Piston motors are classified into the following types:

1. According to the piston of the cylinder block and the drive shaft, piston motors are classified as
follows:

 Axial piston motors.

 Radial piston motors.

2. According to the basis of displacement, piston motors are classified as follows:

 Fixed-displacement piston motors.

 Variable-displacement piston motors.

1.7.1 Axial Piston Motors

In axial piston motors, the piston reciprocates parallel to the axis of the cylinder block. These motors are
available with both fixed-and variable-displacement feature types. They generate torque by pressure
acting on the ends of pistons reciprocating inside a cylinder block. Figure 1.4 illustrates the inline design
in which the motor, drive shaft and cylinder block are centered on the same axis. Pressure acting on the
ends of the piston generates a force against an angled swash plate. This causes the cylinder block to rotate
with a torque that is proportional to the area of the pistons. The torque is also a function of the swash-
plate angle. The inline piston motor is designed either as a fixed- or a variable-displacement unit. The
swash plate determines the volumetric displacement. Refer Fig.1.5.

Figure1.4Inline piston motor

In variable-displacement units, the swash plate is mounted on the swinging yoke. The angle can be varied
by various means such as a lever, hand wheel or servo control.If the offset angel is increased, the
displacement and torque capacity increase but the speed of the drive shaft decreases. Conversely,
reducing the angle reduces the torque capability but increases the drive shaft speed.

stoke(s)
cylinder

swash plate

Figure1.5Swash-plate piston motor

1.7.2 Bent-Axis Piston Motors

A bent-axis piston motor is shown in Fig.1.6. This type of motor develops torque due to pressure acting
on the reciprocating piston. In this motor, the cylinder block and drive shaft mount at an angel to each
other so that the force is exerted on the drive shaft flange.

drive shaft flange

shaft
displacement

Figure1.6Inline piston motor

Speed and torque depend on the angle between the cylinder block and the drive shaft. The larger the
angle, the greater the displacement and torque, and the smaller the speed. This angle varies from 7.5°
(minimum) to 30° (maximum). This type of motor is available in two types, namely fixed-displacement
type and variable-displacement type. Refer Fig.1.7

7.3 Radial Piston Motors

In radial piston-type motors, the piston reciprocates radially or perpendicular to the axis of the output
shaft. The basic principle of operation of the radial piton motors is shown in Fig.1.8.Radial piston motors
are low-speed high-torque motors which can address a multifarious problem in diverse power transfer
applications.
 Figure1.8Radial piston motor

1.8Semi-Rotary Actuators

These are devices used to convert fluid energy into a torque which turns through an angle limited by the
design of the actuator. With the majority of designs, the angle of rotation is limited to 360 although it is
possible to considerably exceed this when using piston-operated actuators.

1.8.1 Vane-Type Semi-Rotary Actuator (Single Vane)

A single-vane rotary actuator is shown in Fig. 1.9. A semi-rotary actuator allows only a partial
revolution.A vane-type semi-rotary actuator consists of a vane connected to an output shaft. When
hydraulic pressure is applied to one side of the vane, it rotates. A stop prevents the vane from rotating
continuously. The rotation angle in the case of a single-vane semi-rotary actuator is 315°.

Figure 1.9Vane-type semi-rotary

1.8.2Two-Vane-Type Semi-Rotary Actuator

A two-vane rotary actuator is shown in Fig.1.10. The advantage of this design is that the torque output is
increased because the area subjected to pressure is large. However, two-vane models cannot rotate as
many degrees as can single-vane models.It is limited to 100°. Passageways are used to connect the
different chambers of the rotary actuator.
 Figure1.10Two-vane type

1.8.3Analysis ofa Semi-Rotary Single-Vane Motor

Let
RR  Outer radius of the output shaft (m)
RV  Outer radius of the vane (m)
L  Width of the vane (m)
p  Hydraulic pressure (Pa)
F  Hydraulic force acting on the vane (N)
A  Surface area of vane in contact with oil (m2 )
T  Torque capacity (N m)
The force on the vane equals the pressure times the vane surface area:
F  pA  p( RV  RR ) L
The torque equals the vane force times the mean radius of the vane:
RV  RR
T  p( RV  RR ) L
2
On rearranging, we have
T  p( R 2 V  R 2 R ) L (1.1)
A second equation for torque can be developed by noting the following relationship for volumetric
displacement VD :
VD  π ( R2V  R2R ) L (1.2)
Combining Equations. (1.1) and (1.2) yields
p  VD
T
2π

Example 1.1A single-vane rotary actuator has the following physical data:

Outer radius of rotor = 0.5 cm

Outer radius of vane = 1.5 cm
Width of vane = 1 cm
If the torque load is 1000 Ncm, what pressure must be developed to overcome the load?

Solution: The volumetric displacement is given by

VD  π (1.52  0.52 )1 = 6.28 cm3
The pressure is
2πT 2π (1000)
p  =1000 N/cm2
VD 6.28
= 1000  104 N/m2
= 10 N/mm2 = 10 MPa

1.9Chain and Sprocket Semi-Rotary Actuator

In this design (Fig. 1.11), an endless chain and a sprocket areused.It is suitable for multi-revolution
applications. The chain is anchored to two pistons, one large and other small, which when in their
respective bores separate the half of the unit. The larger cylinder is the power cylinder and the smaller
cylinder is the chain return or seal cylinder. The idler is automatically a tensioned one, so that a constant
tension is maintained. Pressure is applied to one port of the actuator. The larger piston moves away from
the port due to differential areas of the two pistons. The movement of larger piston pulls the chain,
causing the sprocket and output shaft to rotate.

Figure1.11Chain and sprocket

1.10Rack and Pinion Rotary Actuator

A rack and pinion rotary actuator (Fig. 1.12) is a commonly used design for obtaining partial revolution
actuation. This consists of a hydraulic cylinder with a rack and pinion gear mechanism. The rack gear on
the piston rod turns the pinion gear, thereby converting the linear motion of the piston into rotary motion,
which is transmitted to the load through the output shaft.

Figure1.12Rack and rotary actuator

Another design of a rack and pinion semi-rotary actuator is shown in Fig.1.13. In this design, the cylinder
drives a pinion gear and the rack is an integral part of the piston rod. The angle of rotation depends upon
the stroke of the cylinder, rack and the pitch circle diameter of the pinion. The start and finish of the
stroke are adjusted by means of an internal stop(stroke adjuster).

Figure 1.13Rack and rotary actuator

1.11Hydraulic Motor:Theoretical Torque, Power and Flow Rate

The torque generated by africtionless hydraulic motor is known as a theoretical torque.Theoretical torque
can be calculated by the following formula:
p  VD
TT 
2π
whereVDis the volumetric displacement in m3/rev and p is the pressure in N/m2.The power developed by a
frictionless motor is known as theoretical power.It can be calculated by the following formula:
PT = TT  ω
(W) =(Nm) rad/s = W
where TT is the theoretical torque in Nm, ω is the speed of the motor in rad/s and ω = 2 N / 60, where
N is the speed of the motor in rev/min.The flow ratea hydraulic motor would consume if there were no
leakage is known as the theoretical flow rate QT . Mathematically, theoretical flow rate is given by
QT  VD n
3
where VD is the volumetric discharge in m /rev, n is the speed of motor in rev/s = N/60 and N is the speed
of motor in rpm.
 Lecture 11
HYDRAULIC MOTORS [CONTINUED]

1.12Performance of Hydraulic Motors

The performance of hydraulic motors depends upon many factors such as precision of their parts,
tolerances between the mating parts, etc.Internal leakage between the inlet and outlet affects the
volumetric efficiency. Friction between mating parts affects the mechanical efficiency of a hydraulic
motor.
Gear motors typically have an overall efficiency of 70–75% as compared to vane motors which have 75–
85% and piston motors having 85–95%.
Motor torque is divided into three separate groups:

1. Starting torque: The starting torque is the turning force the motor exerts from a dead stop.
2. Running torque: Running torque is exerted when the motor is running and changes whenever there
is a change in fluid pressure.
3. Stalling torque: Stalling torque is the torque necessary to stop the motor.

In most hydraulic motors, the stalling and starting torques are equal. Usually, starting torque is 75–80%
of the maximum design torque.

1. Volumetric efficiency: The volumetric efficiency of a hydraulic motor is the ratio of theoretical flow
rate to actual flow rate required to achieve a particular speed. The motor uses more flow than the
theoretical due to leakage:
Theoretical flow rate the motor should be supplied with QT
ηv  
Actual flow rate supplied to the motor QA
2. Mechanical efficiency: The mechanical efficiency of a hydraulic motor is the ratio of actual work
done to the theoretical work done per revolution. The output torque of a hydraulic motor is less than
theoretical torque due to mechanical friction between the mating parts:

Actual torque delivered by the motor T

ηm   A
Torque the motor should theoretically deliver TT

Here,theoretical torque and actual torque are given by

VD  p
TT 
2π
Actual wattage delivered by the motor
TA 
N

3. Overall efficiency: The overall efficiency of a motor is the ratio of output power to input power of the
motor. Output power is mechanical power output at the shaft and input power is fluid energy supplied to
the inlet of the hydraulic motor:
Actual power delivered by the motor (mechanical)
ηo 
Actual power delivered to the motor (hydraulic)
TA  N
ηo 
p  QA
 TA  TT  N

TT  p  QA
TA  VD  p  N

TT  p  QA  2π
TA  QT

TT  QA
 o  Vm
So
Overall efficiency = Volumetric efficiency  Mechanical efficiency

Note: The actual power delivered to a motor by a fluid is called hydraulic power and the actual power
delivered to a load by a motor via a rotating shaft is called brake power.
Example 1.2
A hydraulic motor is required to drive a load at 500 rpm with 1000 Nm of torque. What is the output
power?
Solution
500  2π
N = 500 rpm   52.36 rad / s
60
TA  1000 N m
Now
Power  TA (N m)  N (rad/s)
 1000  52.36
 52360 W
The output power is 52.360 kW.

Example1.3
A hydraulic motor receives a flow rate of 72 LPM at a pressure of 12000 kPa. If the motor speed is
800 RPM, determine the actual torque delivered by the motor assuming the efficiency 100%?

Solution
Method I
Actual flow rate
72  103
QA  72 LPM   1.2  103 m3/s
60
Speed of motor N = 800 RPM. So
  800  2 / 60 = 83.78 rad/s
3
Pressure = 12000 × 10 Pa.
Overall efficiency can be calculated using

TA  N
o 
P  QA
Substituting the values we get
TA  83.78
1
12000 103 1.2 103
 TA  171.88 N m
So the actual torque TA  171.88 N m.
 Method II
72
Hydraulic power = pQ = 12000 × × 10−3 = 14.4 kW
60
T (Nm) ×  (rad/s) = 14400 W
So
14400
T  172 N m
2
800 
60
Example 1.4
A hydraulic motor has a 100 cm3 volumetric displacement. If it has a pressure rating of 140 bar and
receives oil from a 0.001 m3 / s theoretical flow rate pump, find the motor (a) speed, (b) theoretical
torque, (c) theoretical kW power.

Solution:

(a) Speed: We have the theoretical flow rate given by

QT  VD  n
 0.001  100 106  n
 n = 10 RPS(revolutions per second)
and N = 600 RPM
(b) Theoretical torque
6
p  VD 140  10  100  10
5
TT    222.82 N m
2 2

(c) Theoretical kW power

P  QT  p =0.001 m3 / s 140 105 N / m2 =14000 W =14 kW
Alternately,
Power = TT = 222.82  10 2 = 14000 W = 14 kW

Example 1.5
The pressure rating of the components in a hydraulic system is 105 kPa. The system contains a hydraulic
motor to turn a 0.3 m radius drum at 30 RPM to lift a weight of load 4000 N as shown in Fig. 1.14.
Determine the flow rate and brake power if the motor efficiency is 90%.
 Figure 1.14
Solution: We have the theoretical torque given by
p  VD
TT 
2π
108  VD
 4000  0.3 
2
 VD = 7.54 105 m3 = 0.0754 L
Theoretical flow rate is
30
QT  VD  N  7.54  105   0.0000377 m3 / s
60
Power
P  pQ  1108 N / m2 (0.0000377 m3 / s)  3770 W  3.77 kW

Example 1.6
A hydraulic system contains a pump that discharges oil at 13.8 MPa and 0.00632 m3 / s to a hydraulic
motor shown in Fig. 1.15. The pressure at the motor inlet is 12.40 MPa due to pressure drop in the line. If
oil leaves the motor at 1.38 MPa, determine the power delivery by the 100% efficient motor.
(a) What torque would a hydraulic motor deliver at a speed of 1750 RPM if it produces 3 kW?
(b) If the pressure remains constant at 13.8 MPa, (i) what would be the effect of doubling the speed on
the torque and (ii) what would be the effect of halving the speed on the torque?
 13.8 12.4 1.38
MPa MPa MPa

Pump Motor

Figure 1.15

Solution: We have

Power  p Q  (12400  1380) kPa  0.00632 m3 / s

 69.6 kW
Note: If the pipeline between the pump and motor is horizontal and of constant diameter, then the cause
of pressure drop (12.4 − 1.38 MPa) is due to friction.
(a) We have
P  T    3000
2    1750
T   3000
60
3000  60
T   16.37 N m
2    1750
(b)
pVD
(i) T  .Since p and VD are both constant, torque remains constant. This would, however, double
6.28
the power.
(ii) The torque T remains constant while the power is reduced by 50%.

Example 1.7
A hydraulic motor has a displacement of 40 cm3/rev and is used in a system with a maximum pressure
of 20000 kPa. Determine the actual torque delivered by the motor assuming that it is 100% efficient.

Solution:
Displacement VD  40  106 m3/rev
Pressure of the system P = 20000 kPa
Theoretical torque
6
V  p 40 10  20000 10
3
TT  D   127.3 N m
2π 2π
Since the motor is 100% efficient, the actual torque is equal to the theoretical torque
TA  127.3 N m
Example 1.8
A motor must produce a torque of 350 Nm in a system with an operating pressure of 25000 kPa. What
size motor should we select? Assume 100% efficiency.
Solution: Given TA  350 N m . Since the motor has 100% efficiency,
Theoretical torque = Actual torque
VD  P
 TT 
2π
VD  25000 103
 350 
2π
 VD  88 cm /rev
3

So we should select a motor having the displacement of 88 cm3/rev.

Example 1.9
A hydraulic motor has a displacement of 164 cm3 and operates with a pressure of 70 bar and a speed
of 2000 rpm. If the actual flow rate consumed by the motor is 0.006 m3/s and the actual torque
delivered by the motor is 170 Nm, find (a) ηv , (b)m , (c) ηo and (d) actual power delivered by the
motor?

Solution:
(a) We have
Theoretical flow rate the motor should consume QT
ηv  
Actual flow rate consumed by the motor QA
Now QA  0.006 m3 / s . Theoretical flow rate is
2000
QT  VD  N  164 106 (m3 / rev)  (rev / s)  0.0055 m3 / s
60
So volumetric efficiency is
0.0055
ηv   100  91.67%
0.006
(b) Mechanical efficiency is given by
Actual torque delivered by the motor T
ηm   A
Theoretical torque motor should deliver TT
Theoretical torque,
p VD 70 105 164 106
TT    182.71 N m
2π 2π
So mechanical efficiency,
170
ηm   93.04%
182.71
(c) We have
ηo  ηm  ηv
 0.9304  0.9167  0.853  85.3%
So overall efficiency is 85.3 %.
(d) Actual power is
  2 π 
TA ω  170   2000    35600 W  35.6 kW
 60 

Example 1.10
A hydraulic motor receives a flow rate of 72 LPM at a pressure of 12000 kPa. If the motor speed is
800 RPM and ifthe motor has a power loss of 3 kW, find the motor actual output torque and overall
efficiency.

Solution: We have
72 LPM = 0.0012 m3 /s
Now we calculate the hydraulic power given to motor using
Hydraulic power = pQ = 0.0012 m3 /s  12000 = 14400 W = 14.4 kW

Actual power is obtained by subtracting the losses,

Actual power = Tω  14.4  3  11.4 kW
11400
T   136 N m
2π
800 
60
The overall efficiency is

11.4
Overall efficiency =  0.792  79.2 %
14.4
Example 1.11
A hydraulic motor has a volumetric efficiency of 90% and operates at a speed of 1750 RPM and a
pressure of 69 bar. If the actual flow rate consumed by the motor is 0.0047 m3/s and the actual torque
delivered by the motor is 147 Nm, find the overall efficiency of the motor.

Solution: The overall efficiency is

1750  2  
147 
T 60
o  A =  0.83 = 83%
pQA 69 105  0.0047

Example 1.12
A hydrostatic transmission operating at 105 bar pressure has the following characteristics:
Pump Motor
3
Vd = 100 cm Vd = ?
ηv = 85% ηv = 94%
ηm = 90% ηm = 92%
N = 1000rpm N= 600 rpm

Find the (a) displacement of motor and (b) motor output torque.
 Solution:

(a) Pump theoretical flow rate

100  106  1000
QT-pump  Vd  N  = 1.667 103 m3/s
60
Actual flow rate
QA-pump  ηV  QT  1.667  103  0.85  1.42 103 m3/s
Actual flow from the pump is the actual flow to the motor. So for the motor
QA-motor  1.42 103 m3/s
3
QT-motor  ηV  QA =1.42 103  0.94  1.332  10
So the theoretical flow rate, QT-motor  1.332  103 m3/s. Now
QT-motor  VD-motor  N
3
QT-motor 1.332  10
 VD-motor    1.332 104  133 cm3/rev
N motor 600 / 60
So for the motor, the displacement is 133 cm3/rev.
(b) Torque delivered by the motor
To calculate torque delivered by the motor, let us first calculate the actual power to motor
Poweractual to motor  p Q  105 105  0.00142  14900 W
Now

Poweractual by motor = Poweractual to motor Mechanical efficiency volumetricefficiency

Poweractual by motor  14900  0.94  0.92  12900 W

12900
Torqueactual by motor  = 205 Nm
600  2π
60

1.13 Performance Curves for a Variable Displacement Motor

The following curves represent typical performance curves obtained for a 100 cm3 variable displacement
motor operating at full displacement.Figure1.16 gives the motor input flow (LPM) and motor output
torque as a function of motor speed(RPM) at two pressure levels.
 Figure 1.16Motor input flow versus motor output torque

Figure 1.17gives the curves of overall and volumetric efficiencies as a function of motor speed(RPM) for
pressure levels of 34.5 and 20.7 MPa.

Figure1.17Performance curves for a 100 cm3 variable displacement motor

Objective-Type Questions

Fill in the Blanks

1. A hydraulic motor is a device which converts fluid power into _____ or converts fluid pressure into
_____.
2. In an axial piston motor, the piston reciprocates _____ to the axis of the cylinder block.
3. In a radial piston-type motor, the piston reciprocates radially or _____ to the axis of the output
shaft.
4. Rack and pinion rotary actuator is a commonly used design for obtaining _____ revolution
actuation.
5. Gear motors typically have an overall efficiency of _____ as compared to _____ for piston motors.

State True or False

1. A hydraulic motor is a hydraulic pump which runs backward.

2. Gear motors are the most efficient and most dirt tolerant.
3. Hydraulic motors can be stalled for any length of time and their direction of rotation can be
instantly reversed and their rotational speed can be infinitely varied.
4. The moment of inertial to torque ratio for a hydraulic motor is nearly 100.
5. A semi-rotary actuator allows only a partial revolution.

Review Questions

1. Differentiate between a hydraulic pump and a hydraulic motor.

2. List the advantages of a hydraulic motor over an electric motor.
3. List four important applications of hydraulic motor.
4. Explain with a neat sketch the working of gear motor.
5. Write the classification of piston motor.
6. Define volumetric efficiency, mechanical efficiency and overall efficiency of hydraulic motor.
7. Why is the actual flow rate required by a hydraulic motor higher than the theoretical flow rate?
8. Why is the actual torque output delivered by a hydraulic motor less than the calculated theoretical
torque?
9. List few applications of a semi-rotary actuator.
10. Where are external gear motors used?
11. List the advantages of external gear motors.
12. What is a limited-rotation hydraulic motor? How does it differ from a hydraulic motor?
13. What are the main advantages of a gear motor?
14. Why are vane motors fixed-displacement units?
15. Name one way in which vane motors differ from vane pumps.
16. Can a piston pump be used as a piston motor?
17. Why does a hydraulic motor use more flow than it should theoretically?
18. Name four advantages of hydrostatic transmission.
19. Why does a hydraulic motor deliver less torque than it should theoretically?
20. Explain why, theoretically, the torque output from a fixed-displacement hydraulic motor operating
at a constant pressure is the same regardless of changes in speed.
21. Define the displacement and torque ratings of a hydraulic motor.
22. Explain how vanes are held in contact with the cam ring in a high-performance vane motor.
23. How is torque developed in an inline-type piston?
24. If a hydraulic motor is pressure compensated, what is the effect of an increase in the working
fluid?
25. Which type of hydraulic motor is generally the most efficient?

Answers
Fill in the Blanks

1.Rotary power, torque

2.Parallel
3.Perpendicular
4.Partial
5. 70–75%, 85–95%

State True or False

1.False
2.False
3.True
4.False
5.True
 Lecture 12
HYDRAULIC ACTUATORS

Learning Objectives

Upon completion of this chapter, the student should be able to:

 Explain the classification of hydraulic actuators.
 Explain various types of hydraulic cylinders.
 Describe the construction and working of double-acting cylinders.
 Derive an expression for force, velocity and power for hydraulic cylinders.
 Analyze various lever systems using hydraulic cylinders.
 Explain the importance of cylinder cushioning.
 Explain various types of cylinder mountings used in fluid power.
 Evaluate the performance of hydraulic systems using cylinders.

1.1 Introduction

Hydraulic systems are used to control and transmit power. A pump driven by a prime mover such as an
electric motor creates a flow of fluid, in which the pressure, direction and rate of flow are controlled by
valves. An actuator is used to convert the energy of fluid back into the mechanical power. The amount of
output power developed depends upon the flow rate, the pressure drop across the actuator and its overall
efficiency. Thus, hydraulic actuators are devices used to convert pressure energy of the fluid into
mechanical energy.
Depending on the type of actuation, hydraulic actuators are classified as follows:

1. Linear actuator: For linear actuation (hydraulic cylinders).

2. Rotary actuator: For rotary actuation (hydraulic motor).
3. Semi-rotary actuator: For limited angle of actuation (semi-rotary actuator).

Hydraulic linear actuators, as their name implies, provide motion in a straight line. The total movement is
a finite amount determined by the construction of the unit. They are usually referred to as cylinders, rams
and jacks. All these items are synonymous in general use, although ram is sometimes intended to mean a
single-acting cylinder and jack often refers to a cylinder used for lifting. The function of hydraulic
cylinder is to convert hydraulic power into linear mechanical force or motion. Hydraulic cylinders extend
and retract a piston rod to provide a push or pull force to drive the external load along a straight-line path.
Continuous angular movement is achieved by rotary actuators, more generally known as a hydraulic
motor. Semi-rotary actuators are capable of limited angular movements that can be several complete
revolutions but 360o or less is more usual.

1.2 Types of Hydraulic Cylinders

Hydraulic cylinders are of the following types:

 Single-acting cylinders.
 Double-acting cylinders.
 Telescopic cylinders.
 Tandem cylinders.

1
1.2.1 Single-Acting Cylinders

A single-acting cylinder is simplest in design and is shown schematically in Fig.1.1. It consists of a piston
inside a cylindrical housing called barrel. On one end of the piston there is a rod, which can reciprocate.
At the opposite end, there is a port for the entrance and exit of oil. Single-acting cylinders produce force
in one direction by hydraulic pressure acting on the piston. (Single-acting cylinders can exert a force in
the extending direction only.) The return of the piston is not done hydraulically. In single-acting
cylinders, retraction is done either by gravity or by a spring.

(by spring)

Figure 1.1 Single-acting cylinders

According to the type of return, single-acting cylinders are classified as follows:

 Gravity-return single-acting cylinder.

 Spring-return single-acting cylinder.

1.2.1.1 Gravity-Return Single-Acting Cylinder

Load

( )
( )
Figure 1.2 Gravity-return single-acting cylinder: (a) Push type; (b) pull type

2
Figure1.2 shows gravity-return-type single-acting cylinders. In the push type [Fig. 1.2(a)], the cylinder
extends to lift a weight against the force of gravity by applying oil pressure at the blank end. The oil is
passed through the blank-end port or pressure port. The rod-end port or vent port is open to atmosphere so
that air can flow freely in and out of the rod end of the cylinder. To retract the cylinder, the pressure is
simply removed from the piston by connecting the pressure port to the tank. This allows the weight of the
load to push the fluid out of the cylinder back to the tank. In pull-type gravity-return-type single-acting
cylinder, the cylinder [Fig. 1.2(b)] lifts the weight by retracting. The blank-end port is the pressure port
and blind-end port is now the vent port. This cylinder automatically extends whenever the pressure port is
connected to the tank.

1.2.1.2 Spring-Return Single-Acting Cylinder

A spring-return single-acting cylinder is shown in Fig.1.3.In push type [Fig. 1.3(a)], the pressure is sent
through the pressure port situated at the blank end of the cylinder. When the pressure is released, the
spring automatically returns the cylinder to the fully retracted position. The vent port is open to
atmosphere so that air can flow freely in and out of the rod end of the cylinder.
Figure 1.3(b) shows a spring-return single-acting cylinder. In this design, the cylinder retracts when the
pressure port is connected to the pump flow and extends whenever the pressure port is connected to the
tank. Here the pressure port is situated at the rod end of the cylinder.

(a) (b)
Figure 1.3 (a) Push- and (b) pull-type single-acting cylinders

1.2.2 Double-Acting Cylinder

There are two types of double-acting cylinders:

 Double-acting cylinder with a piston rod on one side.

 Double-acting cylinder with a piston rod on both sides.
1.2.2.1 Double-Acting Cylinder with a Piston Rod on One Side
Figure 1.4 shows the operation of a double-acting cylinder with a piston rod on one side. To extend the
cylinder, the pump flow is sent to the blank-end port as in Fig. 1.4(a). The fluid from the rod-end port
returns to the reservoir. To retract the cylinder, the pump flow is sent to the rod-end port and the fluid
from the blank-end port returns to the tank as in Fig.1.4(b).

3
 Figure 1.4 Double-acting cylinder with a piston rod on one side

1.2.2.2 Double-Acting Cylinder with a Piston Rod on Both Sides

Figure 1.5Double-acting cylinder with a piston rod on one side

A double-acting cylinder with a piston rod on both sides (Fig.1.5)is a cylinder with a rod extending from
both ends. This cylinder can be used in an application where work can be done by both ends of the
cylinder, thereby making the cylinder more productive. Double-rod cylinders can withstand higher side
loads because they have an extra bearing, one on each rod, to withstand the loading.

4
1.2.3Telescopic Cylinder
A telescopic cylinder (shown in Fig. 1.6) is used when a long stroke length and a short retracted length
are required. The telescopic cylinder extends in stages, each stage consisting of a sleeve that fits inside the
previous stage. One application for this type of cylinder is raising a dump truck bed. Telescopic cylinders
are available in both single-acting and double-acting models. They are more expensive than standard
cylinders due to their more complex construction.
They generally consist of a nest of tubes and operate on the displacement principle. The tubes are
supported by bearing rings, the innermost (rear) set of which have grooves or channels to allow fluid
flow. The front bearing assembly on each section includes seals and wiper rings. Stop rings limit the
movement of each section, thus preventing separation. When the cylinder extends, all the sections move
together until the outer section is prevented from further extension by its stop ring. The remaining
sections continue out-stroking until the second outermost section reaches the limit of its stroke;this
process continues until all sections are extended, the innermost one being the last of all.

Stage 3

Stage 2

Stage 1

Pressure
port

Three stages Retracted position

Extended position

Figure 1.6 Telescopic cylinder

For a given input flow rate, the speed of operation increases in steps as each successive section reaches
the end of its stroke. Similarly, for a specific pressure, the load-lifting capacity decreases for each
successive section.

5
1.2.4 Tandem Cylinder

Figure 1.7Tandem cylinder

A tandem cylinder, shown in Fig. 1.7, is used in applications where a large amount of force is required
from a small-diameter cylinder. Pressure is applied to both pistons, resulting in increased force because of
the larger area. The drawback is that these cylinders must be longer than a standard cylinder to achieve an
equal speed because flow must go to both pistons.

1.2.4.1 Through-Rod Cylinders

These are similar in construction to the standard double-acting cylinders, but have a cylinder rod
extending through both cylinder end caps. Although it is possible to have both the piston rods with
different diameters at each end of the cylinder, generally the rods have the same diameters. The main
applications of through-rod cylinders are as follows: the same speed is required in both the directions,
both ends of the rod can be utilized to do work and the non-working end is used to indicate or signal the
position of the load. In some applications, the rod is fixed at both the ends and the cylinder body carrying
the load moves on the rod.
A major problem in the manufacture of through-rod cylinders is achieving the correct alignment and
concentricity of cylinder bore, piston, end caps and rods. Any misalignment can result in excessive seal
wear and premature cylinder failure.

1.2.4.2 Displacement Cylinders

A displacement-type hydraulic cylinder shown in Fig. 1.8 consists of a rod that is displaced from inside a
tube by pumping hydraulic fluid into the tube. The volume of the rod leaving the tube is equal to the
volume of fluid entering the tube, hence the name “displacement cylinder.”
The rod of the displacement cylinder is guided by bearings in the nose or neck of the cylinder body. A
collar on the end of the rod prevents it from being ejected and limits the stroke of the cylinder. Elastomer
seals in the neck prevent any leakage of fluid along the outside of the rod. This design is a single-acting
“push” or extension cylinder, which has to be retracted by gravity, a spring or some external force. The
bore of the cylinder body does not require machining other than that for the neck bearing and the inlet
port; the manufacturing cost is, therefore, low when compared with other types or hydraulic cylinders.
The maximum thrust exerted by a displacement cylinder is given by
d2
Maximum thrust = Pressure × Rod area = p 
4
where d is the diameter of the rod. The extending speed of the rod is given by
Flow rate of fluid entering the cylinder
Rodspeed 
Area of cylinder rod

6
 Figure 1.8Displacement cylinders

Example 1.1
A displacement-type cylinder has a rod of 65 mm diameter and is powered by a hand pump with a
displacement of 5 mL per double stroke. The maximum operating pressure of the system is to be limited
to 350 bar. (a) Draw a suitable circuit diagram showing the cylinder, pump and any additional valving
required. (b) Calculate the number of double pumping strokes needed to extend the cylinder rod by 50
mm. (c) Calculate the maximum load that could be raised using this system.

Solution:
(a) The circuit diagram is given in Fig. 1.9.

Load

Non-return valve to hold load in the

position when the pump is not
operated
Figure 1.9
(b) The volume of rod displaced is equal to the volume of fluid entering the cylinder. Let the rod diameter
be d, the distance rod extends be L, the displacement per double stroke of pump be V and the number of
double pump strokes be S. Then
Rod volume displaced = Fluid volume entering
d2
  L V S
4

7
Substituting values given in the problem and showing units for each value we get
652
mm2 × 50 mm = 5 mL × S
4
652
 × 50 mm3 = 5S mL
4
The units on both sides of the equation must be the same.
Note:
1 mL = 1 × 103 L
1 L = 1 × 103 m3
1 mL = 1 × 106 m3
1 mm3 = 1 × 109 m3
Thus, for the dimensional equality
652
× 50 × 109 (m3 ) = 5× 106 (m3 ) ×S
4
652
or × 50 (m3 ) = 5× 103 (m3 ) × S
4
Therefore,
652  50
S= =33.17 double strokes
4  5 103
(c) We have
Maximum thrust = Pressure × Rod area
Substituting the values given into the problem and showing units we get
652  N 
Maximum thrust = 350 × 105 × × 106  2 ×m 2 
4  m 
652
= 35 × N = 116080 N = 116.080 kN
4

Example 1.2
A three-stage displacement-type telescopic cylinder is used to tilt the body of a lorry (Fig. 1.10). When
the lorry is fully laden, the cylinder has to exert a force equivalent to 4000 kg at all points in its stroke.
The outside diameters of the tubes forming the three stages are 60, 80 and 100 mm. If the pump powering
the cylinder delivers 10 LPM, calculate the extend speed and pressure required for each stage of the
cylinder when tilting a fully laden lorry.

Solution:
First-stage
First-stage diameter = 100 mm
Quantity flowing
First-stage speed =
Area

10 103  m3  4
 2  2 
= = 1.27 m/min
( / 4)  (0.1)  min m  

8
 Load
First-stage pressure =
Area
4000  9.81
 N/m2 = 5× 106 (N/m2 ) = 50 bar
( / 4)  (0.1) 2

Figure 1.10
Second-stage:
Second-stage diameter = 80 mm
Quantity flowing
Second-stage speed =
Area
10 10 3
 m 3

 2  2 
= 1.99 m / min
( / 4)  (0.08)  min m 
Load
Second-stage pressure =
Area
4000  9.81
 N/m2 = 7.81 × 106 (N/m2 )  78.1bar
( / 4)  (0.08)2
Third-stage:
Third-stage diameter = 60 mm
Quantity flowing
Third-stage speed =
Area
10 10 3
 m 3

  
( / 4)  (0.06)2  min m2 
= 3.54 m / min
Load
Third-stage pressure =
Area
4000  9.81

6
N/m2 = 13.9 × 10 = 139 bar
( / 4)  (0.06) 2

Telescopic cylinders are made in a standard range for vehicle applications. Although non-standard
cylinders can be obtained, they tend to be very expensive if ordered as a single piece.

9
1.3Standard Metric Cylinders
Table 1.1gives preferred sizes for the cylinder bore and rod diameter of metric cylinders. Most cylinder
manufacturers have based their standard range of metric cylinders on these recommendations, offering
two rod sizes for each cylinder bore.
A number of combinations have a piston rod to piston diameter ratio in the region of 0.7, which gives an
annulus area of approximately one-half of the full bore area. This area ratio is of use in regenerative
circuits to give similar values of speed and thrust on both the extension and retraction strokes. Table 1.2
gives the graphical symbols for various kinds of cylinders.

Table 1.1 Recommended cylinder bore and rod sizes

Piston 40 50 63 80 100 125 140 160 180 200 220 250 280 320
diameter (mm)

Piston rod Small 20 28 36 45 56 70 90 100 110 125 140 160 180 200
diameter (mm) Large 28 36 45 56 70 90 100 110 125 140 160 180 200 220

Table 1.2Graphical symbols of different linear actuators

S. Graphical Symbols Explanation
No.
1. Single-acting cylinder with unspecified return

2. Single-acting cylinder with spring return

3. Double-acting cylinder –single piston rod

4. Double-acting cylinder –doublepiston rod

5. Telescopic cylinder–double acting

10
6. Telescopic cylinder–single acting

7. Double-acting cylinder– fixed cushion on one side

1. Double-acting cylinder–variable cushion on one side

9. Double-acting cylinder–variable cushion on both sides

1.4Cylinder Force, Velocity and Power

The output force (F) and piston velocity (v) of double-acting cylinders are not the same for extension and
retraction strokes.

During extension, entire piston

area Ap is subjected to fluid
pressure

During retraction, annulus area

Ap− Ar is subjected to fluid
pressure

Figure 1.11Effective area during (a) extension strokes and (b)retraction strokes

11
During the extension stroke shown in Fig.1.11(a),the fluid pressure acts on the entire circular piston area
Ap. During the retraction stroke, the fluid enters the rod-end side and the fluid pressure acts on the smaller
annular area between the rod and cylinder bore (Ap−Ar) as shown by the shaded area in Fig.1.11(b) (Ar is
the area of the piston rod). Due to the difference in the cross-sectional area, the velocity of the piston
changes.Because Apis greater than (Ap−Ar), the retraction velocity (vret) is greater than the extension
velocity (vext) for the same flow rate.

During the extension stroke, the fluid pressure acts on the entire piston area (Ar), while during the
retraction stroke, the fluid pressure acts on the annular area (Ap−Ar). This difference in area accounts for
the difference in output forces during extension and retraction strokes. Because Ar is greater than Ap−Ar),
the extension force is greater than the retraction force for the same operating pressure.
Force and velocity during extension stroke
Qin
Velocity vext 
Ap
Force
Fext  p  Ap

Force and velocity during retraction stroke

Velocity
Qin
vext 
Ap  Ar

Force,
Fext  p  ( Ap  Ar )
Power developed by a hydraulic cylinder (both in extension and retraction) is

Power  Force ×Velocity  F  V

In metric units, the kW power developed for either extension or retraction stroke is
Power (kW)  vp (m/s)  F (kN)
 Qin (m3 /s)  p (kPa)

Power during extension is

Qin
Pext  Fext  vext  p  Ap   p  Qin (1.1)
Ap
Power during retraction is
Pret  Fret  vret
Qin
 p  ( Ap  Ar ) 
Ap  Ar
 p  Qin (1.2)
Comparing Equation. (1.1) and (1.2), we can conclude that the powers during extension and retraction
strokes are the same.

12
 Lecture 13
HYDRAULIC ACTUATORS[CONTINUED]

1.5Acceleration and Deceleration of Cylinder Loads

Cylinders are subjected to acceleration and deceleration during their operation. Cylinders are decelerated
to provide cushioning and cylinders are accelerated to reduce the cycle time of the operation.

1.5.1 Acceleration
To calculate the acceleration of cylinder loads, the equations of motion must be understood.Let u be the
initial velocity, v the velocity after a time t,s the distance moved during the time t anda the acceleration
during the time t.The standard equations of motion are as follows:

v  u  at
v2  u 2  2as
1
s  ut  at 2
2
1
and s  (u  v)t The force F to accelerate a weight W horizontally
2
with an acceleration a is given by
Force = Mass × Acceleration
W
F= a
g
where g is the acceleration due to gravity and is 9.81 m/s2. The force P required to overcome friction is
given by P = µW, where µ is the coefficient of friction.
Note: Dynamic cylinder thrust
In dynamic applications, the load inertia, seal friction, load friction, etc., must be allowed for calculating
the dynamic thrust.As a first approximation, the dynamic thrust can be taken as 0.9 times the static thrust.
Cylinder seal friction varies with seal and cylinder design. The pressure required to overcome seal friction
is not readily available from the majority of cylinder manufacturers. The seal friction breakout pressure
can be taken as 5 bar for calculation purposes. It reduces when the piston starts to move. The pressure
required to overcome seal friction reduces as the cylinder bore size increases and varies according to the
seal design.

Example 1.3
A cylinder is required to move a 10 kN load 150 mm in 0.5 s. What is the output power?

Solution: The velocity is given by

d 0.15
v  =0.3 m/s
t 0.5
Power is given by
P  F  v  10 103  0.3 =3 kW

Example 1.4
A cylinder is required to extend at a minimum speed of 0.75 m/s in a system with a flow rate of 60 LPM.
What cylinder size is required?

1
Solution:
Let us first convert the LPM to :
60 60
Q  60 LPM  m3 / min   103 m3 / s
1000 1000  60
Now we know flow rate and velocity, so we can calculate the diameter,
Q  Ap  v

 103  Dp2  0.75
4
Therefore,
4  103
Dp   41.2 mm
  0.75

Example 1.5
An 8 cm diameter hydraulic cylinder has a 4 cm diameter rod. If the cylinder receives flow at 100 LPM
and 12 MPa, find the (a) extension and retraction speeds and (b) extension and retraction load carrying
capacities.

Solution:
Let us first convert the flow in LPM to m3/s before we calculate forward velocityQin=100
LPM = 100/(1000 × 60) =1/600 m3/s
Now
DC = Diameter of cylinder = 8 cm = 8 × 10−2 m
dr = Diameter of piston rod = 4 cm = 4 × 10−2 m
p = 12 MPa = 12 × 106 N/m2 or Pa

(a) Forward velocity is given by

Qin 1/ 600
vext= = = 0.3315 m/s
Ap  d 2 / 4

Return velocity is given by

1
Qin 600
vret =   0.442 m/s
( Ap  Ar ) π(dC2  d r2 )
4

(b) Force during extension is given by

 (8  102 )2
Fext  p  ap  12  106  60318.57 N
4

Force during retraction is given by

2
 Fret  p  ( Ap  Ar )
106   [(8 102 ) 2  (4 102 ) 2 ]
 12 
4
 42238.9 N  45.24 kN

Example 1.6
A pump supplies oil at 0.0016 m3/s to a 40 mm diameter double-acting hydraulic cylinder. If the load is
5000 N (extending and retracting) and the rod diameter is 20 mm, find the
(a) Hydraulic pressure during the extending stroke.
(b) Piston velocity during the extending stroke.
(c) Cylinder kW power during the extending stroke.
(d) Hydraulic pressure during the retracting stroke,
(e) Piston velocity during the retracting stroke.
(f ) Cylinder kW power during the retracting stroke.

Solution: We have Qin = 0.016 m3/s, Fext = Fret = 5000 N, dC = 40 mm = 0.04 m, dr = 20 mm = 0.02 m.
(a) Hydraulic pressure during the extending stroke is
Fext 5000 5000
pext     3978.8 kPa
Ap  dC  (0.04)2
2

4 4
(b) Piston velocity during the extending stroke is
Qin Qin 0.016
vext     1.273 m/s
Ap  dC2  (0.04) 2
4 4
(c) Cylinder kW power during the extending stroke is
Pext  Fext  vext  5000 1.273  6.366 kW

(d) Hydraulic pressure during the retracting stroke is

Fret 5000 5000
pret  =  = 5305.16 kPa
Ap  Ar  (dC  d r )  [(0.04)2  (0.02)2 ]
2 2

4 4
(e) Piston velocity during the retracting stroke is
Qin 0.016
vret   =1.697 m/s
Ap  Ar  (0.042  0.022 )
4
(f) Cylinder kW power during the retracting stroke is
Pret  Fret  vret  5000 1.697  8.488 kW

Example 1.7
A hydraulic cylinder has a rod diameter equal to one half the piston diameter. Determine the difference in
load-carrying capacity between extension and retraction stroke if pressure is constant. What would
happen if the pressure were applied to both sides of the cylinder at the same time?

Solution: Forward or extending stroke is

Fext  p  Ap

3
Retracting stroke is
Fret  p  ( Ap  – Ar )
Also, given that
dp = 2dr
Therefore
Ap = 4Ar
Now
Fext p  Ap

Fret p  ( Ap  – Ar )
Ap

Ap  – Ar
Ap

Ap  –0.25 Ap
Fext 4
Therefore, 
Fret 3
Again
Fext  Fret   pAp  p( Ap  –0.25 Ap )
 Ap 
 pAp  p  Ap  
 4
pAp
 Fext  Fret 
4
Therefore,
Pr essure  Piston area
Difference =
4
If the pressure were applied to both sides of the cylinder at the same time, there would be a net force to
extend the cylinder. This net force will be the same as obtained above:
Pr essure  Piston area
Fnet-extending =
4

Example 1.8
A cylinder with a bore of 150 mm and a piston rod diameter of 105 mm, has to extend with a speed of 7
m/s, pressure applied is 150 bar. Calculate
(a) The flow rate in LPM of oil to extend the cylinder
(b) The flow rate in LPM from annulus side to extend the cylinder.
(c) The retract speed in m/min using (a).
(d) The flow rate from full bore end on retract.

Solution: Area of piston is given by

 
Ap   Dp2   (0.15)2  0.01767 m2
4 4
Area of rod is
 
Ar   Dr2   (0.105)2  0.008659 m2
4 4

4
Hence, Ap  Ar  0.00901 m2 .
Given, vext = 7 m/min and p = 150 bar.
(a) Flow rate of oil to extend in LPM:
(Qext ) p  Ap  vext
 0.01767  7
 0.12369 m3 /min  123.69 LPM
(b) Flow rate of oil to extend from annulus in LPM:
(Qext )a  ( Ap  Ar )  vext
 0.00901  7
 0.06307 m3 /min  63 LPM
(c) Retract speed in m/min using (a):
Qret  (Qext )p  ( Ap  Ar )  vret
 0.12369  0.00901 vret
 vret  13.728 m/min
(d) Flow rate from full bore end on retract:
Qret  Ap  vret
 0.01767  13.728
 0.06587 m3 /min  65.87 LPM

1.6Various Methods of Applying Linear Motion Using Hydraulic Cylinders

A cylinder must produce a force equal to the load the cylinder is required to overcome. A cylinder may be
placed with its axis vertical, horizontal or inclined depending on the load to be actuated.

1. Vertical cylinder: Ina vertical cylinder, the load to be actuated is in the vertical direction as
shown in Fig. 1.12. Then the cylinder load F is equal to the weight W of the object, acting in the
vertical direction.

Load

= Cylinder force

Figure 1.12Cylinder load– vertical cylinder

2. Horizontal cylinder:The schematic diagram of horizontal cylinder is shown in Fig. 1.13. Ina
horizontal cylinder, the cylinder load is theoretically zero,because no component of the object’s 
weight acts along the axis of the cylinder. However, when the object slides across the horizontal
surface, the cylinder must overcome the frictional force created between the object and the
horizontal surface.

5
 Load

Figure 1.13Cylinder load –horizontal cylinder

3. Inclined cylinder:In an inclined cylinder as shown in Fig. 1.14, the cylinder load equals the
component of the object’s weight acting along the axis of the cylinder and frictional force

=W

= Cylinder force

Figure 1.14Cylinder load –inclined cylinder

For an inclined cylinder, the load the cylinder must overcome is less than the weight of the object to be
moved if the object does not slide on an inclined surface. The cylinder loads calculated as above are based
on moving an object at a constant velocity. But when the object has to be accelerated from zero velocity
to a steady-state velocity, an additional force called inertia force must be added to the weight component
and any frictional force involved.
LetFload = W = weight or load acting vertically downward, Fcyl = load acting on the cylinder, Fbear = force
on the bearings and α= angle between the load W and the axis of the cylinder.Then,
Fcyl = Floadcos(a)
Fbear = Floadsin(a)

Example 1.9
Find the cylinder force required to move a 6000 N weight along a horizontal surface at a constant velocity
(Fig. 1.15). The coefficient of friction between the weight and horizontal support surface is 0.14.

6
 Load

Figure 1.15

Solution: The cylinder force is given by

Fcyl  Frictional force ( Ff )  W
 Fcyl  0.14  6000  840 N

Example 1.10
Find the cylinder force required to lift a 6000 N weight along a direction that is 30° from the horizontal
direction as shown in Fig. 1.16. The weight is moved at a constant velocity.

= Cylinder force

Figure 1.16

Solution: Let
Fload = W = weight or load acting vertically downward
Fcyl = load acting on the cylinder
Fbear = force on the bearings
= angle between the load W and the axis of the cylinder
Then
Fcyl = Floadcos
Fbear = Floadsin
Hence,

7
 Fcyl  6000  cos60  3000 N

Example 1.11
A 6000 N weight is to be lifted upward in a vertical direction for the system shown in Fig. 1.17. Find the
cylinder force required to
(a) Move the weight at a constant velocity of 1.75 m/s.
(b) Accelerate the weight from zero velocity to 1.75 m/s in 0.5 s.

Load

= Cylinder force

Figure 1.17

Solution:
(a) For a constant velocity, the cylinder force to move weight at a constant velocity of 1.75 m/s
Fcyl  Fa  W  6000 N
(b) Force required to accelerate the weight:
First we shall calculate acceleration
1.75  0
a  3.5 m/s2
0.5
Force required to accelerate the weight is
6000  3.5
Fa  m  a   2140.67 N
9.81
The cylinder force Fcyl required is equal to the sum of the weight and acceleration force
Fcyl  6000  2140.67  8140.67 N

Example 1.12
A 10000 N weight is to be lowered by a vertical cylinder as shown in Fig. 1.18. The cylinder has a 75 mm
diameter piston and 50 mm diameter rod. The weight is to decelerate from 100 m/min to a stop in 0.5 s.
Determine the required pressure in the rod end of the cylinder during the deceleration motion.

8
 10000 N

Figure 1.18

Solution: As per Newton’s law of motion, we have
F  m a
where
m 1min
100 
a min 60 s  1.67 m/s  3.34 m/s 2
0.5 s 0.5 s
Summing forces on the 10000 N weight, we have
10000 N
p( Ap  Ar )  10000 N  2
 3.34 m/s 2
9.81m/s

 p (N/m2 )  (0.0752  0.0502 ) m2  10000 N  3408 N
4
Solving we get
p  5450000 (N/m2 )  5450000 Pa  5450 kPa

Example 1.13
A 27000 N weight is being pushed up on an inclined surface at a constant speed by a cylinder, as shown
in Fig. 1.19. The coefficient of friction between the weight and the inclined surface equals 0.15.
(a) Determine the required cylinder piston diameter for the pressure of 6894 kPa,
(b) Determine the required cylinder piston diameter, if the weight is to accelerate from a 0 mm/s to a 1524
mm/s in 0.5 s.

9
 27000 N

Figure 1.19

Solution:
(a) Cylinder piston diameter for the pressure of 6894 kPa
The component of the weight W acting along the axis of the cylinder is W sin 30. The component of
weight W acting along normal to the incline surface is W cos30. The frictional force equals the
coefficient of friction times the force normal to sliding surfaces.

Therefore, the frictional force f acting along the axis of the cylinder is
f    W cos30
 0.15  27000  cos30
 3507 N

Total force on the cylinder is frictional force and vertical component:

Fcylinder  f  W sin 30

 3507  27000 sin 30
 17007 N
Fcylinder  pAp =17007 N
Diameter to resist 17007 N is given by

Fcylinder  6894000  D2 =17007 N
4
 D = 0.05605 m = 56 mm
(b) Cylinder piston diameter if the weight is to accelerate from a 0 mm/s to a 1524 mm/s in 0.5 s

As per Newton’s law of motion, we have calculate the acceleration 
F  m a
where

10
 1524mm/s
a  3048 mm/s2  3.048 m/s 2
0.5 s
Summing forces on the 27000 N weight using values determined in (a), we have
27000  3.048
pAp  17007 
9.81
 2 27000  3.048
 6894000  D  17007 
4 9.81
 5414535 D2  17007  8389
 D = 0.0685 m = 68.5 mm

Example 1.14
A hydraulic cylinder has a bore of 200 mm and a piston rod diameter of 140 mm. For an extend speed of
5 m/min, calculate
(a) The supply flow rate.
(b) The flow rate from the annulus side on extend.
(c) The retract speed using QE.
(d) The flow rate from the full bore end on retract.

Also, if the maximum pressure applied to the cylinder is 100 bar, calculate the (e) dynamic extend
thrust and the (f) dynamic retract thrust assuming that dynamic thrust = 0.9  static thrust.
Moreover, the hydraulic cylinder having a bore of 200 mm diameter and a rod of 140 mm diameter
are connected regeneratively. (g) If the same flow rate of 157 L/min is used, calculate the extend
speed. (h) If the maximum system pressure is 100 bar, calculate the dynamic extend thrust.

Solution:

(a) Flow rate of oil to extend cylinder at 5 m/min:

QE = Area of piston × Velocity
 5
= × (200/1000)2×
4 60
=0.00262 m3/min
=0.00262 ×60 ×1000
= 157 L/min
(b) Flow of oil leaving cylinder QE is given by
QE = Annulus area × Velocity
 5
= × [(200/1000)2− (140/1000)2] ×
4 60
= 80 L/min
(c) The same fluid flow rate used to extend the cylinder (157 LPM) is used to retract the
cylinder. The retract cylinder velocity v is given by
QE
v
Aa
Now
QE= 157 L/min = 0.00262 m2
(A − a) = Annulus area= 0.01602 m2

11
 0.00262
v= = 0.614 m/s = 9.8 m/min
0.01602
(d) Flow from the full bore end of cylinder QR is given by
Q = A×v= 0.03142×0.164 = 0.00515 m3/s = 309 LPM

(e) We have
  0.22
Full bore area = = 0.0314 m 2
4
Dynamic extend thrust = 0.9 × Pressure × Full bore area
= 0.9 × 100 × 105 × 0.0314  2  m2 
N
m 
= 283 kN
  (0.22  0.142 )
(f) Annulus area =
4
= 0.016 m 2
 N 
Dynamic retract thrust = 0.9 × 100 × 105 × 0.016  2  m2 
m 
= 144 kN

  0.142
(g) Piston rod area = = 0.0154 m 2
4
Flow rate
Extend speed =
Piston rod area
157  103  L m3 
=   
0.0154  min L×m2 
= 10.2 m/min
This compares with 5 m/min when connected conventionally.
(h) For a regenerative system
 N 
Dynamic extend thrust = 0.9 ×100 × 105 × 0.0154  2  m2 
m 
= 138.6 kN
As the area of the annulus is almost equal to that of the rod, the regenerative extend and conventional
retract thrusts and speeds are almost the same.

Example 1.15
A mass of 2000 kg is to be accelerated horizontally up to a velocity of 1 m/s from the rest over a distance
of 50 mm (Fig. 1.20). The coefficient of friction between the load and guide is 0.15. Calculate the bore of
the cylinder required to accelerate this load if the maximum allowable pressure at the full bore end is 100
bar (take seal friction to be equivalent to a pressure drop of 5 bar). Assume that the back pressure at the
annulus end of the cylinder is zero.

12
 Load

P1=100 bar P2 = 0
Figure 1.20

Solution: In this case, u = 0, v = 1 m/s, s = 0.05 m and a is unknown. Using the equation
v2  u 2  2as
We have,
12  02  2a  0.05  a  10 m / s2
The force to accelerate the load is given by
 w  2000  9.81 
F  a  10  20 000 N
 g  9.81 
The force P to overcome the load friction is given by
P  W  0.15  2000  9.81  2943 N
The total force to accelerate the load and overcome friction is
F + P = 20000 + 2943 = 22943 N
The cylinder area required for a given thrust is calculated from
Thrust = Force × Area
The pressure available is pressure at the full bore end of the cylinder minus the equivalent seal break-out
pressure.
Pressure available = 100−5 = 95 bar = 95 ×105 bar
Area is given by
22943
Area 
195  105
 0.002415 m 2  2415 mm 2

Now area is also given by

 D2
Area 
4

where D is the diameter. Comparing the two equations , we get D = 55.4 mm.
The cylinder diameter is thus 55.4 mm. This neglects the effect of any back pressure. The nearest standard
cylinder above has a 63 mm diameter bore.

13
 Lecture 14
HYDRAULIC ACTUATORS [CONTINUED]

1. 7 First-, Second- and Third-Class Lever Systems

Many mechanisms use hydraulic cylinders to transmit motion and power. Among these, lever
mechanisms such as toggles, the rotary devices and the push--pull devices use a hydraulic cylinder. In this
section, the mechanics of cylinder loading used in first-class, second-class and third-class lever systems is
being discussed.

1. 7.1 First-Class Lever System

Fixed
Cylinder hinge pin
rod pin
Fixed
hinge
pin

Cylinder

Figure 1. 21 First-class lever system

In this lever system, the fixed-hinge point is located in between the cylinder and the loading point. The
schematic arrangement of a first-class lever system with a hydraulic cylinder is shown in Fig.1. 21. In this
system, the downward load acts at the lever end. The cylinder has to apply a downward force to lift the
load. The cylinder has a clevis mounting arrangement; it pivots about its eye-end center through an angle.
However, the effect of this angle (around 10° to 15°) is negligible on the force and hence cannot be
considered.
Here, Fload = load to be operated, Fcyl = load to be exerted by a hydraulic cylinder, L1 = distance from the
rod end to the pivot point, L2 = distance from the pivot point to the loading point and θ = inclination of
the lever measured with respect to the horizontal line at the hinge.
When the load is being lifted, the cylinder force rotates the lever in an anticlockwise direction about the
pivot point. Due to this, a moment acts in the anticlockwise direction. At the same time, the force due to
the load acting causes a clockwise moment. At equilibrium, the two moments are equal
Fcyl  ( L1 cos θ )  Fload  L2 cos
L2
Fcyl  Fload (1. 3)
L1

1
Suppose the centerline of the hydraulic cylinder tilts by an offset angle  from the vertical; the
relationship becomes
Fcyl cos   ( L1 )(cos θ )  Fload  L2 cos
L2
Fcyl  Fload (1. 4)
( L1 )cos
Note 1:IfL1> L2, the cylinder force is less than the load force and the cylinder stroke is greater than the
load stroke.
Note 2:Ifthe inclination of cylinder () is less than 10o,its effect can be ignored in equation (2).

1. 7.2 Second-Class Lever System

In this lever system, the loading point is in between the cylinder and the hinge point as shown in Fig.1.
22.

Cylinder
rod pin
Fixed
hinge pin
Lever


Cylinder

Figure 1. 22 Second-class lever system

Using the same nomenclature discussed under the previous lever systems and equating moments about the
fixed-hinge pin, we can write
Fcyl cos   ( L1  L2 )(cos θ )  Fload  L2 cos 
L2
Fcyl  Fload (1. 5)
( L1  L2 )cos

Note 3:Compared to the first-class lever, the second-class lever requires smaller cylinder force to drive
the given load force for same L1 and L2 and load force. In other words, if we use a second-class lever
cylinder, a smaller size cylinder can be used.
Note 4: Compared to the first-class lever, the second-class lever also results ina smaller load stroke for a
given cylinder stroke.

1. 7.3 Third-Class Lever System

For a third-class lever system shown in Fig. 1.23, the cylinder rod pin lies between the load road pin and
the fixed-hinge pin of the lever.

2
 Fixed hinge
 Lever pin

Cylinder

Figure 1. 23 Third-class lever system

Equating moments about the hinge point, we can write
Fcyl cos   ( L2 cos θ )  Fload  ( L1  L2 )cos 
L1  L2
Fcyl  Fload (1. 6)
L2 cos
Note 4: In a third-class lever system, cylinder force is greater than load force.
Note 5: In a third-class lever system, load stroke is greater than the cylinder stroke and therefore requires
a larger cylinder.

Example 1. 16
Following data are given for the first-, second- and third-class lever systems: L1  L2  25.4 cm,   10,
Fload  4444 N . Compare the cylinder force needed in each case to overcome the load force. Repeat this
with   5 and 10 .

Solution: First-class lever system

L  F
Fcyl   2  load
 L1  cos
25
 4444 N
25cos0
 4444 N
Second-class lever system

3
 L2
Fcyl  Fload
( L1  L2 )cos
2
 4444
(25  25)cos10
 2222 N
Third-class lever system
L  L2
Fcyl  1 Fload
L2 cos
25  25
 4444
25cos10
 8888 N
As seen, the cylinder force in the second-class lever system is half of that in the first-class lever system
and one-fourth of that in the third-class lever system.
When   5 and 10 :
First-class lever
4444
Fcyl   5   4461 N
cos5
4444
Fcyl   10    4729 N
cos10
Second-class lever
2222
Fcyl   5   2231 N
cos5
2222
Fcyl   10    2365 N
cos10
Third-class lever
8888
Fcyl (  5)   8922 N
cos 5
8888
Fcyl   10    9458 N
cos10

Example 1. 17
For the system given in Fig. 1. 24 determine the force required to drive a 1000 N load.

Figure 1. 24
Solution: As seen, it is a first-class lever system. Taking moments about the hinge, we get

4
 Fcyl  BC  Fload  CD
CD 500
 Fcyl  Fload   1000   1250 N
BC 400

Example 1. 18
For the crane system, determine the hydraulic cylinder force required to lift a 2000 N load (Figs. 1. 25 and
1. 26).

D
4m

C
3m 2000 N

A B

Figure 1. 25

Figure 1. 26

Solution: The given system is a third-class lever system as the cylinder pin lies in between the load rod
pin and fixed-hinge pin of the lever. Equating moments about fixed pin A due to the cylinder force F and
the 2000 N force we get
2000 × Perpendicular dist. AG = F × Perpendicular dist. AE

From trigonometry of right-angled triangles, we have

AG
cos 45   AG  7 cos 45  4.95 m
7

5
 AE
sin30   AE  3sin 30  1.5 m
3
2000  4.95  F 1.5
 F  6600 N

Example 1. 19
Figure 1. 27 shows a toggle mechanism. Find the output load force for a hydraulic cylinder force of 1000
N.

A
B

Cylinder

Figure 1. 27

Solution: Setting the sum of the forces on pin C equal to zero (from Newton’s law of motion), force (F)
= ma = 0 because a = 0 for constant velocity motion, yields the following for the x- and y-axes:
y-axis: FBC sin 60  FBD sin 60  0  FBC  FBD

x-axis: Fcyl  FBC cos60  FBD cos60  0

Fcyl  2FBC cos60  0
Fcyl
 FBC 
2cos 60

Similarly, setting the sum of forces on pin C equal to zero for the y-axis direction yields

FBC sin 60  Fload  0

Therefore, we have
Fload  FBC sin 60
sin 60
  Fcyl
2cos 60
tan 60
  1000  866 N
2

6
1. 8 Cylinder Cushions

For the prevention of shock due to stopping loads at the end of the piston stroke, cushion devices are
used. Cushions may be applied at either end or both ends. They operate on the principle that as the
cylinder piston approaches the end of stroke, an exhaust fluid is forced to go through an adjustable needle
valve that is set to control the escaping fluid at a given rate. This allows the deceleration characteristics to
be adjusted for different loads. When the cylinder piston is actuated, the fluid enters the cylinder port and
flows through the little check valve so that the entire piston area can be utilized to produce force and
motion. A typical cushioning arrangement is shown in Fig. 1. 28.

Cushion spear

Cushion Retraction stroke

port

Cushion adjusting restrictor

7
 1. Exhaust flow passes freely out of the
cylinder

5. Check valve allows free

flow to the piston to extend
2. Plunger enters the cap

3. No flow takes a restricted

path causing the piston to
4. Rate of deceleration can be decelerate
adjusted here

Figure 1. 28 Operation of cylinder cushions

1. 8.1 Cushioning Pressure

During deceleration, extremely high pressure may develop within a cylinder cushion. The action of the
cushioning device is to set up a back-pressure to decelerate the load.

8
 Straight cushion

Pressure in the cushion

Tapered cushion spear

Ideal

100 %
Position of cushion spike in the cushion

Figure 1. 29 Pressure distribution in cushioning

Ideally, the back-pressure is constant over the entire cushioning length to give a progressive load
deceleration. In practice, cushion pressure is the highest at the moment when the piston rod enters the
cushion(Fig. 1. 29).Some manufacturers have improved the performance of their cushioning devices by
using a tapered or a stepped cushion spear. Wherever high inertia loads are encountered, the cylinder
internal cushions may be inadequate but it is possible for the load to be retarded by switching in external
flow controls. Deceleration can then take place over a greater part of the actuator stroke.

1. 8.2 Maximum Speeds in Cushioned Cylinders

The maximum speed of a piston rod is limited by the rate of fluid flow into and out of the cylinder and the
ability of the cylinder to withstand the impact forces that occur when the piston movement is arrested by
the cylinder end plate.

In an uncushioned cylinder, it is normal to limit the maximum piston velocity to 8m/min. This value is
increased to 12 m/min for a cushioned cylinder, and 30 m/min is permissible with high-speed or
externally cushioned cylinders. Oversize ports are necessary in cylinders used in high-speed applications.
In all cases, the maximum speed depends upon the size and type of load. It is prudent to consult the
manufacturer if speeds above 12 m/min are contemplated.

When only a part of the cylinder stroke is utilized, cushions cannot be used to decelerate the load. In such
cases, it may be necessary to introduce some form of external cushioning especially where high loads or
precise positioning is involved.

Example 1. 20
A cylinder has a bore of 125 mm diameter and a rod of 70 mm diameter. It drives a load of 2000 kg
vertically up and down at a maximum velocity of 3 m/s. The lift speed is set by adjusting the pump
displacement and the retract speed by a flow control valve. The load is slowed down to rest in the cushion
length of 50 mm. If the relief valve is set at 140 bar, determine the average pressure in the cushions on
extend and retract. (Neglect pressure drops in pipe work and valves.)

Solution: Kinetic energy of load

Kinetic energy = (1/2) Mass × Velocity2

9
 = (1/2) (2000) × 32 = 9000 N m
Average force to retard load over 50 mm is
Kinetic energy 9000 10
3
= = 180 kN
Distance 50
The force acting on the load is
Load = 2000 kg = 2000 × 9.81 = 19.6 kN

Annulus area = (0.1252  0.072 )  0.0084 m2
4
 
  (0.125 )  0.0123 m
2 2
Full bore area = 
4
The kinetic energy of the load is opposed by the cushion force and the action of gravity on the load.
Cushion pressure to absorb the kinetic energy of load when extending is
(180 103 ) – (19.6 103 )
3
(N/ m 2 ) = 19.1 × 106 = 191 bar
(8.4  10 )
When the piston enters the cushion, the pressure on the full bore side of the piston rises to relief valve
pressure. This pressure on the full bore side drives the piston into the cushions, and so increases the
cushion pressure needed to retard the load. The cushion pressure to overcome the hydraulic pressure on
the full bore end is
Full bore area 12.3 103
Pressure × = 140 × = 205 bar
Annulus area 8.4 103

Thus, the average pressure in the cushion on the extend stroke is (190 + 205) = 395 bar.
During cushioning, the effective annular area is reduced as the cushion sleeve enters the cushion. This has
been neglected in the calculation, and in practice, the cushion pressure is even greater.
When the load is retracted, forces act on the load. The back pressure owing to the flow control valve in
the circuit is minimal once the piston enters the cushion and is neglected in this calculation.
The force in the cushion has to overcome the kinetic energy of the load, the weight of the load and the
force due to the hydraulic pressure. The force owing to the hydraulic pressure is
Force = Pressure × Annulus area
= (140 × 105 ) × (8.4 × 103 ) N
= 117.6 kN
Also
Cushion force = 180 + 19.6 + 117.6 = 317.2 kN

After knowing the force, we can find cushion pressure =

Force 317.2
Cushion pressure = = (kN/ m2 ) = 25800 = 258 bar
Area 0.0123

The average pressure in the cushion retracting is 258 bar. Again this value is somewhat higher as the
cushion spike reduces the effective cushion area below that used.

Example 1. 21
A pump delivers oil at a rate of 1.15 LPS into the blank end of the 76.2 mm diameter hydraulic cylinder
shown in Fig. 1. 30. The pistons decelerate over a distance of 19.05 mm at the end of its extension stroke.
The cylinder drives a 6672 N weight which slides on a flat horizontal surface having a coefficient of
friction (CF) equal to 0.12. The pressure relief valve setting equals 51.7125 bar. Therefore, the maximum

10
pressure (p1) at the blank end of the cylinder equals 51.7125 bar while the cushion decelerates the piston.
Find the maximum pressure (p2) developed by the cushion.
Cushion plunger

A
B

Figure 1. 30

Solution:
Step 1: Calculate the steady piston velocity v prior to deceleration:
1.15
Qpump 1000 1.15
v    0.255 m / s
Apiston π
(0.07622 ) 4.5
4
1

Step 2: Calculate the deceleration a of the piston during the 19.05 mm displacement S using the constant
acceleration or deceleration equation:
v2  2as
Substituting the values and solving for deceleration we get
v2 0.2552
a  3
 17.06 m/s2
2s 2(19.05  10 )
Step 3: Using Newton’s laws of motion, the net force acting on the system is equated as
F  ma
Consider the forces that tend to slow down the system as positive forces as we are solving for
deceleration. The mass under consideration m is equal to the sum of all the masses of moving members
(piston, road and load). Because the weight of the piston and road is small compared to the weight of the
load, the weight of the piston and rod is ignored. The frictional forces acting between the weight W and
the horizontal support surface equal coefficient of friction (CF) times W. This frictional force is the
external force acting on the cylinder while it moves the weight.
Substituting into Newton’s equations yields
W
p2 ( Apiston – Acushion )  CF  W – p1 ( Apiston ) 
g

11
   17.06    
 6672   9.81    51.7125  4  (76.2  10 )   0.12  6672 
3 2

   
p2    59.0212 bar
  3 2 
 4 (76.2  10 )  4  25.4  10  
3 2

Thus, the hydraulic cylinder must be designed to withstand an operating pressure of 59.0212 bar rather
than the pressure relief setting of 51.7125 bar.

1. 9 Cylinder Mountings and Strength Calculations

The types of mounting on cylinders are numerous, and they can accommodate a wide variety of
applications. One of the important considerations in selecting a particular mounting is whether the force
applied is tensile or compressive. As far as possible, bucking load must be avoided. The ratio of rod
length to diameter should not exceed 6:1 to prevent bucking. Alignment of the rod with the resistive load
is another important consideration while selecting cylinder mounts. The various kinds of mountings
normally used in industries are as follows (for various mounting, refer Fig. 1. 31):

1. Foot mounting: It should be designed to give a limited amount of movement on one foot only to
allow for thermal or load expansion. That is, the cylinder should be positively located or dowelled
at one end only.

2. Rod-end flange or front flange mounting: During the extend stroke, pressure in the hydraulic
fluid acts on the cylinder-end cap, the force set up being transmitted to the front mounting flange
through the cylinder body.

3. Rear flange, back flange or head-end flange mounting: No stress is present in the cylinder
owing to load on the extend stroke; only hoop stress is present. The load acts through the fluid
onto the rear flange.

4. Trunnion mounting: It allows angular movement. It is designed to take shear load only. Bearing
should be as close to the cylinder body as possible.

5. Eye or clevis mounting: There is a tendency for the cylinder to jack knife under load. Side loading of
bearing must be carefully considered.

(a)

(b)

12
(c)

(d)

(e)

Figure 1. 31 (a) Foot mounting; (b) rod-end flange or front flange mounting; (c) rear flange, back
flange or head-end flange mounting; (d) trunnion mounting; (e) eye or clevis mounting.

1. 9.1 Piston Rod Ends

The piston rod ends can be supplied with a male or female thread according to the manufacturer’s
specification. Rod-end eyes with spherical bearings are available from some suppliers.

1. 9.2 Protective Covers

These are fitted to protect the piston rod when the piston works in an abrasive environment or when the
cylinder is not used for long periods and a heavy deposit of dust accumulates on the rod. The protective
covers are of the form of telescope or bellows and completely enclose the rod at all times in the cylinder
movement.

Bellows may either be molded or fabricated. Molded bellows are manufactured from rubber or plastic and
owing to their construction; they are limited to a contraction ratio of about 4:1. An extended piston rod is
required to accommodate the closed length of the bellows. This increases the overall cylinder length and
tends to restrict their use to relatively short stroke cylinders.
Fabric covers made of plastic, leather, impregnated cloth or canvas can have a contraction ratio greater
than 15:1. When a fabricated cover is used on a horizontal cylinder, it must be supported externally to
prevent the cylinder rod from rubbing the cover.
Telescopic covers are made of a rigid material, normally metal, and are used under conditions where
fabric covers are inadequate.

13
1. 9.3 Piston Rod Buckling
A piston rod in a hydraulic cylinder acts as a strut when it is subjected to a compressive load or it exerts a
thrust. Therefore, the rod must be of sufficient diameter to prevent buckling. Euler’s strut theory is used to
calculate a suitable piston rod diameter to withstand buckling. Euler’s formula states that
 2 EI
Fb  2
L

where Fb is the buckling load (kg), E is the modulus of elasticity (kg/cm2; 2.1 × 106 kg/cm2for steel), I is
the second moment of inertia of the piston rod (cm4;  d 2 / 64 for a solid rod of diameter d cm) and L is
the free (equivalent) buckling length (cm) depending on the method of fixing the cylinder and piston rod
and is shown in Fig.1. 32. The maximum safe working thrust or load F on the piston rod is given by
Fb
F=
S
where S is the factor of safety that is usually taken as 3.5. The free or equivalent buckling length L
depends on the method of fixing the piston rod end and the cylinder, and on the maximum distance
between the fixing points, that is, the cylinder fully extended. In cases where the cylinder is rigidly fixed
or pivoted at both ends, there is a possibility of occurrence of excessive side loading. The effect of side
loading can be reduced by using a stop tube inside the cylinder body to increase the minimum distance
between the nose and the piston bearings. Refer Fig. 1. 33 for use of a stop tube to minimize side loading.
The longer the stop tube, the lower the reaction force on the piston owing to the given value of the side
load. Obviously, the stop tube reduces the effective cylinder stroke.

14
 l Deflected strut
Deflected
strut l
Center trunnion
L=l

Rear pivot
(a) load

l
Deflected
strut
l Deflected strut
Rear flange Front flange
L=2l

(b)

l
Deflected
strut l Deflected strut
Rear flange Front flange
L=l/2

(c)

l
Deflected
strut l
Deflected strut
Rear flange Front flange
L=l/√

(d)

Figure 1. 32Relationship between the piston rod, free buckling length and method of fixing. (a) Rear
pivot and center trunnion mounted, guided pivoted. (b) One end rigidly fixed, free load.(c) One end
rigidly fixed, guided load. (d) One end rigidly fixed, pivoted and guided load

15
 Reaction to
side load
Nose bearing Side load

Piston tube Stop tube

Figure 1. 33Use of a stop tube to minimize side loading

Objective-Type Questions
Fill in the Blanks

1. An actuator is used to convert the _______ back into the _______.

2. A telescopic cylinder is used when _______ stroke length and _______ retracted length are required.
3. In a push type, the cylinder _______ to lift a weight against the force of gravity by applying oil
pressure at the _______.
4. The drawback of tandem cylinder is that it is _______ than a standard cylinder, achieves an equal
speed because flow must go to _______.
5. A major problem in the manufacture of through-rod cylinders is achieving _______ and concentricity
of cylinder bore.

State True or False

1. Hydraulic actuators are devices used to convert the pressure energy of the fluid into mechanical energy.
2. A telescopic cylinder is used in applications where a large amount of force is required from a small-
diameter cylinder.
3. Semi-rotary actuators are capable of limited angular movements that can be several complete
revolutions.
4. Single-acting cylinders can exert a force in both the extending and retracting directions.
5. In pull-type gravity, return-type single-acting cylinder, the cylinder lifts the weight by extending.

Review Questions

1. What is the function of a hydraulic cylinder in a hydraulic system?

2. When is a telescoping cylinder used?
3. Explain the operation of tandem-type cylinder and mention its applications.
4. Explain the function of cushioning in cylinders.
5. Why are wiper rings used on cylinder rods?
6. Mention two applications of single-acting cylinders.

16
7. How does a welded type of cylinder differ from a tie-rod type? Mention the major parts of a tie-rod
cylinder.
8. What are the technical specifications of a hydraulic cylinder?
9. Name the materials that are commonly used to manufacture (a) cylinder covers,(b) piston rods,(c)
pistons and (d) tie-rods.
10. What is a hydraulic ram?
11. Mention the different types of mountings used in fixing the hydraulic cylinders.
12. What is the difference between a single-acting and a double-acting hydraulic cylinder?
13. Name four different types of hydraulic cylinder mountings.
14. What is a cylinder cushion? What is its purpose?
15. What is a double-rod cylinder? When would it normally be used?
16. What is a telescoping rod cylinder? When would it normally be used?
17. Differentiate between first-, second- and third-class lever systems used with hydraulic cylinders to
drive loads.
18. When using a lever system with hydraulic cylinders, why must the cylinder be clevis mounted?
19. What is the purpose of a hydraulic shock absorber? Name two applications.
20. What is a hydraulic actuator?
21. How is a single-acting cylinder retracted?
22. What are the advantages of a double-acting cylinder over the single-acting cylinder?
23. For which applications, a double-rod cylinder is best suited?
24. What are the advantages and disadvantages of a tandem cylinder?
25. Name the types of cylinder mounting.

Answers
Fill in the Blanks

1.Fluid energy, mechanical power

2.Long, short
3.Extends, blank end
4.Longer, both pistons
5.Correct alignment

State True or False

1. True
2. False
3. True
4. False
5. False

17
 Lecture 15
DIRECTIONAL CONTROL VALVES
Learning Objectives

Upon completion of this chapter, the student should be able to:

List different types of valves used in fluid power.

Explain various classifications of directional control valves.
Describe the working and construction of various direction control valves.
Identify the graphic symbols for various types of direction control valves.
Explain the different applications of direction control valves.
Explain the working principle of solenoid-actuated valves.
Define valve overlap.
Evaluate the performance of hydraulic systems using direction control valves.

1.1Introduction

One of the most important considerations in any fluid power system is control. If control components are
not properly selected, the entire system does not function as required. In fluid power, controlling elements
are called valves.

There are three types of valves:

1. Directional control valves (DCVs): They determine the path through which a fluid transverses a given
circuit. Pressure control valves: They protect the system against overpressure, which may occur due to a
sudden surge as valves open or close or due to an increase in fluid demand.
2. Flow control valves: Shock absorbers are hydraulic devices designed to smooth out pressure surges
and to dampen hydraulic shock.

In addition, the fluid flow rate must be controlled in various lines of a hydraulic circuit. For example, the
control of actuator speeds can be accomplished through use of flow control valves. Non-compensated
flow control valves are used where precise speed control is not required because the flow rate varies with
pressure drop across a flow control valve. It is important to know the primary function and operation of
various types of control components not only for good functioning of a system, but also for discovering
innovative methods to improve the fluid power system for a given application.

1.2Directional Control Valves

A valve is a device that receives an external signal (mechanical, fluid pilot signal, electrical or
electronics) to release, stop or redirect the fluid that flows through it. The function of a DCV is to control
the direction of fluid flow in any hydraulic system. A DCV does this by changing the position of
internal movable parts. To be more specific, a DCV is mainly required for the following purposes:

 To start, stop, accelerate, decelerate and change the direction of motion of a hydraulic actuator.
 To permit the free flow from the pump to the reservoir at low pressure when the pump’s delivery is
not needed into the system.
 To vent the relief valve by either electrical or mechanical control.
 To isolate certain branch of a circuit.
 Any valve contains ports that are external openings through which a fluid can enter and exit via
connecting pipelines. The number of ports on a DCV is identified using the term “way.” Thus, a valve
with four ports is a four-way valve A DCV consists of a valve body or valve housing and a valve
mechanism usually mounted on a sub-plate. The ports of a sub-plate are threaded to hold the tube fittings
which connect the valve to the fluid conductor lines. The valve mechanism directs the fluid to selected
output ports or stops the fluid from passing through the valve. DCVs can be classified based on fluid path,
design characteristics, control methods and construction.

1.2.1 Classification of DCVs based Fluid Path

Based on fluid path, DCVs can be classified as follows:

 Check valves.
 Shuttle valves.
 Two-way valves.
 Three-way valves.
 Four-way valves.

1.2.2 Classification of DCVs based on Design Characteristics

Based on design characteristics, DCVs can be classified as follows:

 An internal valve mechanism that directs the flow of fluid. Such a mechanism can
either be a poppet, a ball, a sliding spool, a rotary plug or a rotary disk.
 Number of switching positions (usually 2 or 3).
 Number of connecting ports or ways.
 Method of valve actuation that causes the valve mechanism to move into an alternate position.

1.2.3 Classification of DCVs based on the Control Method

Based on the control method, DCVs can be classified as follows:

 Direct controlled DCV:A valve is actuated directly on the valve spool. This is suitable for small-
sized valves.
 Indirect controlled DCV:A valve is actuated by a pilot line or using a solenoid or by the
combination of electrohydraulic and electro-pneumatic means. The use of solenoid reduces the size of the
valve. This is suitable for large-sized valves.

1.2.4 Classification of DCVs based on the Construction of Internal Moving Parts

Based on the construction of internal moving parts, DCVs can be classified as follows:

 Rotary spool type: In this type, the spool is rotated to change the direction of fluid. It has
longitudinal grooves. The rotary spools are usually manually operated.
 Sliding spool type: This consists of a specially shaped spool and a means of positioning the spool.
The spool is fitted with precision into the body bore through the longitudinal axis of the valve body. The
lands of the spool divide this bore into a series of separate chambers. The ports of the valve body lead into
these chambers and the position of the spool determines the nature of inter-connection between the ports.

2
Table 1.1
Table 1.2

3/2 way valve : 3ports and 2 position DCV

 1. Each different switching position is shown by a square.
2. Flow directions are indicated by arrows.
3. Blocked ports are shown by horizontal lines.
4. Ports are shown in an appropriate flow direction with line arrows

The switching position, flow direction, and port for different configurations is represented in Table 1.1. Two-
way, three-way, four-way and five-way representation is shown in Table 1.2.

1.3Actuating Devices
Direction control valves may be actuated by a variety of methods. Actuation is the method of moving the
valve element from one position to another. There are four basic methods of actuation: Manual,
mechanical, solenoid-operated and pilot-operated. Several combinations of actuation are possible using
these four basic methods. Graphical symbols of such combinations are given in Table 1.3.

 Manually operated: In manually operated DCVs, the spool is shifted manually by moving a handle
pushing a button or stepping on a foot pedal. When the handle is not operated, the spool returns
to its original position by means of a spring.
 Mechanically operated: The spool is shifted by mechanical linkages such as cam and rollers.
 Solenoid operated: When an electric coil or a solenoid is energized, it creates a magnetic force
that pulls the armature into the coil. This causes the armature to push the spool of the valve.
 Pilot operated: A DCV can also be shifted by applying a pilot signal (either hydraulic or
pneumatic) against a piston at either end of the valve spool. When pilot pressure is
introduced, it pushes the piston to shift the spool.
 Solenoid operated

Pilot operated

Manual operated

Push button

Foot operated

Pilot-operated solenoid

Two-position detent

Spring return

1.4 Check Valve

The simplest DCV is a check valve. A check valve allows flow in one direction, but blocks the flow in the
opposite direction. It is a two-way valve because it contains two ports. Figure 1.1 shows the graphical
symbol of a check valve along with its no-flow and free-flow directions.

7
 Figure 1.1 Graphical symbol of a check valve.

In Fig. 1.2, a light spring holds the ball against the valve seat. Flow coming into the inlet
pushes the ball off the seat against the light force of the spring and continues to the
outlet. A very low pressure is required to hold the valve open in this direction. If the flow
tries to enter from the opposite direction, the pressure pushes the ball against the seat and
the flow cannot pass through.
Valve seat Ball
Light spring

Inlet Outlet

Figure 1.2 Ball-type check valve.

Figure 1.3 provides two schematic drawings showing the operation of a poppet check
valve. A poppet is a specially shaped plug element held on a valve seat by a light spring.
Fluid flows through the valve in the space between the seat and poppet. In the free flow
direction, the fluid pressure overcomes the spring force. If the flow is attempted in the
opposite direction, the fluid pressure pushes the poppet in the closed position. Therefore,
no flow is permitted

In Out

Figure1.3 Poppet check valve: (a) Open and (b) closed position
1.4.1 Advantages of a poppet valve

 Virtually zero leakage in closed position.

 Poppet elements do not stick even when left under pressure for long periods.
 Fast, consistent response time: typically 15 ms.

1.4.2 Disadvantages of a Poppet Valve

A poppet valve has the following
disadvantages:

 Axial pressure balance is impossible and considerable force may be needed to

open the poppet against the flow at a high pressure. This limits valves that have
direct mechanical actuation to low flow duties.
 Generally individual poppets are required for each flow path that significantly
increases the complexity of multi-port valves.
 Lapping and super finishing of valves add cost.

1.5 Pilot-Operated check Valve

A pilot-operated valve along with its symbol is shown in Fig. 1.4. This type of check v alve always
permits free flow in one direction but permits flow in the normally blocked opposite direction only if the
pilot pressure is applied at the pilot pressure point of the valve. The check valve poppet has the pilot
piston attached to the threaded poppet stem by a nut.
The light spring holds the poppet seated in a no-flow condition by pushing against the pilot piston. The
purpose of the separate drain port is to prevent oil from creating a pressure build-up at the bottom of the
piston. The dashed line in the graphical symbol represents the pilot pressure line connected to the pilot
pressure port of the valve. Pilot check valves are used for locking hydraulic cylinders in position.

No pilot signal

Free flow

No pilot signal

No flow

Pilot signal

Return flow

Figure 1.4Pilot-perated check valve

1.6 Shuttle Valve

A shuttle valve allows two alternate flow sources to be connected in a one-branch circuit. The valve has
two inlets P1 and P2 and one outlet A. Outlet A receives flow from an inlet that is at a higher
pressure. Figure 1.5 shows the operation of a shuttle valve. If the pressure at P 1 is greater than that at
P2, the ball slides to the right and allows P1 to send flow to outlet A. If the pressure at P2 is greater than
that at P1, the ball slides to the left and P2 supplies flow to outlet A

A A

Figure 1.5 Shuttle valve: (a) Flow from left to outlet and (b) flow from right to outlet in Fig. 1.5.

One application for a shuttle valve is to have a primary pump inlet P1 and a secondary pump inlet
P2 connected to the system outlet A The secondary pump acts as a backup, supplying flow to the
system if the primary pump loses pressure. A shuttle valve is called an “OR” valve because
receiving a pressure input signal from either P1 or P2 causes a pressure output signal to be sent to
A. Graphical symbol of shuttle valve is shown in Fig. 1.6.

Fig 1.6 symbol of Shuttle valve

 Lecture 16
DIRECTIONAL CONTROL VALVE [CONTINUED]

1.7.1 2/2-Way DCV (Normally Closed)

Figure 1.7shows a two-way two-position (normally closed) of spool type. A spool valve consists of a
cylindrical spool that slides back and forth inside the valve body to connect or block flow between the
ports. The larger diameter portion of the spool, the spool land blocks flow by covering the port. This
particular valve has two ports labeled P and A. P is connected to the pump line and A is connected to the
outlet to the system. Figure 1.7(a) shows the valve in its normal state and its corresponding symbol. The
valve is held in this position by the force of the spring. In this position, the flow from the inlet port P is
blocked from going to the outlet port A. Figure 1.7(b) shows the valve in its actuated state and its
corresponding symbol. The valve is shifted into this position by applying a force to overcome the
resistance of the spring. In this position, the flow is allowed to go to the outlet port.

P
P
Spool land
(a)

A
A
F

Spool
P

P
(b)

Figure1.7 Two-way–two-position normally closed DCV. (a) Ports A and P are not connected when force is not
applied (valve unactuated). (b) Ports A and P are connected when force is applied (valve actuated).

1.7.2 2/2-Way DCV (Normally Opened)

Figure 1.8 shows a two-way, two-position normally open DCV. The spring holds the valve in a position
in which ports P and Aare connected as shown in Fig1.8.(a). When the valve is actuated, the flow is
blocked from going to A as shown in Fig1.8.(b). The complete graphic symbol for the given DCV is
shown in Fig.1.8(c).

1
 A
A

(a)

A
A
F

Spool
P

(b) P

Figure 1.8 2/2 DCV normally opened. (a) Ports A and P are connected when force is not applied (valve
unactuated). (b) Ports A and P are not connected when force is applied
(valve actuated)

1.7.3 Application of 2/2 DCV

A pair of two-way valves is used to fill and drain a vessel. In Fig.1.9(a), valve 1 is shifted to the open
position, while valve 2 remains closed. This fills the vessel. In Fig.1.9(b), valve 2 is shifted to open
position and valve 1 remains closed. This drains the vessel.

2
 Filling vessel
Draining vessel

10 LPM
0 LPM

Valve 2
Valve 1
Valve 1 Valve 2

1.2 bar
10 bar

(a) (b)
Figure 1.9Application of 2/2

1.8Three-Way Direction Control

1.8.1 3/2-Way DCV (Normally Closed)

Three-way valves either block or allow flow from an inlet to an outlet. They also allow the outlet to flow
back to the tank when the pump is blocked, while a two-way valve does not. A three-way valve has three
ports, namely, a pressure inlet (P),an outlet to the system(A)and a return to the tank(T). Figure 1.10shows
the operation of a 3/2-way valve normally closed. In its normal position, the valve is held in position by a
spring as shown in Fig. 1.10(a). In the normal position, the pressure port P is blocked and outlet A is
connected to the tank. In the actuated position shown in Fig. 1.10(b), the pressure port is connected to the
tank and the tank port is blocked.

3
 A

P T
P T

(a)

A
A

Spool P T

P T

(b)

Figure 1.10 3/2-way DCV (normally closed). (a) Ports A and T are connected when force is not
applied (valve unactuated). (b) Ports A and P are connected when force is applied (valve
actuated).
1.8.23/2-Way DCV (Normally Opened)
Figure 1.11 shows a three-way two-position DCV (normally open)with push button actuation and spring
return. In the normal position, shown in Fig. 1.11(a), the valve sends pressure to the outlet and blocks the
tank port in the normal position. In the actuated position, the pressure port is blocked and the outlet is
vented to the tank.

4
 A

P T
T P

(a)

A
A

Spool P T

T P

(b)

(a) Figure 1.11 3/2-way DCV (normally opened). (a) Ports A and P are connected when force is not
applied (valve unactuated). (b) Ports A and T are connected when force is applied (valve actuated).

1.8.3 Applications of 3/2 DCV and 3/3 DCV

3/2 DCV and 3/2 DCV find application in the following ways: Application of 3/2 DCV for controlling
a single-acting cylinder: A 3/2 DCV is used to control a single-acting cylinder. Figure 1.12(a) shows the
valve in its normal position in which the pressure port is blocked and the outlet is returned to the tank.
This allows the force of the to act on the piston and retract the cylinder. The cylinder remains in the
retracted position as long as the valve is in this position. In Fig.1.12(b), the valve position is shifted by the
actuation of the push button. This connects the pressure port P with outlet A and the tank port is blocked.
This applies pump flow and pressure to the piston and the cylinder extends against the light force of the
spring.
1. Application of 3/3 DCV in filling and draining the vessel: A three-way, three-position DCV
may be used to fill and drain a vessel. In this application, the closed neutral is required to hold the
vessel at some constant fluid level(Fig. 1.13).
2. Application of 3/3 DCV in controlling a gravity return single-acting cylinder: A gravity
return-type single-acting cylinder is controlled by a three-way DCV. A third position called
neutral may be desired for its application. This position shown as the center position in the
symbol blocks all these ports. This position holds the cylinder in a mid-stroke position. Many
cylinder applications require this feature. Figure 1.14 introduces another type of actuation manual
lever and detent. A detent is a mechanism that holds the valve in any position into which it is
shifted. The detented valve has no normal position because it remains indefinitely in the last
position indicated. When the valve is in the closed neutral position or the retract position, the
pump flow goes over the pressure relief valve because the pressure port is blocked.
3. Application of 3/2-way valve for controlling a double-acting cylinder: Double-acting
cylinders can be controlled with two 3/2-way valves so arranged that when one valve pressurizes
one end of the cylinder, the other valve exhausts the other end and vice versa(Fig. 1.15).

5
 Figure 1.12Application of 3/2 valve–control of single-acting cylinder:(a) return; (b) extend.

0 LPM 10 LPM 12 LPM

100 bar 2 bar 1.1 bar

(a) (b) (c)

Figure 1.13Application of 3/2 valve–filling and draining a vessel: (a) hold; (b) fill; (b) drain.

6
 Figure 1.14Application of 3/2 valve –controlling a double-acting cylinder.

0.001 LPM 12 LPM

10 LPM

12 bar 1.1 bar

(a) (b) (c)

Figure 1.15Application of 3/3 valve –controlling a single-acting cylinder.

1.9Four-Way Direction Control Valves

Four-way DCVs are capable of controlling double-acting cylinders and bidirectional motors. Figure 1.16
shows the operation of a typical 4/2 DCV. A four-way has four ports labeled P,T,A and B. Pis the
pressure inlet and T is the return to the tank; A and B are outlets to the system. In the normal position,
pump flow is sent to outlet B. Outlet A is connected to the tank. In the actuated position, the pump flow is
sent to port A and port B connected to tank T. In four-way DCVs, two flows of the fluids are controlled at
the same time, while two-way and three-way DCVs control only one flow at a time. Figure 1.16 (c) shows
the complete graphic symbol for a four-way two-piston DCV.

7
 A B

A B

A
Spool
P T

P T

A B A B

P T
Spool

P T

Figure 1.16Four-way DCV.

1.9.1 Applications of 4/2 DCV and 4/3 DCV

4/2 DCV and 4/3 DCV find applications in the following ways:
1. Application of 4/2-way valve to control a double-acting cylinder: A four-way DCV is used to
control a double-acting cylinder. When the valve is in the normal position, the pump line is
connected to the end of the cylinder and the blind end is connected to the tank as shown in
Fig.1.17(a). The cylinder retracts when the cylinder is in this position. When the cylinder is fully
retracted, the pump flow goes over to the pressure relief valve and back to the tank. In
Fig.1.17(b), the pump line is connected to the blind end of the cylinder and the rod end is
connected to the tank. This causes the cylinder to extend. When the cylinder is fully extended, the
pump flow again goes over the pressure relief valve to the tank.

8
 -50 LPM 40 LPM
Full flow

3 bar 1.7 bar

(a) (b)

Figure 1.17Application of a 4/2-way valve – control of single-acting cylinder: (a) return; (b) extend.

2. Application of 4/2 DCV for controlling bi-directional motors: A four-way DCV is also used to
control bi-directional hydraulic motors. Figure 1.18shows the schematic for this application.
Unlike the cylinder, the motor rotates continuously and does not force the fluid over the pressure
relief valve.

9
 -50 LPM 40 LPM

11 bar
13 bar

(a) (b)

Figure 1.18Application of 4/2-way valve – control of a bi-directional motor.

The four-way, two-position DCVs used in the previous two applications are sometimes impractical
because they continually send pump flow and pressure to the actuator in one direction or the other. Many
cylinder and motor applications require a third DCV position or neutral in which the actuator is subjected
to pump pressure. Four-way three-position circuits are therefore used in many hydraulic circuits. Many
types of neutrals are available; the most common of them are as follows:

 Closed neutral.
 Tandem neutral.
 Float neutral.
 Open neutral.
 Regenerative neutral.

3. Application of 4/3 DCV (closed neutral) for controlling a double-acting cylinder: Figure 1.19
shows it in a simple cylinder circuit. The valve shown here is spring centered, which means that it
always returns to the neutral position automatically when not actuated. For closed neutral, the
pump line is blocked so that the flow must pass over the pressure relief valve the pressure is at the
system maximum. This is wasteful thing because it generates power in the form of pressure and
flow, but does not use it. The wasted energy in the system goes as heat. This is undesirable
because the hydraulic fluid becomes thinner (less viscous) as it heats up. When the fluid becomes

10
 too thin, it does not lubricate effectively. This is the result of increased wear.The outlet lines to
the cylinder are blocked, so the cylinder is held trimly in position. This is because the lines are
full of hydraulic fluid that is incompressible. This type of neutral could also be used to control a
motor. Just like cylinder, the motor is held tired in position when the valve is in the neutral.

0 LPM

30 bar

Figure 1.19Application of 4/3-way valve – closed neutral.

4. Application of 4/3 DCV (tandem neutral) for controlling a double-acting cylinder: Figure
1.20 shows it in a simple cylinder circuit. The pump flow is allowed to flow back to the tank
through the DCV when it is in the neutral. This is a very desirable situation because only pressure
in the pump line is due to the flow resistance of the lines and DCV. This keeps the pressure low
when the valve is in the neutral. In this situation, the system is said to be unloaded because the
power consumption is reduced. This wastes much less energy than does a closed central neutral
that forces the fluid over the pressure relief valve at a high pressure. The cylinder is held in
position with a tandem neutral because the outlet port is blocked.

11
 0 LPM 0 bar

1.05bar

Figure 1.20 Application of 4/3-way valve – tandem neutral.

5. Application of 4/3 DCV (float neutral) for controlling a bidirectional motor: Figure 1.21
shows a four-way with a float neutral controlling a bidirectional motor. The pressure port is
blocked so that the pump flow is forced over the pressure relief valve. Because both the outlets
are connected to the tank, the motor floats or spins freely when the DCV is in the neutral. This
type is used in motor circuits because it allows the motor to spin to a stop when the valve is
shifted to the neutral. This is often preferable to shifting to a closed position because motors often
build up a great deal of momentum. Shifting the valve closed in this situation causes a large
pressure hike in the outlet line because the motor tends to keep spinning and tries to push the fluid
into its outlet. This is known as shifting shock. Float neutrals are often desirable for cylinder
circuits in some applications.

12
 0 LPM

200 bar

Figure 1.21 Application of 4/3-way valve – floating neutral.

6. Application of 4/3 DCV (open neutral) for controlling a double-acting cylinder: Figure 1.22
shows the four-way with an open neutral controlling a cylinder. Flow always follows the path of
least resistance, so the pump flow goes back to the tank. Because the outlets are also connected to
the tank, the cylinder floats when this valve is in neutral. This is desirable in a circuit in which
some external force must position the cylinder when in the neutral.

13
 0 LPM 1.3 bar

1.5bar

Figure 1.22 Application of 4/3-way valve – open neutral.

Application of 4/3 DCV (regenerative neutral) for controlling a double-acting cylinder: A

regenerative neutral is considerably different in its function than other types. A regenerative term is used
to describe a system in which the waste is fedback into the system to supplement the input power. In this
neutral, the pressure port is connected to both outlets and the tank port is blocked. Figure 1.23 shows a
four-way with a negative neutral controlling a cylinder. When this valve is shifted to the neutral, the
pump pressure is applied to both sides of the piston. Because the piston area in the rod side of the cylinder
is smaller than that on the blind side, there is a net force applied to extend the piston rod. As the piston
extends, it forces the outlet flow from the rod side back into the valve, where it combines with the pump
flow and goes to the blind end of the cylinder. This causes the considerable increase in cylinder speed.
This is the purpose of the regenerative neutral that instead of sending the return flow back to the tank, it
sends it into the inlet side of the cylinder, thereby increasing its speed.

14
 50 LPM

37 bar

Figure 1.23 Application of 4/3-way valve – regenerative neutral.

1.10 Solenoid-Actuated Valve

A spool-type DCV can be actuated using a solenoid as shown in Figure. 1.24. When the electric coil
(solenoid) is energized, it creates a magnetic force that pulls the armature into the coil. This causes the
armature to push on the push pin to move the spool of the valve.
Like mechanical or pilot actuators, solenoids work against a push pin, which in turn actuates a spool.
There are two types of solenoid designs used to dissipate the heat developed in electric current flowing in
the coil. The first type dissipates the heat into surrounding air and is referred to as an “air gap solenoid.”
In the second type “wet pin solenoid,” the push pin contains an internal passage way that allows the tank
port oil to communicate between the housing of the valve and the housing of the solenoid. Wet pin
solenoids do a better job in dissipating heat because the cool oil represents a good heat sink to absorb heat
from the solenoid. As the oil circulates, the heat is carried into the hydraulic system where it can be easily
dealt with.

15
 1. When the 2. Armature is pulled against the push
coil is pin Coil
Pushpin
energized

3. Push pin moves the Spool Armature

spool
Figure 1.24Solenoid valve.

In the case of direct current (DC) solenoids, the current develops a magnetic field of fixed polarity. The
DC solenoids are practically safe from burning out if the correct voltage is applied. The solenoid force
depends not only on the solenoid design and current but also on the core position. The available
commercial solenoids produce a force of 60–70 N. For a greater force, the number of turns of coil or
current should be increased.
Alternating current (AC) solenoids function in the same manner as DC solenoids but their magnetic
fields are influenced by the alternating current. The magnetic force is high when AC current is at its
positive or negative peak. As the current changes from positive to negative, it must pass through neutral
points where there is no current or no force. Due to this, load can push the core slightly out of
equilibrium. This is commonly referred to as buzz. To eliminate buzz, shading coils are used. A shading
coil creates its own magnetic field but the current produced lags behind the coil current and thus helps to
prevent buzz. A comparison between AC and DC solenoids is given in Table 1.3.
Table 1.3Comparison between AC and DC solenoids
Parameter DC Solenoid AC Solenoid

Switching time 50–60 ms 20 ms

Service life expectations 20–50 million cycles 10–20 million cycles
Max. switching frequency Up to 4 cycles/s Up to 2 cycles/s
Continuous operation Unlimited 15–20 min for dry solenoids. 60–
80 min for wet solenoids
Relative cost 1 1.2
Occurrence rate 10 2

1.11Pilot-Operated Direction Control Valves

Pilot-operated DCVs are used in a hydraulic system operating at a high pressure. Due to the high pressure
of the system, the force required to actuate the DCV is high. In such systems, operation at a high pressure
uses a small DCV that is actuated by either a solenoid or manually. This pilot DCV in turn uses the
pressure of the system to actuate the main DCV as shown in Figure. 1.25.

16
 Main valve

Pilot valve

Figure 1.25 Pilot-operated DCVs.

17
 Lecture 17
DIRECTIONAL CONTROL VALVE [continued]

1.11.1 Applications of Pilot-Operated Valve to Control the Table of a Surface Grinder

Figure 1.26shows the application of a pilot-operated DCV where the actuation of a double-acting cylinder
is used to reciprocate the table of a surface grinder. The table is fitted with adjustable stops as shown in
the figure. The pilot valve is a DCV that is actuated by a push button. During the operation when stop S 1
hits push button B1, the pilot valve sends a pilot signal to the main valve to shift the configuration shown
in the right envelope of the main valve. This actuates the double-acting cylinder to extend. At the end of
the extension, stroke S2 hits push button B2, which causes the pilot signal directions to be reversed. Due to
this change in the pilot signal direction, the main valve moves to the configuration shown in the left
envelope of the main valve. This in turn actuates the double-acting cylinder to retract.
Thus, a pilot valve controls a main valve and the main valve used to control the double-acting cylinder.

Workpiece

Table

S1 S2
B1 B2
Pilot valve

Main valve

Electric motor

Figure 1.26 Application of pilot-operated DCVs.

1.12Piston Overlap
The switching characteristics of a valve are decided by the piston overlap. A distinction is made between
the positive, negative and zero overlap. Overlap is defined as the longitudinal difference between the

1
length of land and that of the port. The magnitude of overlap changes during unoperated and operated
conditions.
The piston overlap determines the oil leakage rate. Overlapping is significant for all types of valve. The
most favorable overlap is selected in accordance with the application.

1. Positive switching overlap: During the reversing procedure, all parts are briefly closed against
one another. Hence, switching imparts “pressure peaks” and make hard advance.
2. Negative switching overlap: During the reversing procedure, all ports are briefly interconnected.
Pressure collapses briefly (load drops down).
3. Zero overlap: Edges meet. Important for fast switching, short switching paths.
4. Pressure advanced opening: The pump is first of all connected to the power componentand then
the power component is discharged into the reservoir.
5. Outlet advanced opening:The outlet of the power component is first discharged to the reservoir
before the inlet is connected to the pump.

(a) (b) (c)

Figure 1.27Valve overlap: (a) Positive overlap; (b) negative overlap; (c) zero overlap.

1.12Miscellaneous Industrial Circuits

This section examines some simple circuits that are commonly used in industry. This will help the reader
to develop the ability to read hydraulic schematics and to understand the operation of basic circuits.
Figure1.28shows a circuit in which a cylinder is used to raise and lower a large weight from above. The
cylinder is controlled by a four-way DCV with a tandem neutral. In Fig. 1.28(a), the DCV is in the
neutral.Therefore, the pump flow is unloaded to the tank at a low pressure. The cylinder should hold
position because the outlet ports from the DCV that connect to the cylinder are blocked. It does not hold
position, however, if the cylinder is in the orientation shown because the weight pulls the cylinder down,
causing pressure in the rod end line. The pressure causes a small amount of leakage within the DCV, and
the cylinder begins to creep downward. This can be remedied by placing a pilot-to-open check valve in
the rod end line, as shown. The pilot-to-open check valve does not allow flow out of the rod end of the
cylinder unless pressure is applied to the pilot line, thereby preventing cylinder creep. The check acts to
counterbalance the weight. When the DCV is shifted to extend the cylinder (lowering the weight), the
pump pressure from the blind end line holds open the check and allows flow to return to the tank from the
blind end. When the cylinder is retracted (the weight is raised), flow from the pump goes through the
check to the rod end. The check has no effect in this direction.

2
 1000 N 1000 N 1000 N
40 LPM -29 LPM
0 LPM 0 LPM -53 LPM 40 LPM

6 bar 1.05 bar

4.5
bar
80 bar 80 bar
80 bar

(a) (b) (c)

Figure 1.28 Raising and lowering large weights: (a Extend cylinder; (b) hold cylinder; (c) return cylinder.

Figure1.29 shows a circuit that utilizes a shuttle valve. This circuit allows either of the two three-way
buttons to operate a single-acting cylinder. The figure shows both three-ways in their normal positions.
The cylinder is vented to the tank and remains retracted under the force of the spring. In Fig. 1.30, three-
way number 1 is shifted and pump flow is sent to the cylinder through the path shown. In Fig. 1.31, the
cylinder is extended with valve number 2. This circuit could be used on a long machine with buttons on
either end for convenience. A shuttle valve is used in many other applications in which one of two flow
paths may supply a single branch of circuit.

3
 DCV 1 DCV 2

400 bar

Figure 1.29Use of shuttle valves to control single-acting cylinders(return).

4
 DCV 1 DCV 2

2 bar

Figure 1.30Use of shuttle valves to control single-acting cylinders (forward).

5
 DCV 1 DCV 2

Figure 1.31 Use of shuttle valves to control single-acting cylinders (forward).

Figure1.32 shows a regenerative circuit that automatically switches off regeneration when full force is
necessary. This circuit could be used in a hydraulic press where the cylinder must extend quickly under
no load, then bottoms out and must apply full force to the work piece. Instead of using a four-way with a
regenerative neutral, this circuit uses a four-way DCV in conjunction with a three-way, pilot-operated
DCV. The three-way is shifted when sufficient pressure is applied to its pilot line, which is connected to
the blind end of the cylinder. In the figure, the four-way is shifted to the left position and flow is sent to
the blind end of the cylinder. Because the cylinder is not loaded, the pressure in the blind end is very low
and is not sufficient to shift the three-way. The flow from the rod end combines with the pump flow,
causing the cylinder to extend rapidly. When the cylinder bottoms out, pressure immediately builds up in
the blind end line to the relief valve setting because there is no other path for pump flow. The three-way
valve is then shifted into the left position and pressure is relieved from the rod side because it is
connected to the tank port. The pressure is then applied to the blind sidethat causes full force to be applied
to the work piece. When the four-way DCV is shifted into the right position, the cylinder retracts at a
normal speed. In this circuit, the reduction in force capability caused by regeneration is not an issue
because during the regeneration portion of the cycle, the cylinder is not loaded. The primary advantage of
using regeneration is that a smaller pump can be purchased that is less expensive to buy and operate.

6
Figure 1.32 Regenerative circuit (position 1).

Figure 1.33 Regenerative circuit (position 2).

7
 Figure 1.34 Regenerative circuit (position 3).

1.13Direction Control Valve Mounting

DCVs can be mounted in two ways:

1. Inline: There are threaded connections in the valve itself. Fittings are screwed directly into the
valve. This method has several major disadvantages:

 Each time the valve is disconnected; there is a probability of damaging the valve by stripping the
threads.
 The threads wear each time the unit is disconnected, causing contamination and increased
probability of leakage.

2. Sub-plate: The bottom of the valve has unthreaded connections. The valve is then attached to a
sub-plate that has matching connections. The sub-plate has threaded connections to which the
fittings are attached. Sealing at the valve interface is by using O-rings, which fit into small
recesses around the DCV port. The advantages are as follows:

 The sub-plate has less leakage, less contamination and a smaller probability of doing damage
during assembly and disassembly.
 Valve replacement is simpler and easier.
 Multiple valves can be connected on a manifold.

The valves and sub-plates are available with several standard patterns for the valve ports.

8
 Figure 1.35 DCV mountings.

A manifold is a sub-plate that has connection for two or more valves. This method can be used to create
an integrated hydraulic circuit in which many connections are inside the manifold itself, eliminating the
need for fittings and plumbing between the valves. The advantages are a more compact design, less
leakage, less contamination, easy replacement of valves, etc. The only drawback is that it requires more
design and testing time thereby increasing the expense.

Figure 1.36 DCV mounting manifold.

Cartridge valves are also used in conjunction with manifolds. They are very compact and alternative to a
spool-type design. They screw directly into a cavity in a manifold and therefore do not require a separate
valve port and mounting holes. The advantages of manifold circuits are magnified when cartridge valves
are used. ******
1.8DCVSpecifications

9
The most critical specification when selecting a DCV is its maximum pressure and flow ratings. It is
common for a high pressure rating to be given for the pressure and outlet ports and a lower value to tank
port. Ratings of 3000–5000 psi are typical for the former, while the latter has ratings of 500–1000 psi.
The different ratings are because the spool seal is often exposed to the tank port, but no other ports.
Valves that can handle a high pressure to all of their ports are also available. Operating above the
maximum pressure rating leads to increased leakage and also permanent damage to the valve.
The flow rate is largely determined by the size of the valve itself. Larger valves can handle larger flow
rates but are heavy and expensive. Standard valves have ratings 10–250 GPM. Operating a DCV above its
maximum flow rating most likely results in a large pressure drop across the valve. This lost energy is
converted into heat and is not wasteful, but leads to increased component wear as the oil becomes thinner
and doesnot lubricate. Operating above the maximum flow rating leads to permanent damage to the valve
itself.
When selecting a DCV for an application, we may also know what the pressure drop will be across the
valve at a particular flow rate. Manufacturers typically provide graphs that relate pressure drop to flow
rate through valve for each model. Separate curves are given for different port-to-port connections. These
curves represent data for a particular fluid and viscosity, most commonly standard hydraulic oil at 100
SSU. Manufacturers often give a correction factor for fluids at other viscosities. A fluid with a higher
viscosity has a higher pressure drop at a given flow rate because a thicker fluid is more difficult to move
through the valve.

1.9Material for DCVs

Following are the materials for DCVs:

1. Valve body: It is made of carbon steel, ductile cast iron and stainless steel. Aluminum alloys are
also preferred for low-pressure applications. High-strength aluminum alloys are used for aircraft
applications. Stainless steel is used for corrosive environment. Sometimes plastics are also used
for low-temperature applications.
2. Valve spool: It is made of hardened steel, ground and polished 15 Ni2Cr1Mo15 of hardness 60-
62 HRC, machined to 2–3 µm tolerance. Valve spool bore clearance is usually in the order of 5–
10 µm.

Example 1 A cylinder with a bore diameter of 7 cm and a rod diameter of 3.125 cm is to be used in a
system with a 45 LPM pump. Use the graph in Fig. 1.36to determine the pressure drops across the DCV
when the cylinder is retracting (P->B,A->T).

Solution
The flow from P to B is the pump flow into the rod end, so this can be read from the graph
p =3.2 bar (approx.)
The flow from A->T is the return flow out of the blind end. This flow rate is greater than the pump flow
and must be determined by the following method:
(a) Calculate the piston area:
  2
Ap = 2
( DP )  (7 )  38.5 cm
2

4 4
(b) Calculate the rod area:
 
AR  ( DR 2 )  (3.1252 )  7.7 cm2
4 4
(c) Calculate the return flow:

10
 Qpump
Qreturn, R   Ap
Ap  AR
Qpump
  38.5
38.5  7.7
 1.25  45
 56.25 LPM
The flow from A to T can now be read from the graph
p =6.2 (approx.)

13.5
P-T
12.0
10.5

9.0
A – T, B - T
Pressure drop in bar

7.5

6.0
P – A, P – B
4.5

3.0

1.5

7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Flow in LPM
Figure 1.36

Example 2 Derive an expression to estimate leakage through the spool and housing bore for concentric
leakage path. Refer Fig.1.37and the description of symbols.

d
L r
r

Figure 1.37

11
Solution
The typical pressure in the hydraulic system is in the order of 700–800 bar. The internal leakage is one of
the major problems and it results from wear of the components. Figure 1.37shows the internal leakage
through a radial clearance between two concentric cylindrical bodies, a spool and sleeve, for example.
Let
a  Constant (m/s)
c  Radial clearance (m)
D  Spool diameter (m)
Fp  Pressure force acting on the fluid element (N)
Fr  Shear force acting on the fluid element (N)
QL  Leakage flow rate (m3 /s)
L  Length of the leakage path (m)
c  Radial clearance from the midpoint of gap (m)
RL  Resistance to leakage (Ns/m5 )
y  Distance between the element side surface and solid boundary (m)
p  Pressure drop across the radial clearance (Pa)
Assuming the steady-state flow and forces at equilibrium, we can write the following:
The pressure force is Fp  2r Ddp
The frictional force is Fr  2 Ddx
Also,
r  0.5c  y
du du

dy dr
From Newton’s law of viscosity,
du du
   
dy dr
Fp  Fr
du r dP r dP
  or du   dr
dr dx  dx
dP
The pressure gradient  constant
dx
dP P
 , where P  P1  P2
dx L
The velocity distribution in the radial clearance is found by integrating
r dP
du   dr
 dx
r dP r 2 dP
u dr  a  a 
 dx 2 dx
Applying boundary conditions,
1 P  c 2 2
u  r 
2 L  4 
The leakage flow rate

12
 c
2
 D c3 P
QL   Ddr 
c 12 L
2

12 LQL
P   RL  QL
 D c3
It is important to note that leakage is inversely proportional to the viscosity and directly proportional to
the cube of the radial clearance. If the radial clearance is doubled due to wear, the internal leakage
increases eight times. The power loss due to leakage is given by
N  QL  P
 D c3 P 2

12 L
P 2
  RL  QL 2
RL
The internal leakage reduces the effective flow rates and increases the power losses. The dissipated power
is converted to heat and leads to serious oil overheating problems. Therefore, it is important to keep the
oil viscosity within the predetermined limits over the whole operating temperature range. This is done by
using hydraulic oils of convenient viscosity index and implementation of oil coolers.

Example 3 Write an expression to estimate leakage through spool and housing bore for eccentric leakage
path. Refer Fig.1.38and the description of symbols. Compare with concentric leakage path and comment.

Figure 1.38

Solution
In the case of eccentric mounting, the radial clearance is not constant and the flow rate is given by

13
  D c3 P  3    
3

QL   1    
12 L  2  c  

This is highly significant finding because if the inner cylinder just touches the outer cylinder, the flow rate
is increased by 2.5 times the valve with the concentric cylinders assuming the same pressure drop.

Example 4 The land in a spool valve separates two fluid passages. The land has a 25mm length and
18.7325 0.005mm diameter and operates in a 18.75 0.01 mm bore. We assume that the spool is
concentric. The pressure difference across the land is 20.68 MPa. Calculate the leakage flow rate past this
land for minimum, nominal and maximum leakage conditions assuming a fluid with minimum, nominal
and maximum viscosities of 5.84, 32.1 and 800 mm2/s.

Solution
The minimum height of the passage is achieved for the maximum diameter of the spool and the minimum
diameter of the bore
(18.75  0.01)  (18.7325  0.005)
cmin   0.00125 mm
2
Thenominal height of the passage is achieved when both the spool and bore have their nominal
dimensions
(18.75)  (18.7325)
cnom   0.00875 mm
2
Themaximum height of the passage is achieved for the minimum diameter of the spool and the maximum
diameter of the bore
(18.75  0.01)  (18.7325  0.005)
cmax   0.01625 mm
2
Conversion of viscosity
2
cSt (mm /s) cP Ns/m2
(SG = 0.9) Pascal seconds
5.84 5.256 0.005256
32.1 28.89 0.02889
880 792 0.792
Case 1: Minimum height of the passage
 D c3 P
Qmin 
12 L
 (0.01875) (0.00125  103 )3  20.68  106

12  0.005256  0.0025
 1.5088  108 m3 /s
Case 2: Nominal height of the passage
 D c3 P
Qnom 
12 L
 (0.01875) (0.00875 103 )3  20.68  106

12  0.02889  0.0025
 9.4146  107 m3 /s

14
Case 3: Maximum height of the passage
 D c3P
Qmax 
12 L
 (0.01875) (0.01625103 )3  20.68 106

12  0.792  0.0025
7
 2.199 10 m3 /s

Review Questions

1. Explain briefly the function of DCVs.

2. Draw a schematic of 4/3 DCV that is direct operated electrically and briefly explain its function.
3. Draw a schematic of 3/2 DCV that is manually operated and briefly explain its function.
4. State the different ways of control of DCVs.
5. How are DCVs classified?
6. Explain the construction and operation of electric solenoids and compare the DC and AC solenoids.
7. Cite the classification of check valves and explain the function of pilot-operated check valve, giving the
necessary drawing.
8. What is the difference between an open-center and closed-center type of DCV?
9. What is a shuttle valve? Name one application.

Objective-Type Questions
Fill in the Blanks

1. A valve is a device that receives an external signal to release, ------ the fluid that flows through it.
2. DCVs determine-----through which a fluid transverses a given circuit.
3. A check valve allows flow in --------, but blocks the flow in the opposite direction.
4. In 4/3 DCV,for-------- the pump line is blocked so that the flow must pass over the pressure relief valve
the pressure is at the system maximum.
5. In 4/3 DCV, for float neutral,the ------- is blocked and the outlet is connected to the tank.
6. In 4/3 DCV, for open neutral, the pressure port and the outlets are both connected to the ----.

State True or False

1. Pressure control valves protectthe system against overpressure, which may occur due to a sudden surge.
2. A pilot-operated check valve always permits flow in one direction only.
3. A shuttle valve allows two alternate flow sources to be connected in a one-branch circuit.
4. In 4/3 DCV, tandem neutral, the pump flow is allowed to flow to the system.
5. The purpose of the regenerative neutral is that instead of sending the return flow back to the tank, it
sends it into the inlet side of the cylinder, thereby decreasing its speed.

Answers
Fill in the Blanks

15
 1.Stop or redirect
2.Path
3.Only one direction
4.Closed neutral
5.Pressure port
6. Tank

State True or False

1.True
2.False
3.True
4.False
5.False

16
 Lecture 18
PRESSURE-CONTROL VALVES
Learning Objectives

Upon completion of this chapter, the student should be able to:

 Explain various functions of pressure-control valves.
 Explain various classifications of pressure-control valves.
 Describe the working construction of various pressure-control valves.
 Differentiate between a pressure relief valve, a pressure-reducing valve, a sequence valve and an
unloading valve.
 Identify the graphic symbols for various types of pressure-control valves.
 Explain different applications of pressure-control valves.
 Explain the working principle of solenoid-actuated valves.
 Calculate the pressure loss in pressure relief and unloading valves.
 Evaluate the performance of hydraulic systems using pressure-control valves.

1.1 Introduction

Hydraulic energy is produced as long as the prime mover (usually an electric motor) drives the pump, and
hydraulic pressure develops by resistance to pump flow.Hence, the hydraulic system suffers damage if the
pump flow is not stopped or off loaded (recirculate) back to the tank during non-action periods of the
circuit.Non-action periods arise from stalling an actuator, or by reaching the end of the stroke or the
circuit sequence, or during the time-delay periods of the circuit sequence.

In order to avoid hydraulic system damage, power wastage and overheating of the hydraulic fluid, circuit
designers use a variety of cleverly designed systems to control maximum system pressure and pump flow
during non-action periods.
Pressure-control valves are used in hydraulic systems to control actuator force (force = pressure × area)
and to determine and select pressure levels at which certain machine operations must occur.Pressure
controls are mainly used to perform the following system functions:

 Limiting maximum system pressure at a safe level.

 Regulating/reducing pressure in certain portions of the circuit.
 Unloading system pressure.
 Assisting sequential operation of actuators in a circuit with pressure control.
 Any other pressure-related function by virtue of pressure control.
 Reducing or stepping down pressure levels from the main circuit to a lower pressure in a
sub-circuit.

Pressure-control valves are often difficult to identify mainly because of the many descriptive names given
to them. The function of the valve in the circuit usually becomes the basis for its name. The valves used
for accomplishing the above-mentioned system functions are therefore given the following names:

 Pressure-relief valve.
 Pressure-reducing valve.
 Unloading valve
 Counterbalance valve.
  Pressure-sequence valve.
 Brake valve.
1.2 Pressure-Relief Valves

Pressure-relief valves limit the maximum pressure in a hydraulic circuit by providing an alternate path for
fluid flow when the pressure reaches a preset level. All fixed-volume pump circuits require a relief valve
to protect the system from excess pressure. Fixed-volume pumps must move fluid when they turn. When
a pump unloads through an open-center circuit or actuators are in motion, fluid movement is not a
problem. A relief valve is essential when the actuators stall with the directional valve still in shifted
position.

A relief valve is similar to a fuse in an electrical system. When circuit amperage stays below the fuse
amperage, all is well. When circuit amperage tries to exceed fuse amperage, the fuse blows and disables
the circuit. Both devices protect the system from excess pressure/current by keeping it below a preset
level. The difference is that when an electrical fuse blows, it must be reset or replaced by maintenance
personnel before the machine cycles again. This requirement alerts electrician’sabouta possible problem
before restarting the machine. Without the protection of a fuse, the electrical circuit would finally
overheat and start a fire.

Similarly, in a hydraulic circuit, a relief valve opens and bypasses fluid when pressure exceeds its setting.
The valve then closes again when pressure falls. This means that a relief valve can bypass fluid anytime,
or all the time, without intervention by maintenance. Many fixed-volume pump circuits depend on this
bypassing capability during the cycle, and some even bypass fluid during idle time. A well-designed
circuit never bypasses fluid unless there is a malfunction, such as a limit switch not closing or an operator
over-riding the controls. This eliminates most overheating problems and saves energy.
There are two different designs of relief valves in use: direct-acting and pilot-operated. Both types have
advantages and work better in certain applications.

1.2.1 Simple Pressure-Relief Valve

The most widely used type of pressure control valve is the pressure-relief valve because it is found in
practically every hydraulic system. Schematic diagram of simple relief valve is shown in Fig. 1.1 and
three-dimensional view is shown in Fig. 1.2. It is normally a closed valve whose function is to limit the
pressure to a specified maximum value by diverting pump flow back to the tank. A poppet is held seated
inside the valve by a heavy spring. When the system pressure reaches a high enough value, the poppet is
forced off its seat. This permits flow through the outlet to the tank as long as this high pressure level is
maintained. Note the external adjusting screw, which varies spring force and, thus, the pressure at which
the valve begins to open (cracking pressure)(Fig. 1.3).
It should be noted that the poppet must open sufficiently to allow full pump flow. The pressure that exists
at full pump flow can be substantially greater than cracking pressure. The pressure at full pump flow is
the pressure level that is specified when referring to the pressure setting of the valve. It is the maximum
pressure level permitted by the relief valve.
Pressureport Adjustment screw

Pressure
port

Tank port Spring

Figure1.1 Simple pressure-relief valve.

Figure 1.2Three-dimensional view of simple pressure-relief valve.

Flow pump flow pressure

Cracking pressure
Pressure

Full pump flow

Flow through the relief

valve
Figure 1.3Characteristics of a relief valve.
If the hydraulic system does not accept any flow, then all the pump flow must return to the tank via the
relief valve. The pressure-relief valve provides protection against any overloads experienced by the
actuators in the hydraulic system. Of course, a relief valve is not needed if a pressure-compensated vane
pump is used. Obviously one important function of a pressure-relief valve is to limit the force or torque
produced by hydraulic cylinders or motors.
The main advantage of direct-acting relief valves over pilot-operated relief valves is that they respond
very rapidly to pressure buildup. Because there is only one moving part in a direct-acting relief valve, it
can open rapidly, thus minimizing pressure spikes.

1.2.2 Compound Pressure Relief Valve(Pilot-Operated Pressure Relief Valve)

A pilot-operated pressure-relief valve consists of a small pilot relief valve and main relief valve as shown
in Fig. 1.4. It operates in a two-stage process:

1. The pilot relief valve opens when a preset maximum pressure is reached.
2. When the pilot relief valve opens, it makes the main relief valve open.

Figure 1.4Compound relief valve.

The pilot-operated pressure-relief valve has a pressure port that is connected to the pump line and the tank
port is connected to the tank. The pilot relief valve is a poppet type. The main relief valve consists of a
piston and a stem. The main relief piston has an orifice drilled through it. The piston has equal areas
exposed to pressure on top and bottom and is in a balanced condition due to equal force acting on both the
sides. It remains stationary in the closed position. The piston has a light bias spring to ensure that it stays
closed. When the pressure is less than that of relief valve setting, the pump flow goes to the system. If the
pressure in the system becomes high enough, it moves the pilot poppet off its seat. A small amount of
flow begins to go through the pilot line back to the tank. Once flow begins through the piston orifice and
pilot line, a pressure drop is induced across the piston due to the restriction of the piston orifice. This
pressure drop then causes the piston and stem to lift off their seats and the flow goes directly from the
pressure port to the tank.
The advantages of pilot-operated pressure-relief valves over direct-acting pressure-relief valves are as
follows:
 1. Pilot-operated pressure-relief valves are usually smaller than direct-acting pressure-relief
valves for the same flow and pressure settings.
2. They have a wider range for the maximum pressure settings than direct-acting pressure-
relief valves.
3. They can be operated using a remote while direct-acting pressure-relief valves cannot.

Graphic symbol of a pressure-relief valve is shown in Fig. 1.5. The symbol shows that the valve is
normally closed (the arrow is offline). On one side of the valve, pressure is fed in (the dashed line) to try
to open the valve, while on the other side, the spring tries to keep it adjustable, allowing the adjustment of
pressure level at which the relief valve opens. The arrow through the spring signifies that it is adjustable,
allowing the adjustment of pressure level at which the relief valve opens.

Figure 1.5Symbolic representation of a simple pressure-relief valve.

Example 1.1

A pressure-relief valve has a pressure setting of 140 bar. Compute the kW loss across this valve if it
returns all the flow back to the tank from a 0.0016 m3 / s pump.

Solution: We have

kW power  pQ
 (140 105 )  (0.0016 103 )
 22.4 kW

Example 1.2

A pressure-relief valve contains a poppet with an area of 4.2 cm2 on which the system pressure acts.
During assembly, a spring with a spring constant of 3300 N/cm is installed in the valve to hold the poppet
against its seat. The adjustment mechanism is then set so that the spring is initially compressed to 0.5 cm
from its free-length condition. In order to pass full pump flow through the valve at the pressure-relief
valve pressure setting, the poppet must move 0.30 cm from its fully closed position.
(a) Determine the cracking pressure.
(b) Determine the full pump flow pressure (pressure-relief valve pressure setting).
(c) What should be the initial compression of the spring in pressure-relief valve if the full pump flow is to
be 40% greater than the cracking pressure?
Solution:
(a) Cracking pressure:

Force required to fully close is the product of initial displacement and spring constant
Fvalve closed  K Sinitial  3200 N/cm  0.50 cm  1600 N
Now we can calculate the cracking pressure knowing the cracking force

pcracking Apoppet  1600 N

 pcracking (4.20 104 m2 )  1600 N
 pcracking  381104 N/m2  3.81 MPa
(b) Full pump flow pressure (pressure-relief valve pressure setting):

Force required to fully open is the product of final displacement and spring constant
Ffully open  K Sfully open  3200 N/cm  0.8 cm  2560 N
Now this force must be equal to product of full pump pressure and area of poppet.

pfull pump flow Apoppet  2650 N

 pfull pump flow (4.20 104 m2 )  2650 N
 pfull pump flow  610 104 N/m2  6.10 MPa
(c) Initial compression of spring:
Fvalve closed  K l  3200l  pcracking Apoppet
Now cracking pressure can be calculated as follows

Force 3200 l
pcracking    762 104 l
Area 4.20 104
Also we know that force required to fully open is given by product of full pump flow and area of poppet.

Ffully open  K (l  0.3)

 3200(l  0.3)
 3200l  960
 pfull pump flow Apoppet
Now

3200l  960
pfull pump flow  4
 (762l  229)104
4.20 10

We can now calculate the ratio of pump full flow pressure to cracking pressure as

pfull pump flow (762l  229)104

  1.40
pcracking (762l )104
Solving we get l = 0.75 cm.
Example 1.3

A pressure-relief valve has a pressure setting of 200 bar. Determine the power loss across the valve if all
the pump flow of 120 L/min flows back to the reservoir through this valve.

Solution:
Pump flow Q = 120 L/min = 2 L/s = 0.002 m3 /s
Pressure setting of the valve = 200 bar = 200 × 105 N/ m 2
Therefore, the power loss across the pressure-relief valve is
200  105  0.002
= 40 kW
1000

Example 1.4

A pressure-relief valve contains a poppet with a 3.87 cm2 area on which the system pressure acts. The
poppet must move 0.381 cm from its fully closed position in order to pass pump flow at the pressure-
relief valve setting (full pump flow pressure). The pressure required to overcome the external load is
68.95 bar. Assume that the pressure-relief valve setting is 50% higher than the pressure required to
overcome the external load. If the valve-cracking pressure is 10% higher than the pressure required to
overcome the external load, find the following:
(a) The required spring constant of the compression in the valve.
(b) The required initial compression of the spring from its free length condition as set by the spring
adjustment mechanism of the pressure-relief valve.

Solution:

a) At full pump flow pressure, spring force equals hydraulic force on the poppet: Total spring
compression (S) = Initial compression (L) + Full poppet stroke
 k ( L  0.00381)  4002.5 N
 kL  0.00381 k  4002.5 N
Also at cracking pressure, spring force equals hydraulic force on the poppet. Thus, we have
Spring force= Cracking force
kL  0.00381 k
 1.1  68.95 105 N/m 2  3.87 104 m 2
 2935.8 N
Substituting values of kin kL  0.00381 k  4002.5 N , we get
2935.8  0.00381 k  4002.5 N
 k  279986.22 N/m
(b) From part (a), we have
k  279986.22 N/m
kL  2935.8 N
This implies

279986.22  L  2935.8 N
2935.8
 L m  0.0104 m  1.04 cm  10.4 mm
279986.22
1.3 Pressure-Reducing Valve

The second type of valve is a pressure-reducing valve. This type of valve (which is normally open) is
used to maintain reduced pressures in specified locations of hydraulic systems. It is actuated by
downstream pressure and tends to close as this pressure reaches the valve setting. Schematic diagram of
pressure reducing valve is shown in Fig. 1.6, symbolic representation is shown in Fig. 1.7 and three-
dimensional view is shown in Fig. 1.8.
A pressure-reducing valve uses a spring-loaded spool to control the downstream pressure. If the
downstream pressure is below the valve setting, the fluid flows freely from the inlet to the outlet. Note
that there is an internal passageway from the outlet which transmits outlet pressure to the spool end
opposite the spring. When the outlet (downstream) pressure increases to the valve setting, the spool
moves to the right to partially block the outlet port. Just enough flow is passed to the outlet to maintain its
preset pressure level. If the valve closes completely, leakage past the spool causes downstream pressure to
build up above the valve setting. This is prevented from occurring because a continuous bleed to the tank
is permitted via a separate drain line to the tank.

Adjustable screw

Drain line

Spring

Main
pressure
line

Reduced
pressure
line

No pilot signal Pilot signal

Figure 1.6Pressure-reducing valve.

Reverse free flow through the valve is only possible if the pressure exceeds the valve setting.The valve
then closes, thus making reverse flow impossible. Therefore, pressure-reducing valves are often equipped
with a check valve for reverse free flow.
External forces acting onto a linear actuator increase the pressure between the pressure-reducing valve
and the actuator. In some systems, it is therefore desirable to relieve excess fluid from the secondary
system to the tank in order to maintain a constant downstream pressure, regardless of such external forces.
 Figure1.7 Symbolic representation of a pressure-reducing valve.

A reducing valve is normally open. It reads the downstream pressure. It has an externaldrain.This is
represented by a line connected from the valve drain port to the tank. The symbol shows that the spring
cavity has a drain to the tank.

Figure 1.8 Three-dimensional view of a pressure-reducing valve.

Cylinder 1 Cylinder 2

PRV
Pressure-reducing
valve

Figure 1.9Application of a pressure-reducing valve.

Figure1.9shows an application for a pressure-reducing valve. Here two cylinders are connected in
parallel. The circuit is designed to operate at a maximum pressure p1, which is determined by the relief
valve setting. This is the maximum pressure at which cylinder 1 operates. By the function of the machine,
cylinder2 is limited to pressurep2 (p2<p1).This can be accomplished by placing a pressure-reducing valve
in the circuit in the location shown in Fig. 1.9.If the pressure in the cylinder2 circuit rises above p2, the
pressure-reducing valve closes partially to create a pressure drop across the valve. The valve then
maintains the pressure drop so that the outlet pressure is not allowed to rise above p2 setting.
The disadvantage of this method is that the pressure drop across the reducing valve represents the lost
energy that is being converted into heat. If the pressure setting of the reducing valve is set very low
relative to the pressure in the rest of the system, the pressure drop is very high, resulting in excessive
heating of the fluid. When the hydraulic oil becomes too hot, its viscosity reduces causing increased
component wear.

Example 1.5

The primary part of a circuit is operating at 180 bar. A secondary circuit supplied from the primary circuit
via a pressure-reducing valve requires a constant flow of 30 L/min at 100 bar. Find the power loss over
pressure-relief valve. Comment on the type of cooling.

Solution: The power loss over the pressure-reducing valve is

(180  100)  30
= 4 kW
600
4 kW heat cannot be dissipated by natural cooling and heat exchanger may be required. In practice, the
cost of fitting a heat exchanger and operating costs should be weighed against alternative circuitry such as
a two-pump system.

1.4Unloading Valves
Unloading valves are pressure-control devices that are used to dump excess fluid to the tank at little or no
pressure. A common application is in high-low pump circuits where two pumps move an actuator at a
high speed and low pressure.The circuit then shifts to a single pump providing a high pressure to perform
work.
Another application is sending excess flow from the cap end of an oversize-rod cylinder to the tank as the
cylinder retracts. This makes it possible to use a smaller, less-expensive directional control valve while
keeping pressure drop low.

1.4.1 Direct-Acting Unloading Valve

A direct-acting unloading valve consists of a spool held in the closed position by a spring. The spool
blocks flow from the inlet to the tank port under normal conditions. When a high-pressure fluid from the
pump enters at the external-pilot port, it exerts force against the pilot piston. (The small-diameter pilot
piston allows the use of a long, low-force spring.) When the system pressure increases to the spring
setting, the fluid bypasses to the tank (as a relief valve would function). When the pressure goes above the
spring setting, the spool opens fully to dump the excess fluid to the tank at little or no pressure.

1.4.2 Pilot-Operated Unloading Valve

A pilot-operated unloading valve has less pressure override than its direct-acting counterpart.So it does
not dump part of the flow prematurely.
A pilot-operated unloading relief valve is the same as a pilot-operated relief valve with the addition of an
unloading spool. Without the unloading spool, this valve would function just like any pilot-operated relief
valve. Pressure buildup in the pilot section would open some flow to the tank and unbalance the poppet,
allowing it to open and relieve excess pump flow.

Schematic diagram of unloading valve is shown in Fig. 1.10.In a pilot-operated unloading valve; the
unloading spool receives a signal through the remote-pilot port when pressure in the working circuit goes
above its setting. At the same time, pressure on the spring-loaded ball in the pilot section starts to open it.
Pressure drop on the front side of the unloading spool lowers back force and pilot pressure from the high-
pressure circuit forces the spring-loaded ball completely off its seat. Now there is more flow going to the
tank than what the control orifice can keep up with. The main poppet opens at approximately 20 psi.
Now, all high-volume pump flow can go to the tank at little or no pressure drop and all horsepower can
go to the low-volume pump to do the work. When pressure falls approximately 15% below the pressure
set in the pilot section, the spring-loaded ball closes and pushes the unloading spool back for the next
cycle.

An unloading valve requires no electric signals. This eliminates the need for extra persons when
troubleshooting. These valves are very reliable and seldom require maintenance, adjustment or
replacement.An unloading valve unloads the pump when the desired pressure is reached.It allows rapid
discharge of pressurized oil near atmospheric pressure.As soon as the system pressure reaches the setting
pressure that is available at the pilot port, it lifts the spool against the spring force.When the spool is held
by the pilot pressure, the delivery from the pump goes to the tank.An unloading valve is used to perform
operations such as stamping, coining, punching, piercing, etc.

Adjustable screw

Drain line

Spring

Main
pressure
line

Reduced
pressure
line

No remote pilot signal Remote pilot signal

Figure 1.10Unloading valve.

 Cylinder

4/3 DCV (solenoid operated)

CV1

Pressure relief
CV2 valve

Pressure
unloading
valve

Low-pressure High
high-flow pump pressure
low flow
pump

Figure1.11Application of unloading valve in a punching press (high–low circuit).

Figure1.11shows the application of unloading valve in a punching press. It is a circuit that uses a high-
pressure, low-flow pump in conjunction with a low-pressure, high-flow pump. In a punching press, the
hydraulic cylinder must extend rapidly over a great distance with low-pressure, high-flow requirements.
This rapid extension of cylinder occurs under no external load (when the punching tool approaches the
sheet metal).But during punching operation for short motion, the pressure requirements are high due to
punching load. During this cylinder travel, high-pressure, low-flow requirements are needed.

When punching operation begins, the increased pressure opens the unloading valve to unload the low-
pressure pump. The purpose of relief is to protect the high-pressure pump from over pressure at the end of
the cylinder stroke and when direction control valve (DCV) is in its spring centered mode. The check
valve protects the low-pressure pump from high pressure, which occurs during punching operation that
occurs at the end of cylinder extension and when the DCV is in its spring centered mode.
The above circuit given in Fig. 1.11 eliminates the necessity of having a very expensive high-pressure,
high-flow pump.
Example 1.6
Consider a 100 kN press as shown in Fig. 1.22. Weight of the tool = 5 kN. Cylinder bore =80
mm. Cylinder rod = 60 mm. (a) Find the pressure at annulus side to balance tools.
(b) Find the pressure to achieve 100 kN pressing force.
(c) If an over-center valve is used instead of a counterbalance valve, what is the pressure to
achieve 100 kN pressing force. Comment on the results obtained.

In part (c), use an over-center valve with a 2:1 pilot input ratio set at 23 bar to balance the tools instead of
the counterbalance valve.

From pump 80 cm From pump 80 cm

To tank 60 cm To tank 60 cm

35000 N

With counterbalance valve With over-center valve

Figure 1.22

Solution:
Full bore area Ap = 0.082 × π/4 = 0.005 m2
Annulus area AA = (0.0082−0.0062) × π/4 = 0.0028 m2
Case 1: Using counterbalance valve:
5  103
Pressure at annulus side to balance tools =  105 = 17.8 bar
0.0028
Suggested counterbalance valve setting = 17.8 × 1.3 = 23 bar
Pressure at the full bore side of cylinder to overcome counterbalance = 23 × 0.0028/0.005 = 13 bar
100103  105
Pressure to achieve 100 kN pressing force = +13 = 213 bar
0.005
Case 2: Using over-center valve (brake valve): Let us use an over-center valve with a 2:1 pilot input
ratio set at 23 bar to balance the tools instead of the counterbalance valve.
Pressure on the pilot required to open the valve = 23/2 = 11.5 bar
Pressure at the full bore side to drive down the tooling = 11.5 bar
Pressure required to achieve 100 kN pressing force is
(100  5) 103 105
= 190 bar
0.005
This is greater than 11.5 bar pressure needed to pilot the over-center valve open. Therefore, there will be
no back-pressure set up on the annulus side of the piston during the pressing operation.
Example 1.7
(a) An unloading valve is used to unload the 0.0016 m3/s pump. If the pump discharge pressure during
unloading equals 2 bar, how much hydraulic kW power is being wasted?

(b) In the counterbalance circuit shown in Fig. 1.13, load to be lifted is 10 kN and a cylinder bore area of
0.002 m2 (equivalent to 50 mm diameter) is used. Find the counterbalance valve setting.

10 kN

Figure 1.13

Solution:
(a) We have
kW power  pQ
 (2 105 )  (0.0016 103 )
 0.32 kW
(b) We have
10  103
Load-induced pressure = = 50 bar
0.002  105
The counterbalance valve setting should be 50 × 1.3 = 65 bar
 Lecture 19
PRESSURE-CONTROL VALVES [CONTINUED]

1.5 Counterbalance Valve

Schematic diagram of counterbalance valve is shown in Fig. 1.14. These normally closed valves are
primarily used to maintain a back pressure on a vertical cylinder to prevent it from falling due to gravity.
They are used to prevent a load from accelerating uncontrollably. This situation can occur in vertical
cylinders in which the load is a weight. This can damage the load or even the cylinder itself when the load
is stopped quickly at the end of the travel.

Spring Spring

Figure 1.14 Counterbalance valve.

valve’s primary port is connected to the cylinder’s rod end and the secondary port to the directional
control valve. The pressure setting is slightly higher than that required to keep the load from free-falling.
When the pressurized fluid flows to the cylinder’s cap end, the cylinder extends, increasing pressure in
the rod end and shifting the main spool in the counterbalance valve. This creates a path that permits the
fluid to flow through the secondary port via the directional control valve and to the reservoir. As the load
is raised, the integral check valve opens to allow the cylinder to retract freely.

If it is necessary to relieve back pressure at the cylinder and increase the force at the bottom of the stroke,
the counterbalance valve can be operated remotely. Counterbalance valves are usually drained internally.
When the cylinder extends, the valve must open and its secondary port should be connected to the
reservoir. When the cylinder retracts, it matters little that load pressure is felt in the drain passage because
the check valve bypasses the valve’s spool. Graphic symbol of a pressure-reducing valve is shown in Fig.
1.15.
 Figure1.15 Symbolic representation of a counterbalance valve.

1.5.1Application of a Counterbalance Valve

Counterbalance
valve

Figure 1.16Application of a counterbalance valve.

Counterbalance valves are commonly used to counterbalance a weight or external force or counteract a
weight such as a platen or a press and keep it from freefalling.Figure1.16 illustrates the use of a
counterbalance or back-pressure valve to keep a vertically mounted cylinder in the upward position while
the pump idles, that is, when the DCV is in its center position. During the downward movement of the
cylinder, the counterbalance valve is set to open at slightly above the pressure required to hold the piston
up (a check valve does not permit flow in this direction). The control signal for the counterbalance valve
can be obtained from the blank end or rod end of the cylinder.
If derived from the rod end, the pressure setting of the counterbalance valve equals the ratio of the load to
the annulus area of the piston. If derived from the blank end, the pressure setting equals the ratio of load
to the area of piston. This pressure is less and hence usually it has to be derived from the blank end. This
permits the cylinder to be forced downward when pressure is applied on the top. The check valve is used
to lift the cylinder up as the counterbalance valve is closed in this direction. The directional control valve
unloads the pump.

1.6 Source of Pilot Pressure in Counterbalance Valves

When a counterbalance valve is used in large vertical presses, it may be important to analyze the source
of pilot operating pressure. Figure 1.17 shows a comparison between direct pilot and remote pilot
operation.
Through the application of Pascal’s law, we have
Force 35000
p   55 bar
Area 65 104
If the pilot pressure is taken directly, then the counterbalance valve operates at about 55 bar or slightly
higher because of inertia and friction. In the other case, where the remote pilot pressure is taken from the
pressure line at the top of the cylinder, a choice of operating pressure can be made for the valve. A
counterbalance valve is normally a closed valve and remains closed until acted upon by the remote pilot
pressure source. Therefore, a much lower spring force can be selected to allow the valve to operate at a
lesser pilot pressure. It should also be noted that the press load cannot move downward unless flow from
the pump is directed into the top of the cylinder, which isa normal function of the machine.

From the 130 cm2 130 cm2

From the pump
pump
65 cm2 65 cm2
To the To the tank
tank

35000 N

55 + bar

(a) (b)
Figure 1.17(a) Direct pilot and (b) remote pilot.
1.7 Pressure Sequence Valve

A sequence valve is a pressure-control valve that is used to force two actuators to operate in sequence.
They are similar to pressure-relief valves. Schematic diagram of sequence valve is shown in Fig. 1.18.
Instead of sending flow back to the tank, a sequence valve allows flow to a branch circuit, when a preset
pressure is reached. The check valve allows the sequence valve to be bypassed in the reverse direction.
The component enclosure line indicates that the check valve is an integral part of the component. The
sequence valve has an external drain line; therefore, a line must be connected from the sequence valve’s
drain port to the tank. The symbol for a sequence valve is shown in Fig. 1.19.

Drain

Secondar
y port
In
Out

Direct
pilot

Remote pilot

Figure 1.18Sequence valve.

Figure 1.19Sequence valve with a check valve.

1.7.1 Application of a Sequence Valve

The hydraulic circuit shown in Fig. 1.20 is an example of an application of a sequence valve in which a
clamp cylinder extends first to hold a workpiece and then a second cylinder extends to bend the
workpiece in the desired shape.
 Sequence valve 1

Bending cylinder (B)

Clamp cylinder (A)

Sequence valve 2 W

Figure 1.20Application of a sequence valve.

In this circuit, two cylinders are connected in parallel. Without the sequence valve, these cylinders would
extend together as they are both unloaded. In order for this circuit to function properly, the clamp cylinder
must extend completely before the bending cylinder begins to extend. The sequence valve accomplishes
this by not allowing flow into the bending cylinder branch of circuit until the clamp cylinder has reached
the end of its stroke. When the clamp cylinder extends completely, the pressure rises and opens the
sequence valve,thus allowing the bending cylinder to extend. The sequence valve must be set high enough
so that it opens only after the complete extension of the clamp cylinder.

During the retraction of cylinders, the check valve allows the sequence valve to be bypassed. The
sequence valve has no effect on the circuit in this situation. Both cylinders retract together because both
are unloaded and split the pump flow.

1.8 Cartridge Valves

Cartridge valves consist of a valve shell that can be mounted in a standard recess in a valve block or
manifold. The machine manufacturer does not have to worry about tolerances of moving spools and
poppets because these are taken care by the hydraulic valve manufacturer. This is very advantageous for
batch production and modularized packages or integrated circuits. Cartridge valves eliminate expensive
and potentially leaking pipework and connectors.Cartridge valves can be used as follows:

1. Leak-proof direction control valve.

2. Check valve to obtain unidirectional flow.
3. Throttle valve to control and limit the rate of flow.

The valve shell or body has two main ports (A and B) that are connected or separated by a poppet or a
spool. The poppet-type cartridge valve is basically a check valve that can be pilot operated in a number of
ways, whereas the spool-type cartridge valve is used as a variable restrictor that is either normally open or
closed by the action of the control or vice versa. The actions of the two types of cartridge valvesare
completely different.

1.8.1 Poppet-Type Cartridge Valves

In some designs, a poppet fits into cavity and is held in position by a cover or a top plate that contains all
pilot connections. Others are designed to fit the standard cavities used by some conventional cartridge
valves. Logic elements that have a balanced poppet or spools can be modulated and are largely used as
pressure controls. Those with unbalanced poppets are primarily used for switching functions such as
directional controls or where the poppet movement can be limited as flow controls.

The principal advantages of poppet-type valves are as follows:

1. A very high flow rate for a relatively small physical size.

2. A positive seal can be obtained.
3. May be extremely rapid acting but can also be easily adopted for soft switching.
4. The shape of the poppet or spool together with its seat can be varied to give different operating
characteristics to the valve assembly.

The major disadvantage is that unbalanced poppets, being responsive to pressure changes on all ports,
may malfunction owing to pressure surges. Particular care has to be taken in the circuit design to ensure
the safe operation. The opening and closing movements of the poppet in a cartridge valve are pressure-
dependent and a function of the forces in these areas:
AA  Effective area of the poppet at port A
AB  Effective area of the poppet at port B
AX  Effective area of the poppet at port X
Then

AX  AA  AB
In a balanced poppet-type shown diagrammatically and symbolically in Fig.1.21, AB  0 and the areas
AX and AA are equal.Pilot X controls the function of the valve. If X is connected to port B, the valve
operates as a check valve allowing flow from A to B by opening the poppet but preventing flow from B to
A by closing the poppet. If port X is connected to the external pressure, the valve can be used to control
closing or opening pressure.
 x X

B
B

A
A
Figure 1.21Balanced poppet cartridge valve area ratio, .

In an unbalanced poppet-type valve shown diagrammatically and symbolically in Fig.1.22, it is possible

to obtain a different area ratio, typically
AX : AA  1:1.1, where AB  0.1AA
AX : AA  1:1.05, where AB  0.05 AA
AX : AA  1: 2, where AB  AA

AX

X
A

A
 Figure 1.22Unbalanced poppet cartridge valve area ratio, AX  AA  AB .

With the pilot X vented, pressure at port A or B has to overcome the bias spring force only for flow in
either direction. However, it can be held closed by a pressure on the pilot port that is dependent on the
poppet area ratios.

Figure 1.23 shows how a large double-acting cylinder can be controlled using cartridge valves. A small
double-solenoid-operated directioncontrol valve feeds pilot pressure signals to four cartridge valves that
are coupled in pairs to each end of the double-acting cylinder. One cartridge valve from each pair is
permanently connected to the tank drain line and the other to the pump pressure line. In the position
drawn, all the four valves are held closed by the pilot pressure signals and the cylinder position is locked.
When solenoid A is energized, pilot pressure is maintained on valves 1 and 3 which remain closed. But
valves 2 and 4 are released and open under the influence of fluid pressure in the main system. The fluid
under pressure, therefore, flows from the pump through the cartridge valve to the piston side of the
cylinder and the cylinder extends. The fluid from the rod end of the cylinder flows through valve 4 back
to the tank. When solenoid B is energized, cartridge valves 2 and 4 are closed under pilot pressure and
valves 1 and 2 are released, causing the cylinder to retract.

B A

T
T
1 2 3 4

Figure 1.23 Control of a double-acting cylinder using cartridge logic valves.

Objective-Type Questions
Fill in the Blanks

1. A relief valve is similar to a ______ in an electrical system.

2. A pilot-operated pressure relief valve consists of a small ______ and a main relief valve.
3. ______ is used to maintain reduced pressures in specified locations of hydraulic systems.
4. ______ is used to maintain a back pressure on a vertical cylinder to prevent it from falling due to
gravity.
5. A pilot-operated unloading relief valve is the same as a pilot-operated relief valve with the addition of
an ______ spool.

State True or False

1. Pressure-relief valves limit the maximum pressure in a hydraulic circuit by providing an alternate path
for fluid flow when the pressure reaches a preset level.
2. A pilot-operated pressure-relief valve cannot be operated using a remote.
3. A common application of an unloading valve is in high–low pump circuits and punching press.
4. Sequence valves are similar to pressure-relief valves.
5. An unloading valve requires electric signals.

Review Questions

1. Explain the function of pressure-control valves in hydraulic power systems.

2. Discuss in detail the static characteristics of a direct-operated relief valve, and explain how to reduce
the over-ride pressure.
3. Draw schematically a pilot-operated relief valve and explain its function.
4. Discuss the application of a pilot-operated relief valve.
5. Discuss the principle of pressure reduction in fluid power systems.
6. Discuss briefly the operation of a pilot-operated pressure reducer.
7. Explain the function of a direct-operated sequence valve.
8. What are the differences between relief and sequence valves?
9. Discuss the application of a sequence valve used in hydraulic systems.
10. Name two applications of a counterbalance valve.
11. What is the function of a sequence valve?
12. What is the function of an unloading valve?
13. How is the unloading valve different from a pressure relief valve?
14. What is the function of a pressure relief valve in fluid power systems?
15. What is the advantage of using an unloading circuit when feed and speed of a machine need to be
varied?
Answers
Fill in the Blanks

1.Fuse
2.Pilot relief valve
3.Pressure-reducing valve
4.Counterbalance
5. Unloading

State True or False

1.True
2.False
3.True
4.True
5.False
 Lecture 20
FLOW-CONTROL VALVES

Learning Objectives
Upon completion of this chapter, the student should be able to:

 Explain various functions of flow-control valves.

 Explain various classifications of pressure-control valves.
 Describe the working and construction of various non-compensated flow-control valves.
 Differentiate between compensated and non-compensated flow-control valves.
 Identify the graphic symbols for various types of flow-control valves.
 Explain different applications of flow-control valves.
 Explain the working principle of bleed-off circuits.
 Evaluate the performance of hydraulic systems using flow-control valves.

1.1 Introduction
Flow-control valves, as the name suggests, control the rate of flow of a fluid through a hydraulic
circuit. Flow-control valves accurately limit the fluid volume rate from fixed displacement pump
to or from branch circuits. Their function is to provide velocity control of linear actuators, or speed
control of rotary actuators. Typical application include regulating cutting tool speeds, spindle
speeds, surface grinder speeds, and the travel rate of vertically supported loads moved upward and
downward by forklifts, and dump lifts. Flow-control valves also allow one fixed displacement
pump to supply two or more branch circuits fluid at different flow rates on a priority basis.
Typically, fixed displacement pumps are sized to supply maximum system volume flow rate
demands. For industrial applications feeding two or more branch circuits from one pressurized
manifold source, an oversupply of fluid in any circuit operated by itself is virtually assured.
Mobile applications that supply branch circuits, such as the power steering and front end loader
from one pump pose a similar situation. If left unrestricted, branch circuits receiving an
oversupply of fluid would operate at greater than specified velocity, increasing the likelihood of
damage to work, hydraulic system and operator.

1.1.1 Functions of Flow-Control Valves

Flow-controlvalves have several functions, some of which are listed below:

1. Regulate the speed of linear and rotary actuators:They control the speed of piston that
is dependent on the flow rate and area of the piston:
Flow rate in the actuator (m3 / s) Q
Velocity of piston (Vp) (m/s) = 
Piston area (m2 ) Ap
2. Regulate the power available to the sub-circuits by controlling the flow to them:
Power (W) = Flow rate (m3/s) ×Pressure (N/m2)
 P = Q×p

3. Proportionally divide or regulate the pump flow to various branches of the circuit:It
transfers the power developed by the main pump to different sectors of the circuit to
manage multiple tasks, if necessary.
A partially closed orifice or flow-control valve in a hydraulic pressure line causes resistance to
pump flow. This resistance raises the pressure upstream of the orifice to the level of the relief-
valve setting and any excess pump flow passes via the relief valve to the tank (Fig. 1.1).

In order to understand the function and operation of flow-control devices, one must comprehend
the various factors that determine the flow rate(Q) across an orifice or a restrictor. These are given
as follows:

1. Cross-sectional area of orifice.

2. Shape of the orifice (round, square or triangular).
3. Length of the restriction.
4. Pressure difference across the orifice (Δp).
5. Viscosity of the fluid.

Variable load

Figure 1.1 simple restrictor-type flow-control valves.

Thus, the law that governs the flow rate across a given orifice can be approximately defined as
Q2  p
This implies that any variation in the pressure upstream or downstream of the orifice changes the
pressure differential Δp and thus the flow rate through the orifice (Fig. 1.2).

2
 Adjustable range

Flow rate

Pressure differential (

Figure 1.2 Variation of flow rate with pressure drop.

1.1.2Classification of Flow-Control Valves

Flow-control valves can be classified as follows:

1. Non-pressure compensated.
2. Pressure compensated.

1.1.2.1 Non-Pressure-Compensated Valves

Non-pressure-compensated flow-control valves are used when the system pressure is relatively
constant and motoring speeds are not too critical. The operating principle behind these valves is
that the flow through an orifice remains constant if the pressure drop across it remains the same. In
other words, the rate of flow through an orifice depends on the pressure drop across it.
The disadvantage of these valves is discussed below. The inlet pressure is the pressure from the
pump that remains constant. Therefore, the variation in pressure occurs at the outlet that is defined
by the work load. This implies that the flow rate depends on the work load. Hence, the speed of
the piston cannot be defined accurately using non-pressure-compensated flow-control valves when
the working load varies. This is an extremely important problem to be addressed in hydraulic
circuits where the load and pressure vary constantly.

Needle Valve stem

A B

(a) (b) (c)

Figure 1.3 Non-pressure-compensated needle-type flow-control valve. (a) Fully closed; (b)
partially opened; (c) fully opened.

3
Schematic diagram of non-pressure-compensated needle-type flow-control valve is shown in Fig.
1.3. It is the simplest type of flow-control valve. It consists of a screw (and needle) inside a tube-
like structure. It has an adjustable orifice that can be used to reduce the flow in a circuit. The size
of the orifice is adjusted by turning the adjustment screw that raises or lowers the needle. For a
given opening position, a needle valve behaves as an orifice. Usually, charts are available that
allow quick determination of the controlled flow rate for given valve settings and pressure drops.
Sometimes needle valves come with an integrated check valve for controlling the flow in one
direction only. The check valve permits easy flow in the opposite direction without any
restrictions. As shown in Fig. 1.4, only the flow from A to B is controlled using the needle. In the
other direction (B to A), the check valve permits unrestricted fluid flow.

A B A B

Restricted flow Free flow

Figure 1.4Flow-controlvalve with an integrated check valve.

1.1.2.2Pressure-Compensated Valves

Pressure-compensated flow-control valvesovercome the difficulty causedby non-pressure-

compensated valves by changing the size of the orifice in relation to the changes in the system
pressure. This is accomplished through a spring-loaded compensator spool that reduces the size of
the orifice when pressure drop increases. Once the valve is set, the pressure compensator acts to
keep the pressure drop nearly constant. It works on a kind of feedback mechanism from the outlet
pressure. This keeps the flow through the orifice nearly constant.

4
 Compensator
spool A

Pilot
Compression
line A
spring

Adjustment
knob
Drain
line

Pilot line B

Main spool
B
Figure 1.5 Sectional view of a pressure-compensated flow-control valve.

Figure 1.6 Graphic symbol of a pressure-compensated flow-control valve.

Schematic diagram of a pressure compensated flow-control valve is shown in Fig. 1.5 and its
graphical symbol in Fig. 1.6. A pressure-compensated flow-control valve consists of a main spool
and a compensator spool. The adjustment knob controls the main spool’s position, which controls
the orifice size at the outlet. The upstream pressure is delivered to the valve by the pilot line A.
Similarly, the downstream pressure is ported to the right side of the compensator spool through the
pilot line B. The compensator spring biases the spool so that it tends toward the fully open
position. If the pressure drop across the valve increases, that is, the upstream pressure increases
relative to the downstream pressure, the compensator spool moves to the right against the force of
the spring. This reduces the flow that in turn reduces the pressure drop and tries to attain an
equilibrium position as far as the flow is concerned.

In the static condition, the hydraulic forces hold the compensator spool in balance, but the bias
spring forces it to the far right, thus holding the compensator orifice fully open. In the flow
condition, any pressure drop less than the bias spring force does not affect the fully open
compensator orifice,but any pressure drop greater than the bias spring force reduces the
compensator orifice. Any change in pressure on either side of the control orifice, without a
corresponding pressure change on the opposite side of the control orifice, moves the compensator
spool. Thus, a fixed differential across the control orifice is maintained at all times. It blocks all
flow in excess of the throttle setting. As a result, flow exceeding the preset amount can be used by
other parts of the circuit or return to the tank via a pressure-relief valve.

5
Performance of flow-control valve is also affected by temperature changes which changes the
viscosity of the fluid. Therefore, often flow-control valves have temperature compensation.
Graphical symbol for pressure and temperature compensated flow-control valve is shown in Fig.
1.7.

Figure 1.7Pressure- and temperature-compensated flow-control valve.

1.2Speed-Controlling Circuits

In hydraulic operations, it is necessary to control the speed of the actuator so as to control the
force, power, timing and other factors of the operation. Actuator speed control is achieved by
controlling the rate of flow into or out of the cylinder.

Speed control by controlling the rate of flow into the cylinder is called meter-in control.Speed
control by controlling the rate of flow out of the cylinder is called meter-out control.

1.2.1 Meter-In Circuit

Figure 1.8 shows a meter-in circuit with control of extend stroke. The inlet flow into the cylinder
is controlled using a flow-control valve. In the return stroke, however, the fluid can bypass the
needle valve and flow through the check valve and hence the return speed is not controlled. This
implies that the extending speed of the cylinder is controlled whereas the retracing speed is not.

CV FCV

Figure 1.8Meter-in circuit.

6
1.2.2 Meter-Out Circuit

Figure 1.9 shows a meter-out circuit for flow control during the extend stroke. When the cylinder
extends, the flow coming from the pump into the cylinder is not controlled directly. However, the
flow out of the cylinder is controlled using the flow-control valve (metering orifice). On the other
hand, when the cylinder retracts, the flow passes through the check valve unopposed, bypassing
the needle valve. Thus, only the speed during the extend stroke is controlled.

Both the meter-in and meter-out circuits mentioned above perform the same operation (control the
speed of the extending stroke of the piston), even though the processes are exactly opposite to one
another.

QFCV

FCV
CV

Figure 1.9 Meter-Out circuit.

1.2.3 Bleed-Off Circuit

Compared to meter-in and meter-out circuits, a bleed-off circuit is less commonly used. Figure
1.10 shows a bleed-off circuit with extend stroke control. In this type of flow control, an additional
line is run through a flow-control valve back to the tank. To slow down the actuator, some of the
flow is bledoff through the flow-control valve into the tank before it reaches the actuator. This
reduces the flow into the actuator, thereby reducing the speed of the extend stroke.
The main difference between a bleed-off circuit and a meter-in/meter-out circuit is that in a bleed-
off circuit, opening the flow-control valve decreases the speed of the actuator, whereas in the case
of a meter-in/meter-out circuit, it is the other way around.

7
 PRV PRV

(a) (b)

Figure 1.10 Bleed-off circuits:(a) Bleed-off for both directions and (b) bleed-off for inlet to the
cylinder or motor.

Example 1.1

A 55-mm diameter sharp-edged orifice is placed in a pipeline to measure the flow rate. If the
measured pressure drop is 300 kPa and the fluid specific gravity is 0.90, find the flow rate in units
of m3 /s .

Solution: For a sharp-edged orifice, we can write

p
Q  0.0851 ACV
SG
where Q is the volume flow rate in LPM, CV is the capacity coefficient = 0.80 for the sharp-edge
orifice, c = 0.6 for a square-edged orifice, A is the area of orifice opening in mm2, p is the
pressure drop across the orifice (kPa) and SG is the specific gravity of the flowing fluid = 0.9.
Now,
 
Aorifice  ( Dorifice 2 )  (552 )  2376 mm2
4 4
Using the orifice equation we can find the flow rate as

300
Q (LPM)  0.0851 2376 0.80
0.9
= 2953.3 LPM = 0.0492 m3 /s

8
Example 1.2

For a given orifice and fluid, a graph can be generated showing a p versus Q relationship. For
the orifice and fluid in Example 1.1, plot the curves and check the answers obtained
mathematically. What advantage does the graph have over the equation? What is the disadvantage
of the graph?

Solution: From Example 1.1, we have

300
Q (LPM)  0.0851 2376 0.80
0.9
We can write the general expression as
p p
Q (LPM)  0.0851  2376  0.80
 161.76  170.5 p
0.9 0.9
Using Excel, the graph shown in Fig. 1.11 is obtained.
450
400
350
300
Pressure drop (kPa)

250
200
150
100
50
0
0 500 1000 1500 2000 2500 3000 3500 4000
Flow rate (LPM)

Figure 1.11 Pressure drop versus flow rate.

From the graph, corresponding to p  300 kPa, we get Q = 2950 LPM which is close to 2953.3
LPM.A graph is quicker to use but is not as accurate as the equation. A pressure gauge can be
calibrated (according to this relationship) to read Q directly rather than p .

Example 1.3

Determine the flow rate through a flow-control valve that has a capacity coefficient of
2.2LPM/ kPa and a pressure drop of 687 kPa. The fluid is hydraulic oil with a specific gravity of
0.90.

Solution:For a sharp-edged orifice, we can write

p 687
Q  2.2  2.2  60.8 LPM
SG 0.9

9
Example 1.4

The system shown in Fig. 1.12 has a hydraulic cylinder with a suspended load W. The cylinder
piston and rod diameters are 50.8 and 25.4 mm, respectively. The pressure-relief valve setting is
5150 kPa. Determine the pressure p2 for a constant cylinder speed:

(a) W = 8890 N
(b) W = 0 ( load is removed)
(c) Determine the cylinder speeds for parts (a) and (b) if the flow-control valve has a
capacity coefficient of 0.72LPM/ kPa . The fluid is hydraulic oil with a specific gravity
of 0.90.

Figure 1.12 Hydraulic cylinder with a suspended weight.

Solution:
For a constant cylinder speed, the summation of the forces on the hydraulic cylinder must be equal
to zero. Thus, we have
W  p1 Ap  p2 ( Ap  Ar )  0
where p1  pressure-relief valve setting  5150 kPa . Now

10
  
Ap  ( DP 2 )  (0.05082 )  0.00203 m 2
4 4
 
Ar  ( DR 2 )  (0.02542 )  0.000506 m 2
4 4
So
Ap  Ar  0.00152 m2
Case 1: If W = 8890 N.
W  p1 Ap  p2 ( Ap  Ar )  0
 8890  5150 103 N/m2  2.03 103 m2  p2 (0.00152 m2 )  0
 8890  10450 m2  p2 (0.00152)  0
 p2  12700 kPa
Case 2: If W = 0.
0  5150 103 N/m2  2.03 103 m2  p2 (0.00152 m2 )  0
 p2  6880 kPa
Case 3: Cylinder speed for case 1: For a sharp-edged orifice, we can write
p 12700
Q  CV  0.72  85.5 LPM
SG 0.9
where p  p2 because the flow-control valve discharges directly to the oil tank. This is the flow
rate through the flow-control valve and thus the flow rate of the fluid leaving the hydraulic
cylinder. Thus, we have
vp ( Ap  Ar )  Q
1 m3 1 min
 vp (m/s)(0.00152) m2  85.5 L/min  
103 L 60 s
 vp  0.938 m/s
Case 4: Cylinder speed for case 2. We have
p 6880 1 m3 1 min m3
Q  CV  0.72  63 LPM=63 L/min  3   0.00105
SG 0.9 10 L 60 s s

Also we can write

Q  Velocity×Area
 vp  A
m3
 0.00105
s
 vp (m/s)(0.00152) m2  0.00105
 vp  0.691 m/s

Example 1.5

A cylinder has to exert a forward thrust of 100 kN and a reverse thrust of 10 kN. The effects of
using various methods of regulating the extend speed will be considered. In all the cases, the
retract speed should be approximately 5 m/min utilizing full pump flow. Assume that the

11
maximum pump pressure is 160 bar and the pressure drops over the following components and
their associated pipe work (where they are used):
Filter = 3 bar
Directional control valve (DCV) = 2 bar
Flow-control valve (controlled flow) = 10 bar
Flow-control valve (check valve) = 3 bar
Determine the following:

(a) The cylinder size (assume the piston-to-rod area ratio to be 2:1).
(b) Pump size.
(c) Circuit efficiency when using the following:
Case 1: No flow controls (calculate the extend speed).
Case 2: Meter-in flow control for extend speed 0.5 m/min.
Case 3: Meter-out flow control for extend speed 0.05 m/min.

Solution:

Case 1: No flow controls (Fig. 1.13)

Part (a) No flow controls
Maximum available pressure at the full bore end of cylinder = 160 − 3 − 2 = 155 bar
Back pressure at the annulus side of cylinder = 2 bar.
This is equivalent to 1 bar at the full bore end because of the 2:1 area ratio. Therefore, the
maximum pressure available to overcome load at the full bore end is 155 − 1 = 154 bar
100  103
Full bore area = Load/Pressure = =0.00649 m2
154  105
Piston diameter =  4  0.00649 
1/ 2

 
  
Select a standard cylinder, say with 100-mm bore and 70-mm rod diameter. Then

Full bore area = 7.85 × 103 m2

Annulus area = 4.00 × 103 m2
This is approximately a 2:1 ratio.
Part (b)No flow controls
Flow rate for a return speed of 5 m/min is given by
Area × Velocity = 4.00 × 103× 5 m3/min = 20 LPM

20  103
Extend speed = = 2.55 m/min
7.85  103

100  103
Pressure to overcome load on extend = = 12.7 MPa = 127 bar
7.85  103

10  103
Pressure to overcome load on retract = = 2.5 MPa = 25 bar
4.00  103

12
(i) Pressure at pump on extend (working back from the DCV tank port)

Pressure drop over DCV B to T 2 × (1/2) 1

Load-induced pressure 127
Pressure drop over DCV P to A 2
Pressure drop over filter 3

Therefore, pressure drop required at the pump during extend stroke = 133 bar

Relief-valve setting = 133 + 10% = 146 bar

(ii) Pressure required at the pump on retract (working from the DCV port as before) is

(2 × 2) + 25 + 2 + 3 = 34 bar
Note: The relief valve will not be working other than at the extremities of the cylinder stroke.
Also, when movement is not required, pump flow can be discharged to the tank at low pressure
through the center condition of the DCV.
Part (c) No flow controls
System efficiency:
Energy required to overcome load on the cylinder Flow to the cylinder  Pressure owing to load

Total energy into fluid Flow from the pump  Pressure at the pump

20  127
Efficiency on extend stroke = × 100 = 95.5 %
20  133

20  25
Efficiency on retract stroke = × 100 = 73.5 %
20  34

13
 Figure 1.13 Hydraulic cylinder with no control.

Case 2: Meter-in flow control for the extend speed of 0.5 m/min(Fig. 1.14)

Part (a) meter in controls

From case 1,
Select a standard cylinder, say with 100-mm bore and 70-mm rod diameter.
Cylinder 100-mm bore diameter × 70-mm rod diameter
Full bore area 7.85 × 10–3 m2
Annulus area = 4.00 × 10–3 m2
Load-induced pressure on extend = 127 bar
Load-induced pressure on retract = 25 bar
Pump flow rate = 20 L/min
Part (b) meter in controls
Flow rate required for the extend speed of 0.5 m/min is
7.85 × 10–3× 0.5= 3.93 × 10–3 m3/min = 3.93 L/min
Working back from the DCV tank port:
Pressure required at the pump on retract is
(2 × 2) + (2 × 3) + 25 + 2 + 3 = 40 bar
Pressure required on the pump at extend is
2 × (1/2) + 127 + 10 + 2 + 3 = 143 bar
Relief-valve setting = 143 + 10% = 157 bar

This is close to the maximum working pressure of the pump (160 bar). In practice, it would be
advisable to select either a pump with a higher working pressure (210 bar) or use the next standard

14
size of the cylinder. In the latter case, the working pressure would be lower but a higher flow rate
pump would be necessary to meet the speed requirements.

Part (c) meter in controls

Now that a flow-control valve has been introduced when the cylinder is on the extend stroke, the
excess fluid will be discharged over the relief valve.

3.93  127
System efficiency on extend = × 100 = 15.9%
20  157

20  25
System efficiency on retract = 100 = 62.5%
20  40

Figure 1.14 Hydraulic cylinder with meter-in control

Case 3: Meter-out flow control for the extend speed of 0.5 m/min(Fig. 1.15)
Cylinder, load, flow rate and pump details are as before (partsa and b of meter in control).

Part (c) meter out controls

Working back from the DCV tank port:

15
Pressure required at the pump on retract is
(2 × 2) + 25 + 3 + 2 + 3 = 37 bar
Pressure required at the pump on extend is
[2 ×(1/2)] + [10 × (1/2)] + 127 + 2 +3 = 138 bar
Relief-valve setting = 38 + 10 % = 152 bar

3.93  127
System efficiency on extend = × 100 = 16.4%
20  152

20  25
System efficiency on retract = × 100 = 67.6%
20  37

Discussion of results of all three cases: No control, meter-in and meter-out.

As can be seen, meter-out is marginally more efficient than meter-in owing to the ratio of piston to
piston rod area. Both systems are equally efficient when used with through-rod cylinders or
hydraulic motors. It must be remembered that meter-out should prevent any tendency of the load
to run away.

In both cases, if the system runs light, that is, extends against a low load, excessive heat is
generated over the flow controls in addition to the heat generated over the relief valve.
Consequently, there is further reduction in the efficiency. Also, in these circumstances, with
meter-out flow control, very high pressure intensification can occur on the annulus side of the
cylinder and within the pipe work between the cylinder and the flow-control valve. Take a
situation where meter-out circuit is just considered. The load on extend is reduced to 5 kN without
any corresponding reduction in the relief-valve settings.

Flow into the full bore end is 3.91 L/min.

Therefore, excess flow from the pump is
20 – 3.93= 16.07 L/min
that passes over the relief valve at 152 bar.
The pressure at the full bore end of the cylinder is = 152 – 3 – 2 = 147 bar
This exerts a force that is resisted by the load and the reactive back pressure on the annulus side:
 5 103  4.00
147 –  3 5 
= (2 + 10 + p) ×
 7.85  10  10  7.85
wherep is the pressure within the annulus side of the cylinder and between the cylinder ant the
flow-control valve. So

p = [(147 – 6.4) × 7.85/4.00] – 12 = 264 bar

The system efficiency on extend is

3.93  6.4
× 100 = 0.83%
20  152
Almost all of the input power is wasted and dissipates as heat into the fluid, mainly across the
relief and flow-control valves.

16
 Figure 1.15 Hydrauliccylinder with meter-out control.

Example 1.6

Figure 1.16 shows a hydraulic circuit where the actuator speed is controlled by a meter-in system
employing a series pressure-compensated valve. Determine the power input to the pump under a
steady-state condition. If the series compensation is replaced by parallel compensation, and the
load and speed of the actuator remain unchanged, determine the change of overall efficiency of the
circuit.

17
 B

Figure 1.16 Hydraulic cylinder with a pressure-compensated valve.

Solution:
For valve A we have Q = 0.5 p
For valve B we have Q = 0.4 p
For valve C we have Q = 0.3 p
Now referring to Fig. 1.16, let us calculate the flow to piston side of the cylinder:

Q1 = × 602× 600 = 1.7 L/s
4
Flow from the return side of the cylinder is
Q2 = 1.4 L/s
Pump flow is given by
Qp= 2π × 1000/60 × 20 = 2.1 L/s
Q3 = ηvol× Qp = 1.93 L/s
Power input to the pump = 150 × 105× 2.1 × 10-3× 1/0.8 W = 39.4 kW
Power output to the actuator = 6100/1000 × 600/1000 = 3.6 kW
Therefore, system efficiency = 3.66/39.4 × 100 = 9%
Pressure loss at valve B due to Q2 = 1 × (1.4/0.4)2 = 12.2 bar
Pressure at the head end of actuator

18
  
p× × 602× 10–6 = 6100 + 12.2 × 105 × × (602 – 252) × 10–6
4 4
 p = 29 bar
Pressure losses at B due to Q1 = (1.7/0.4)2 = 18 bar
Pressure losses at valve A = (1.7/0.5)2 = 11.6 bar
Therefore, the total pressure, excluding that lost in the pressure-compensated valve if it is of series
type, is
29 + 18 + 11.6 + 4 = 62.6 bar
Hence, 150 – 62.6 = 87.4 bar is dropped in the pressure-compensated valve if it is of series type.
For a parallel pressure-compensated valve, the excess oil Q – Q1 would bypass at

62.6 bar – 11.6 bar = 51 bar

The pump delivery would be at 62.6 bar and hence the total power consumption is

62.6 × 105× 2.1 × 103× 1/0.8 W = 16.5 kW

System efficiency = 22.2%

Example 1.7

A flow-control valve is used to control the speed of the actuator as shown in Fig. 1.17 and the
characteristics of the system are given in Table 1.1. Determine the variable flow area Av, the
pressure downstream of the valve fixed orifice p2, the valve displacement x and the spring preload
F for the given motor operating conditions.
Table 1.1
Parameters Value

Valve flow constant ( Cd ) 0.6

Length h 7.8 mm

Valve area gradient for flow area ( 1.25 mm2/mm

Av ), b

Fixed orifice flow area ( Ao ) 4.9 mm2

Valve face area (A) 125 mm2

Spring constant 57 kN/m

Motor displacement ( Dm ) 40 cm3/rev

Motor torque 60 Nm

Motor speed 350 RPM

Motor volumetric efficiency (  v ) 96 %

Motor mechanical efficiency ( m ) 97 5

19
 System pressure ( p1 ) 14.5 MPa

Return pressure ( p4 ) 1 MPa

Fluid density 840 kg/m3

Figure 1.17
Solution: Refer to Fig. 1.17, flow from the pump divides as Q1 and Q2 . The pressure drop p1  p2
occurs across orifice Ao. This makes the valve to move to right against the spring force F. The area
of orifice Av then adjusts to control the flow to the motor:

Let us first convert all the given variables to appropriate units

7.8 1.25
h m, w  mm, k  57000 N/m, Ao  4.9 106 m 2 , A 125  106 m2
1000 1000

40 3
3
m
Dm  100 , T  60 N m, n  350 RPM,   840 kg/m3 , p`1  145000  1000 N/m2
rev

2    350
V  96%, m  97%, p`4  1000 1000 Pa,    36.652 rad/s
60

First let us calculate the discharge Q2 through valve

20
 Motor displacement Speed
Q2  
Revolution Volumetric efficiency
(40 / 1003 ) m3 350
 
0.96 60
 2.431104 m3 /s

Pressure drop across motor is p3  p4 . So

Torque
p3  p4 
Flow rate × Mechanical efficiency

T 2
p3    p4
0.97 (40 /1003 ) m3
60 2
  3 3
 106
0.97 (40 /100 ) m
 1.072 107 Pa

Also flow through orifice from motor side is given by

2
Q2  cd Ao  p2  p1
840
2
2.431104  0.6  4.9  106  p2  14500000
840
Substituting all the known values we can get p2
p2  1.163107 Pa
Also flow through orifice from pump side is given by

2 2
Q2  cd AV  p2  p3  0.6  AV  1.163  107  1.072  107
840 840
Solving we get the value of AV as

AV  8.688106 m2 or 8.688 mm2

But area of the valve is

Solving we get

h  w  AV
x  8.499104 m
w
Now let us write the force balance we get (see Fig. 1.18)

p1 A  p2 A   K x  F 
Substituting all the values we get

21
14500 1000 N/m2 125 106  1.163107 125  106  57000 8.499104  F

F  310.4 N

Figure 1.18

22
Objective-Type Questions

Fill in the Blanks

1. Non-pressure-compensated flow-control valves are used when the system pressure is relatively
________ and motoring speeds are not too critical.
2. A pressure compensator acts to keep the ________ nearly constant.
3. In ________ flow-control valve consists of a main spool and a compensator spool.
4. Speed control by controlling the rate of flow ________ the cylinder is called meter-in control.
5. In a meter-________ circuit, only the speed during the extend stroke is controlled.

State True or False

1. The speed of a piston can be defined accurately using non-pressure-compensated flow-control

valves when the working load varies.
2. Speed control by controlling the rate of flow out of the cylinder is called meter-in control.
3. In a meter-in circuit, the extending speed of the cylinder is controlled whereas the retracing
speed is not.
4. Compared to the meter-in and meter-out circuits, the bleed-off circuit is more commonly used.

5. In a meter-in circuit, flow coming from the pump into the cylinder is not controlled directly.
However, the flow out of the cylinder is controlled using a flow-control valve.

Review Questions

1. What is the function of a flow-control valve?

2. What are the three ways of applying flow-control valves?
3. What is meant when a flow-control valve is said to be pressure compensated?
4. What is a meter-in circuit and where is it used?
5. What is a meter-out circuit and where is it used?
6. What are the advantages of a meter-in circuit?
7. What are the disadvantages of a meter-in circuit?
8. What are the advantages of a meter-out circuit?
9. What are the disadvantages of a meter-out circuit?
10. What are the advantages of a by-pass or bleed-off circuit?
11.What are the disadvantages of a by-pass or bleed-off circuit?
12. What is a modular valve and what are its benefits?
13. What is a hydraulic fuse?
14.What is the need for temperature compensation in a flow-control valve?
15. What is the difference between a hydraulic fuse and a pressure-relief valve?

23
Answers
Fill in the Blanks

1.Constant
2.Pressure drop
3.Pressure compensated
4.Into
5.Out

State True or False

1.False
2.False
3.True
4.False
5.False

24
 Lecture 21
FLOW AND FORCE ANALYSIS OF VALVES

Learning Objectives
Upon completion of this chapter, the student should be able to:

 Understand the mathematical equation for flow through anoverlapped four-way spool valve.
 Understand the mathematical equation for flow through an underlappedfour-way spool valve.
 Understand the mathematical equation for flow through athree-way critical center valve.
 Understand the mathematical equation for flow through athree-way open center valve.
 Describe the working and construction of a flapper nozzle valve and performits mathematical
analysis.
 Analyze poppet, single-stage relief and pressure-compensated valves.
 Carry out mathematical analysis of valves used inhydraulic systems.

1.1 Introduction
Most hydraulic servo mechanisms or other high-performance systems rely for their operation on the
metering of fluid through a valve. This chapter deals with a linearized method of analysis for “four-
way valves.” They are called so because they have four connections, one for the supply pressure and
another for the exhaust, and two control ports through both of which fluid may be metered, from the
supply to either the system or the exhaust.
Metering valves are never fully open and their use is for accurately metering the flow of fluid through
them. In this case of spool valves, longitudinal displacements of the spool are always small as
compared with the spool’s diameter.

1.2 Four-Way Spool Valves

A spool valve used for metering purposes controls flow rate by throttling.Each port in a valve that is
partially closed by a land on the spool becomes a control throttle.
The rate of flow of fluid through such a valve depends on the spool displacement from the null
position “x” and on the pressure upstream and downstream of the valve. One way of representing the
flow rate q through a valve is
q  Kq x  Kc pm (1.1)
whereqis the volume flow rate of the oil, Kq is the flow gain, Kc is the pressureflow coefficient and
pmis the pressure difference across the load.Equation(1.1) implies that the flow rate is directly
proportional to the valve opening and directly proportional to the pressure drop.

1.2.1 Critical Center Valve

In critical center valves, the lands of the spool are exactly of the same width as the annual ports of the
valve body in the central or null position where the lands exactly cover the ports (Fig. 1.1).

1
 c

x x

Load
Figure 1.1 Four-way valve.

1.2.1.1 Flow Rate Prediction

Orifices are a basic means for the control of fluid power. Flow characteristics of orifices play a major
role in the design of many hydraulic control devices. An orifice is a sudden restriction of short length
in a flow passage and may have a fixed or variable area. Two types of flow regime exist depending on
whether inertial or viscous forces dominate. The flow through orifice must increase above that in the
upstream region to satisfy the law of continuity. At high Reynolds number, the pressure drop across
the orifice is caused by the acceleration of the fluid particles from the upstream velocity to the higher
jet velocity. At low Reynolds numbers, the pressure drop is caused by the internal shear forces
resulting from fluid viscosity.

The pressure difference required to accelerate the fluid particles from the lower upstream velocity to
higher upstream velocity is found by applying Bernoulli’s equation and continuity equation. Here we
will not derive the basic equations. Students are advised to go through any standard fluid mechanics
books for the derivation of flow through orifice.

From fluid mechanics, flow through the orifice is given by

q1  Cd πd1 x( ps  p1 )1/2 (2 / ρ)1/2 (1.2)

q2  Cd πd1 x( p2  pe ) (2 / ρ) (1.3)
1/2 1/2

Let us make following assumptions:

1. q1  q2

2. ( ps  p1 )  ( p2  pe )

3. the supply pressure ( ps ) is constant

4. pe is negligible

2
By introducing the term pm  p1  p2 , and using assumptions 2 and 4 we can write

( ps  p1 )  ( p2  pe )
 ( ps  p1 )  ( p2  0)

 ps  p1  p2
Solving ps  p1  p2 and pm  p1  p2 simultaneously we get
ps  pm  2 p2 (1.4)

ps  pm  2 p1 (1.5)

Using all assumptions in Eqs. (1.2) and (1.3) we get

q  Cd πd1 x( ps  pm )1/2 (1/ ρ)1/2 (1.6)

With the type of configuration illustrated in Fig. 1.1, it is usually accepted that
Cd  5/8 (1.7)
ρ = 870 kg/ m3 (1.8)

Using values given in Eqs. (1.7) and (1.8) in Eq. (1.6) we get

q  6.7πd1 x( ps  pm )1/2 (1.9)

The assumption that the valve opening can be treated as orifices pre-supposes that x is small

compared to
d1 so that the pressure drop across each orifice will be significant compared with ps . In
p p
practice the pressure difference across the load m rarely exceeds 0.666 s . Allowing further
p  0.666 ps , then less than 10% error is involved using the binomial
simplification of Eq. (1.9) if m
approximation. Using binomial approximation, we have

p   1  p 
ps  pm  ps  1   m   ps  1   m   (1.10)
 ps   2  ps  

Hence Eq. (1.9) becomes

q  6.7πd1 xps1/2  6.7πd1 xps1/2 pm / 2 ps (1.11)

andEq. (1.11) is similar in form to Eq. (1.1). Now
Kq  6.7πd1 ps1/2 (1.12)
Kc  6.7πd1 xp 1/2
s / 2 ps (1.13)

The above analysis predicts that the flow gain K q can be treated as constant for a particular valve and
supply pressure but the pressure flow coefficient K c varies with the valve opening x. The variation of
K c is of minor significance for linear analysis.

3
In reality, spool lands never exactly match the annular ports in the valve body. Actual test results with
a constant pressure drop across the valve ports show variations, particularly near the central or null
position of the spool as those illustrated in Fig. 1.2.
The flow gain K q is the slope of the approximate line in the figure, which can double its valve near
null with negative lap. The magnitude of K q is the most important parameter of a valve and often also
of any system incorporating the valve.

Zero lap

Overlap

Underlap

Figure 1.2Flow rates versus valve displacement for constant pressure drop.

1.2.2 Open Center Valve (Underlapped Four-Way Valve)

A valve in which the land of the spool never completely covers the ports of the valve body is said to
be underlapped(or to have negative lap)(Fig. 1.3).

a b c d

(u+x) (u+x)
(ux)
(ux)
x

Load motion

Load

Figure 1.3 Open center–four-way valve.

4
Referring to Fig. 1.3,a displacement of x(say to the left) unbalances the symmetry of the ports. Two of
the annular orifices increase in width from u to u + x and two decrease from u to u−x.The flow
ratesare estimated as follows:
1/2 1/2
2 2
q1  Cd πd1 (u  x)( ps  p1 )  
1/2
 Cd πd1 (u  x)( p1  pe )   (1.14)
1/2

 ρ  ρ
1/2 1/2
2 2
q2  Cd πd1 (u  x)( p2  pe )  
1/2
 Cd πd1 (u  x)( ps  p2 )  
1/2
(1.15)
 ρ  ρ
Let us make following assumptions:

1. q1  q2

2. ps  p1  p2

3. The supply pressure ( ps ) is constant

4. pe is negligible

Writing pm  p1  p2 , we can use these assumptions in Eqs. (1.14) and (1.15) and get
1/2
1
q  Cd πd1{(u  x)( ps  pm )1/2  (u  x)( ps  pm )1/2 }  (1.16)
 ρ
that may be approximated as

 1/2
1 pm  
1/2 1/2
 1/2  1 pm  1/ 2   1 
q1  Cd πd1 (u  x)( ps ) 1    (u  x)( ps ) 1     (1.17)
ρ
   2 ps    
 2 p
 s

1/ 2 1/2
1 1 ps1/2 pm
q  Cd πd1   p s
1/2
2 x  Cd πd1u   (1.18)
 ρ  ρ ps
Equation (1.18) is similar in form to Eq. (1.1):

Kq  13.4πd1 ps1/2 (1.19)

Kc  6.7πd1 xps1/2 / ps (1.20)

The values refer to operation within the underlap region. Outside this region, these valves act as
K
critical center valves with only two active ports. Note particularly that the flow gain q is double that
for a comparable critical center valve (Fig. 152) in the underlap region. Note also significant leakage
flow when the valve is centered (leakage flow at null when the load flow q is zero)becomes
13.4πd1 ps1/2 .

1.3 Three-Way Spool Valves

Three-way valves have only one critical length dimension which helps to ease manufacture. However
they cannot be used for hydraulic motors requiring flow reversal and are usually used in differential
ram and is discussed below.

5
1.3.1 Critical Center Valve
The central spool position just closes both the supply and the exhaust port of the valve. A
displacement of the spool to the left causes fluid to be metered into the ram chamber from the supply,
whereas one to the right causes metering of fluid from the chamber to the exhaust (Fig. 1.4).

Positive valve
displacement
c

x
x

Positive load
displacement

Figure 1.4 Three-way valve.

Oil flow rate is
1/ 2
2
qc = Cdπ d1x ( ps  pc )   forxpositive
1/ 2
(1.21)
 ρ
1/ 2
2
qc = Cdπ d1x ( pc  pe )   for x negative
1/ 2
(1.22)
 ρ
Substituting pm = pc −ps/2 we get
1/ 2
 2
1/ 2
p
qc = Cdπ d1x  s – pm    for x positive (1.23)
 2   ρ
1/ 2
 2
1/ 2
p
qc = Cdπ d1x  s  pm    for x negative (1.24)
 2   ρ
thatmay be approximated.Noting that

 1 2 pm 
1/ 2 1/ 2
 p  2 p 
  ps 
1/ 2
 ps  
 2  pm  =  s 1  m  ≈   1   (1.25)
  2
 ps 
  2   2 ps 
we get
1/ 2
1 1
qc = Cdπ d1x ( ps )1/ 2    Cdπ d1x ( ps )1/2 pm (1.25)
 ρ ps

where the positive sign is associated with negative values of x and negative sign with positive
ones.Using Cd (1/ ρ)1/2  6.7 for SI units with pressure in bars we get
Kq= 6.7 π d1 ( ps )1/ 2 (1.26)

Kc= 6.7 π d1 x  pm (1.27)

ps

6
1.3.2 Open Center Valve (Underlapped Three-Way Valve)

(u+x) (ux)

Figure 1.5 Open center–three-way valve.

Referring to Fig. 1.5, The orifice equation for q1 can be written as

1/ 2
2
q1 = Cdπ d1(u + x) ( ps  pc )  1/ 2
(1.28)
 ρ

Using binomial approximation we can write

1/2
1  pm 
q2 ≈Cdπ d1(u + x)  ps 
1/2
  1   (1.29)
 ρ  ps 

Similarly orifice equation for q2 can be written as

1/ 2
2
q2 = Cdπ d1(u − x) ( pc )   1/ 2
(1.30)
 ρ

Using binomial approximation we can write

1/2
1  pm 
q2 ≈ Cdπ d1(u − x)  ps 
1/2
  1   (1.31)
 ρ  ps 

The flow rateqc is the difference of q1 and q2, that is

qc = q1 – q2
1/ 2 1/ 2

≈ Cdπ d1  ps 1/ 2  1  2x − Cdπ d1  ps 1/ 2  1  2u

pm (1.32)
 ρ  ρ ps

Comparing with Eq. (1.1) we can write

Kq= 13.4 π d1 ( ps )1/2 (1.33)

 ps 
1/ 2

Kq= 13.4 π d1u (1.34)

ps

7
1.4 Flapper Nozzle Valve
Commonly used asthe first stage of two-stage servo valves, nozzles and the fixed upstream orifices
used with them are made with diameters d n and d 0 in the range 0.2–0.8 mm and the distance x0
between each nozzle and the flapper in a double valve is often less than 0.2 mm.Each nozzle and
orifice is as nearly a sharp-edged orifice as possible and treated as such for analytical purposes. The
curtain area formed by the flapper at a nozzle exit modulates the control pressure caused by the fixed
upstream orifice.

Orifice area
diameter

Load
Flapper

Figure 1.6 Flapper nozzle valve.

Consider a flopper nozzle valve indicated in Fig. 1.6. We assume that the valve has a balanced
condition such that x = 0 and pm = 0, q = 0. This occurs with the pressure downstream of each of the
fixed orifices iequal tops/2 and when the flow through each orifice equals that through each nozzle,
that is

q1 (steady state) = q3 (steady state) = Cd0 A0 ( ps  ps / 2)1/2 (2 / ρ)1/2 (1.35)

q2 (steady state) = q4 (steady state) = Cdn πdn x0 ( ps / 2)1/2 (2 / ρ)1/2 (1.36)
and q1  q2  q3  q4
This also implies that the orifice size and the curtain area in the null position are approximately equal

Cd0 A0 = Cdn πd n x0
Let us assume feasible ratio of
3
d n    do  d n = 8x0 (1.37)
2

Consideringthat the valve is not in balance, that is,x has the same value as pm has, we have
q = q1  q2
1/ 2
 p   x  x   ps pm 
1/ 2
p
 K n  ps   s  m    Kn  0   (1.38)
  2 2   x0   2 2 
where
Kn  Cd0 A0 (2 / ρ)1/ 2 = Cdn πdn x0 (2 / ρ)
1/ 2

Also
q = q3  q4
1/ 2
 p   x  x   ps pm 
1/ 2
p
  K n  ps   s  m    Kn  0   (1.39)
  2 2   x0   2 2 

8
Using binomial approximations, we have
p   p  p   p   p   x  p
1/2 1/2 1/2
p 
q  K n  s  1  m   K n  s  1  m   K n  s     s  m  (1.40)
 2   2 ps   2   2 ps   2   x0   2 2 

p     ps     ps   x   ps pm 
1/2 1/2 1/2
p pm
q   K n  s  1  m   K n   1    Kn       (1.41)
  
2 2 ps    
2 2 ps   2   x0   2 2 
Adding and dividing by 2, we get
q=  Kn ( ps / 2)1/2 pm / ps + Kn ( x / x0 )( ps / 2)1/2 (1.42)
thatis in the form of q  Kq x  Kc pm . Now
Kq  Kn / x0 ( ps / 2)1/2 = Cdn πdn (2 / ρ)1/2 ( ps / 2)1/2
Kc  Kn / ps ( ps / 2)1/2 = (Cdn πdn / ps )(2 / ρ)1/2 ( ps / 2)1/2
= (Cd0 A0 / ps )(2 / ρ)1/2 ( ps / 2)1/2

1.5 Special-Purpose Valves

The dynamic characteristics of hydraulic devices such as relief valves or flow-control valves are not
well understood. For design purposes, it is useful to know the likely influence of spool mass, spring
rate, orifice size or other parameter on the response of any particular valve to changes in pressure or
flow rate or to other disturbances. A pressure-control valve and a flow-control valve are considered
below.
1.5.1 Poppet Valves

Pressure control valve and flow control valves employs a poppet valve (Fig. 1.7) and their
characteristics will be influenced by the flow pattern existing at or near the valve seat.

Figure 1.7 Poppet valve.

For a poppet displacement x, the area of flow is Cdx π d sin ψ , where Cd is the flow coefficient. For a
pressure drop of p across the orifice formed between the seat and poppet, the fluid velocity v is
taken as equal to
1/ 2
 2p 
  (1.43)
 ρ 
and the volume flow rate as
1/2
 2p 
q= Cdx π d sin ψ   (1.44)
 ρ 
The momentum of the jet has an axial component equal to ṁv cosψ (where ṁ is the mass flow rate)
that may be written as
Axial component of momentum of jet ( = Mass flow rate ×Velocity

9
= Density ×Volume flow rate ×Velocity component

  2p   
1/ 2
 2p 
1/ 2


(maxial )   Cd x  d sin ψ      cos ψ  (1.45)
  ρ     ρ  

Please checkEq. (1.45)
where
λ = Cdπ d sin2ψ (1.46)
The axial component of jet momentum is λp x.

1.5.2 Single-Stage Relief Valve

Spring loaded valve is illustrated in Fig. 1.8. Let the pressure applied to valve to open is pIt is the
effects of small changes in this pressure from po to po  p that are to be considered. The outlet
(exhaust) pressure is assumed to be zero throughout.

( )

(m)

Figure 1.8 Relief valve.

With the poppet closed (i.e.,x = 0), there is some spring-related preload force holding it down that is
designated as F. Under a steady-state condition with a greater pressure applied than that needed to
overcome the preload, the valve partly opened and the poppet stationary, there is a steady-state
balance of forces relating this pressure to the poppet displacement. For the applied pressure p0 and the
poppet displacement x0, the relation is
πd 2
po = F+ ksx0+ λ po x0 (1.47)
4

If the approach velocity is negligible then λ , given in Eq. (1.46), and the fluid frictional drag force
across the poppet face is neglected.

For some other steady-state position of the poppet (displacement xo  x ), another pressure po  p
would occur according to
πd 2
( po  p )  F+ks( xo  x ) + λ ( po  p )( xo  x ) (1.48)
4
Note that Eqs. (1.47) and (1.48) refer to steady state with poppet stationary. Under dynamic
conditions with the poppet moving, the balance of forces has to take into account the effective mass of
the poppet m and any damping (assumed viscous of rate f) as well as spring, pressure and momentum
forces. For a pressure po  p and a poppet displacement xo  x , the balance forces become
πd 2
( po  p )  F+ ksx0 + λ po x0 + λ x0 p + (ks + λ p0) x + f Dx + mD2x (1.49)
4

10
Assume that the terms involving px are negligibly small. Subtracting Eq. (1.47) from Eq. (1.49), we
get
πd 2
p − pλ x0= (ks+ λ po ) x +f Dx + mD2x
4
Indicating a second-order relation between changes in pressure p and changes in poppet
displacement x given by
x K
 (1.50)
p  1  2  2 
 2  D    D 1
 n   n 
where
(πd 2 / 4 )  λ x0
K
(ks  λ po )

= (ks+ λ po ) /m
This relation suggests that any oscillation of the poppet is associated with much stiffer spring than the
physical spring constant would suggest. As a numerical example, consider a valve of diameter d =
6mm for use at a nominal pressure of po = 70 bar. The projected area equals 28 mm2 , so that the
value of F is approximately 20 N andif this is obtained by initially compressing the spring 10mm, the
spring rate would have a valve of ks = 20 N/mm. Assume that the poppet has a 90 cone angle and
flow coefficient cd = 0.7, then λ for the valve is about 13.2 mm and λ po = 92.4 N/mm. The
effective spring rate is not 20 but 112.4 N/mm. If the effective mass were 0.001 kg, then the natural
frequency n of poppet oscillations would be 533 Hz.

1.6 Pressure-Compensated Flow-Control Valve

Figure 1.9 illustrates a pressure-compensated flow-control valve which is designed to pass a constant
flow rate of fluid despite fluctuations of the inlet and outlet pressures. The device has two orifices in
series:one is preset manually to select the desired flow rate, while the other varies with the pressure
difference across the valve. The aim is to keep the flow rate constant by maintaining a constant
pressure difference across the present orifice.

For analysis, changes in the outlet pressure pL represent the disturbances externally imposed on the
device with the inlet (supply) pressure ps assumed constant. This simulates a meter-in control with
the poppet valve partly open and this analysis concerns small changes in this valve opening. The fully
open or fully closed conditions are not dealt with. The datum for spring force acting on the spool is
taken from some arbitrary position of the spool represented by the poppet (i.e., control orifice)
opening of xo .

11
 Annular
control orifice Oil inlet
Moving spool

Spring

Manually Oil outlet

preset orifice

Figure 1.9 Pressure-compensated flow-control valve.

1.6.1 Forces
The steady-state balance of forces for some equilibrium operating position with the poppet stationary
and open distance x0 , for a supply pressure ps , outlet pressure pLo and consequent chamber pressure
pCo is given by

( pCo − pLo ) Ap = F− λ ( ps − pCo ) xo (1.51)

Under dynamic conditions with the spool in motion for the outlet pressure pLo + pL , with the
instantaneous spool position distance x to the left of its initial position, noting that pCo + pc is the
instantaneous chamber pressure, the balance of forces is given by

{( pCo + pc ) −( pLo + pL } Ap = F− ks x– λ { ps –( pCo + pc )}(x+ xo )−f Dx – mD2x (1.52)

Assuming that pc pL and xare small and the terms pc x may be neglected, subtracting Eq. (1.52) from
Eq. (1.51) gives
ks  λ ( ps  pCo ) f m Ap
− pc = x+ Dx + D2x− pL (1.53)
Ap  λxo Ap  λxo Ap  λxo Ap  λxo
1.6.2 Flow Rates
Under steady-state condition, the flow rate through control orifice must be equal to that through the
preset orifice. Hence, for the steady conditions previously used with the constant ps , the outlet pLo ,
the chamber pressure pCo and control orifice opening xo using the subscript e for the preset orifice,

1/ 2
 2( p  pCo ) 
1/ 2

q0 = Cdx0π d  s  = Cdeae  2( pCo  pLo )  (1.54)

 ρ   ρ 

Under dynamic conditions, the flow rate through the control orifice will no longer be equal – the flow
through the control orifice is qo  qi and that through preset orifice qo  qe . The difference between the
two flow rates (into and out from the valve chamber) causes compression of the oil in the valve
chamber or
V
qo  qi  D pc (1.55)


12
whereV is the volume of oil and  is the effective bulk modules. In Eq. (1.55),V is assumed to be
constant.The flow rate through the control orifice may be written as
1/2
2
qo  qi  Cd ( x  xo ) π d   { ps – ( pCo  pc )}2  Ap Dx (1.56)
 ρ
Subtracting Eq.(1.54)from Eq. (1.56) neglecting the terms involving pc x we get

qo pc q
qi = − + o x +ApDx (1.57)
2 ps  pCo xo
and similarly for the change in flow rate through the preset orifice,
qo pc q pL
qe = = − o (1.58)
2 ps  pLo 2 pCo  pLo

Now subtracting Eq. (1.58) from Eq.(1.57) gives

qo q pL q  1 1 
qi  qe = Ap Dx+ x+ o  o   pc (1.59)
xo 2 pCo  pLo 2  ps  pCo pCo  pLo 
Also equating Eqs. (1.55) and (1.59) after substituting Eq. (1.53) for pc and after differentiating, for
D pc to obtain pc andD pc terms of pL and x leads to (closed loop) relation between displacements of
the spool and changes of the outlet pressure
ao D3 x + a1 D 2 x + a2 D x + a3 x = K pL + TD pL (1.60)
x K  TD
  (1.61)
pL ao D3  a1 D 2  a2 D  a3
where
qo
a3  ks Q  ( Ap   xo )
xo
V 
a2  fQ  ks    Ap ( Ap   xo )
 
V 
a1  mQ  f  
 
V 
a0  m  
 
V 
T  Ap  
 
qo qo
K = Ap  λxo
2  ps  pCo  2  pCo  pLo 
qo qo
Q= 
2  ps  pCo  2  pCo  pLo 
ks  ks  λ( Ps  PCo )
This linear equation is obviously difficult to apply particularly as the coefficients depend on the initial
conditions that might be classed as the “normal” operating conditions. In practice,the valves of this
type can be unsatisfactory at initial stage. The relation does indicate that a value is stable if a1a2 is
greater than a3 ao and confirms that increasing the viscous damping helps to stabilize the valve,
increasing both a1 and a2 .

13
Example 1.1
A four-way valve with full periphery annular ports has a 6 mm diameter spool and it may be assumed
that the spool lands fully cover the valve ports in zero or mid-position. Estimate the flow rate through
one port when the pressure drop across it is 70 bar for every mm of spool displacement.

Solution
Spool diameter (d) = 6mm
Pressure drop (Δp) = 70 bar
Spool displacement (x) = 1mm
By the orifice flow equation, theflow rate is
q  Cd πdx 2Δp / ρ
Letting Cd = 5/8 and ρ = 870 kg/m3 and Δpin bar, we have
q  6.7πdx 2Δp
Therefore,
q= 6.7  π(6 × 103) × (1 × 103) × 2  70
 q= 1.494 × 103 m3/s

Example1.2
What would be the flow coefficient Kq of the above valve if it is used as part of a servo system
having oil supply pressure: (a) 140 bar, (b) 210 bar?

Solution:

(a) Supply pressure (ps) = 140 bar. We know Kq  6.7πd ps . Therefore,

Kq = 6.7×π(6 × 103) × 140 = 1.494 m3/s/mm
(b)Supply pressure (ps) = 210 bar. We know Kq  6.7πd ps . Therefore,
Kq = 6.7 × π (6 × 103) × 210 = 1.83 m3/s/mm

Example1.3
A three-way spool valve with half the annular periphery of the valve port blocked off and spool
diameter 9 mm is used in a system supplied with oil at 120 bar pressure. The half-area piston has
areas 0.004 m2 and 0.002 m2 and a maximum required velocity 0.3 m/s. Estimate the maximum spool
displacement required. (Assume one-third pressure drop through valve.)

Solution: Supply pressure (ps) = 120 bar. Spool diameter (d) = 9mm. Piston area (Ap) = 0.004m2.
Maximum velocity (v) = 0.3m/s. Maximum valve flow rate is
Q = Ap × v = 0.004×0.3 = 1.2 × 10–3 m3/s
Pressure difference across load (pm) = 40 bar (one-third of supply pressure).
For a three-way valve with half-area piston, the pressure drop is
Δp = (ps/2) −pm = 20 bar
Also from the orifice equation we can write

14
 q= 6.7 × π (9 × 10–3) × x × 2  20

 q= 1.198 × x
Equating two values of Q and q, we have
1.2 × 103 = 1.198 × x
 x = 1.0016mm.
As half the annular periphery of valve is blocked, for the same flow rate, the displacement required is
twice the calculated value.Therefore, the valve displacement is
y = 2 × x = 2.003mm

Example 1.4
In a 240-bar servo system employing a four-way valve, a valve underlap is used to assist in damping
system oscillations. The valve has a 4-mm-diameter spool, full periphery ports and nominal underlap
of 0.0127 mm. Estimate the pressureflow coefficient Kc for the valve.

Solution: Supply pressure (ps) = 240 bar. Spool diameter (d) = 4mm. Underlap(u) = 0.0127mm. We
know
6.7 pdu 6.7    (4 103 )(0.0127 103 )
Kc    6.9 109 m3 /s/bar
ps 240

15
Objective-Type Questions
Fill in the Blanks
1. In critical center valves, the lands of the spool are of the ______ as the annual ports of the valve
body in the central or null position where the lands exactly cover the ports.
2. A valve in which the land of the spool never completely covers the ports of the valve body is said
to be ______.
3. ______ is commonly used as the first stage of two-stage servo valves.
4. A pressure-compensated flow control valve is designed to pass a ______ of fluid despite
fluctuations of the inlet and outlet pressures.
5. Flow gain can be treated as ______ for a particular valve and supply pressure.

State True or False

1. The central spool position just closes both the supply and the exhaust port of the valve.
2. Most hydraulic servo mechanisms or other high-performance systems rely for their operation on the
metering of fluid through a valve.
3. Metering valves are always fully open and their use is for accurately metering the flow of fluid
through them.
4. A spool valve used for metering purposes controls flow rate by throttling.
5. A pressure flow coefficient will vary with valve opening and the variation of pressure flow
coefficient are of major significance for linear analysis.

Review Questions
1. Discuss in detail the flow–displacement relationship of a critical center spool valve, giving its
possible applications in hydraulic control valves.
2. Discuss in detail the flow forces acting on apressure-compensated flow control valve and derive an
expression for these forces.
3. Derive an expression for the flow–displacement relations of anunderlapped four-way valve.
4. Derive an expression for the flow for a flapper nozzle valve.
5.What is the major limitation of a flapper nozzle amplifier and how it can be overcome?
6.Why is a feedback system used in a multistage servo valve?
7. What is a critical center valve?
8. What does an underlapped four-way valve mean?
9. Give two applications of a flapper nozzle valve.
10. How is a higher flow rate achieved in an electrohydraulic servo valve?
11. Why is a feedback system used in a multistage servo valve?
12. Illustrate the two different types of feedbacks used in a multistage electrohydraulic valve?
13. What is the major limitation of a flapper nozzle amplifier and how it can be overcome?

Answers
Fill in the Blanks

1.Same width
2.Underlapped
3.Flapper nozzle valve
4.Constant flow rate
5.Constant

State True or False

1.True
2.True
3.False
4.True
5.False

16
17
 Lecture 22
PROPORTIONAL CONTROL VALVES

Learning Objectives

Upon completion of this chapter, the student should be able to:

 Appreciate the history of proportional control valves.

 Explain the operation of proportional solenoids.
 Describe various design considerations for proportional control valves.
 Describe various proportional direction and proportional pressure control valves.
 Explain the working of two-stage proportional valves.
 Compare a proportional valve and a servo valve.
 Describe the various applications of proportional valves.

1.1 Introduction

Proportional control valves can be operated easily using a solenoid. Solenoid controls have a
digital control system: A valve is opened when the solenoid is energized and is closed when it is
de-energized or vice versa. They are very quick in their operation and thus give rise to pressure
and flow surges in the fluid power control units. If the control valves can be gradually opened or
closed as a manually operated house tap, it results in a gradual transition between a fully opened
and a fully closed position. These valves are operated by the application of electronics rather than
just electrical switching. The advantage of these valves is that they give greater flexibility in the
system design and operation. They also decrease fluid power circuit complexity especially for
processes requiring multiple speed or force outputs.

1.2. History of Proportional Control Valves

A proportional valve is a valve that produces an output (direction, pressure, flow) that is
proportional to an electronic control input. The output force exerted by the armature of a DC
solenoid depends on the current flowing through it. This can be utilized in the design of a
proportional DC solenoid in which the force exerted by the armature is proportional to the current
flowing and independent of the armature over the working range of the solenoid.

In earlier days, there were only two types of electrically operated valves – solenoid valves and
servo valves – that had a huge performance gap. Solenoid valves were either actuated or
unactuated (i.e., fully open or fully closed) and had no intermediate position; thus, solenoid
valves facilitated very little control. These were simply ON–OFF valves and their maximum
frequency was 5 Hz or less. Servo valves, in contrast, were continuously controlled, high-
frequency response devices that received commands through their electronic control systems that
provided a high degree of control over position, velocity, acceleration, etc. They had high
accuracy. They could accept and accurately respond to command signals at frequencies exceeding
100 Hz. The continuous feedback from electronic transducers ensured high accuracy. Between
these extremes, there was nothing just a huge gap in performance, control capability and cost.
With the advent of proportional control valves, the situation changed. The design of their
actuating device allowed the spool to be stopped at intermediate positions rather than only at the
ends of the solenoid stroke. The associated electronics controlled the spool positions and offered
a high degree of flexibility compared with the operation of the solenoid valve. The new valves
had a maximum frequency response of 10 Hz that was better than solenoids but less when
compared to servo valves. Thus, these valves were an intermediate between solenoids and servo
valves. There was no feedback from the circuit, so the controllability and control accuracy were
poor as compared to the parameters of the servo valves but greatly exceeded anything that could
be achieved by solenoid valves. The final result was a valve that stood comfortably between a
solenoid and a servo valve in performance, cost and complexity.

With the evolution of performance and application of proportional control valves, the efficiency
increased. First a spool position feedback loop was added; next came improvements in the design
of spools and the electronics; then came the external feedback systems, high-frequency
responses, better performance in accuracy, hysteresis, dead band, threshold and other parameters.
In short, the proportional valves began to look more and more like servo valves in capability. This
was accompanied by an increase in cost and thus blurred the distinction between servo valves and
proportional valves. As a result, performance and control are no longer distinguishing criteria.
Rather physical features such as design and manufacturing processes are the defining
characteristics. For instance, proportional valves are operated by proportional solenoids whereas
servo valves are operated by torque motors. The spools in proportional valves are almost entirely
machine produced, while the spools in servo valves require a great deal of manual lapping and
finishing. The clearances and tolerances in servo valves are much tighter than in proportional
valves. These differences mean that servo valves are still more expensive than proportional valves
and also that they outperform proportional valves in terms of accuracy, hysteresis, leakage, etc. It
is fair to say that a proportional valve can be linked to a low-cost, low-performance-range servo
valve. These valves are divided into three types – directional, pressure and flow controls.

1.3 Proportional Solenoids

A directional control valve is the most common electrohydraulic proportional control valves
(EHPV). The general aspects of its operation can also be applied to pressure and throttle valves.
Though they look like solenoid valves, there are significant differences between the two. Both
types have solenoids, and both have a valve body with a movable spool port and other
components. We will look at the differences beginning with solenoids.

1.3.1 Proportional Solenoids

All standard solenoids have no intermediate positions; rather they are always at one end or the
other of the solenoid stroke. The magnetic flux attempts to drive the plunger to its fully closed
position when the coil is energized. The force developed by the solenoid is a function of square of
the solenoid current and inverse function of square of the air gap. The result is that the force
increases as the air gap closes as well as when the current increases. A typical force–displacement
curve is shown in Fig. 1.1.
 Force (N)
Plunger displacement

Figure 1.1 Solenoid force versus stroke atconstant current.

The solenoid force is at its minimum when the plunger is at the maximum position. By
incrementally increasing the current in a particular solenoid, we can generate a family of curves
(Fig. 1.2).

2A
1.5
Force (N)

A 1A

Stroke

Figure 1.2 Solenoid force versus stoke curves with increasing current.

If there is a spring, then it is an additional design requirement. Let us assume a spring whose
force is a linear function of its compressed distance ( F  kx ). If we plot the spring force versus air
gap dimension, we get a graph shown in Fig. 1.3. From this plot, we can see that for a valve to
operate at all, we must provide a current that ensures sufficient force to overcome the spring force
throughout the plunger stroke. If the solenoid force ever drops below the spring force, the
solenoid stops. The dependence of spring force on its compressed distance is shown in Fig. 1.3.
 Spring force curve

2A
1.5

Force (N)
A 1A

Stroke

Figure 1.3 Solenoid force versus stroke with spring force.

A proportional solenoid differs from a standard solenoid in the design of the area near the end of
the plunger stroke. In the design of a basic solenoid, the air gap is closed at a uniform rate as the
plunger moves in. Because the square of the air gap dimension appears in the denominator of the
force equation, the solenoid force increases exponentially as the gap closes. The design of a
proportional solenoid eliminates the effect of diminishing air gap dimension at the end of the
plunger stroke by utilizing constructional features that maintain a constant effective air gap or by
using a magnetic impervious material to which the solenoid appears as a constant air gap. The
results for any given current are a force curve similar to that in Fig. 1.4.

Constant air gap portion

of stroke
Force (N)

Stroke

Figure 1.4 Proportional solenoid force versus stroke at constant current.

The flat portion of the curve occurs in the constant air-gap portion of the stroke. Figure 1.5 shows
the variation of force versus stroke for various values of current.
 2A
1A

Force (N)
0.5 A

Stroke

Figure 1.5 Proportional solenoid force versus stroke for varying current.

Use of a carefully designed, calibrated spring to oppose the solenoid force results in a solenoid
force versus spring force arrangement as shown in Fig. 1.6. The concept is to have the spring
force curve intersect the solenoid force lines in the flat portion of the solenoid force lines. Thus,
the solenoid plunger position (and, subsequently, the valve spool position) can be controlled by
the current applied. A higher current produces a higher solenoid force that compresses the spring
until the spring force balances the solenoid force. When this force is balanced, the plunger stops.
The position at which the plunger (spool) stops determines the size of the flow path through the
valve. This along with the pressure differential across the valve determines the fluid flow rate
through the valve. The functional result is that flow direction and flow rate can be controlled with
a single valve. This portion of the solenoid stroke is known as the control zone. The length of this
zone is only about 0.06–0.08 inch (0.15–0.20 cm). The total plunger stroke is also small, usually
about 0.120 inch (0.3 cm).

represents discrete spool positions

2A
1A
Force (N)

0.5 A

Stroke

Figure 1.6 Proportional solenoid force versus stroke with spring force overlaid.

1.4 Design Considerations of Proportional Control Valves

The output force exerted by the armature of a DC solenoid depends on the current flowing
through it (Fig. 1.7). This fundamental concept can be used in the design of a proportional DC
solenoid in which the force exerted by the armature is proportional to the current flowing through
it and independent of the armature movement over the working range of the solenoid. A typical
characteristic is shown in Fig. 1.7.

Working range
Armature force (N)

Armature force
0.5 A

(N)
Armature movement
Solenoid current

Figure 1.7 Proportional solenoid characteristics.

1.4.1 Force Position Control

The electrical control to the proportional valve normally uses a variable current rather than a
variable voltage. If a voltage control system is adopted, any variation in coil resistance caused by
temperature change will result in a change in current. This problem is eliminated by using a
current control system. It is possible to control a force electrically. By applying the force to a
compression spring, its deflection can be controlled. If the spool in a valve (as in Fig. 1.8) is acted
on by a spring at one end and a proportional solenoid on the other, the orifice size can be varied
along with the control current.

Figure 1.8 Diagrammatic section of a proportional control valve.

The flow from the valve is proportional to the current flowing through the solenoid. Because of
the difficulties in manufacturing a zero lap spool, overlapped spools are used in proportional
spool valves. This means that the spool has to move a distance equal to the overlap before any
flow occurs through the valve, giving rise to a dead zone as shown in Fig. 1.9.

Dead zone
Flow

200 mA
Solenoid current

Figure 1.9 Flow current characteristics of a proportional control valve.

Notched spools gives better control of the flow rate because the orifice is progressively opened.
Notch shape determines the amount of maximum flow. A diagrammatic representation of the
notched spool valve is shown in Fig. 1.10(a)together with an electrical control diagram in Fig.
1.10(b). A proportional directional control valve with a double solenoid and spring centered is
similar to the notched spool valve except that it has a solenoid at each end of the spool and
spring-centering device. The symbol for such a valve is shown in Fig. 1.11as either a five-
position [Fig. 1.11(a)] or a three-position valve [Fig. 1.11(b)]; both symbols are in common use.
The extremes on a five position valve represent fully operated conditions.

(a)

(b)
 Figure 1.10 Notched spool proportional valve.(a) Valve construction;(b) electrical control
diagram.

(a) (b)
Figure 1.11 The symbols of a proportional directional control valve: (a) Five position;(b) three
position .

1.4.2 Spool Positional Control

In order to increase the accuracy and extend the range of applications of proportional control
valves, a linear transducer may be fitted to measure the spool position. The output from the
transducer is a voltage that is proportional to the spool displacement and it continuously varies
through the total spool movement. The actual position of the spool is fed back via the transducer
to the electrical control system and then compared with the required position, the control current
being adjusted accordingly. Such a system is shown in Fig. 1.12.

Figure 1.12 The symbols of a proportional directional control valve.

, In such valves spool opening and the flow rate is controlled in both forward and return direction.
The transducer used for the position feedback of the spool does not monitor the quantity of fluid
flowing through the valve. So it is an open-loop control system. If additional accuracy is required,
it is possible to use a transducer to measure the system output and feed this back to the control
circuit. In the speed control circuit of a hydraulic motor shown in Fig. 1.13, a tachogenerator or a
similar device is used to measure the speed, in which case the effect of the “dead zone” must be
considered. This will be more critical in the case of position control rather than speed control.
 Figure 1.13 Closed-loop speed control with a proportional valve.

1.4.3 Proportional Pressure Control

In a conventional pressure control valve, a spring is used to control the pressure at which the
valve operates. The spring is replaced by a DC solenoid in the case of proportional valves; the
force set up by the solenoid is controlled by being dependent on the current flowing through it.

1.4.3.1 Single-Stage ProportionalRelief Valves

Direct-acting proportional relief valves are shown in Fig. 1.14. The proportional solenoid exerts a
force on the poppet keeping the valve closed, until the hydraulic pressure at port P overcomes this
force and opens the valve. In the design of the relief valve, the proportional solenoid acts directly
on the valve poppet.

Solenoid
coil

Armature

P T Light
return
spring
Figure 1.14 Direct-acting proportional relief valve.

1.4.3.2 Proportional Pressure-Reducing Valves

This operates in a manner similar to a conventional pressure-regulating valve, with the control
spring being replaced by a proportional solenoid. When this solenoid is not energized, the
proportional valve is closed unlike the conventional pressure reducing, which is normally open.
The output pressure of the valve, shown diagrammatically in Fig.1.15 is proportional to the
current flowing through the solenoid.

Figure 1.15 Proportional pressure-reducing valve.

When the solenoid is energized, it moves the spool to the right, the control orifice A opens and
allows fluid to flow to the output port X. As the aperture of orifice A increases, the aperture of
orifice B reduces; the pressure at the control output X is dependent upon the openings of control
orifices A and B. This is shown in Fig. 1.16.

Figure 1.16 Principle of a pressure-reducing valve.

Let the supply pressure be p1. The pressure drops across the control orifices A and B are pA and
pB, respectively, and the output pressure is px.Then

p pA  pB and pX  pB

If the control orifice B is fully closed, px equals the supply pressure p1.The output pressure is
applied to the right-hand end of the spool and if this is greater than the equivalent pressure
exerted by the proportional solenoid, the spool moves to the left. This increases the opening of
orifice B and reduces that of orifice A, reducing the output pxa = F. The output pressure is
proportional to the current flowing in the proportional solenoid. There is always a flow to the tank
from this type of valve if the output pressure px is less than the supply pressure p1.It is essential
that there is no back pressure in the tank line if the valve is to function properly.

1.4.4 Two-Stage Proportional Valves

The valves already discussed have a maximum flow capacity of 5 LPM; to obtain higher flow
rates in valves, two-stage versions are available. A single-stage proportional pressure control
valve is used to pilot the main valve. These operate in a manner similar to conventional two-stage
valves.

1.4.5 Two-Stage Proportional Directional Control Valves

The pressure output from a proportional pressure-reducing valve is directed to move the spool of
the main valve against a control spring. Energizing solenoid 1 causes pressure to be applied to
pilot port X and hence to current in solenoid 1. As the main spool lands are notched, a movement
to the right progressively opens the flow paths from P to B and A to T. De-energizing solenoid 1
de-pressurizes spring chamber C and the control spring centralizes the spool.

(a)

Increasing pressure drop

across the valve

Dead zone
Flow

200 mA
Solenoid current
 (b)

Figure 1.17 Two-stage directional control.

Similarly, solenoid 2 controls the flow paths P to A and B to T. The symbol for such a valve is
shown in Fig. 1.1. The operating time of valve from mid-position to one extreme is the minimum
of 40–60 ms. The operating time can be dependent on the rate of increase or decrease of the
control current. The output flow from the valve depends on the pressure drop across the valve and
the control current in the solenoid.

1.4.6 Two-Stage Proportional Relief Valve

This is similar to a conventional two-stage relief valve but with a proportional pilot relief valve
controlling the main spool. The system pressure is applied via the control orifice to the pilot
stage.When the pressure exceeds the force generated by the proportional solenoid, the pilot stage
opens. This causes a flow across the control orifice with a resultant pressure drop. The pressures
on the main spool are out of balance and so the spool lifts thereby relieving the fluid. A small
conventional direct-acting relief valve can be incorporated into the design as an overload pilot to
protect the system from any possible malfunction of the proportional valve or electrical control
circuit.

1.4.7 Proportional Flow Control

Small flows may be controlled by using one pair of ports of a four-port, two-position proportional
directional control valve and higher flows may be controlled if two ports are coupled together.
These methods of connections are illustrated in Fig. 1.18. The flow through the valve is
proportional to the current flowing in the solenoid and to the pressure drop across the valve. The
flow characteristic is not precisely linear because the flow opening is not exactly proportional to
the applied current. By carefully designing notches in the spool, it is possible to obtain a variable
sharp-edged orifice; this reduces the effect on the flow of variations in the fluid viscosity.

Figure 1.18 Connection of a four-port proportional direction control valve single-path flow and
double-path flow capacity.
1.4.7.1 Pressure-Compensated Proportional Flow Control

If a constant pressure drop is maintained across the flow control valve orifice, the flow through
the valve is independent of any upstream or downstream pressure variations. This is achieved by
using a pressure-compensating cartridge, as employed in conventional flow control valves. The
compensator can be considered as a remotely operated pressure control valve, which continuously
varies its orifice opening to maintain a fixed pressure drop over the flow control orifice. The
pressure difference between the two pilots on the compensator valve, that is the pressure drop
across the flow control orifice, is equivalent to the fixed force set by the control spring of the
compensator valve.

1.4.7.2 Electrical Control of Proportional Valves

A block schematic for a proportional amplifier together with a current–time graph showing
ramping is shown in Fig. 1.19. The ramp-up control determines the rate at which the control
signal increases and hence the acceleration of the actuator. The ramp-down control corresponds to
the deceleration[Fig.1.19(b)]. The input level control determines the maximum value of the
control signal. A low-level dither signal is superimposed onto the control signal. It is an AC level
at 100 Hz. Its function is to keep the spool oscillating to overcome the effects of static
friction[Fig. 1.19(a)].

The feedback signal is either from the output current or from the spool position in the valve. The
feedback does not indicate the actuator conditions and it is still an open-loop system. In order to
close the loop, the transducer has to measure of the actuator (either position or speed), feed the
signal back and compare it with the output of the actuator, feed the signal back and compare with
the desired values. The difference between these values is converted into a new input signal. A
block diagram of a closed loop control system is shown in Fig. 1.20. Although closed-loop
control can be achieved using proportional valves, it would not be as accurate or have as fast
response as an electrohydraulic servo-valve-based system.
 Ramp-up Ramp-down
control control
Dither

Feedback

Ramp generator
Current
amplifier

Input level Output current

Maximum output current set

by input level control
Output current

Ramp up
Ramp-
set by
down
ramp-up
time set
control
by ramp-
down
control

Figure 1.19 Proportional amplifier:(a) Block schematic diagram;(b) current–time characteristics.

 Figure 1.20 Closed-loop control.

1.5.1 Response Speed and Dynamic Characteristics

A short travel speed of minimum mass and consequently low inertia is used in servo valves,
giving high response speeds and making servo valves suitable for dynamic applications. On the
other hand, a proportional valve spool has a longer travel and is biased to one position by a
control spring – the spool and spring combination have a much higher inertia than an equivalent
servo valve. The application of a dither signal reduces the effects of spool “stiction” and inertia in
both proportional and servo valves. Its value is usually adjustable and is set to give maximum
response speed without any flow or pressure fluctuations being set up by the dither current.

1.5.2 Hysteresis Effect

Spool position in a servo valve is controlled by a nozzle and flapper or jet pipe system with a
feedback link correction for the spool position. A proportional valve relies on the force exerted
by a DC coil acting against a spring to position the spool. There is a considerable difference in the
valve output depending on whether the current is increasing or decreasing. Proportional valves
have higher hysteresis than servo valves.

1.5.3 Null Position

Because of the underlap spool, a very slight change in the control current varies the output of a
servo valve about the zero flow position. In a proportional valve, there is no output until the
control current exceeds 200 mA that is required to overcome the spring preload and spool
overlap . Wherever fast response and accurate control are required, servo valves are best suited,
whereas proportional valves are economic. The differences between proportional and hydraulic
servo valves are given in Table 1.1. However, proportional valves are much more dirt-tolerant
and provide economical and satisfactory alternative for many applications.
Table 1.1 Comparison of proportional and servo valves

Parameter Proportional Hydraulic Valve Electrohydraulic Servo Valve

Valve lap Overlap spool, causing a “dead Zero or underlap valve spool.
zone” on either side of the null No dead zone.
position.

Response time for the 40–60 ms 5–10 ms

valve spool to move
fully over

Maximum operating Approx. 10 Hz Approx. 100 Hz

frequency

Hysteresis Without armature feedback approx. Approx. 0.1%

5%
With armature position feedback
approx. 1%
 Lecture 23
PROPORTIONAL CONTROL VALVES [CONTINUED]

1.6 Some Applications of Proportional Control Valves

There are many applications in which the precision of servo valves (discussed in Chapter 18) is
not needed, but more accuracy is needed than can be obtained with conventional valves.
Proportional valves were developed to fill this gap. Their use has increased significantly since the
mid-1970s. The following sub-sections present few applications of proportional control valves.

1.6.1 Control of Actuators

Proportional control valves are commonly used in speed control of actuators such as
counterbalancing circuits in broaching machine, three-axis CNC(computer numerically
controlled) machines, etc.

1.6.1.1 Speed Control of Cylinders

The conventional speed control of a cylinder is by meter-in, meter-out or spill-off flow control
valves. This sets a cylinder speed that can be manually varied. Alternatively, a cam drive can
progressively close or open an adjustable orifice in accordance with a preset speed profile that is
altered by changing the cam profile. Examples of these types of circuits are shown in Fig. 1.21.
The acceleration and retardation of a cylinder can be controlled by the following:

 Relief valves limiting the maximum pressure available to accelerate the load.
 Using a two-stage directional control valve with a choke pack to control the speed of
movement of the main spool.
 Using a variable displacement pump.
 Using internal cylinder cushions or external shock absorbers to decelerate the
cylinder.
 Building brake, deceleration and counterbalance valves into the circuit to control the
deceleration and sometimes the acceleration of the actuator.

All these manual methods are incapable of continuous variations whilst the system operates. A
proportional control valve in the cylinder circuit enables continuous regulation of speed,
acceleration and retardation. If a proportional control card is used to drive the valve, any
adjustments to the maximum current ramp-up and ramp-down have to be carried out by adjusting
potentiometers on the card. However, a microprocessor or minicomputer may be employed to
control the proportional valve by varying the solenoid current over different parts of the cycle.
(a) (b)

Figure 1.21 (a) Meter-out speed control. (b) Cam-operated speed control.

1.6.2 Speed Control of Hydraulic Motors

This is similar to the speed control of cylinders but it is relatively simple to monitor the motor
speed and use a feedback system to control the proportional solenoid as seen in Fig. 1.13. The
speed of response to changes in load or command limits the applications. For high response and
accurate speeds, servo valves must be used.

1.6.2.1 Position Control of Hydraulic Cylinders

In order to control the position of the piston rod, a transducer has to be used to monitor the actual
position. The output of the transducer is compared with the desired piston rod position and the
difference is fed to the current amplifier and then to the proportional solenoid. The output of the
current amplifier has to be biased so that any error signal that it receives provides a sufficiently
large output to drive the proportional valve out of the dead zone. Otherwise the system will
become unstable.

1.6.2.2 Pump Control Systems

In an ideal hydraulic system, the output of the power pack in terms of quantity flowing and
maximum pressure is matched exactly to the system demand but this situation is rarely ever
achieved. A proportional relief valve can be used as the main relief valve to set the maximum
pressure and the setting remotely varies with the system sequence. A secondary relief valve
should be fitted into the system as a safety feature in case of failure of the proportional relief
valve. Supply pressure is matched to the system demand by controlling the proportional relief
valve. It is only useful if the flow requirement of the system is constant.

In order to match the pump delivery to a system demand, a variable displacement pump has to be
used. One possibility is to use a pressure-compensated pump with a proportional relief valve
acting as a compensator (Fig. 1.22). The circuit has to include flow control valves. This method
has limited versatility and can be adopted when there is a series of actuators demanding different
pressures and the flows are operated sequentially.

Figure 1.22 Pressure-compensated pump with proportional pressure control.

In any system using flow control valves, there are associated pressure drops that can be
eliminated by removing the valves. In this case, the full pump output has to be utilized at all
times. Wherever the flow demand varies within different parts of the sequence, this can be
achieved by varying the pump displacement by electric motor drives and cam drives. But both
have limitations – the motor drive in response speed and cam in versatility. An alternative is a
proportional flow control valve and a proportional pressure control (Fig. 1.23). The pump output
can be exactly matched to the system demand. This gives a power efficient system with little heat
generation. This is shown in Fig. 1.23.

With valve A in the closed position, the directional valve C is piloted to the right which opens the
large pump control piston to the tank. The small piston causes the pump to move to zero
displacement. When a current is applied to the proportional solenoid on valve A, the orifice
partially opens and the fluid flows and provides the system pressure that is below the set pressure
of valve B. The pressures occurring across the orifice formed are applied to the pilots of valve C.
Valve C spool centralizes locking the displacement of the pump. The system pressure is set by the
proportional relief valve B. If the system pressure is greater than the setting pressure of B, the
valve opens causing a reduced pressure on the right-hand pilot of valve C that moves to the right,
thereby opening the large pump control piston to the tank. Pump displacement reduces until the
system pressure matches that set by valve B that balances valve C locking the displacement.
Thus, in this system the pump delivery and pressure can be matched to the system by remotely
operating the proportional flow and proportional pressure control valves A and B.

The response time is of the order of 50–100 ms. If a pressure surge occurs in the system, the
pump may not respond quickly enough to reduce the surge; therefore, the conventional pressure
relief valve D is fitted to cater for pressure surges. This valve should be set 20% above the
maximum operating pressure of the system.

The precise continuous regulation of flow pressure and displacement with consequential control
of speed, thrust, position, etc., achievable from modern servo and proportional systems has made
hydraulics indispensable in the field of modern drive and control techniques. The special
characteristics of this sophisticated equipment involve electronic circuitry matched to the
individual components. Therefore, system design and construction are naturally much more
complex than electrohydraulic digital control. Here commissioning a prototype may be time
consuming than in the case with conventional hydraulic equipment. Nevertheless, these
developments have presented the hydraulic design engineer with many exciting opportunities and
extended the application of the subject to new areas.

Figure 1.23 Pump with proportional pressure and flow control.

1.7 Analysis of Proportional Valves

2:1 Area ratio

A B

Figure 1.24 Cylinder circuit with a proportional valve.

The diagram of a proportional valve in a simple cylinder circuit is shown in Fig. 1.24. Let p1 be
the pressure drop between ports A and P, p2 the pressure drop between ports B and T, as shown
in Fig. 1.24. Q1 the flow corresponding to the pressure drop p1 and Q2 the flow corresponding to
the pressure drop p2 .The cylinder has an area ratio of 2:1 and proportional valve with 2:1area
ratio is used.

Using the orifice equations, we can write the expression for flow as

Q1  Cd A1 p1 (1.1)
Q2  Cd A2 p2 (1.2)

where Q1 is the flow into the cap end of the cylinder, Q2 is the flow out of the rod end of the
cylinder, A1 is the area of the orifice between ports P and A and A2 is the area of the orifice
between ports B and T.

The orifices have the same shape on both sides of the spool land. The number of grooves on one
side is twice the other side for a 2:1 area ratio proportional valve. The same orifice coefficient for
both sides shall be used.

The area ratio of the cylinder is 2:1; therefore, during the extension,

Q1
Q2 
2

Also

A1
A2 
2

Using the flow equations, we get

Q1  Cd A1 p1 (1.3)
Q1 A 
Q2  Cd A2 p2   Cd  1  p2 (1.4)
2 2
or we can write Q1 in terms of p2 as
Q1  Cd A1 p2

If A1  A2 , then we can show that

p1
p2 
4
(It is left as an exercise to the students.)

1.7.1 Overrunning Load

Suppose that the circuit shown in Fig. 1.24 has overrunning load during forward stroke. We can
write the force balance on the cylinder as
 pc Ac  Ff  FL  pr Ar (1.5)

where FL = W = load on the cylinder (N),Ff is the frictional force (N), pr is pressure at port B(Fig.
1.24). In this case, FL is negative, since the load is overrunning, that is, it is acting in the direction
of the movement of the cylinder. Solving for pr we get

pc Ac  Ff  FL
pr  (1.6)
Ar

The pressure drop across port P to a orifice in the proportional valve is

p1  ps  pc (1.7)

Neglecting any drop between the proportional valve outlet and the tank, we can write po  0 .
Then pressure drop from ports A to T is

p2  pr  po  pr (1.8)

If the area ratio is unity (i.e., A1  A2  A ), the orifice equation becomes

Q1  Cd A p1 (1.9)
Q2  Cd A p2 (1.10)

Squaring both sides and eliminating Cd A we get

Q12 p1
 (1.11)
Q22 p2
Q22
 p2  p1  (1.12)
Q12

Using Eqs. (1.7), (1.8) and (1.12) we can write

Q22
pr  ( ps  pc )  (1.13)
Q12

Equating Eqs.(1.6) and (1.13), we can now solve for the pressure at the cap end of the cylinder as

pc Ac  Ff  FL Q2
pr   ( ps  pc )  22
Ar Q1
Rearranging we get relationship between pc and other system parameters as
  Q 2  [ F  FL ]
ps  22   f
pc   1 
Q Ar
 Ac   Q2 
2

  2
 Ar   Q1 

Under certain conditions, pc can be negative, which means that a vacuum exists in the cap end of
the cylinder and the cylinder is not completely filled with oil. When this condition develops, the
positive control of the load is lost during extension.

Example 1.1

Consider the hydraulic system shown in Fig. 1.24 The cylinder ratio is 2:1, pressure
ps  100 bar, Ac  0.002032 m2 , Ar  0.001070 m2 , Ff  290 N .

(a) Find the load that will cause negative pressure at the cap end of the cylinder and
corresponding pressure at the rod end and pressure drop across port P to A and port B to T.

(b) If the load is 4450 N, find the pressure drop across port P to port A and corresponding
pressure at the rod end. Is it possible to obtain this pressure drop valve area ratio 1:1?

(c) If the valve area ratio is 2:1, what is the overrunning load? Comment on the result.

Solution

(a) Because the cylinder area is 2:1, we have

Q1  Q2 
Q2  or  12   0.25
2  Q2 

To find the load that causes the negative pressure on the cap end, set pc = 0. We know that

 Q 2  [ F  FL ]
ps  22   f
pc   1 
Q Ar
 Ac   Q2 
2

  2
 Ar   Q1 
 Q 2  F  FL
 0  ps  12   f
 Q2  Ar
 Q2 
 FL  ps  12  Ar  [ Ff ]
 Q2 
Substituting the values we get FL  100 105 [0.25]  0.001070  [290]  2965 N

Any load greater than 2965 N will cause a negative pressure at the cap end of the cylinder. If the
overrunning load is 2965 N, the pressure at the rod end is given by

pc Ac  Ff  FL
pr 
Ar
0  290  2965
  25 bar
0.001070
The pressure drop across the port P to port A orifice is

p1  ps  pc  100  0  100 bar

p2  pr  po  pr  25 bar
For any overrunning load greater than 2965 N, the valve will not create enough pressure drop
across port B to port A orifice to maintain the control of load.

(b) When the load FL  4450 N , we have

 Q 2  [ F  FL ]
ps  22   f
pc   1 
Q Ar
 Ac   Q2 
2

  2
 Ar   Q1 
[290  4450]
100  105 [0.25] 
 0.001070
 0.002032 
 0.001070   [0.25]

13.8785  105
  6.4579  105  6.4579 bar
2.14907
To create pc = −6.67 bar, the pressure drop across port P to port A orifice must be

p1  ps  pc
 100  (6.4579)
 106.4579 bar

which is not possible. Using Eq.(1.6) the required pressure at the rod end is

pAc  Ff  FL
pr 
Ar
6.4579  105  0.002032  290  4450
  26.61 bar
0.001070

(c) Let us use the valve with the area ratio of 2:1. We have A1 =2 A2
 Q1  Cd A1 p1 (1.14)
A1
Q2  Cd A2 p2  Cd p2 (1.15)
2

SolvingEqs. (1.14) and (1.15) we get

Q12 p
 1
4Q2 p2
2

Q12
 p1  p2 (1.16)
4Q22

Using Eqs.(1.7) and (1.8) and substituting in Eq. (1.16). Solving for the pressure at the end of the
cylinder, we can get

4Q22
pr  ( ps  pc )  (1.17)
Q12

Equating Eqs.(1.6) and (1.17) , we can now solve for pressure at the cap end of the cylinder as
 4Q 2  [ F  FL ]
ps  22   f
pc   1 
Q Ar
 Ac   4Q2 
2

  2 
 Ar   Q1 

Under certain conditions pc can be negative. This means a vacuum will exist in the cap end of the cylinder;
the cylinder will not be completely filled with oil. When this condition develops, positive control of load is
lost during the extension. It is instructive to determine what load will cause pc to go negative,

Setting pc  0 , we can find the maximum overrunning load that can be controlled as

 4Q 2 
FL  ps Ar  22   [ Ff ]
 Q1 

For 2:1 area ratio,

Q1
Q2 
2

Therefore

 4Q22 
 2  1
 Q1 

So
  4Q 2 
FL  ps Ar  22   [ Ff ]
 Q1 
 100  105  0.001070  290
 10990 N

Therefore, the 2:1 area ratio valve can control the overrunning load more than three times the size
load controlled with a 1:1 area ratio valve.Now the cap end pressure can be calculated using the
equation

 4Q 2  [ F  FL ]
ps  22   f
pc   1 
Q Ar
 Ac   4Q2 
2

  2 
 Ar   Q1 
100  105 [1]  [290  4450] / 0.001070
pc 
 0.002032 
 0.001070   [1]
61.12  105

2.8990
 21.0826 bar
Also
pc Ac  Ff  FL
pr 
Ar
21.0826  105 [0.002032]  290  4450

0.001070
 78.91bar

The pressure drop across the valve is

p1  ps  pc
 100  (21.0826)
 78.91bar

p2  pr  0  78.91bar
The total pressure drop across the valve is

p1 + p2 = 78.9178.91157.82 bar

Example 1.2
 Consider the hydraulic circuit with resistive load shown in Fig. 1.25. The cylinder ratio is 2:1,
pressure Ps  100 bar, Ac  0.002032 m2 , Ar  0.001070 m2 , Ff  290 N, FL  4450 N . If the valve
has 2:1 area ratio. Determine pr, pc and total pressure drop.

Figure 1.25 Control of resistive load.

Solution: We can write the force balance on the cylinder as

pc Ac  Ff  FL  pr Ar

where FL = W is the load on the cylinder (N) and Ff is the frictional force (N). Solving for pc we
get

pr Ar  Ff  FL
pc  (1.18)
Ac

If the area ratio is unity (i.e., A1  A2  A ), the orifice equation becomes

Q1  Cd A p1
Q2  Cd A p2

Solving we get
 Q12 p1

Q22 p2
Q12
 p1  p2
Q22

Also also using Eqs.(1.7) and (1.8) in Eq. (1.12) we get

Q12
pc  ps  pr  (1.19)
Q22
Equating Eqs.(1.18) and (1.19) and solving for pr we get

ps  [ Ff  FL ] / Ac
pr 
 Ar   Q12 
  2
 A1   Q2 

If FL  4450 N and other parameters as the same as Example 1.1, then

ps  [ Ff  FL ] / Ac
pr  (1.20)
 Ar   Q12 
  2
 A1   Q2 
100  105  [290  4450] / 0.002032

 0.001070 
 0.002032   4
 16.94 bar

Now substituting back into Eq.(1.18) we get

pr Ar  Ff  FL
pc 
Ac
16.94 105  0.001070  290  4450
  32.25 bar
0.002032

The pressure drop across the valve are

p1  ps  pc  100  32.25  67.75 bar

p2  pr  16.94 bar

So
ptotal  p1  p2
 67.75  16.94
 84.69 bar

If the valve has a 2:1 area ratio, we have

 Q12
p1  p2
4Q22
Equation (1.20) becomes
ps   Ff  FL  / Ac
pr 
 Ar   Q12 
  2
 A1   4Q2 
100  105  [290  4450] / 0.002032

 0.001074 
 0.002032   [1]
 50.16 bar
Substituting back into Eq.(1.18), we get
pr Ar  Ff  FL
pc 
Ac
50.16  105  0.001074  290  4450
  49.84 bar
0.002032

The pressure drop across the valve are

p1  ps  pc  100  49.84  50.16 bar

p2  pr  50.16 bar

So
ptotal  p1  p2
 50.16  50.16
 100.32 bar

To select a valve for this application, the designer must look in manufacturer’s literature and choose a valve
with 2:1 area ratio spool having an operating curve for ~100 bar pressure drop. The best control is achieved
if full spool stroke, or almost full spool stroke, is used to obtain the desired flow at the desired pressure
drop. For large pressure drop like 100 bar, here, we may have to use less than the full spool stroke. Sample
data for 2:1 spool area ration rated for 27 GPM with 10bar pressure drop is given in Fig. 1.26.
 Flow (GPM)

Control current (%)

Figure 1.26

From Fig. 1.26 it is clear that, a 65% current will give 30 GPM flow at 100 bar pressure drop.
Objective-type questions

Fill in the Blanks

1. A proportional valve is a valve that produces an output (direction, pressure, flow) that is _____
to an electronic control input.

2. The performance of a proportional valve is a compromise between a conventional solenoid

valve and _____ valve.

3. Proportional valves are operated by proportional _____, whereas servo valves are operated by
torque motors.

4. A proportional valve has a maximum frequency response of _____.

5. In a conventional pressure control valve, a spring is used to control the pressure at which the
valve operates. The spring is replaced by a _____ in the case of proportional valves.

State True or False

1. The response time for a proportional valve spool to move fully over is around 50 ms.

2. Notched spools give a better control of the flow rate.

3. All standard solenoids have no intermediate positions; rather they are always at one end or the
otherof the solenoid stroke.

4. A proportional solenoid maintains a diminishing air gap dimension at the end of the plunger.

5. An electrical control to a proportional valve normally uses a variable voltage rather than a
variable current.
Review Questions

1. Compare electrohydraulic servo valves with proportional hydraulic valves.

2. Where are proportional valves preferred?
3. Explain the principle of a proportional pressure-reducing valve.
4. With the help of a neat sketch, explain how the speed of a cylinder can be controlled using a
proportional valve.
5. Discuss the various controls of proportional valves.
6. What is the difference between a standard solenoid and a proportional solenoid?
7. Explain the concept of operation of a proportional solenoid.
8. What is the purpose of dither in a proportional circuit?
9. Explain the difference between force control and position control in proportional control
valves.
10. What is a proportional valve?
11. What is a proportional solenoid?
12. Draw the symbols of proportional 3/2-way DCV.
13. Define resolution, accuracy and repeatability as applied to proportional valves.
14. Name three applications of proportional valves.
15. What is the difference between force-controlled and stroke-controlled proportional valves?
Answers

Fill in the Blanks

1. Proportional
2. Servo
3. Solenoids
4. 100 Hz
5. DC solenoid

State True or False

1. True
2. True
3. True
4. False
5. True
 Lecture 24

HYDRAULIC CIRCUIT DESIGN AND ANALYSIS

Learning Objectives
Upon completion of this chapter, the student should be able to:

 Identify the graphic symbols for various types of hydraulic components.

 Explain various hydraulic circuits to control single-acting and double-acting cylinders.
 Explain a regenerative circuit and determine the load-carrying capacities.
 Describe the working of a double-pump circuit along with its advantages.
 Explain the working of a sequencing circuit and a counterbalancing circuit.
 Differentiate between series and parallel synchronization circuits.
 Calculate the speed, pressure and load-carrying capacity of hydraulic circuits.
 Evaluate the performance of hydraulic circuits using various hydraulic elements.

1.1 Introduction
A hydraulic circuit is a group of components such as pumps, actuators, control valves, conductors and
fittings arranged to perform useful work. There are three important considerations in designing a
hydraulic circuit:

1. Safety of machine and personnel in the event of power failures.

2. Performance of given operation with minimum losses.
3. Cost of the component used in the circuit.

1.2Control of a Single-Acting Hydraulic Cylinder

Figure 1.1 Control of a single-acting cylinder.

Figure 1.1 shows that the control of a single-acting,spring return cylinder using a three-way two-position
manually actuated, spring offset direction-control valve (DCV). In the spring offset mode, full pump flow
goes to the tank through the pressure-relief valve (PRV). The spring in the rod end of the cylinder retracts
the piston as the oil from the blank end drains back into the tank. When the valve is manually actuated
into its next position, pump flow extends the cylinder.
After full extension, pump flow goes through the relief valve. Deactivation of the DCV allows the
cylinder to retract as the DCV shifts into its spring offset mode.

1.3Control of a Double-Acting Hydraulic Cylinder

2
 Figure 1.2 Control of a double-acting cylinder.

The circuit diagram to control double-acting cylinder is shown in Fig. 1.2. The control of a double-acting
hydraulic cylinder is described as follows:

1. When the 4/3 valve is in its neutral position (tandem design), the cylinder is hydraulically locked and
the pump is unloaded back to the tank.
2. When the 4/3 valve is actuated into the flow path, the cylinder is extended against its load as oil flows
from port P through port A. Oil in the rod end of the cylinder is free to flow back to the tank through the
four-way valve from portB through portT.
3. When the 4/3 valve is actuated into the right-envelope configuration, the cylinder retracts as oil flows
from port P through port B. Oil in the blank end is returned to the tank via the flow path from port A to
port T.

At the ends of the stroke, there is no system demand for oil. Thus, the pump flow goes through the relief
valve at its pressure level setting unless the four-way valve is deactivated.

3
1.4Regenerative Cylinder Circuit

Figure 1.3Regenerative circuit.

Figure 1.3 shows a regenerative circuit that is used to speed up the extending speed of a double-acting
cylinder. The pipelines to both ends of the hydraulic cylinder are connected in parallel and one of the
ports of the 4/3 valve is blockedby simply screwing a thread plug into the port opening. During retraction
stroke, the 4/3 valve is configured to the right envelope. During this stroke, the pump flow bypasses the
DCV and enters the rod end of the cylinder. Oil from the blank end then drains back to the tank through
the DCV.
When the DCV is shifted in to its left-envelope configuration, the cylinder extends as shown in Fig.
1.3.The speed of extension is greater than that for a regular double-acting cylinder because the flow from
the rod end regenerates with the pump flow Qp to provide a total flow rate QT .

1.4.1 Expression for the Cylinder Extending Speed

The total flow rate QT entering the blank end of the cylinder is given by
QT  Qp  Qr
where Qp is the pump flow rate and Qr is the regenerative flow or flow from the rod end.Hence,
Pump flow rate (Qp )  QT  Qr
But the total flow rate acting on the blank rod end is given by
(QT )  Ap vext
Similarly, theflow rate from the rod end is given by
(Qr )  ( Ap  Ar )vext
So pump flow rate is
Qp  Ap vext  ( Ap  Ar )vext

4
  Qp  Ar vext
The extending speed of the piston is given as
Qp
vext 
Ar
Thus, a small area provides a large extending speed. The extending speed can be greater than the
retracting speed if the rod area is made smaller. The retraction speed is given by
Qp
vret 
Ap  Ar
The ratio of extending and retracting speed is given as

vext Qp / Ar Ap  Ar Ap
   1
vret Qp / ( Ap  Ar ) Ar Ar

When the piston area equals two times the rod area, the extension and retraction speeds are equal. In
general, the greater the ratio of the piston area to rod area, the greater is the ratio of the extending speed to
retraction speed.

1.4.2 Load-Carrying Capacity During Extension

The load-carrying capacity of a regenerative cylinder during extension is less than that obtained from a
regular double-acting cylinder.The load-carrying capacity Fload-extension for a regenerative cylinder during
extension equals pressure times the piston rod area. This is because system pressure acts on both sides of
the piston during extension. Then
Fload-extension  pAr
Thus, wedo not obtain more power from the regenerative cylinder during extension because the extension
speed is increased at the expense of reduced load-carrying capacity.
1.5Pump-Unloading Circuit

Figure 1.4 Pump-unloading circuit.

5
Figure 1.4 shows a hydraulic circuit to unload a pump using an unloading valve.When the cylinder
reaches the end of its extension stroke, the pressure of oil rises because the check valve keeps the high-
pressure oil. Due to high-pressure oil in the pilot line of the unloading valve, it opens and unloads the
pump pressure to the tank.

When the DCV is shifted to retract the cylinder, the motion of the piston reduces the pressure in the pilot
line of the unloading valve. This resets the unloading valve until the cylinder is fully retracted. When this
happens, the unloading valve unloads the pump due to high-pressure oil. Thus, the unloading valve
unloads the pump at the ends of the extending and retraction strokes as well as in the spring-centered
position of the DCV.

1.6 Double-Pump Hydraulic System

Cylinder

4/3 DCV (solenoid-operated)

CV1

Pressure-relief
CV2 valve

Pressure-
unloading
valve

Low–pressure, High–
high-flow pump pressure,
low-flow
pump

Figure 1.5 Double-pump circuit.

Figure 1.5 shows an application for an unloading valve. It is a circuit that uses a high-pressure, low-flow
pump in conjunction with a low-pressure, high-flow pump. A typical application is a sheet metal punch
press in which the hydraulic cylinder must extend rapidly over a great distance with low-pressure but
high-flow requirements. This occurs under no load. However during the punching operation for short
motion, the pressure requirements are high, but the cylinder travel is small and thus the
flowrequirementsare low. The circuit in Fig. 1.5 eliminates the necessity of having a very expensive high-
pressure, high-flow pump.
When the punching operation begins, the increased pressure opens the unloading valve to unload the low-
pressure pump. The purpose of relief valve is to protect the high-pressure pump from over pressure at the
end of cylinder stroke and when the DCV is in its spring-centered mode. The check valve protects the
low-pressure pump from high pressure, which occurs during punching operation, at the ends of the
cylinder stroke and when the DCV is in its spring-centered mode.

6
1.7Counterbalance Valve Application

Load

Counterbalance
valve

Figure 1.6 Counterbalance valvein circuit.

A counterbalance valve (Fig. 1.6) is applied to create a back pressure or cushioning pressure on the
underside of a vertically moving piston to prevent the suspended load from free falling because of gravity
while it is still being lowered.

1.7.1 Valve Operation (Lowering)

The pressure setting on the counterbalance valve is set slightly higher than the pressure required to
prevent the load from free falling. Due to this back pressure in line A, the actuator piston must force down
when the load is being lowered. This causes the pressure in line A to increase, which raises the spring-
opposed spool, thus providing a flow path to discharge the exhaust flow from line A to the DCV and then
to the tank. The spring-controlled discharge orifice maintains back pressure in line A during the entire
downward piston stroke.

1.7.2Valve Operation (Lifting)

Asthe valve is normally closed, flow in the reverse direction (from port B to port A) cannot occur without
a reverse free-flow check valve. When the load is raised again, the internal check valve opens to permit
flow for the retraction of the actuator.

1.7.3 Valve Operation (Suspension)

When the valve is held in suspension, the valve remains closed. Therefore, its pressure setting must be
slightly higher than the pressure caused by the load. Spool valves tend to leak internally under pressure.
This makes it advisable to use a pilot-operated check valve in addition to the counterbalance valve if a
load must be held in suspension for a prolonged time.

7
1.8 HydraulicCylinder Sequencing Circuits

Sequence valve 1

Bending cylinder (B)

Clamp cylinder (A)

Sequence valve 2
W

Figure 1.7 Sequencing circuit.

Hydraulic cylinders can be operated sequentially using a sequence valve. Figure 1.7 shows that two
sequence valves are used to sequence the operation of two double-acting cylinders. When the DCV is
actuated to its right-envelope mode, the bending cylinder (B) retracts fully and then the clamp cylinder
(A) retracts.
This sequence of cylinder operation is controlled by sequence valves. This hydraulic circuit can be used
in a production operation such as drilling. Cylinder A is used as a clamp cylinder and cylinder B as a drill
cylinder. Cylinder A extendsand clamps a work piece. Then cylinder B extends to drive a spindle to drill a
hole. Cylinder B retracts the drill spindle and then cylinder A retracts to release the work piece for
removal.

1.9Automatic Cylinder Reciprocating System

8
 4/3 DCV (pilot-operated)

Figure 1.8Sequencing circuit.

The hydraulic circuit shown in Fig. 1.8 produces continuous reciprocation of a double-acting cylinder
using two sequence valves. Each sequence valve senses the completion of stroke by the corresponding
build-up pressure. Each check valve and the corresponding pilot line prevent the shifting of the four-way
valve until the particular stroke of the cylinder is completed.
The check valves are needed to allow pilot oil to leave either end of the DCV while the pilot pressure is
applied to the opposite end. This permits the spool of the DCV to shift as required.

1.10Locked Cylinder Using Pilot Check Valves

9
 4/3 DCV (solenoid-operated)

Figure 1.9 Locked cylinders with pilot check valves.

A check valve (Fig. 1.9) blocks flow in one direction but allows free flow in the opposite direction. A
pilot-operated check valve permits flow in the normally blocked opposite direction when pilot pressure is
applied at the pilot pressure port of the valve.
Pilot-operated check valves are used to lock the cylinder, so that its piston cannot be moved by an
external force. The cylinder can be extended and retracted by the DCV. If regular check valves are used,
the cylinder could not extend or retract. External force acting on the piston rod does not move the piston
in either direction thus locking the cylinder.

10
1. 11Cylinder Synchronizing Circuits

In industry, there are instances when a large mass must be moved, and it is not feasible to move it with
just one cylinder. In such cases we use two or more cylinders to prevent a moment or moments that
might distort and damage the load. For example, in press used for molding and shearing parts, the platen
used is very heavy. If the platen is several meter wide, it has to be of very heavy construction to prevent
the damage when it is pressed down by a single cylinder in the middle. It can be designed with less
material if it is pressed down with two or more cylinders. These cylinders must be synchronized. There
are two ways that can be used to synchronize cylinders: Parallel and series.

1.11.1 Cylinders in Parallel

F1 F2 F1 F2

Parallel Series
Figure 1.10Cylinders in parallel and series.

Figure 1.10shows a hydraulic circuit in which two cylinders are arranged in parallel. When the two
cylinders are identical, the loads on the cylinders are identical, and then extension and retraction are
synchronized. If the loads are not identical, the cylinder with smaller load extends first. Thus, the two
cylinders are not synchronized. Practically, no two cylinders are identical, because of
packing(seals)friction differences. This prevents cylinder synchronization for this circuit.

1.11.2 Cylinders in Series

During the extending stroke of cylinders, fluid from the pump is delivered to the blank end of cylinder 1.
As cylinder 1 extends, fluid from its rod end is delivered to the blank end of cylinder 2 causing the
extension of cylinder 2. As cylinder 2 extends, fluid from its rod end reaches the tank.
For two cylinders to be synchronized, the piston area of cylinder 2 must be equal to the difference
between the areas of piston and rod for cylinder 1. Thus, applying the continuity equation,

11
 Qout (cylinder1)  Qin (cylinder 2)
we get

( Ap1  Ar1 )v1  Ap2 v2

For synchronization, v1  v2 . Therefore,
( Ap1  Ar1 )  Ap2 (1.1)
The pump must deliver a pressure equal to that required for the piston of cylinder 1 by itself to overcome
loads acting on both extending cylinders. We know that the pressure acting at the blank end of cylinder 2
is equal to the pressure acting at the rod end of cylinder 1.
Forces acting on cylinder 1 give
p1 Ap1  p2 ( Ap1  Ar1 )  F1
Forces acting on cylinder 2 give
p2 Ap2  p2 ( Ap2  Ar2 )  F2
UsingEq. (1.1)and noting that p3  0 (it is connected to the tank), we have
p1 Ap1  p2 ( Ap2 )  F1 (1.2)
p2 ( Ap2 )  0  F2 (1.3)
Now, Eq. (1.2) + Eq. (1.3) gives
p1 Ap1  F1  F2 (1.4)
If Eqs. (1.1) and (1.4) are met in a hydraulic circuit, the cylinders hooked in series operate in
synchronization.

1.12SpeedControl of a Hydraulic Cylinder

The speed control of a hydraulic cylinder circuit can be done during the extension stroke using a flow-
control valve (FCV). This is done on a meter-in circuit and meter-out circuit as shown in Fig. 1.11. Refer
to Fig. 1.11(a). When the DCV is actuated, oil flows through the FCV to extend the cylinder. The
extending speed of the cylinder depends on the FCV setting. When the DCV is deactivated, the cylinder
retracts as oil from the cylinder passes through the check valve. Thus, the retraction speed of a cylinder is
not controlled. Figure 1.11(b) shows meter-out circuit; when DCV is actuated, oil flows through the rod
end to retract the cylinder.

12
 QFCV

CV FCV FCV
CV

(a) (b)

Figure 1.11Speed control of cylinders:(a) Meter in and (b)meter out.

1.12.1 Analysis of Extending Speed of Cylinder (Controlled)

When theFCV is fully open during extension, all the flow from the pump goes to the cylinder to produce
a maximum cylinder speed.When the FCV is partially closed, its pressure drop increases across the FCV.
This causes an increase in pressure p1. If closing is continued, pressure p1 reaches and exceeds the
cracking pressure of the PRV. This results in a slower cylinder speed because part of the pump flow goes
through the PRV.
The flow rate to the cylinder Qcyl is given by
Qcyl  Qpump  QPRV (1.5)
where Qpump is the flow rate of the pump and QPRV is the flow rate through the PRV. The flow rate
through the FCV is given by

p p  p2
QFCV  CV  CV 1 (1.6)
SG SG
where p is the pressure drop across the FCV, CV is the capacity coefficient of the FCV and SG is the
specific gravity of oil.The pressure p1 can be determined by summing forces on the hydraulic cylinder:
p2 Ap  Fload
Fload
 p2 
Ap
The extending velocity (controlled speed) of the cylinder is given by

13
 Qcyl QFCV
vcyl  
Ap Ap
Fload
pPRV 
CV Ap
 vcyl 
Ap SG

1.12.2 Meter-In Versus Meter-Out Flow-Control Valve Systems

In Section 1.12, the FCV is placed in the line leading to the inlet port of the cylinder. Thus, it is called the
meter-in control of speed. Meter-in flow controls the oil flow rate into the cylinder.
A meter-out flow control system is one in which the FCV is placed in the outlet line of the hydraulic
cylinder. Thus, a meter-out flow control system controls the oil flow rate out of the cylinder.
Meter-in systems are used primarily when the external load opposes the direction of motion of the
hydraulic cylinder. When a load is pulled downward due to gravity, a meter-out system is preferred. If a
meter-in system is used in this case, the load would drop by pulling the piston rod, even if the FCV is
completely closed.
One drawback of a meter-out system is the excessive pressure build-up in the rod end of the cylinder
while it is extending. In addition, an excessive pressure in the rod end results in a large pressure drop
across the FCV. This produces an undesirable effect of a high heat generation rate with a resulting
increase in oil temperature.

1.12.3 Speed Control of a Hydraulic Motor

Figure 1.12shows the speed control circuit of a hydraulic motor using a pressure-compensated FCV.The
operation is as follows:

 In a spring-centered position of the tandem four-way valve, the motor is hydraulically blocked.
 When the valve is actuated to the left envelope, the motor rotates in one direction. Its speed can
be varied by adjusting the throttle of the FCV. Thus, the speed can be infinitely varied and the
excess oil goes through the PRV.
 When the valve is deactivated, the motor stops suddenly and becomes locked.
 When the right envelope is in operation, the motor turns in the opposite direction. The PRV
provides overload protection if, for example, the motor experiences an excessive torque load.

14
 Figure 1.12 Speed control of a motor.

1.13Fail-Safe Circuits

Fail-safe circuits are those designed to prevent injury to the operator or damage to the equipment. In
general, they prevent the system from accidentally falling on an operator and also prevent overloading of
the system. In following sections we shall discuss two fail-safe circuits: One is protection from
inadvertent cylinder extension and other is fail-safe overload protection.

1. Protection from inadvertent cylinder extension: Figure 1.13 shows a fail-safe circuit that is designed
to prevent the cylinder from accidentally falling in the event when a hydraulic line ruptures or a person
inadvertently operates the manual override on the pilot-actuated DCV when the pump is not working. To
lower the cylinder, pilot pressure from the blank end of piston must pilot open the check valve to allow oil
to return through the DCV to the tank. This happens when the push button is actuated to permit the pilot
pressure actuation of DCV or when the DCV is directly manually actuated when the pump operates. The
pilot-operated DCV allows free flow in the opposite direction to retract the cylinder when this DCV
returns to its offset mode.

15
 M

Figure 1.13 Fail-safe circuits – inadvertent cylinder extension.

2. Fail-Safe System with Overload Protection: Figure 1.14 shows a fail-safe system that provides
overload protection for system components. The DCV V1 is controlled by the push-button three-way
valve V2. When the overload valve V3 is in its spring offset mode, it drains the pilot line of valve V 1. If
the cylinder experiences excessive resistance during the extension stroke, sequence valve V 4 pilot-
actuates overload valve V3. This drains the pilot line of valve V1 causing it to return to its spring offset
mode. If a person then operates the push-button valve V2 nothing happens unless overload valve V3 is
manually shifted into its blocked-port configuration. Thus, the system components are protected against
excessive pressure due to an excessive cylinder load during its extension stroke.

16
Sequence valve

V4

V3

V1

V2

Figure 1.14 Fail-safe circuits –overload protection.

17
18
 Lecture 25

HYDRAULIC CIRCUIT DESIGN AND ANALYSIS [CONTINUED]

1.14 Circuit for Fast Approach and Slow Die Closing

A machine intended for high volume production has a high piston velocity. If not controlled, the high-
speed platen approaching the job instead of making a smooth contact will bang on the job. This is not
desirable. In all such cases,“rapid traverse and feed circuits” are employed.

(5)

(6)

(3) (4)

Figure 1.15 Rapid traverse and feed circuit.

In the circuit shown in Fig. 1.15, pump delivery normally passes through FCV(3). During fast
approach,the solenoid-operated DCV (4) is energized. This diverts pump delivery to the cap end of the
cylinder through valve (4). Full flow is thus available for the actuator to advance at the rated speed. A few
millimeters before the platen makes contact with the die, solenoid valve (4) is de-energized forcing the
pump delivery to pass through FCV (3). The platen now approaches the die at a controlled speed because
the flow to cylinder (6) is now regulated. Directional valves (4) and (5), however, must be energized
simultaneously for the approach phase to begin.

Valves (4) to (5) are solenoid-controlled pilot-operated valves intended for handling large flows with
minimum pressure drop. While valve (5) requires a 4.5 bar check valve (6) in the return line to develop
the pilot pressure required to move the main spool, no such facility is required in the case of valve(4)
because the back pressure generated by valve (3) would serve as the pilot pressure for this valve.

1.15Rapid Traverse and Feed, Alternate Circuit

In this circuit (Fig. 1.16), full flow from the pump is allowed to the cap end through the directional valve
(3)for fast approach and the rod end oil freely passes through the normally open deceleration valve back
to the tank. Near about the end of the stroke, a cam depresses a roller attached to the deceleration valve
spool and therefore the valve shifts blocking the flow from the rod end. The flow now has only one
pathway back to the tank and that is through FCV (4). The approach speed is now governed by the setting
of this valve. During piston retraction stroke, full flow is allowed to the rod end through check valve (6).

(5)

(4)
(6)

(3)

(2)

(1)

Figure 1.16 Rapid traverse and feed circuit – alternate circuit.

Example 1.1
A double-acting cylinder is hooked up in a regenerative circuit. The relief-valve setting is 105 bar. The
piston area is 130 cm2 and the rod area is 65 cm2. If the pump flow is 0.0016 m3/s, find the cylinder speed
and load-carrying capacity for the

(a) Extending stroke.

(b) Retracting stroke.

Solution:

(a) We have
Qp 0.0016
vext    0.246 m/s
Ar 65  104
Fload-extension  pAr
 105  105  65 104
 68250 N

(b) We have
Qp 0.0016
vret    0.246 m/s
Ap  Ar (130  65)  104

2
 Fload-extension  p( Ap  Ar )
 105  105  (130  65)  104
 68250 N
Example 1.2
What is wrong with the circuit diagram given in Fig. 1.17?

Unloading Valve

Figure 1.17

Solution: A check valve is needed in the hydraulic line just upstream from where the pilot line to the
unloading valve is connected to the hydraulic line. Otherwise the unloading valve would behave like a
pressure-relief valve and thus, valuable energy would be wasted.

Example 1.3
What unique feature does the circuit of Figure 1.18 provide in the operation of the hydraulic cylinder?

3
 Figure 1.18

Solution:

1. It provides mid-stroke stop and hold of the hydraulic cylinder (during both the extension and
retraction strokes) by deactivation of the four-way, three-position DCV.
2. It provides two speeds of the hydraulic cylinder during the extension stroke:

 When the three-way, two-position DCV is unactuated in spring offset mode, extension speed is
normal.
 When this DCV is actuated, extension speed increases by the regenerative capability of the circuit.

Example 1.4
For the circuit of Fig. 1.19, give the sequence of operation of cylinders 1 and 2 when the pump is turned
ON. Assume that both cylinders are initially fully retracted.

Figure 1.19

4
Solution: Cylinder 1 extends, cylinder 2 extends. Cylinder 1 retracts, cylinder 2 retracts.

Example 1.5
What safety features does Fig. 1.20possess in addition to a pressure-relief valve. If the load on cylinder 1
is greater than the load on cylinder 2, how will the cylinder move when DCV is shifted into the extending
or retracting mode? Explain your answer.

Figure 1.20

Solution: Both solenoid-actuated DCVs must be actuated in order to extend or retract the hydraulic
cylinder.
Cylinder 2 will extend through its complete stroke receiving full pump flow while cylinder 1 will not
move. The moment cylinder 2 will extend through its complete stroke, cylinder 1 will receive full pump
flow and extend through its complete stroke. This is because the system pressure builds up until load
resistance is overcome to move cylinder 2 with the smaller load. Then the pressure continues to increase
until the load on cylinder 1 is overcome. This then causes cylinder 1 to extend. In retraction mode, the
cylinders move in the same sequence.

Example 1.6
Assuming that the two double-rod cylinders of Fig. 1.21 are identical, what unique feature does the circuit
in Fig. 1.21 possess.

5
 Figure 1.21

Solution: Both cylinder strokes would be synchronized.

Example 1.7
For the hydraulic system is shown in Fig. 1.22
(a) What is the pump pressure for forward stroke if the cylinder loads are 22000 N each and cylinder 1
has the piston area of 65 cm2 and zero back pressure?
(b) What is pump pressure for retraction stroke (loads pull to right), if the piston and rod areas of cylinder
2 equal to 50 cm2 and 15 cm2, respectively, and zero back pressure?
(c) Solve using a back pressure p3 of 300 kPa instead of zero, the piston area and rod area of cylinder 2
equal 50 and 15 cm2, respectively.
Solution:

(a)Pressure acting during forward stroke is

F1  F2 22000  22000
p1    6.77 MPa
Ap1 65  104
(b)For cylinder 2 we can write
p3 ( Ap2  Ar2 )  p2 Ap2  F2
For cylinder 1, force balance gives

p2 ( Ap1  Ar1 )  F1
But Ap2  Ap1  Ar1 . So we can write

p2 Ap2  F1
and rod side pressure of second cylinder is given by

6
 F1  F2 22000  22000
p3    12570000 Pa  12.57 MPa
Ap2  Ar 2 35  104

F1 F2

Ar1 Ar2

p2 p3

p1 Ap2 p2
Ap1

Figure 1.22

(c)For cylinder 1, we have

p1 Ap1  p2 ( Ap1  Ar1 )  F1
Similarly for cylinder 2, we have
p2 Ap2  p3 ( Ap2  Ar2 )  F2
Adding both equations and noting that Ap2  Ap1  Ar1 yield
p1 Ap1  p3 ( Ap2  Ar2 )  F1  F2


 F1  F2  p3 ( Ap2  Ar 2 ) 

 p1   

 Ap1 

 22000 N  22000 N  300000 N / m 2 (50  15) cm 2  104 m 2 
 p1   
 65 cm2  104 m2 
 p1  6.93 MPa

7
Example 1.8
For the double-pump system in Fig. 1.23, what should be pressure setting of the unloading valve and
pressure-relief valve under the following conditions:

(a) Sheet metal punching operation requires a force of 8000 N.

(b) A hydraulic cylinder has a 3.75 cm diameter piston and a 1.25 cm diameter rod.
(c) During the rapid extension of the cylinder, a frictional pressure loss of 675 kPa occurs in the line
from the high-flow pump to the blank end of the cylinder. During the same time, a 350 kPa
pressure loss occurs in the return line from the rod end of the cylinder to the oil tank. Frictional
pressure losses in these lines are negligibly small during the punching operation.
(d) Assume that the unloading valve and relief-valve pressure setting (for their full pump flow
requirements) should be 50% higher than the pressure required to overcome frictional pressure
losses and the cylinder punching load, respectively.

4/3 DCV (solenoid operated)

Pressure relief
CV1
valve

High-
pressure
line Pressure
unloading
valve

High-
pressure Electric motor
low-flow
pump Low-pressure
high-flow pump
Low-pressure line

Figure 1.23

Solution:
8
Unloading valve: Back pressure force on the cylinder equals pressure loss in the return line times the
effective area of the cylinder ( Ap  Ar ) :
N π
Fback pressure  350000  (0.03752  0.01252 ) m2  344 N
m2 4
Pressure at the blank end of the cylinder required to overcome back pressure force equals the back
pressure force divided by the area of the cylinder piston:
344 N
pcyl blank end   311 kPa
π
(0.03752 )m2
4
Thus,the pressure setting of unloading valve equals

1.50  675  311 kPa  1480 kPa

Pressure relief valve: Pressure required to overcome the punching operation equals the punching load
divided by the area of the cylinder piston:
8000 N
ppunching   7240 kPa
π
(0.03752 )m2
4
Thus, the pressure setting of pressure-relief valve equals
1.50 ×7240 kPa = 10860 kPa

Example1.9
Design a suitable hydraulic circuit to raise and lower a load of magnitude 10000 kgf at a speed of 100
mm/s. The speed must be equal both during raising and lowering of the load. The load is essentially
overrunning. The load must be lowered gradually onto the platform. Calculate the flow through the
control valves and indicate the pressure gauge readings both at the cap end and at the rod end during
raising and lowering. Explain your reasons for your choice of the hydraulic components. Neglect
mechanical and hydraulic losses. Assume 100 mm bore for the cylinder and a rod diameter = 45 mm.

Solution: In any double-acting cylinder the rod end area is smaller than the cap end area to the extent of
the piston rod cross-sectional area and so the pressure required to raise/lower the load is derived from the
rod end area. Accordingly, the pressure required to raise the load is
10000
 160 kgf/cm2  160 bar
 (10  4.5 )
2 2

4
The relief-valve setting pressure is 175 bar.
The cap end area =.7584(10)2 = 75.84 cm2.
If the cylinder has to extend and retract at the rate of 100 mm/s,the flow required at the cap end of the
cylinder is

(75.84 ×10) = 758.4 cm3/s or 47 LPM

Flow required at the rod end would be (62.6 ×10) = 626 cm3/s or 37.5 LPM.
Referring to the circuit in Fig. 1.24, a constant delivery pump with a pressure rating of 175 bar capable of
delivering 50 LPM has been chosen. A variable delivery pump would not help because both velocity and
pressure are constant throughout the cycle. It is required that the piston must travel both during extension

9
and retraction at the same speed. Thus, flow control valve (1) is used on the cap end of the cylinder
because pump supply is constant but cap end and rod end areas differ. Since it is an overrunning load, a
flow control valve became necessary (2) on the rod end (meter-out flow control).
Because it is required that the load must be positioned on the platform gradually, flow control (3) and
solenoid-operated DCV (4) become necessary. Toward the end of the stroke, the load makes contact with
a limit switch. This energizes valve (4) to divert rod end flow through the flow control valve (3) so that
the load is decelerated from 100 mm/s to 30 mm/s. In order to ensure accurate speed control pressure- and
temperature-compensated flow, flow control valves were chosen. Flow through the flow control valve (3)
during deceleration would be = 188 cm3/s or 11 LPM.
While raising the load, the required flow to the rod end of the cylinder is 37.5 LPM. But the pump is
supplying 50 LPM. The excess flow must pass over the relief valve which is set at 175 bar. The relief-
valve setting pressure of 175 bar creates a retracting force on the rod end equaling
(175 × 62.6) = 10955 kgf
Of this, 10000 kgf is required just to balance the load.

10000 kgf
pC PR

(4)
(4)

(2)
(1)

(3) Sensor
(1)
(3)
(2)

Figure 1.24
The remaining 955 kgf acting in the retracting direction has to be balanced by the backpressure due to the
flow control valve (1). Consequently, the pressure gauge Pc at the cap end during retraction would read
955/62.6 = 15 bar. When the load is lowered at a speed of 100 mm/s, the cylinder extends at a velocity of
100 mm/s. The flow entering the cap end of the cylinder is 47 LPM, which is less than the pump delivery,
which is 50 LPM.
The pressure gauge Pc would read 175 bar because the extra flow must be dumped over the relief valve.
In this operating condition, the extension force (175 ×75.84) = 13744 kgf, together with the load force =
10000 kgf, tries to extend the cylinder.

10
According to Newton’s first law of motion the net force must be equal to zero for an object moving at a
constant velocity, neglecting friction. So the balancing force at the rod end should be 23744 kgf.
Therefore, the pressure gauge Pr at the rod would read 23774 / 62.6 = 379 bar. At the end of high-speed
extension solenoid valve (2) is energized to decelerate the load from 100 mm/s to 30 mm/s. The time
duration around which this occurs depends on the valve response time that can be assumed as 20 ms or
0.020 s.
The deceleration
V  Vi
a f
t
where final velocity Vf  30 mm/s , initial velocity Vi  100 mm/s , δtis the time element = 0.020 s during
which time the change occurs. Substituting the relevant values, we obtain the value of a as 3500
mm/s2.Therefore, the force required to decelerate the cylinder is
F = ma
Now m= 10000/9.81 = 1019 kg . So
F = 1019 ×3.5 = 23566 kgf
Therefore
pR = (23744 + 3566)/62.6 = 436 bar

Example 1.10
For the fluid power system shown in Fig. 1.25,
(a) Determine the external loads F1 and F2 that each hydraulic cylinder can sustain while moving in an
extending direction. Take frictional pressure losses into account. The pump produces a pressure of
increase of 6.90 MPa from the inlet port to the discharge port and a flow rate of 0.00252 m3/s. The
following data are applicable:
Kinematic viscosity of oil 2
0.0000930 m /s
Specific weight of oil 7840 N/m
3

Cylinder piston diameter 0.203 m

Cylinder rod diameter 0.102 m
All elbows are 90 with k factor 0.75

Pipe lengths and diameters are given:

Pipe Number Length (m) Diameter Pipe number Length(m) Diameter
1 1.83 0.0508 6 3.05 0.0254
2 9.15 0.0317 7 3.05 0.0254
3 6.10 0.0317 8 12.2 0.0317
4 3.05 0.0254 9 12.2 0.0317
5 3.05 0.0254

(b)Determine the heat generation rate.

(c) Determine the extending and retracting speeds of cylinder.

11
 Cylinder 1 Cylinder 2

F1 F2
Tee k=1.8
1

6 7

4 5

Tee k=1.8 3

DCV, k=5

9 Elbow
2
Check valve
PRV k=4

1 Elbow

Figure 1.25

Solution:

(a) Cylinders 1 and 2 are identical and are connected by identical lines. Therefore, they receive equal
flows and sustain equal loads (F1 = F2).

Velocity is calculated from discharge and area as

Q (m3 /s)
v
A (m2 )
Head loss in the systems is given by

13  f L  v2
HL   K
p

1  Dp
 2g

Reynolds number is given by

12
 VD  VD VD
Re   
 / 
Flow through path 4 (Fig. 1.26) is given by

0.00252
Q4   0.00126 m3 /s
2
Flow through path 6 (Fig 1.26) is given by

(0.2032  0.1022 )
Q6  0.00126   0.000945 m3 /s
0.203
Similarly for paths 8 and 9 we can write

Q8  Q9  2  0.000945  0.00189 m3 /s
Velocity calculation:
0.00252 (m3 /s)
v1   1.24 m/s
 (0.0508)2 2
(m )
4
0.00252 (m3 /s)
v2, 3   3.19 m/s
 (0.0317)2 2
(m )
4
0.00126 (m3 /s)
v4   2.49 m/s
 (0.0254)2 2
(m )
4
0.000945 (m3 /s)
v6   1.86 m/s
 (0.0254)2 2
(m )
4
0.00189 (m3 /s)
v8, 9   2.39 m/s
 (0.0317)2 2
(m )
4

Reynolds number calculation:

1.24  0.0508
Re(1)   677
0.000093
3.19  0.0317
Re 2, 3   1087
0.000093
2.49  0.0254
Re(4)   680
0.000093
1.86  0.0254
Re(6)   508
0.000093
2.39  0.0317
Re(8, 9)   815
0.000093

All flows are laminar; hence we can calculate the losses in each branch. The general formula is
13  f L  v2
HL   K
p

1  Dp
 2g

where

13
 64
f 
Re
Hence the losses are

 64 1.83  1.24
2
H L (1)    7.5   0.33 m  7840  0.33 Pa  2560 Pa
 677 0.0508  2  9.81
 64 9.15  3.19
2
H L (2)    4  10.9 m  85500 Pa
 1087 0.0317  2  9.81
 64 12.2  3.19
2
H L (3)    6.8   15.3 m  120000 Pa
 1087 0.0317  2  9.81
 64 3.05  2.49
2
H L (4)    1.8   4.14 m  32500 Pa
 680 0.0254  2  9.81
 64 3.05  1.86
2
H L (6)   0  2.67 m  20900 Pa
 508 0.0254  2  9.81
 64 6.1  12.2  2.39
2
H L (8)  H L (9)    5.75   12.8 m  100500 Pa
 815 0.0317  2  9.81

Total force can now be calculated as

 (0.2032 )
F1  F2  [(6900000)  (2560  85500  120000  32500)]  –
4
  (0.2032  0.1022 ) 
(20900  100500)  
 4 

F1  F2  [216000]  [2940] =213000 N

(b)We have
Heat generation rate (power loss in W) = Pressure × Discharge

= {(2560  85500  120000)  (0.00252)  (2  20900  0.000945)  (2  32500  0.00126)  (100500  0.00189)}

= 524 + 39.5 + 81.9 + 190 = 835W = 0.835 kW

(c) Cylinder piston diameter = 0.203 m

 (0.2032 ) 2
Area of piston ( Ap ) = m
4
Cylinder rod diameter = 0.102 m
 (0.1022 ) 2
Area of rod = m
4
 (0.2032 )  (0.1022 )
Annulus area  Aannulus = 
4 4
Now

14
 Qcyl (m3 /s)
v
A (m 2 )

where each cylinder receives one half of pump flow because of the configuration of cylinder. Extension
velocity is given by

Qblank end (m3 /s)

vext 
Ap (m 2 )
0.00126
  0.0389 m/s
 (0.2032 )
4
Retracting velocity is given by

Q (m3 /s)
vret 
Aannulus (m 2 )
0.00253

 (0.2032 )  (0.1022 )

4 4
 0.0521 m/s

Example 1.11
Figure 1.26 shows a regenerative circuit in which an 18.65 kW electric motor drives a 90% efficient
pump. The pump discharge pressure is 6897 kPa. Take frictional pressure losses into account.
(a)Determine the external load F that the hydraulic cylinder can sustain in the regenerative mode (spring-
centered position of DCV).
(b) Determine the heat generation rate due to frictional pressures losses in the regenerative mode.
(c) Determine the cylinder speed for each position of the DCV.
The following data are applicable:

Kinematic viscosity of oil 0.0000930 m2 /s

Specific weight of oil 7850 N/m3
Cylinder piston diameter 0.203 m
Cylinder rod diameter 0.102 m
All elbows are 90 with k factor 0.75

Pipe lengths and diameters are given

Pipe number Length (m) Diameter
1 0.61 0.0508
2 6.10 0.0445
3 9.15 0.0445
4 9.15 0.0445
5 6.10 0.0445

15
 Cylinder

4
2 3 Elbow

Elbow
Elbow
1
5
K=5
Strainer in the
tank K = 10

Figure 1.26

Solution:

(a) Determination of external load, considering all losses: Let us first calculate the flow rate at different
branches as shown in Fig. 1.27. Before we calculate the losses, we calculate the pump power as

Pump power  η  Ppump  0.90 18.65  16.79 kW

The flow rate is given by
16.79 kW
Qpump   0.00243 m3 /s
6897 kPa
We can write the force balance
Fregen  pblank end AP  prod end Aannulus
Now
Qpump  Q1  Q2  0.00243 m3 /s

From the derivation of regenerative circuits, we can write

Ap
Q3  Qpump
Ar
 (0.203)2 / 4
  0.00243
 (0.102)2 / 4
 0.00972 m3 /s

16
 Ap  Ar
Q4  Qpump
Ar
 [(0.203) 2  (0.102) 2 ] / 4
  0.00243
 (0.102) 2 / 4
 0.00729 m3 /s

Velocity calculation

0.00243 (m3 /s)

v1   1.20 m/s
 (0.05082 ) 2
(m )
4
0.00243 (m3 /s)
v2   1.56 m/s
 (0.04452 ) 2
(m )
4
0.00972 (m3 /s)
v3   6.24 m/s
 (0.04452 ) 2
(m )
4
0.00729 (m3 /s)
v4   4.69 m/s
 (0.04452 ) 2
(m )
4

Reynolds number calculation

1.20  0.0508
Re(1)   655
0.000093
1.56  0.0445
Re(2)   746
0.000093
6.24  0.0445
Re(3)   2990
0.000093
4.69  0.0445
Re(4)   2240
0.000093

Assume that all flows are laminar; head losses can be calculated as follows:

 64 6.10  1.20
2
H L (1)    10   0.74 m  7850  0.33 Pa  5840 Pa
 655 0.0508  2  9.81

 64 6.10  1.56
2
H L (2)    5  2.08 m  16300 Pa
 746 0.0445  2  9.81

 64 9.15  6.24
2
H L (3)    0.75   10.2 m  80300 Pa
 2990 0.0445  2  9.81

17
  64 9.15  4.69
2
H L (4)    0.75   7.43 m  58400 Pa
 2240 0.0445  2  9.81

The force is given by

 (0.203)2
F  [(6897 kPa)  (5.84  16.3  80.3)]  –
4
  [(0.203)2  (0.102)2 ] 
[6897 kPa  (5.84  16.3  58.4)]  
 4 

Solving we get

F  220  168 =52 kN

(b) Determination of heat generation rate

Power loss = QΔp
= Pipe 1 loss + pump loss+ pipe 2 loss + pipe 3 loss + pipe 4 loss
= 0.00243 × 5.84 + (18.7−16.8) + 0.00243 × 16.3 +0.00972 × 80.3 + 0.00729 × 58.4
= 0.014+1.9+0.04+0.78+0.43

Power loss = Heat generation rate = 3.16 kW

(c) Cylinder speed for each position of DCV

Qpump  Q1  Q2  0.00243 m3 /s
Upper position of DCV

Qpump (m3 /s) 0.00243

vext    0.0751 m/s
2
Ap (m )  (0.2032 )
4

Spring-centered position of DCV

Qpump (m3 /s) 0.00243

vext    0.297 m/s
Arod (m ) 2
 (0.1022 )
4

Lower position of DCV

Qpump (m3 /s) 0.00243

vret    0.100 m/s
Aannulus (m )2
 (0.2032 )  (0.1022 )

4 4

18
Example 1.12
For the meter-in flow control valve system of Fig. 1.27, the following data are given:

Desired cylinder speed 0.254 m/s

Cylinder piston diameter 0.508 m
Cylinder load 13340 N
Specific gravity of oil 0.9
Pressure-relief valve setting 6895 kPa

Determine the required capacity coefficient of flow control valve.

13340 N

Figure 1.27

Solution: We have

Vcyl  Apiston
CV  (1.7)
pPRV  ( Fload / Apiston )
SG
CV are LPM / kpa .Therefore, we have the following units for the terms in the above equation:

Q  vcyl Ap  LPM, pPRV  kPa, (Fload ) / ( Apiston )  Pressure  kPa

19
The flow rate is given by

Q  vcyl Ap
m 1L 60 s
 0.254  0.00203m 2 
s 0.001 m3 1 min
 30.9 LPM

Now it is given that pPRV  6895 kPa and

Fload 13340 N 1kPa

   6570 kPa
Apiston 0.00203 m2 1000 N/m 2
Substituting values in Eq. (1.7), we get

vcyl  Apiston
CV 
pPRV  ( Fload / Apiston )
SG
30.9

6895  6570
0.9
30.9 LPM
  1.63
19.0 kpa

20
 Lecture 26

HYDRAULIC CIRCUIT DESIGN AND ANALYSIS

Example 1.14
Design a car crushing system. The crushing force required is such that a 15 cm diameter cylinder is
required at a working pressure of 126.5 kg/cm2. Time for crushing is about 10 s and the stroke required to
flatten the car is 254 cm. Compare the power required by the circuit without and with accumulator.
Accumulator details:
It is a gas-loaded accumulator
Time taken for charging =5 mm
Initial pressure of charging (pre-charged),p1 = 85 kg/cm2
Charged pressure of accumulator,p2= 210 kg/cm2
Minimum pressure for crushing, p3= 126.5 kg/cm2

Solution: Given
Diameter of piston = 15 cm
Distance traveled in 10 s=254cm
Distance traveled in 1 s= 25.4 cm
Therefore, the stroke velocity, v = 25.4 cm/s
Pressure required to crush= 126.5 kg/cm2
Circuit requirements without accumulator
Area of piston=(/4)D2= (/4)152= 176.71 cm2= 176.71 × 102mm2
Volume of flow,
V=Area ×Stroke=176.71 × 102× 2540
=44884340mm3 = 4.488 × 10–2m3
Flow rate
Q = V/10 = 4.488 ×102/ 10 = 4.488 ×10–3m3/s
Power required
P= Q× p = 4.488 ×10–3× 126.5×10×104
= 56773.2 W = 56.77 kW
If accumulator is not used, the flow rate of 4.488 ×10 m–3/s is required from a pump with capacity of
56.77 kW.
Circuit requirements with accumulator:
Time taken for charging the accumulator=5 mm
Initial pressure of charging (pre-charged),p1=85 kg/cm2
Charged pressure of accumulator,p2 =210 kg/cm2
Minimum pressure for crushing,p3=126.5 kg/cm2
This can be shown by the diagram shown in Fig. 1.29.
The pressure relation in the accumulator can be given as
p1v1 = p2v2 = p3v3 (at a constant temperature)
Let us first equate
p2v2 = p3v3
Rearranging we get
 p2 v2
v3 
p3

Substituting the valves of p2 and p3, we get

210  v2
v3   1.66v2
126.5

Figure 1.29

We know that the oil supplied by the accumulator after charging isv3−v2.
This is used for the cylinder displacement for crushing.
The amount of oil required for crushing with the given constructional details as calculated above is 4488
×10–2 m3.
Therefore, equating the above volume required, we get
v3−v2 =4.488 ×10–2 m3
 1.66 v2−v2=4.488 × 10–2 m3
Solving the above relation, we get
v2 = 0.068 m3
and v3 = 1.66 × 0.068 = 0.1129 m3
Now
p1v1 = p2v2
 v1 = p2v2 /p1
Substituting known values, we get
v1 = (210 × l0 × l04 × 0.068)/(85 × 10 × 104) = 0 = 168 m2
While charging the accumulator, the oil pumped is
v = v1−v2 = 0.168 − 0.068 = 0.1 m3
Time taken for charging the accumulator (given) = 5 min = 300 s.
Therefore, the flow rate is
v 0.1
Q   3.33  104 m3 /s
t 300

Charged pressure (given) p= 210 ×107 N/m2

Power required
P= Q×p= 3.33 ×10–4 × 210 × 107 = 7kW
Power required without accumulator = 56.77 kW
Power required with accumulator = 7 kW
The circuit to do the crushing can be seen in Fig. 1.30.

2
 Figure 1.30

Example 1.15
A pump delivers oil at a rate of 18.2 gallons/min into the blank end of a cylinder of diameter 75 mm (Fig.
1.31). The piston contains a 25 mm diameter cushion plunger that is 25 mm; therefore, the piston
decelerates over a distance of 25 mm at the end of the suction stroke. The cylinder drives a load of 7500
N that slides on a horizontal bed with coefficient of friction = 0.1. The pump relief valve pressure setting
is 5.5 N/mm2. What is the pressure acting due to cushioning deceleration?

Solution: Pump flow rate is

18.2
Q = 18.2 gallons/min(GPM)   80.15 m3 /s
3.785  103  60
Note: 1 gallon = 3.785 L,1 L = 1000 cc = 10–3 m3
Piston diameter = 75 mm
Plunger diameter = 25 mm
Plunger length = 25 mm
Load acting = 7500 N
Friction coefficient () = 0.1
Relief pressure p1= 5.5 N/mm2
This can be visualized in Fig. 1.31.

3
 Load

Figure 1.31

Velocity of extension until cushioning=v1

Final velocity at the end of extension stroke=v2 = zero (if smoothly it stops)
The velocity of extension until cushioning is given by
Q
v1 
A
Area of the piston blank is
     75 
2

 4
 
A=   D 2    
 4   100 
So
80.15 m3 /s
v1   0.2598 m/s
   75 
2

  
 4  100 
The final velocity v2= 0. Writing the equation of motion
v12  2a  s
the deceleration due to the cushioning effect can be given as
v2 0.25982 m
a 1  3
 1.349 2
2  s 2  25  10 s
Now equating the forces on the piston we get
Blank end force−Rod end force−Frictional force + Inertial force = 0 (1.8)

We have
Blank end force=p1 × (/4)D2
Rod force=p2 × ( /4) (D2−d2)
Frictional force =µ× w
Inertial force= Mass × Acceleration
Substituting all the values in Eq. (1.8), we get
[5.5 ×106× ( /4) (0.075)2]−[p2 × (/4) {(0.075)2− (0.025) }]− (0.12 ×7500) −
2

(7500/9.81) × 1.349 = 0
This gives
p2= 6216183.35 N/m2 = 6.22 N/mm2 = 6.22 MPa
This is the pressure required during deceleration due to cushion effect.

4
Example 1.16
A double-acting cylinder is used in a regenerative circuit as shown in Fig. 1.32. The relief valves is set at
7.5 N/mm2, the piston area is 150 cm2, the rod area is 40 cm2 and the flow is 20 gallons/min. Find the
cylinder speed and load-carrying capacities for various DCV.

Figure 1.32

Solution: Given data

Pump flowQp= 20 gallons/min= [(20 ×3.785 ×103)/60] m3/s
Piston areaAp =150 ×104 m2 = 150 ×102 mm2
Rod area Ar= 40 ×104 m2 = 40 × 102 mm2
Relief pressurep = 7.5 N/mm2

Now
Center position of the DCV = Center position of the valve −Regenerative forward stroke
Velocity = Pump flow/area of the rod
Q
Velocity in the forward stroke = p
Ar
20  3.785  105
=
60  40  104
= 0.315 m/s
(Recollect from the regenerative circuit that because pressure acts on both sides, the load carrying
capacity is less.) The load-carrying capacity, that is, the force that can be applied is
Ff = p× [Ap − (Ap− Ar)]
= p× Ar
= 7.5 ×40 ×102
= 30000 N
= 30kN
We shall consider the left envelop of the DCV.In this position, the cylinder extension is similar to the
regular double-acting cylinder where the pump flow is divertedtothe blank side (without regeneration).
Q
Velocity in the forward stroke = p
Ap
20  3.785  103
=
60  150  104
= 0.08411 m/s

5
The force that can be carried in this position is
Ff(normal)= p× (Ap)
= 7.5 ×150 ×102
= 112500 N
= 112.5 kN
Now we consider the right envelop of the DCV, when the cylinder retracts as a regular double-acting
cylinder.
Qp
Velocity during the return stroke=
Ap  Ar
20  3.785  103
=
60  (150  104  40  104 )
= 0.1147 m/s
The force that can be applied would be less than the forward stroke because the rod reduces the actual
piston area to do work:
Fr(normal)= p× (Ap −Ar)
=7.5 ×(150 × 102− 40 × 102)
= 82500 N
= 82.5 kN

Example 1.17
Two double-acting cylinders are to be synchronized connecting them in series as shown in Fig. 1.33.The
load acting on each cylinder is 4000 N. Cylinder 1 has the piston diameter 50 mm and rod diameter 20
mm. If the cylinder extends 200 turns in 0.05 s, find the following:

(a) The diameter of the second cylinder.

(b) The pressure requirement of the pump.
(c) The capacity of the pump assuming the efficiency of the pump to be 85% and overall efficiency of the
system as 90%.

6
 F1 F2

d1 d2

p2 p3

p1 D2 p2
D1

Figure 1.33

Solution:
Force on both cylindersp = 4000 N
Diameter of the piston of cylinder lD1 = 50 mm
Diameter of the rod of cylinder 1d1 = 20 mm

(a) Diameter of second cylinder

Pressure on the rod side of cylinder l = Pressure of fluid leaving cylinder 1

= Force/(Area of piston 1 −Area of rod 1)
=p/(Ap1 – Ar1)
= 4000 × 4/[ × (Dl2−d12)]
= 4000 × 4/ [ × (502−202)]
= 2.425 N/mm2
Also, for serial synchronizing circuits,
Pressure of fluid leaving cylinder 1 = Pressure of fluid coming into cylinder 2
Pressure of fluid coming into cylinder 2 = 2.425 N/mm2
= Force/area of the piston of cylinder 2
So
1.425 = 4000 × 41 ( × D22)
 D2= 45.825 mm
(b) The pressure requirement of the pump

7
Let us now determine the pressure required at the piston side of cylinder 1:
F1 =4000 N = [( /4) × D12 × p1]−[( /4) × (D12−d12) × p2]
Substituting the known values, we get
4000 N = [( /4) ×502×p1]−[( /4) ×(502 − 202)× 2.425]
2
We getp1 = 4.074N/mm .

Length of the cylinderL = 200 mm

Time taken to extend 200mmt = 0.05 s
Efficiency of the pump = 0.9
Efficiency of the system =0.85
The forward stroke velocity is
vf = L/t = 200/0.05 = 4000 mm/s
The flow rate required from the pump is
Q = Area of the piston of cylinder 1 × vf
= (/4) × D12 × vf
= ( /4) ×502×4000
=7.85 ×103m3/ s

(c) Capacity of the pump

Let us now calculate the pump capacity in kW:

Input capacity in kW
p1Q 4.074 106  7.85  103
  41.805 kW
pumpo 0.9  0.85
Output capacity of the pump = Q× p
=7.85 ×10–3×4.074×106
= 31.981 kW

Example 1.18
A high–low circuit uses a low-pressure pump of 1.4 N/mm2 and a high-pressure pump of 12.6 N/mm2.
The press contains eight cylinders and the total load of the press is 5600 kN. The length of cylinder is 200
mm whereas the punching stroke is only for 6 mm. The time for lowering is 0.05 s and the time for
pressure build-up and pressing is 0.03 s. Determine the following:

(a) The piston diameter of cylinder.

(b) Pump flow rates.
(c) Total motor capacity.
(d) If a single pump of 12.6 N/mm2 is used, find the kW capacity required.

Solution:
(a) Piston diameter of cylinder

Number of cylinders = 8

8
Total force = 5600 kN
High-flow pump pressure= 1.4 N/mm2 = phigh = 1.4 ×106 N/m
Low-flow pump pressure= 12.6 N/mm2 = plow = 12.6 ×106 N/m
Stroke length, L= 6 mm
Force acting in one cylinder= Total load/Number of cylinders
= 5600000 / 8
= 700000 N
Pressure during punching = 126 N/mm2
Piston diameter of the cylinder,
D2 = 700000 ×4 (×12.6)
 D = 266 mm = 0.266 m

(b) Pump flow rate

The flow requirements of the low-pressure pump:

Stroke velocity = Stroke length/time taken
= 6/0.05 = 120 mm/s = 0.120m/s
Flow from the low-pressure pump= Area × Stroke velocity
= (/4) ×0.2662×0.120
= 0.00667 m3/s
Power output is
Plow = Qlow × plow
= 1.4 × 106 ×0.00667 W = 9.338 kW
When the pressure of oil is increased in a compartment, the volume changes. Usually,

1
Volume change = % of initial volume for 70 bar
2
1
Compressed volume = % of (/4) ×D2×L
2
=0.005 ×(/4) ×(0.266)2×0.006
= 1.667 ×l06 m3
This volume is compressed because of the difference in the pressure level of the high- and low-pressure
pumps:
Difference in pressure = 12.6 − 1.4 N/mm2= 11.2 ×106 N/m2
Therefore, the volume change for 11.2 ×106 N/m2 is
11.2 ×106×1.667 ×l0-6 / 70×106= 2.6558 ×106 m3
Therefore, the flow from the high-pressure pump
Qhigh =2.6558 ×106/0.03 (volume/time taken)
=8.85×105 m3/s
(c) Motor capacity

Hence, the power output is

Phigh = Qhigh × phigh
= (8.85 ×l05) × (12.6 ×106)
= 1.115 kW
The total kilowatt capacity required is
Phigh + Plow= 9.338 + 1.115=10.453 kW
(d) If a single pump is used, capacity requirement

9
Instead, if a single pump with high-pressure capacity is required, then
Flow required (Qcombined) = Flow from the low-pressure pump+ flow from the high-
pressure pump
= 0.00667 + 8.85 ×105m3/s
= 0.00676 m3 /s
The power capacity required for the above pump is
Power capacity = Qcombined × phigh
=0.00676 ×12.6 ×106
= 85157.1 W
= 85.157 kW
From the above calculations, it is evident that when a high–low circuit is used instead of a single high-
pressure pump, the power requirement is reduced considerably.

Example 1.19
A high–low circuit with an unloading valve is employed for press application. This operation requires a
flow rate of 200 LPM for high-speed opening and closing of the dies at the maximum pressure of 30 bar.
The work stroke needs a maximum pressure of 400 bar, but a flow rate between 12 and 20 LPM is
acceptable. Determine the suitable delivery for each pump.

Solution: A high–low circuit uses a high-pressure, low-volume pump and a low-pressure, high-volume
pump.During closing or opening, both the pumps supply fluids. During work stroke, the high-pressure
pump alone supplies fluid. Power requirement is the same for both processes.
Theoretical power required to open or close the dies is
200  103  30  105
P  10000 W
60
To utilize this power for the pressing process, the flow required is calculated. We know that
Power = Flow  Pressure
10000 = Q  400 105
Solving we get
Q= 2.5 104 m3 /s
= 2.5 104  60 m3 /min
= 15 103 m3 /min
= 15 LPM
This is acceptable. Therefore, the delivery of the high-pressure, low-volume pump = 15 LPM.
The delivery of the low-pressure, high-volume pump = 200 – 15 =185 LPM.
An equivalent single fixed displacement pump having a flow rate of 200 LPM and working at a pressure
of 400 bar requires a theoretical input power of 133.3kW.

Example 1.20
A press with the platen weighing 5 kN is used for forming. The force required for pressing is 100 kN and
a counterbalance valve is used to counteract the weight of the tools. The cylinder with a piston diameter
80 mm and a rod diameter 60 mm is used. Calculate the pressure to achieve 100 kN pressing force.

10
Solution:
Weight of the tools = 5 kN = 5 103 N
π
 0.082 = 0.005 m
2
Full bore area=
4
Annulus area,
π
Ap − Ar =  (0.082  0.062 )  0.0022 m2
4
Pressure required at rod side to balance tools is
5 103
105  22.7 bar
0.0022
Suggested counterbalance valve setting =1.3  22.7 = 29.5 bar
0.0022
Pressure at full bore side to overcome counterbalance = 29.5  = 13 bar
0.005
100  103  10 5
Pressure to achieve 100 kN pressing force at full bore side = + 13 = 213 bar
0.005

Example 1.21
In a meter-in circuit, a cylinder with 100 mm bore diameter and 70 mm diameter is used to exert a
forward thrust of 100 kN, with a velocity of 0.5 m/min. Neglect the pressure drop through the piping
valves. If the pump flow is 20 LPM, find the following:

(a) Pressure required at the pump on extend.

(b) Flow through the flow-control valve.
(c) Relief-valve setting.
(d) Flow out of the pressure-relief valve.
(e) System efficiency during extend.

Solution:Both Q and q are being used. Kindly check for correctness

(a)Force needed during extend,F = 100 kN. Therefore, thepressure required at pump on extend p ' is
100 103
p'   127 bar

 0.12
4
(b) Velocity during extend,v = 0.5 m/min.
Flow through the flow control valve is
q = v  Ap

= 0.5   0.12
4
= 3.9 103 m3 /min
= 3.9 LPM

11
(c) Relief-valve setting, p = 127 + 10 % (127) = 140 bar
(d) Flow out of the pressure-relief valve is
q= Q – q = 20−3.9 = 16.99 LPM
(e) System efficiency is
p 'q 127  3.9
100 = 100  17.6%
pQ 140  20

Example 1.22
A hydraulic intensifier is meant to enhance the fluid pressure from 50 to 200 bar. Its small-cylinder
capacity is 23 L and has a stroke of 1.5 m. Find the diameter of the larger cylinder to be used for this
intensifier.

Solution:
The capacity of small cylinder Q = Area of small cylinder × Stroke
Diameter of the small cylinder is
1/ 2
 Q  4  103  23 4 
1/ 2

d= 
   s 
= =0.140m = 140mm
   1.5 

Let ps be the supply pressure and pi be the intensifier pressure. Then intensification ratio is
Ai ps D 2 200
  
As pi d 2 50
D
 2
d
Diameter of larger cylinder is
D = 2 × d = 2 ×140 = 280 mm

Example 1.23
A punch press circuit with five stations operated by five parallel cylinders is connected to an intensifier.
The cylinders are single-acting cylinders with spring return and the piston diameter of the cylinder is 140
mm. The cylinders are used for punching 10 mm diameter holes on sheet metal of 1.5 mm thickness. The
ultimate shear strength of sheet material is 300 MN/m2. The punching stroke requires 10 mm travel. If the
intensification ratio is 20 and the stroke of the intensifier is 1.3 m, determine the following:

(a) Pressure of oil from the pump.

(b) Diameter of small and large cylinders of intensifier.

Solution:
(a) Pressure of oil from the pump
The force required to punch the hole is

12
 F = Shear area × Shear strength
=  × Diameter of hole × Thickness of sheet × Shear strength
=  ×10 × 10–3 × 1.5 × 10–3 × 300 × 106
= 14137 N
Pressure developed at the load cylinder is
F 14137
  9.2 bar
A   (0.14)2
4
This is the pressure developed by the intensifier. The pressure from the pump is the pressure exerted on
the large cylinder of intensifier.
Pump pressure
 As  1
pi = ps ×    9.2   0.46 bar
 Ai  20
(b) Diameter of small and large diameter
Volume of oil required in the cylinders during punching strokeis
Voil = 5 × Area of cylinder × Punch stroke
 3 4
 5  0.14  10  10  7.7  10 m3
2

4
This is supplied by the intensifier. Now

Area of small cylinder × Stroke of intensifier = 7.7  104 m3

So
7.7  104
Area of small cylinder As=
1.3
Also
Area of larger cylinder AL = Intensification ratio ×As
= 20 ×5.9 ×10-4
= 0.118 m2
Diameter of the small cylinder is
1/ 2
 5.9  104  4 
d =  = 0.027m
 
Diameter of the larger cylinder
 0.0118  4 
1/ 2

D=   = 0.122m
 

Example 1.24
A double-acting cylinder is hooked up in a regenerative circuit for drilling application. The relief valve is
set at 75 bar. The piston diameter is 140 mm and the rod diameter is 100 mm. If the pump flow is 80
LPM, find the cylinder speed and load-carrying capacity for various positions of direction control valve.

Solution:
Center position of the valve: Regenerative extension stroke

13
  80  103 
Qp  60 
Cylinder speed    0.169 m/s
Ar  2
  0.1 
4 
Load-carrying capacity is

p×Ar = 75 ×105× × (0.1)2= 58905 N
4
Left position of the valve: Extension stroke without regeneration:
 80  103 
Qp  60 
Cylinder speed    0.86 m/s
Ap   2
  0.14 
4 
Load-carrying capacity is

p  Ap = 75×105× × (0.14)2 = 115453N
4
Right position of the valve: Retraction stroke
 80  103 
 
Cylinder speed 
Qp
  60 
 0.177 m/s
Ap  Ar   2
  0.14 2
 0.1 
4 
Load-carrying capacity is
p( Ap  Ar )  75105  (0.142  0.12 )  56548 N

Example 1.25
Two double-acting cylinders are to be synchronized by connecting them in series. The load acting on each
cylinder is 4000 N. If one of the cylinders has the piston diameter 50 mm and rod diameter 28 mm, find
the following:

(a) The diameter of the second cylinder.

(b) Pressure requirement of the pump.
(c) Power of the pump in kW if the cylinder velocity is 4 m/s.

Solution: The area of second cylinder is


Ap2 =Ap1−Ar1= (0.052−0.0282)= 1.35 ×103 m2
4
Diameter of the second cylinder is
 Ap2  4   1.35103  4 
Dp2        0.041 m
     
The pump supplies oil to the first cylinder, so the pressure requirement of the pump is

14
 F1  F2 4000  4000
p1    40.7 bar
Ap1  2
(0.05)
4
Cylinder velocity = 4m/s
Flow requirement of pump
 –3
Q=  0.052  4 = 7.85×10 m3/s
4
Power of pump in kW
p1  Q 40.7 105  7.85103
  32 kW
1000 1000

Example 1.26
A pump delivers 60 L/min, the system maximum working pressure is 250 bar and the return line
maximum pressure is 80 bar. Select suitable tubes.Use the data provided in Table 1.1: Cold-drawn
seamless CS tubes (DIN 2391/C)(DIN is a German Standard).
Table 1.1 Cold-drawn seamless CS tubes (DIN 2391/C)
Cold-Drawn Seamless Carbon Steel Tubes for Pressures Purposes to DIN 2391/C

Outer Diameter × Approximate Maximum Working Pressures (bar)

Wall Thickness Weight
Safety Factor Safety Factor Safety Factor

6  1.5 0.166 703 586 441

6  1.0 0.123 428 359 269
8  1.5 0.240 496 414 310
8  1.0 0.173 310 255 193
10  3.5 0.561 1089 903 676
10  2 0.395 531 441 331
10  1.5 0.314 386 317 241
10  1.0 0.222 241 200 152
12  2.5 0.586 552 462 345
12  1.5 0.388 310 262 193
14  2.5 0.709 324 282 217
14  1.5 0.462 262 221 166
15  2.5 0.771 428 352 262
15  1.5 0.499 241 207 152
16  3.0 0.962 490 407 303
16  2.5 0.832 393 331 248

15
16  2.0 0.691 310 255 193
16  1.5 0.536 228 186 145
18  1.5 0.610 200 166 124
20  4.0 1.58 531 441 331
20  3.0 1.26 379 317 234
20  2.5 1.08 303 255 193
20  2.0 0.888 241 200 152
20  1.5 0.684 179 152 110
22  3.0 1.41 338 283 214
22  2.0 1.07 221 179 138
22  1.5 0.758 159 138 103
25  4.0 2.072 394 263 210
25  3 1.63 297 248 186
25  2 1.13 193 159 117
28  4 2.37 359 297 221
28  3.5 2.11 310 255 193
28  2.5 1.57 214 179 131
28  2.0 1.28 166 138 103
28  1.0 0.6666 83 69 52
30  4.0 2.56 332 276 207
30  3.5 2.00 241 200 152
30  3.0 2.367 242 161 121
38  4.0 4.07 324 269 228
38  3.5 3.35 255 214 159
38  3.0 2.59 186 159 117
40  6.0 5.03 379 317 234
40  5.0 4.32 310 255 193
42  3.0 2.885 201 133 101
48  5.0 6.21 310 255 193
65  8.0 11.24 303 255 186

Solution:
Return line:Select a velocity of 1.0 m/s. Now
3
Discharge 60 10 1
Flow area = =  = 0.001 m2
Velocity 60 1.0

16
Now
 0.001  4 
1/ 2

Inner diameter of tube =   = 0.035m= 35 mm

 
Select a standard tube size of inner diameter 36mm, outer diameter 42 mm and wall thickness 3mm.This
has a safe working pressure of 101 bar, so it is suitable for the return lines.
Delivery lines: Select a velocity of 3.5m/s. Now
 60  1
Flow area    103    2.857  104 m2
 60  3.5
 2.857 104  4 
Inner diameter     0.019 m  19 mm
  
Select a standard tube size of inner diameter 19mm, outer diameter 25 mm and wall thickness 3mm. This
has a safe working pressure of 297 bar and is suitable for the delivery lines.

Example 1.27
A flow control valve has a controlled flow Cv of 10.5 LPM/ bar and a free flow Cv of 32.4 LPM/ bar
. Determine the pressure drop across the valve in both the controlled flow and free flow directions. The
system has a flow rate of 19 L/min and uses standard hydraulic oil of specific gravity 0.9.

Solution: Pressure drop in the controlled flow direction

Q2 192
p  2  SG =  0.9  2.94 bar
CV 10.52
Pressure drop in the free flow direction
Q2 192
p  2  SG   0.9  0.309 bar
CV 32.42

Example 1.28
A cylinder has to exert a forward thrust of 150 kN and a reversible thrust of 15 kN (Fig. 1.34). The retract
speed should be approximately 5 m/min utilizing full pump flow. Assume that the maximum pump
pressure is 150 bar. Pressure drops over the following components and their associated pipe work are as
follows:
Filter = 3 bar
Direction control valve (each flow path) = 2 bar
Determine the following:

(a) Suitable cylinder (assume 2:1 ratio; piston area to rod area).
(b) Pump capacity.
(c) Relief-valve setting pressure.

17
 Figure 1.34

Solution:

(a) Back pressure at the annulus side of cylinder is 2 bar. This is equivalent to 1 bar at the full
bore end because of the 2:1 area ratio.Therefore,
Maximum available pressure at the full bore end of cylinder = Maximum pump pressure –
(Pressure drops + Back pressure)
= 150−3 − 2 −1
= 144 bar
Now
Load 150  103
Full bore area = = = 0.0104 m2
Pressure 144  10 5

1/2
4 
Piston diameter=   0.0104 = 0.115m = 115mm
 
Now select a cylinder with 125mm bore ×90 mm rod diameter. So
Bore area = 12.26 ×103 m2
Rod area = 6.3×103 m2
This is approximately in the 2:1 ratio.

(b) Now
Flow rate required for a retract speed of 5 m/min (full pump flow)= (Bore area – Rod area)
×Retract velocity
= (12.26 ×103−6.35×103) ×5

18
 = 0.02955m3/min
= 29.55 L/min

(c) We have
150  103
Pressure to overcome the load while extending= = 12.2 ×106 N/m2= 122 bar
12.26  106
Pressure drop over the direction control valve P to A = 2 bar
1
Pressure drop over the direction control valve B to T(because of 2:1 area ratio 2 bar × )= 1 bar
2
Pressure drop over the filter = 3 bar
Therefore,
Pressure required at the pump during the extend stroke= 122 +2+1+3 =128 bar
15  103
Pressure to overcome load during retraction= = 2.5 ×106 N/m2=25 bar
(12.26  103  6.35  103 )
Pressure drop over the direction control valve P to B = 2 bar
Pressure drop over the direction control valve A to T (because of the 2:1 area ratio, 2 bar ×2 ) = 4 bar
Pressure drop over the filter =3 bar
Therefore,
Pressure required at the pump during the retract stroke= 25 + 2+ 4+ 3=34 bar
Relief-valve setting = Maximum pressure + 10%=128 +(0.1 ×128)=141 bar

Example 1.29
A press cylinder having a bore diameter of 140 and a 100 mm diameter rod is to have an initial approach
speed of 5 m/min and a final pressing speed of 0.5 m/min. The system pressure for a rapid approach is 40
bar and for final pressing is 350 bar. A two-pump, high–low system is to be used. Both pumps may be
assumed to have the volumetric and overall efficiencies of 0.95 and 0.85, respectively. Determine the
following:

(a) The flow to the cylinder for the rapid approach and final pressing.
(b) Suitable deliveries for each pump.
(c) The displacement of each pump if the drive speed is 1720 RPM.
(d) The pump motor power required during the rapid approach and final pressing.
(e) Retract speed if the pressure required for retraction is 25 bar maximum.

Solution:A high–low circuit uses a high-pressure, low-volume pump and a low-pressure, high-volume
pump.
(a) The flow to the cylinder rod for the rapid approach is
Qrapid = Bore diameter ×Velocity of initial approach
 m3
=  0.1402  5  0.077  77 LPM
4 min
The flow to the cylinder for final pressing is
Qhigh pressure = Bore diameter ×Velocity of final pressing

19
  m3
=  0.1402  0.5  0.0077  7.7 LPM
4 min
(b) During final pressing, only a high-pressure, low-volume pump supplies fluid.
Pump delivery = 7.7 LPM
During the rapid approach, both pumps supply fluid. The high-volume pump delivery is
Qrapid  Qhigh pressure  77  7.7  69.3 LPM
(c) The displacement of a low-volume pump
Qhigh pressure 7.7
DP-high pressure    4.7 103  4.7 mL
N p  V 1720  0.95
The displacement of a high-volume (low pressure) pump
Qlow pressure 69.3
DP-low pressure    42.3103 L  42.4 mL
N p  V 1720  0.95
(d) Pump motor power required during the rapid approach:
Plow pressure  Q 40 105  0.077
  6.04 kW
o 60  1000  0.85
Pump motor power required during final pressing:
Phigh pressure  Qhigh pressure (low volume) 350 105  0.0077
  5.3 kW
o 60  1000  0.85
(e)We have
Q 4  0.077
Retract speed =   10.2 m/s
 2 
(D  d 2 ) (0.1402  0.1002 )
4 4

20
Objective-Type Questions
Fill in the Blanks

1. In a regenerative circuit, the speed of extension is greater than that for a regular double-acting cylinder
because the flow from the ______ regenerates with the pump.
2. For two cylinders to be synchronized, the piston area of cylinder 2 must be equal to ______ between
the areas of piston and rod for cylinder 1.
3. Meter ______ systems are used primarily when the external load opposes the direction of motion of the
hydraulic cylinder.
______
4. One drawback of a meter system is the excessive pressure build-up in the rod end of the
cylinder while it is extending.
5. Fail–safe circuits are those designed to prevent injury to operator or damage to ______.

State True or False

1. In a regenerative circuit, when the piston area equals two-and–a-half times the rod area, the extension
and retraction speeds are equal.
2. The load-carrying capacity for a regenerative cylinder during extension equals pressure times the piston
rod area.
3. When two cylinders are identical, the loads on the cylinder are not identical, and then extension and
retraction can be synchronized.
4. When a load pulls downward due to gravity, in such a situation a meter-in system is preferred.
5. A machine intended for high-volume production uses rapid traverse and feed circuits.

Review Questions

1. List three important considerations to be taken into account while designing a hydraulic circuit.
2. What are the advantages of a regenerative circuit?
3. Explain the regenerative circuit for a drilling machine.
4. With the help of a neat sketch, explain the pump-unloading circuit.
5. With the help of a circuit diagram, explain a double-pump hydraulic system (Hi–Lo circuit).
6. Explain the application of a counterbalance valve.
7. Explain the application of a pilot check valve for locking a double-acting cylinder.
8. Explain the speed control circuit for a hydraulic motor.
9. What are the conditions for the two cylinders to be synchronized?
10. What is a fail-safe circuit?

21
Answers
Fill in the Blanks

1.Rod end
2.Difference
3.In
4.Out
5.Equipment/machine

State True or False

1.False
2.True
3.False
4.False
5.True

22
 Lecture 27

SERVO VALVES

Learning Objectives
Upon completion of this chapter, the student should be able to:

 Define servo valve.

 Compare servo valves with proportional valves.
 Appreciate the history of servo valves.
 Describe the working of a servo torque motor.
 Describe the working of single-stage spool-type servo valves.
 Describe the working of jet-type servo valves.
 Analyze the valve performance.
 Define dead band and hysteresis.
 Analyze mathematically the simple servo systems.

1.1 Introduction
Servo valves were developed to facilitate the adjustment of fluid flow based on changes in the load
motion. Simply put, it is a programmable orifice.In machine motion control, servo systems involve
continuous monitoring, feedback and correction. Also they are used to improve efficiency, accuracy
and repeatability. The most common applications of servo valves are in aerospace vehicles,
particularly in primary flight controls. In aircraft, control surfaces such as ailerons, elevators and
rudders are positioned by servo units. In space vehicles, control during launch is provided by movable
thrust nozzles that are positioned by servo units. Even the drill bits for angle drilling of oil wells are
servo controlled.

A servomechanism is defined as an automatic device for controlling a large amount of power by

means of a very small amount of power and automatically correcting the performance of a
mechanism. The automatic and continuous correction requires return of information from the
mechanism– feedback, in other words. Therefore, a servo valve is operated without feedback and it is
not a true servomechanism. In Chapter 17 we have studied about proportional valves and Table 1.1
gives comparison between servo valve and electrohydraulic proportional control valves (EHPV).

Table 1.1 Comparison of servo valves and electrohydraulic proportional valves

Feature Servo Valve EHPV

Electrical operator Torque motor Proportional solenoid

Manufacturing precision Extremely high Moderately high
Feedback circuitry Main system as well as Valve (depending on type),
valve main system (seldom)
Cost (compared with a solenoid Very expensive Moderately expensive
valve)

1.2 History of Electrohydraulic Servomechanisms

The earliest recognized servomechanism is the water clock invented around 250 BC(Fig. 1.1) by the
Alexandrian inventor Ktesbios. In this device, time was recorded by the level of water in a graduated
vessel. Water flows into the vessel at a controlled and constant rate from a water reservoir above it.
The control of the flow rate from the reservoir involves a mechanism.Velocity flow rate from the
outlet of a reservoir is determined by the equation
v  2 gh
where V is the velocity, g is the acceleration due to gravity and h is the height of water above the
outlet.The volume flow rate through the outlet depends upon the size of the outlet and the fluid
velocity. Thus,
Q = Velocity × Area
From these equations, we can see that as the water level in Ktesbios’s reservoir goes down, the flow
rate from the reservoir decreases. Ktesbios’s solution to the problem was to use a second reservoir
mounted above the first. He used a float to modulate an orifice through which water was fed into the
primary reservoir. This kept the water level constant, resulting in hours of constant length.
Numerous servomechanisms were invented during Industrial Revolution in the mid-1700s and
afterward. Many were associated with steam boiler technology where they were used to control water
level, water and steam flow, steam pressure and the speed and position of steam-operated
mechanisms.

Figure 1.1 Water clock by Ktesbios.1.3 Electrohydraulic Servomechanism Concepts

Figure 1.2 represents a typical fluid power system that uses a proportional valve to control the speed
of hydraulic motor. The EHPV is set to provide the necessary flow to drive the motor at the required
speed. As long as there are no disturbances, the speed remains constant. If there is any change in the
operating parameters such as load, fluid temperature, viscosity and wear then the motor speed is
likely to change. There is nothing designed in the system to detect the change and present the
information to the valve controller that can automatically correct the change and return the speed to
the required level. Speed correction is the responsibility of the operator who must make the required
control adjustments.

Operator Control Proportional Valve Hydraulic Load

electronics valve spool motor

Figure 1.2Proportional valve block diagram.

Although this type of circuit is perfectly satisfactory for a very large number of applications, some
require automatic and continuous corrections. These circuits require servomechanisms. These
mechanisms can be simply referred to as servo valves.

Figure 1.3 shows the circuit that has the same purpose as that of Fig.1.2, but in this circuit the operator
has been relieved from the responsibility of speed corrections. Instead, a tachometer generator has
been installed that senses the load speed. This information is automatically and continuously fed back
to the control electronics (usually a printed circuit board) where it is compared with the operator
command signal input.
Operator Control Proportion Valve Hydraulic Load
electronics al valve spool motor

Tachometer
generator
Figure 1.3Servo control provides automatic and continuous corrections for any changes in motor
rpm.

If any difference is found between these signals, the electronic circuitry automatically generates a
correction signal proportional to the difference. This signal repositions the valve to correct the flow
rate as required. This “sense and correct” function is continuous, so any and every change in load
speed is automatically corrected. The system required to perform this function includes three major
segments: the servo valve, the command electronics and the feedback transducer.

1.4 Servo Valves

Servo valves can be used in virtually any aspect of fluid power system operations, including the
following:

1. Positioning of cylinders and rotary actuators.

2. Speed of cylinders and motors.
3. Cylinder force and motor torque.
4. Acceleration and deceleration.
5. System pressure.
6. Flow rate.

The most common applications are for cylinder positioning and motor speed control. The valves for
these functions incorporate both direction and flow control in sliding spool arrangement that is
positioned by a torque motor.
1.4.1 Torque Motor
A torque motor is illustrated in Fig. 1.4. It is a simple electromagnetic device consisting of one or two
permanent magnets, two pole pieces, a ferromagnetic armature and two coils. The permanent magnet
polarizes the upper and lower pole pieces, so that they present equal and opposite magnetic fields.
Torque motors are very low-power devices operated on low-voltage DC power.

Figure 1.4 Servo valve torque motor.

The armature is mounted at its mid-point so that it is free to rotate through a very limited are either
clockwise or counter-clockwise. The ends of the armature are extended into the gaps between the pole
pieces. The magnetic field holds the armature in a neutral position. The two coils surround the arms of
the armature to form two small electromagnets. When a current is passed through the coils, a
magnetic field is generated. The polarity of the field depends on the direction of the current flow. In
Fig. 1.5, the current flow causes the left end to become the South Pole and right end to become the
North Pole, resulting in counter-clockwise rotation of the armature.

Figure 1.5Servo torque motor operation.

The two coils of a torque motor may be connected in three different configurations: parallel, series
and the so-called push–pull arrangement. These options are illustrated in Fig. 1.6. The push–pull
arrangement is the most common. In this arrangement, both the leads B and D are connected to
ground through the control circuit amplifier. Leads A and C are connected to separate output
terminals on the command amplifier. When the voltage input to both coils equals, the armature is
centered. Increasing the voltage input to one coil while simultaneously reducing the input to the other
coil by the same amount causes the armature to rotate. The voltage can be varied from zero to its
maximum value for each coil, but the polarity is never reversed. This means that the position of the
armature is determined by the differential torque. When the voltage is the same for both coils, the
torque is equal and the armature is centered. Any change in the voltage to either coil results in the
rotation of the armature.
This push–pull method of connecting the coil is preferred for at least three reasons:

1.Any change in the current as a result of voltage fluctuations, temperature changes or other causes is
canceled by the equal and opposite effects on the coil.
2. There is more stability in armature positioning because of the opposing torque.
3. The power consumption is lower than in the other two configurations for the other two circuits.

(a) (b) (c)

Figure 1.6Torque motors can be connected in several combinations. (a) Parallel (aiding) , (b) series
(aiding), (c) push–pull (opposing).

The input to this arrangement is expressed as a differential current ΔI, where ΔI is the difference
between the coil currents. The control power is calculated from the equation
P  (I )2 R
where P represents the control power, I represents the differential current  I AD  I BC andRrepresents
the resistance of one coil.In parallel connection, the direction of rotation depends on the polarity of
the input signal. The coils in the parallel circuitassist each other rather than oppose (as in a push–pull
circuit). That is, both of them attempt to move either clockwise or counter-clockwise. Reversing the
polarity of coils reverses the polarity of the rotation. The control power is then found from
R
P  ( I p )2  
2
where I p is the total current through the circuit and R is the resistance of the coil.In a series circuit,
the coils assist, rather than oppose, the armature rotation. As with the parallel circuit, a polarity
change is required to change the direction of rotation. The control power of a series circuit is given by
P  ( IS )2 2 R
where I S is the current in the series circuit and R is the resistance of each coil.Notice that the series
and parallel circuits have the same maximum power requirement, which is exactly twice that of the
push–pull circuit.
It is interesting to note that these two low-power torque motors can control a two- or three-stage valve
that may be flowing 300–400 LPM or more at 140–300 bar. Taking in-between values, we see that the
power output of the valve approaches 90000 W. If we define the power gain of the valve as the output
power divided by the control power, we have
90000 W
Power gain = = 5.625 × 104
1.6 W

1.4.2 Valve Spools

At first glance, the hardware of a servo valve looks very similar to that of any spool-type directional
control valve, that is, a sliding spool that operates in the bore of the valve body to open and close the
flow path between ports. The actual differences are found more in the manufacturing process and
clearance specifications than in the basic design.
The servo valve spool and the bore (in which spool moves) are very high precision components.
Typically, spool and bore straightness and diametrical tolerances are held to ±1 m. The radial
clearance between the spool and the bore is typically 3–5 m. In most valves, the radial expansion
that results from holding the spool in hand for a few minutes would prevent its insertion into the bore.
To achieve this precision, a great deal of hand finishing is involved in the manufacturing process. The
spool and the body are quite often a matched set, and the parts are not interchangeable.
Special spool surface finishes are often employed. Nitriding is often used to provide extra surface
hardness and a glass-like smooth finish. This reduces the friction and improves the wear
characteristics. Servo valves may be either three- or four-way. The spool may have two, three or four
lands, depending on the function and on the manufacturer’s preference. It has been shown that four-
land spools can have slightly large clearances without incurring unacceptable leakage. This means
that they have improved wear characteristics and are somewhat more tolerant of contaminants in the
fluid. The two outer lands also assist in keeping the spool precisely centered.
As with most spool-type valves, circumferential grooves are machined into the spool lands. The
purpose of the grooves is to reduce the side loading by equalizing the pressure around the spool and
holding it centered into the bore. A spool with three grooves can have as little as 6% of the side force
as found in the ungrooved spools.
Spool “lap” defines the width of the lands relative to the width of the ports in the valve bore. There
are three possible lap configurations: Overlap, underlap and line-to-line. These are shown in Fig. 1.7.
 (a) (b) (c)
Figure 1.7 (a) Zero overlap. (b) Underlapped. (c) Overlapped

By far, the most common condition is the line-to-line (or zero-overlap) spool. Here, the bandwidth
exactly matches the port width. Thus, when the spool is centered, there is no flow. Any movement of
the spool, regardless of how little, results in flow through the valve. This valve is suitable for closed-
loop position, speed, and force control applications because of its precise metering characteristics
about the null (neutral) position. Unfortunately, even a small amount of wear on either the land or port
edge results in leakage in the null position.

Overlapped spools have lands that are 0.5–5% wider than the ports. These spools have the advantage
of providing lower leakage flow in the null position than the line-to-line configuration.However, the
overlap means that the precision achievable about the null position is compromised because of the
relatively large dead band. For instance, when used as a position controller, a cylinder that is being
extended stops at a different position when being retracted even with the same command input. An
overlapped valve can be satisfactorily employed as a speed controller as long as it is operated well
away from its null position.

In many servo valve control circuits, dither is used to reduce the effects of static friction (termed
stiction). Dither is a very low amplitude command signal superimposed over the normal command
signal that results in a continuous, very short stroke, lateral oscillation of the spool. In such systems, a
slight overlap may be used to prevent unexpected leakage in the null position.

An underlapped spool has lands that are 0.5–1.5% narrower than the ports. This design is often
referred to as “open center” although there really are no open-center servo valves. The underlap is far
too small to be a true open center. This type of valve provides very rapid response to commands about
the null position, but it has the disadvantage of having non-linear flow characteristics near null. This
compromises control to some extent.

1.4.3 Valve Configurations

Servo valves may be single-stage (also called direct-acting), two-stage or three-stage, depending
primarily on the flow requirements of the system.Single-stage valves may be used when the flow
requirements are low (usually less than 20 LPM, depending on the valve design). These valves
commonly utilize a sliding spool mechanically connected to the torque motor armature. The flow
capacity is dictated by the low force available from the torque motor and the limited stroke of the
spool.

1.4.4 Single-StageSpool-Type Servo Valve

Figure 1.8 shows a single-stage servo valve. The mechanical connection between the torque motor
armature and the spool is a stiff wire. When there is no command input to the torque motor, the
armature is in the neutral (nulled) position, which, in turn, causes the spool to be in the nulled
position, and there is no flow through the valve. A clockwise deflection of the armature pushes the
spool to the left, opening up flow path from P to B and A to T. A counter-clockwise deflection opens
P to A and B to T.
 Figure 1.8Single-stage spool-type servo valve.
For higher flow rates, two- or even three-stage valves must be used. In these valves, second and third
stages are always sliding spools that are pilot operated from the previous stages. The first stage may
use the sliding spool, but there are other designs also.

1.5.5Two-Stage Servo Valve

Figure 1.9 shows a two-stage servo valve, pilot operated. This valve can be used to control the
direction and speed of a hydraulic motor. The pilot spool is positioned by the torque motor. The pilot
stage is sleeve. This sleeve is associated with the internal feedback mechanism of the valve. There are
two pressure sources: pc is the control pressure for piloting the main spool and ps is the supply
pressure for operating the system.
In neutral position, as shown in Fig. 1.9, the middle spool land blocks off the pilot part to the left
(large) end of the main (second-stage) spool. The pressure on the large end of the spool is half the
control pressure. The pressure at the small end of the spool is always equal to the control pressure. In
order to be balanced, the large end must have twice the area of the small end. The result is that the
main spool is static. Because no input has been made to the pilot spool, the main spool is static.
Because no input has been made to the pilot spool, the main spool is in neutral position, and so there
is no flow to the hydraulic motor.
 Figure 1.9Two-stage spool-type servo valve.
A counter-clockwise movement of torque motor armature pushes the pilot spool to the left. This opens
up the port (through the pilot-stage sleeve) to the large end of the main spool. The pressure in that end
increases, causing a force imbalance that shifts the main spool to the right and opens flow paths P to
A and B to T.

This movement of the main spool also initiates the internal feedback action. As the main spool moves
to the right, it pushes the feedback linkage. This linkage transmits the main spool movement to the
pilot-stage sleeve, causing the sleeve to slide to the left. When the sleeve port moves to the point
where it is blocked by the pilot spool land, flow to the large end of the main spool stops.
Consequently, the main spool stops. The exact stopping point is predetermined and is controlled by
the deflection of the torque motor. Because the opening created by the movement of the main spool
constitutes a control orifice, both the direction and the speed of rotation of the hydraulic motor are set.

De-energizing the torque motor returns the pilot spool to its neutral position, which opens up a flow
path through the pilot-stage sleeve and ports the large end of the main spool to the tank. The resulting
force imbalance shifts the spool to the left. This allows the pilot-stage spring to push the spool back to
the right. When the sleeve port realigns with the pilot spool land, all pilot flow stops, the main spool
stops (in its neutral position), and the hydraulic motor stops. A similar but opposite sequence takes
place when the torque motor armature is deflected clockwise.

1.5.6Double-Flapper Nozzle Pilot Stage

Figure 1.10 shows a double-flapper nozzle pilot stage. The nozzle is a physical part of the torque
motor armature and extends into a fluid cavity inside the valve. Control pressure for piloting the main
spool enters the pilot section through the ports on opposite sides of the flapper. The pressure is then
channeled to nozzles located in the fluid cavity into which the flapper extends. These channels are
also connected to the pilot chambers at the ends of the main spool.

Figure 1.10Two-stage spool-type servo valve.

When the torque motor is not energized, the armature is centered, which positions the flapper exactly
in the middle of the cavity. Because the distances between the nozzle lands and the flapper are very
small, this, in effect, forms small orifices that restrict the flow and generate a pilot pressure. With the
flapper exactly centered, both orifices are of the same size, resulting in the same pressure in both pilot
chambers. This causes a force balance on the main spool and holds it in its neutral position.

If the armature is deflected counter-clockwise, the flapper moves toward the right-hand nozzle. This
movement reduces the orifice associated with that nozzle while increasing the orifice for the opposite
nozzle. This increases the pressure in the right-hand pilot chamber and decreases the opposite
pressure. The result is a force imbalance that shifts the main spool to the left and opens the related
flow paths.

The internal feedback mechanism in the flapper-nozzle valve is flexible metal rod (usually termed a
spring) that is attached to the end of the flapper and inserted into a ball joint in the main spool. As the
main spool shifts to the left, the feedback spring exerts a force on the flapper (and on the armature)
that tends to return it to its neutral position. The force is proportional to the distance moved by the
spool. So as the spool shifts to the left, the restoring force in the flapper increases. When the force is
sufficient to center the flapper, the control orifices are again equal, as are the pressures in the pilot
chambers, and so the main spool stops. It remains in that position until a subsequent command signal
causes the armature to move again.

1.5.7Jet Pipe Servo Valve

Figure 1.11 shows another pilot stage – jet pipe stage. In this device, the jet nozzle is attached to and
moves with the torque motor armature. The pilot fluid is directed by the jet nozzle into two receiver
ports that connect to the pilot chambers at the ends of the main spool. In neutral position, the fluid is
evenly divided, which results in equal pressures in the pilot chambers. As a result, the main spool
remains stationary. A deflection of the torque motor directs the jet more directly into one of the
receiver ports, causing the force imbalance and main spool movement. Internal feedback is provided
by a feedback spring in a manner similar to that in the flapper nozzle system.
 Figure 1.11Two-stage spool-type servo valve.
A variation of the jet pipe concept is the deflector jet valves shown in Fig. 1.12. In this valve, the jet
pipe concept does not change. Rather, deflectors are moved into the fluid jet, which direct it into the
appropriate receiver ports.

Figure 1.12Deflector jet valve.

The standard symbols for servo valves are shown in Fig. 1.13. The symbols do not hint the number of
stages or type of pilot stage used. They show only function. The directional flow control valves are
always three-position, infinitely positionable units and usually have closed centers. The actuator
symbols represent the summing junction of the electronic amplifier, which receives two input signals
(reference and feedback) and produces a single output signal.
 (a) (b)

Figure 1.13Servo symbols: (a) Line-to-line and overlapped spool; (b) underlapped spool.

1.5.8Pressure Flow Characteristics

Servo valves are generally considered to be “high-pressure” devices. Usually the pressure rated is 200
bar, although most are capable of operating higher than 300 bar. Servo valves are typically flow rated
at 60–70 bar differential; that is, the flow rate stated for the valve is the flow that occurs at 60–70 bar
pressure drop across a fully opened valve. There is a very deliberate logic in the choice of 60–70 bar.
The majority of servo systems use a working pressure of 200 bar. It can be mathematically shown that
the maximum transmission of power from the pump to the cylinder or motor occurs when the pressure
drop through the valve is one-third of the system working pressure. This parameter is related to the
basic orifice equation, which describes the flow rate through orifice. Thus, the valves are flow rated at
the maximum power transfer pressure drop based on the popular 200 bar. It has also been determined
that valve control is optimized at the 65 bar pressure drop.

If the pressure drop across the valve is different from the optimum, the flow rate changes
proportionately. The non-optimum flow rate can be calculated using the equation
p
q  qr (1.1)
pr
where q is the adjusted flow rate, qris the rated flow, p is the actual pressure drop and pr is the rated
pressure drop (usually 65 bar).
1.5.9Valve Performance
The performance of a valve can be described by numerous parameters. They are generally divided
into two categories: dynamic response and static response. The dynamic response characteristics are
the same as those for proportional valves, frequency response and amplitude ratio. Figure 1.14 is a
Bode diagram showing these characteristics(frequency response and amplitude ratio) for a specific
valve.

During the normal operation of a valve, the valve is likely to experience the same current input (set
point) frequently. Sometimes, this specific current input is approached from a lower current setting.
At other times, it is approached from higher settings. All valves have the characteristic that this
current set point results in different spool positions, depending on whether it is approached from a
lower or higher current.
 Figure 1.14 Valve performance.
This characteristic is termed hysteresis. Typical hysteresis curves for servo valves and proportional
control valves are shown in Fig. 1.15. Hysteresis is expressed as the percent difference in the rated
current required to give the same output when approached from higher and lower inputs. For servo
valves, it is typically 1–2%. To overcome the problem of hysteresis, some controllers are designed so
that the set point is always approached from the lower side. This requires a deliberate undershoot
when approaching from the high side.

Proportional valve + Flow

performance

Servo Proportional valve

valve hysteresis
hysteresis

Servo valve
performance
Flow

Ideal valve
performance
Figure 1.15 Hysteresis for a servo valve and a typical proportional valve.
A second important valve characteristic is the valve dead band. Dead band occurs only at the null
position, as shown in Fig. 1.16. It is defined as the current required to move the spool from the exact
centered position to the position where the first flow output is seen. It is usually expressed in
milliamps or percent-rated current. Dead band is the result of the spool inertia, overlap, static friction
and any other forces that might impede the initial motion.
 +Flow

1 +1
Deadband

Flow

Figure 1.16 Dead band of a valve.

A similar phenomenon is threshold. Threshold current is the smallest input current required to
overcome spool inertia and other impending forces to cause the spool to move. The primary
difference between threshold and dead band is that threshold occurs throughout the spool stroke,
whereas dead band occurs only at the null position. Threshold contributes to the dead band rating.

Information concerning hysteresis, dead band and other valve performance characteristics is available
from the valve manufacturers. These characteristics can be significant in evaluating the suitability of a
valve for a specific application.Threshold is the current that must be applied before a response is
detected. Good-quality two-stage valves have a threshold less than 0.5% of rated current.

1.4.10Gain and Feedback

One of the most important concepts of servo system is its ability to constantly monitor its output and
automatically make corrections to ensure that the output remains at the commanded level. This is
accomplished through the use of some type of feedback from a transducer that monitors the output
parameter. Gain is defined as the ratio of output by input. Two gains are defined for servo valves:
flow gain and pressure gain. Flow gain is the ratio of flow to input current. Flow gain is determined
by measuring control flow versus input current. Flow gain is the slope of the graph of control flow
versus input current. Pressure gain is defined as the ratio of pressure and input current. Pressure
transducers are mounted on the output ports and pressure difference is measured as a function of input
current. The range of input current to produce a load pressure change from −40% to +40% of supply
pressure is determined. Pressure gain is difficult to measure.

1.4.10.1 The Control Ratio Equation

R E
G C

Figure 1.17 A basic feedback – closed loop.

One of the most important aspects of system analysis is an understanding of system gain.Figure 1.17
is a block diagram of a generic system with feedback. The command input signal is given a designator
R for reference. The gain of the loop leg is designated G and termed the forward loop gain. The gain
of the feedback loop is denoted by H and the controlled output is shown as C.
As the system operates, a feedback signal F is continuously generated. Its value is based on the value
of C and the feedback gain. Thus,
F  CH
This feedback signal is fed to the summing junction (in the op-amp), where it is compared with the
reference signal. The result is an error signal E whose value is
E  R – F  R –CH (1.2)
This results in a change in the controlled variable C, which then becomes
C  EG (1.3)
and the process repeats itself.Equating Eqs. (1.2) and (1.3), we get
C  ( R –CH )G  RG –CGH
so that
RG  C  CGH  C(1  GH )
and, eventually,
C G
 (1.4)
R 1  GH
This equation is known as the control ratio, and closed-loop gain or the closed-loop transfer function
of the system. The right-hand side of Eq. (1.4) defines the system gain and is commonly referred to as
the closed-loop gain of the system.

Example 1.1
A torque motor is connected in a push–pull circuit. Each coil has a resistance of 20 Ω and is rated at
200 mA.Find
(a) The voltage of each coil when the armature is centered.
(b) The maximum value of Δl.
(c) The maximum control power for the torque motor.

Solution

(a) The maximum voltage for the coil is

E = IR = 200 mA × 20 Ω = 4 V
The armature is centered when
Emax
E  2 Volts
2
(b) The differential current is
I = IAD – IBC
The maximum value will occur when the maximum voltage is applied to one coil, so that zero
voltage is applied to the other. In this case,
Emax 4V
I  I AD  I BC  0  200 mA
R 20 
(c) The maximum control power is then
P = (ΔI2)R = (200 mA)2(20 Ω) = 0.8 W

Example 1.2
A torque motor is connected in a parallel circuit. Each coil has a resistance of 20 Ω and is rated at
200 mA.Find
(a)The voltage of each coil when the armature is centered.
 (b) The maximum value of ΔI.
(c) The maximum control power for the torque motor

Solution: (a)The voltage to each coil will remain the same (4 V).
(b) The current through the circuit will increase because of lower resistance. For a parallel circuit
made up of two equal resistors, the equivalence resistance is R/2; in this case, 10 Ω.The value of I is
the total current, which we find from
E 4V
IP    0.4A=400mA
R 10
(c) Control power is given by
P = (IP)2(R/2) = (400 mA)2(20 Ω/2) = 1.6 W

Example 1.3
A torque motor is connected in a series circuit. Each coil has a resistance of 20 Ω and is rated at 200
mA. Find
(a)The voltage of each coil when the armature is centered.
(b) The maximum value of ΔI.
(c) The maximum control power for the torque motor

Solution: (a) A torque motor is connected in a series circuit. Therefore, total resistance is 2R or 40 Ω.
The maximum current will be 200 mA.
(b) A torque motor is connected in a series circuit thereforethe maximum voltage is
Voltage (E) = IR = (200 mA)(40 Ω) = 8 V
(c)The control power is
P = (Is)2 (2R) = (200 mA)2(2)(20 Ω) = 1.6 W

Example 1.4
A servo valve is flow rated at 56 LPM at 65 bar differential (Fig. 1.5). It is to be operated in a 130 bar
system. What will its adjusted flow rate be at the optimum power transfer p?

Solution: For optimum power transfer, the pressure drop across the valve should be
130
= 43.33 bar
3
From Eq. (1.1), we have
p 43.3
q = qr = 56 = 45 LPM
pr 65

example>
Example 1.5
Figure 1.18 shows a servo valve which is rated at 65 bar pressure drop across the valve in a 195 bar
system.
(a) Find the pressure drop when motor is fully loaded.
(b) Find the pressure drop when motor is not fully loaded.
 (c) Find the pressure drop when motor is overloaded. Will there be a flow?
(d) Derive an expression for fluid temperature rise across the valve.

Note that the term “6 bar pressure drop” imply that the drop across one flow path through the valve.

195 bar

Figure 1.18

Solution:
(a) When motor is at full load: From Fig. 1.18, with the pump compensator set at 195 bar, the pressure
is reduced to 195 – 32.5 = 162.5 bar across the P to A path through the valve. If we assume the motor
to be operating at full load, 130 bar is dropped across the motor. The final 32.5bar is then dropped
through the B to T side of the valve.

(b) When motor is not at full load: If the motor is not fully loaded, then the system pressure drops
below 195 bar. In this case, the 65 bar drop across the valve still occurs, but the power transfer
diminishes. (c) When motor is overloaded: If the motor is overloaded so that more than 130 bar is
required to rotate it, then the 65 bar drop across the valve is not possible. The result is a lower flow
rate [Eq.(1.1) applies], so the motor will turn more slowly. The extreme of this condition is a stalled
motor. In this case, the full 195 bar will be dropped across the motor. Obviously, there is no flow in
this case.
(d) Heat generation and fluid temperature rise: Because the servo valve represents a major pressure
drop, it will also generate a considerable amount of heat. Let
HGR = Heat generation rate = WCp T
P = Power loss across the valve = pQ
The fluid temperature rise across the valve can be found using the equation
HGR
T = (1.5)
CpW
where T = temperature rise (  C ), Cp = specific heat of the oil = 1.8 kJ/kg K,W (kg/s) = weight flow
rate = γQ,andγ = fluid-specific weight.
Example 1.5
For the servo valve of Example 1.5, determine the power loss, heat generation rate and the
temperature rise across the valve. The fluid has a specific weight of 8620 N/mm3.

Solution: The power loss is

P = Δp × q = 43.3×105 × (45/1000) × (1/60)
= 3.25 kW
The resultant heat generation rate is found from Eq.(1.5). The increase in the fluid temperature is
T  HGR / CpW
The weight flow rate is
W  Q
Oil flow rate in kg/s   Q (oil flow rate in m3 /s)
103
 895  45 
60
 0.67125 kg / s
Therefore,
T  HGR / CpW
4.97
  2.689 C
1.8  0.889
This is the temperature rise experienced by every drop of oil that flows through the valve. The rise
occurs in the time required for the fluid to flow through the portion of the valve where the pressure
drop occurs.
Although the weight flow rate appears in the equation, the temperature rise is actually independent of
flow rate. So the temperature rise for any fluid is a function of pressure drop only.

Example 1.7
In the given servo system (Fig. 1.19), suppose the forward loop contains a hydraulic motor. The
forward loop gain is 300 rpm/V and the feedback loop consists of a tachogenerator that has a gain of
0.2 V/rpm. What will be the speed of the hydraulic motor for an input of 3.5 V?

R E
G C

Figure 1.19

Solution: Given R C
Reference input, R = 3.5V
Forward loop gain, G = 300 rpm/V
Feedback loop gain, H = 0.2 V/rpm
The equation of closed-loop transfer is given by
 C G
 (1.6)
R 1  GH
This gives
 G 
C  R
 1  GH 
 300 
  (3.5)
 1  300  0.2 
 17.2 rpm
Normally, if the feedback system is not included, the 3.5 V input should give 1050 rpm. Because there
is feedback, the output is 17.6 rpm.

Example 1.8
Figure 1.20 shows a closed-loop feedback system with multiple elements in the forward loop. Derive
an expression for closed-loop gain.

R C
G1 G2 G3
E

Figure 1.20

Solution:Let us have a system that has more elements in the forward loop. The gain can still be found
by using the Eq.(1.6). Let us first resolve all the forward loop gains into a single value G. The forward
loop gain G is the product of all the individual element gains between the summing junction and the
output. Thus,
G  G1G2G3 (1.7)
So
C G G1G2G3
  (1.8)
R 1  GH 1  G1G2G3 H

Example 1.9
Determine the speed of the hydraulic motor in the circuit shown in Fig. 1.21.
 Amplifier Servo valve Hydraulic motor
R=5V C
Valve
G
GA GSV M
E
GA = 50 mA/V GSV = 0.1 gpm/mA GM = 30 RPM/gpm
mA/V mA/V
F Tech-generator

HT

HT = 0.2 V/rpm
Figure 1.21

Solution: Using Eq.(1.7) we can write

G  GAGSVGM
 (50 mA/V)(0.1gpm/mA)(30 rpm/gpm)
150 rpm/V
Using the closed-loop transfer equation, we have

C G

R 1  GH
 G 
C  R
 1  GH 
 150 
C   (5)  24.2 rpm
 1  150  0.2 
Objective-Type Questions
Fill in the Blanks

1. A servomechanism is defined as an automatic device for controlling a large amount of power by

means of a very small amount of _______.
2. Servo valves are operated by _______ motors.
3. Typically, spool and bore straightness and diametrical tolerances are held to _______.
4. Overlapped spools have lands that are 0.5% to _______% wider than the ports.
5. In many servo valve control circuits, _______ is used to reduce the effects of static friction (termed
stiction).
6. ______ valves may be used where the flow requirements usually less than 20 LPM_______.

State True or False

1. Servo valves are less expensive than proportional valves.

2. There is no dead zone for a servo valve.
3. A servo valve uses always zero or underlap spool.
4. The maximum operating frequency of a servo valve is 10 Hz.
5. Servo that uses feedback electronics is more accurate.

Review Questions

1. Define a servo valve.

2. How do servo valves differ from proportional control valves?
3. Explain the operation of a torque motor.
4. Define underlap, overlap and line to line in the context of servo valve spools.
5. Define dead band.
6. Define threshold.
7. Define hysteresis.
8. List and define the types of hydraulic amplifiers.
9. At what pressure drop are servo valves usually rated?
10. Define gain.
11. Define flow gain.
12. Define pressure gain.
13. What are the uses of servo valves?
14. What is a torque motor?
15. What is a spool lap?
16. What are the three types of servo valves?
Answers
Fill in the Blanks

1. Power
2. Torque
3. ±1 m
4. 5%
5. Dither
6. single stage

State True or False

1. False
2. False
3. False
4. True
5. True
 Lecture 28

ACCUMULATORS

Learning Objectives
Upon completion of this chapter, the student should be able to:

 Define an accumulator.
 Explain various types of accumulators.
 Differentiate between separator and non-separator types of accumulators.
 Size an accumulator for various applications.
 Describe various applications of accumulators.
 Analyze the performance of hydraulic systems using accumulators.

1.1 Introduction
A hydraulic accumulator is a device that stores the potential energy of an incompressible fluid held under
pressure by an external source against some dynamic force. This dynamic force can come from different
sources. The stored potential energy in the accumulator is a quick secondary source of fluid power
capable of doing useful work.
There are three basic types of accumulators:

1. Weight-loaded or gravity accumulator:Schematic diagram of weight loaded accumulator is shown

in Fig. 1.1.It is a vertically mounted cylinder with a large weight. When the hydraulic fluid is pumped
into it, the weight is raised. The weight applies a force on the piston that generates a pressure on the fluid
side of piston. The advantage of this type of accumulator over other types is that it applies a constant
pressure on the fluid throughout its range of motion. The main disadvantage is its extremely large size
and heavy weight. This makes it unsuitable for mobile application.

Dead load
Fluid pressure

Breather

Maximum
Fluid 0
under Volume of fluid in accumulator
pressure

Figure 1.1 Dead weight accumulator.

2. Spring-loaded accumulator: A spring-loaded accumulator stores energy in the form of a compressed
spring. A hydraulic fluid is pumped into the accumulator, causing the piston to move up and compress the
spring as shown in Fig. 1.2. The compressed spring then applies a force on the piston that exerts a
pressure on the hydraulic fluid.
This type of accumulator delivers only a small volume of oil at relatively low pressure. Furthermore, the
pressure exerted on the oil is not constant as in the dead-weight-type accumulator. As the springs are
compressed, the accumulator pressure reaches its peak, and as the springs approach their free lengths, the
accumulator pressure drops to a minimum.

Fluid pressure
Breather hole

Spring preload
Full

Fluid 0
under Volume of fluid in accumulator
pressure

Figure 1.2 Spring-loaded accumulator.

3. Gas-loaded accumulator: A gas-loaded accumulator is popularly used in industries. Here the force is
applied to the oil using compressed air. Schematic diagram of a gas loaded accumulator is shown in Fig.
1.3.A gas accumulator can be very large and is often used with water or high water-based fluids using air
as a gas charge. Typical application is on water turbines to absorb pressure surges owing to valve closure
and on ram pumps to smooth out the delivery flow. The exact shape of the accumulator characteristic
curve depends on pressure–volume relations:

 Isothermal (constant temperature): This occurs when the expansion or compression of the gas
is very slow. The relationship between absolute pressure p and volume V of the gas is constant:
pV = constant (1.1)

 Isentropic (adiabatic processes): This is where there is no flow of energy into or out of the
fluid. The law that the gas obeys is given by pV = constant, where  is ratio of specific heat and is
approximately equal to 1.4.
 Polytropic: This is somewhere between isothermal and isentropic. This gas change is governed
by the law pVn = constant, where n is somewhere between 1 and 1.4 and is known as the
polytropic coefficient.
 Charging valve

Fluid pressure
Full
Gas
Free 0
surface Volume of fluid in accumulator
Fluid

Figure 1.3 Gas-loaded accumulator.

There are two types of gas-loaded accumulators:

 Non-separator-type accumulator: Here the oil and gas are not separated. Hence, they are
always placed vertically.
 Separator-type accumulator: Here the oil and gas are separated by an element. Based on the
type of element used to separate the oil and gas, they are classified as follows:

(a) Piston-type accumulator:Schematic diagram of a piston type accumulator is shown in Fig. 1.4.It
consists of a cylinder with a freely floating piston with proper seals. Its operation begins by charging
the gas chamber with a gas (nitrogen) under a pre-determined pressure. This causes the free sliding
piston to move down. Once the accumulator is pre-charged, a hydraulic fluid can be pumped into the
hydraulic fluid port. As the fluid enters the accumulator, it causes the piston to slide up, thereby
compressing the gas that increases its pressure and this pressure is then applied to the hydraulic fluid
through the piston. Because the piston is free sliding, the pressure on the gas and that on the hydraulic
fluid are always equal.
 Gas valve

Nitrogen

Piston separator

Liquid

Figure 1.4 Piston-type accumulator.

(b) Diaphragm accumulator:In this type, the hydraulic fluid and nitrogen gas are separated by a
synthetic rubber diaphragm. Schematic diagram of diaphragm accumulator is shown in Fig. 1.5.
The advantage of a diaphragm accumulator over a piston accumulator is that it has no sliding
surface that requires lubrication and can therefore be used with fluids having poor lubricating
qualities. It is less sensitive to contamination due to lack of any close-fitting components.
Plug

Steel
case

Shut-off
Diaphragm button

Figure 1.5 Diaphragm-type accumulator.

(c) Bladder accumulator: It functions in the same way as the other two accumulators. Schematic
diagram of bladder accumulator is shown in Fig. 1.6. Here the gas and the hydraulic fluid are
separated by a synthetic rubber bladder. The bladder is filled with nitrogen until the designed pre-
charge pressure is achieved. The hydraulic fluid is then pumped into the accumulator, thereby
compressing the gas and increasing the pressure in the accumulator. The port cover is a small
piece of metal that protects the bladder from damage as it expands and contacts the fluid port.
 Gas valve

Nitrogen

Bladder
separator

Liquid

Poppet valve

Bleed plug

Figure 1.6 Bladder-type accumulator.

In an accumulator, at any point of time, we either compress a pre-charged gas or allow it to expand. This
compression or expansion brings about a status change in the gas, which is governed by the perfect gas
equation:
pV  mRT (1.2)
3
where pis the absolute pressure in bar, V is the gas volume in m , m is the mass in kg and R is the
universal gas constant. (The most common gas used in industry is nitrogen.) For the particular gas and the
accumulator, the value of mR is constant and the gas equation is written as
pV
 constant
T

p0V0 p1V1
or  (1.3)
T0 T1
When the change takes place over a long period of time, the temperature of the gas remains constant and
such a change is called isothermal, resulting in the equation
p0V0  p1V1  p2V2 (1.4)
When the change occurs instantaneously, there is no time for heat transfer from the work to the
environment.Such a change is called isentropic or reversible adiabatic and is given by
p0V0n  p1V1n  p2V2n (1.5)
All changes between isothermal and isentropic are called polytropic. The pressure–volume diagram
shown in Fig. 1.7 helps us to understand how the volume variation as a function of pressure depends on
the value of the polytropic exponent n that for nitrogen is contained within the limits 1  n  1.4 . The
value of n is taken to be equal to 1 if the compression and expansion process takes place under the
isothermal process. For adiabatic conditions, the value of n is taken equal to 1.4.
Isothermal conditions can be considered to exist if the accumulator is used as a volume compensator,
leakage compensator and pressure compensator or as a lubrication compensator. In all other cases, such as
energy accumulation, pulsation damping, emergency power source, dynamic pressure compensator, shock
absorber, hydraulic spring, etc., expansion and compression process may be considered to take place
under “adiabatic” conditions. Generally, the adiabatic condition is considered to exist if the compression
or expansion period is less than 3 min.
 Max.working pressure

Min.working pressure

Precharge
pressure

Figure 1.7 Pressure–volume diagram.

1.2 Accumulator Selection
After ascertaining the type of accumulator that is appropriate for the purpose envisaged, what remains is
determining the volume of the form of “high pressure fluid.” Accumulators are manufactured to a variety
of pressure ratings and the one chosen should be rated for a pressure more than the maximum system
working pressure p2.
However, the values of the following basic parameters should be established before proceeding further:
Working pressures p1 and p2. The value of p2 is found from the ratio p2 / p0  4 .The maximum gas pre-
charge pressure is found from the relationship p0  0.9 p1 or p0  0.25 p1 . The gas pre-charge pressure
must be as close as possible to the minimum working pressure p1 to obtain maximum storage. Special
values for p0 are used in pulsation damping and shock absorber applications ( p0  0.8 p1 ). Other
parameters to be determined are the volume of fluid V that needs to be stored ( V  0.75V0 ), the
maximum required flow rate and the operating temperature.
1.2.1 Sizing Accumulators for Isothermal Condition
For isothermal condition, the Boyle–Mariotte law can be rewritten in terms of V1 and V2 as
p 
V1  V0  0  (1.6)
 p1 
p 
and V2  V0  0  (1.7)
 p2 
The difference between V1 at the minimum operating pressure p1 and V2 at the maximum operating
pressure p2 gives the amount of the stored fluid V. Thus,

p  p 
V  V1  V2  V0  0   V0  0 
 1
p  p2 
p p 
 V V0  0  0 
 p1 p2 
V
 V0  (1.8)
p0 / p1  p0 / p2
In the above equations, V1 and V2 are nitrogen volumes at the pressures p1 and p2, and V0 is the nitrogen
pre-charge volume at the pressure p0 in liters. It is the maximum volume of gas that can be stored in the
accumulator. The size of the accumulator, while conforming to the standard available sizes, should be at
least 5–10% more than this volume V0. Any increase in the value of V results in a corresponding
increase in the size of the accumulator. Likewise any decrease in the value of p0 or the value of (p1 – p2)
requires an accumulator of higher volume.
1.2.2 Sizing Accumulators for Adiabatic Condition
Starting from the basic formula p0V0n  p1V1n  p2V2n , it can be shown that for adiabatic conditions, the
values of maximum nitrogen volume V0 at the pre-charge pressure p0 and the stored volume of oil are
given by the following equations:
 p 0.7143  p 0.7143 
V V0  0   0  
 1 
p  p2  
V
 V0  (1.9)
[( p0 / p1 ) 0.7143
 ( p0 / p2 )0.7143 ]
Here, the value of the polytropic exponent n is taken equal to 1.4 and therefore 1/n becomes 0.7143. Here
again intermediate values can be used for more accurate results.

1.2.3 Sizing Accumulators for Emergency Reserve

This is a typical application where both isothermal and adiabatic conditions prevail due to slow storage
and quick discharge. For this condition, the accumulator volume is given by
V ( p2 / p0 )
V0 
[( p2 / p1 )0.7143 1]
 p 0.7143 
 2   1
 p1  
 V V0 p0 (1.10)
p2
1.2.4 Sizing Accumulators for Pulsation Damping
Pulsation damping is typically an adiabatic condition because both storage and discharge have to be
accomplished in a very short time. Because pressure pulsation is a phenomenon associated with piston
pumps, the stored volume V is a product of the pump displacement q in liters and a constant k that
depends on whether the pump is single-acting or double-acting and the number of pistons involved.
Pressure pulsation is highest in a single-acting single-piston pump delivering large flows at high
pressures. Here the k factor is about 0.69. A single-piston double-acting pump has the same k factor as
that of a double-piston single-acting pump whose k factor is equal to 0.29. A three- or four-piston single-
acting pump has a k factor of 0.12. For any other pump configuration, an average k factor of 0.05 can be
taken with reasonable accuracy.
The stored volume is given by
V  kq where q is the pump flow rate in LPM/RPM × number of piston. Now

V
V0  (1.11)
[( p0 / p1 )0.7143  ( p0 / p2 )0.7143 ]

wherep1 = (p − x) and p2 = (p + x). Here, p is the average working pressure in bar and x is given by
(a × p)/100 bar , where a is percentage of pulsation.

1.2.5 Sizing Accumulators for Hydraulic Line Shock Damping

A suitable accumulator can neutralize water hammering in pipes due to shock waves caused by sudden
closure of valves. Typical applications can be found in water, fuel and oil distribution circuits. The
volume of the accumulator required to absorb the shock waves is given by
 4Qp2 (0.0164 L 2t )
V0 
1000 ( p2 2 p1 )
where Q is the flow rate in LPM;p2 is the maximum pressure in bar;L is the length of the pipe in meters;t
is the acceleration, deceleration or the valve shut-off time in s and p1 is the operating pressure with free
flow in bar. In some applications such as hydraulic lift trucks, accumulators may be used to absorb
hydraulic shocks when the valve shifts or to absorb load-induced pressure surges when the truck runs over
uneven ground.

1.2.5.1 Influence of Variation in Temperature on Accumulator Volume

The nitrogen pre-charge pressure in an accumulator is based on the expected maximum rise in the
circulating hydraulic oil temperature. This temperature can drop due to changes in environmental factors
resulting in a comparable drop in the pre-charge pressure. According to Gay Lussac’s law, this variation
in pressure affects the volume resulting in lower accumulator capacity. It is therefore necessary to have an
accumulator of higher volume so that the useful volume V remains unaffected.

1.2.5.2 Influence of Pressure on Accumulator Volume

The fact that n, the value of adiabatic index, lies between 1 and 1.4 is true for perfect gases. But nitrogen
used in accumulators does not behave like a perfect gas when pressure increases and this affects the value
of n and consequently the accumulator volume V0. So for pressures between 200 bar and 350 bar, the
value of adiabatic index n may be assumed to lie in the range 1.5–1.6.

1.2.6 Sizing of Additional Gas Bottles

Sometimes the size V0 as determined by Eqs. (1.6)–(1.12) may be more than the available accumulator
sizes or the size so determined is too big for accommodation within the frame of the machine. Also
sometimes it may become necessary to maintain a small difference between p1 and p2, which results in a
higher stored volume V and a much larger accumulator volume V0. In such cases, it is convenient to get
required volume by additional bottles.
For example, if an application requires 43 L of fluid to be discharged adiabatically between 70 and 55 bar,
the total volume required would be close to 434 L. The volume requirement is high because the pressure
difference is small. If a 22.5 cm bore piston accumulator can hold 125 L, then auxiliary gas bottles can be
installed some distance away to meet the balance of volume requirement.
In applications such as energy reserve volume compensation and hydraulic line shock damping, it is
recommended that a higher pre-charge pressure p0 = 0.97p1 be maintained. After obtaining the value of V0
in the normal way, it must be split into two portions: The minimum indispensable portion that is
contained in the accumulator and the portion that is contained in additional gas bottles.
 Lecture 29

ACCUMULATORS [CONTINUED]

1.3 Applications of Accumulators

There are five basic applications where accumulators are used in a hydraulic system:

1. Accumulator as an auxiliary power source: The purpose of accumulator in this application is to

store the oil delivered by the pump during a portion of the work cycle. The accumulator then
releases the stored oil on demand to complete the cycle, thereby serving as a secondary power
source.

Figure 1.8 Accumulator as an auxiliary power source.

The schematic diagram is shown in Fig. 1.8. When the four-way valve is manually activated, oil flows
from the accumulator to the blank end of the cylinder. This extends the piston until it reaches the end of
the stroke. When the cylinder is in its fully extended position, the accumulator is being charged. The four-
way valve is then deactivated for retraction of the cylinder oil flows from both the pump and accumulator
to retract the cylinder rapidly.

2.Accumulator as a leakage compensator: An accumulator can be used as a compensator for internal

and external leakage during an extended period in which the system is pressurized but not in operation.
The pump charges the accumulator and the system until the maximum pressure sets the pressure switch
ON. The schematic diagram is shown in Fig. 1.9. The contacts on the pressure switch then open to
automatically stop the electric motor that drives the pump. The accumulator then supplies leakage oil to
the system during a long period. Finally, when the system pressure drops to the minimum pressure setting
of the pressure switch, it closes the electrical circuit of the motor until the system gets recharged. The
check valve is placed between the pump and accumulator so that the pump does not reverse when the
motor is stopped and does not permit all the accumulator charge to drain back into the power unit. With
this circuit, the only time the power unit operates is when the pressure drops to an unsafe operating level.
This saves electric power and reduces the heat in the system.
 Figure 1.9 Accumulator as a leakage compensator.
3.Accumulator as an emergency power source: In some hydraulic systems, safety dictates that a
cylinder be retracted even though the normal supply of oil pressure is lost due to a pump or electrical
power failures. The schematic diagram is shown in Fig. 1.10. In it, a solenoid activated three-way valve
is used along with the accumulator. When the three-way valve is energized, oil flows to the blank end of
the cylinder and also through the check valve into the accumulator and the rod end of the cylinder. The
accumulator charges as the cylinder extends.
If the pump fails due to an electric failure, the solenoid de-energizes, shifting the valve to its spring offset
mode. Then the oil stored under pressure is forced from the accumulator to the end of the cylinder. This
retracts the cylinder to its starting position.

Figure 1.10 Accumulator as an emergency power source.

4. Accumulator as a hydraulic shock absorber: One of the important applications of accumulators is
the elimination of hydraulic shock.The schematic diagram is shown in Fig. 1.11. Hydraulic shock is
caused by the sudden stoppage or declaration of a hydraulic fluid flowing at relatively high velocity in a
pipe line. Rapidly closing a valve creates a compression wave. This compression wave travels at the
speed of sound upstream to the end of the pipe and back again to the closed valve, which causes an
increase in pressure.
The resulting rapid pressure pulsations or high-pressure surges may cause damage to the hydraulic system
components. If an accumulation is installed near the rapidly closing valve, the pressure pulsations or high-
pressure surges are suppressed.

To system

Shut-off valve

Figure 1.11 Accumulator as a hydraulic shock absorber.

5. Accumulator as a thermal expansion compensator: When closed-loop hydraulic systems are
subjected to heat conditions, both the pipe lines and the hydraulic fluid expand volumetrically. Because
the coefficient of cubical expansion of most fluids is higher than that for pipe material, this expanded
liquid volume increases the entire system pressure. This condition may cause pressures to exceed the
limits of safety and may damage the system components. Under these conditions, an accumulator of
proper capacity pre-charged to the normal system working pressure is installed. It takes up any increase in
the system fluid volume, thus reducing the system pressure to its safe limits. The accumulator also feeds
the required volume into the system as thermal contraction takes place.The schematic diagram of such an
arrangement is shown in Fig. 1.12.
 Figure 1.12 Accumulator as a thermal expansion compensator.

Example 1.1
A hydraulic cylinder has to move a certain load through a certain distance in 1 s at a pressure of 140 bar.
An accumulator is integrated into the circuit to provide peak power. The accumulator is charged for the
first 20 s and discharged in 2 s. The delivery expected from the accumulator is 0.6 L in 2 s as the pressure
falls from 250 to 140 bar. Calculate the accumulator volume. The operating temperature is +25–70ºC.
Also calculate the reduction in input power due to the accumulator.

Solution: This is a case of isothermal compression and adiabatic expansion. The equation considered here
is
V ( p2 / p0 )
V0 
[( p2 / p1 )0.7143 1]
Because the maximum system pressure is above 200 bar, we consider a higher value of 1.6 for the
adiabatic index n. Therefore, 1/1.6 = 0.625. Inserting this value into the above equation, we have
p0  0.8 p1  0.9  140  126 bar (gauge) =127 bar (absolute). So
V ( p2 / p0 )
V0 
[( p2 / p1 )0.7143 1]
0.6(251 / 127)

[(251 / 141)0.7143 1]
 2.74 L
If we apply the correction for temperature change because the pre-charge pressure p0 was based on the
maximum temperature indicated, we have the new corrected volume
V0T = 2.74 (343/298) = 3.15 L
A 3.5 L accumulator would effectively serve the purpose. The delivery from the accumulator is 0.6 L in 2
s, 0.3 L/s or 18 L/min.
In the absence of accumulator, the pump has to supply all of this delivery at a pressure of 140 bar. The HP
required would be
(18  140)/600 = 4.2 kW
Here the efficiency of the pump is not considered. If the accumulator is included in the circuit, the pump
has to deliver 0.6/20 = 0.03 L/s or 1.8 L/min sufficient to charge the accumulator to a pressure of 250
kgf/cm2 within the time interval of 20 s. Here again the flow required to retract the cylinder is not
considered.
The power requirement in this case would be (1.8 × 250)/600 = 0.75 kW.
The power saved is (4.2 – 0.75) = 3.45 kW.

Example 1.2
A hydraulic molding press is kept closed at a maximum system pressure of 200 kgf/cm2 for a duration of
60 min during the curing period. The maximum leakage permitted during this period is 2 cm3/minute and
minimum fall in pressure permitted is 198 kgf/cm2. Calculate the accumulator volume.

Solution: This is an application where the accumulator is used as a leakage compensator under isothermal
conditions. Therefore, the equation used for this is
V
V0 
[ p0 / p1  p0 / p2 ]
Here V = (2×60)/1000 = 0.12 L, p0 = (0.9×198) = 178 kgf/cm2.Inserting these values in the above
equation, we have
0.12
V0   13.3 L
[179 / 199 –1 79 / 201]
A standard 15 L accumulator would meet the requirement.

Example 1.3
A three-piston single-acting pump of flow rate Q = 133 LPM is operating at 20 bar and at 148 RPM. The
working temperature is 400C. Calculate the accumulator volume needed to limit the remaining pulsation
to –2.5%.

Solution: This is a typical condition of pulsation damping in adiabatic phase due to high-speed
compression and expansion. For this condition,
V
V0 
[( p0 / p1 ) 0.7143
 ( p0 / p2 )0.7143 ]
Here –V = kq where k for a three-piston single-acting arrangement can be taken as 0.12. The pump
displacement q is given by

q =133/3 × 148 = 0.3 L

Now
2.5
a  100  0.5
100
Nowp1 =(p − )= (20−0.5)  =  1.5 bar,p2=(p+ )= (20 + 0.5) = 20.5 bar,p0 = (0.7 × 20) = 14 bar.
Substituting these values into the above equation, we have
(0.12  0.3)
V0   1.5 L
[(15 / 19.5)0.7143  (15 / 20.5)0.7143 ]
A 2 L accumulator would be adequate. Because all calculations are based on the absolute temperature and
pressure, the temperatures must be expressed in degree Kelvin (K) that is obtained by adding 273 to the
operating temperatures recorded in °C. Similarly to obtain absolute pressure, 1 bar is added to the values
of P given.

Example 1.4
A dead-load accumulator has a cylinder bore of 500 mm and is to operate at a system pressure of 200 bar.
What is the dead load required?

Solution: The dead load required will be the product of piston area times the pressure.
Load = /4 × (500/1000)2 × 200 × 105 N
= 3.93 × 106 N (approx. 400 Ton)

Example 1.5
Calculate the increase in pressure if a cylinder 300 mm length × 500 mm stroke is locked in the extended
condition and then subjected to a 20C rise in temperature. What is the volume of fluid to be stored in an
accumulator fitted to compensate for thermal expansion? (Take the bulk modulus to be 15000 bar).

Solution: Total volume of fluid contained in the cylinder is

/4 ×(0.3)2 × 0.5 m3 = 35.3 L
Change in volume is
35.3 × 0.0007 × 20 = 0.49 L
which is the additional volume to be stored. Without an accumulator, the change in pressure in the closed
system is ∆p, that is,
∆p = ∆V/V)
= 15000 ×0.49/35.3
= 210 bar

Example 1.7
What size of accumulator is necessary to supply 500 cc of fluid in a hydraulic system of maximum
pressure of 200 bar that drops to 100 bar minimum? Assuming N2 gas pre-charged of 66 bar, find
adiabatic and isothermal solution.

Solution:Stages of pre-charging, charging and delivery are shown in Fig. 1.13.

P3

V2 V3 P2
Figure 1.13
We shall assume the expansion and compressions as isothermal and adiabatic.
(a) Isothermal condition:
V3 − V2 = volume of oil that can be delivered = 0.005m3
V3 = V2 + 0.005
Using p2V2 = p3V3 we get
p  100  1.013 
V2 = 3  V3     [V2  0.005]
p2  200  1.013 
= 0.5025 V2 + 0.002512
= 0.00505 m3
Using p1V1 = p2V2 we get
p  200  1.013 
V1 = 2  V2     0.00505 = 0.01663 m
3
p1  60  1.013 
(b) Adiabatic condition:
p2V21.4 = p3V31.4
1/1.4
 p1 
 V2 = V3   
 p2 
0.714
 101.013 
= (V2  0.005) 
 201.013
= 0.6118V2 + 0.003059
= 0.00788 m3
Using p1V11.4 = p2V21.4 we get
0.714
 201.013
V1 = 0.00788  = 0.01726 m3
 67.013 

Example 1.8
What size of accumulator is necessary to supply 4917 cm3 of fluid into a hydraulic system of maximum
operating pressure of 207 bar that drops to minimum 103.5 bar? Assuming a nitrogen gas pre-charge of
accumulator to be 67 bar, obtain both isothermal and adiabatic solutions.

Solution:Stages of pre-charging, charging and delivery are shown in Fig. 1.14.

VP13 V3 P3 V1 V2

Figure 1.14
We shall assume the expansion and compressions to be isothermal and adiabatic.
(a) Isothermal condition:
V3 − V2 = volume of oil that can be delivered = 0.004917 m3
V3 = V2 + 0.004917
Using p2V2 = p3V3 we get
p 103.5  1.013 
V2 = 3  V3     V2  0.004917 
p2  207  1.013 
= 0.5025 V2 + 0.00247
= 0.00496 m3
Using p1V1 = p2V2 we get
p  207  1.013 
V1 = 2  V2     0.00496 = 0.01518 m
3
p1  67  1.013 
(b) Adiabatic condition:Using p2V21.4 = p3V31.4 we get
1/1.4
p 
V2 = V3   1 
 p2 
0.714
 104.013 
= (V2  0.004917) 
 208.013
= 0.0117V2 + 0.003007
= 0.007740 m3
Using p1V11.4 = p2V21.4 we get
0.714
 208.013
V1 = 0.007746 
 68.013 
= 0.0172 m3

Example 1.9
A gas-charged accumulator supplies energy to a system with 15 L of oil within the pressure range of 125–
175 bar. If the accumulator has pre-charged pressure of 90 bar, size the accumulator for (a) isothermal
and (b) adiabatic pressures.

Solution: Stages of pre-charging, charging and delivery

V are shown in Fig. 1.15.
P23  210 V3
= 175bar
=90bar

Figure 1.15

Let the pre-charging pressures be p1 and V1. Gas is compressed by incoming oil from pressure 90–175
bar. When the bladder is compressed to 175 bar, the volume of oil inside the accumulator is 15 L.
Therefore, we can write
 V3 − V1=15
(a) Isothermal condition:
p1V1 = p3V3
 90 × V1 = 175 × (V1 − 15)
 90 V1 = 175V1 − 2625
2625
 V1 =  30.88 L
86
(b) Adiabatic condition:
p1V1γ = p3V3γ
 90(V1 ) = 175(V1 – 15)
since there will be some heat loss and perfect adiabatic condition is not possible.Take  = 1.3. We get
90(V1)1.3 = 175 (V1 – 15)1.3
1.3
90  V  15 
 = 1 
175  V1 
V1  15  90 
1/1.3

 =
V1  175 
 V1 – 15 = 0.6 V1
 V1 = 37.5 L

Example 1.10
An accumulator has a ram diameter of 0.4 m and lift of 10 m. It is loaded with 1000 kN of total weight.
The packing friction is 5% of the load on the ram. Find the power delivered to the main if the RAM
descends steadily through its full stroke in 5 min while the pump delivers 50 LPS through the
accumulator.

Solution: The pressure developed in an accumulator due to weight is

net load
Pressure =
Area
1000  0.95
=  7560 kPa
 / 4  0.42
Pressure energy (head) supplied by the accumulator to water is
p 7560
  770 m of water
  g 9810
Energy supplied by the accumulator (during ascend) is
Q × g × h= 50 × 9.81 × 770
= 377685 W
Energy supplied by the accumulator (during descend)
Net load  Stroke 1000  1000  0.95  10
=
Time of descent 300
= 31667 W
Total power delivered is
377685 + 31667 = 409352 W = 409.4 kW
Example 1.11
A gas-charged accumulator supplies energy to a system with 6.7 L of oil within the pressure range of
150–110 bar. The accumulator has the pre-charge pressure of 85 bar. What should be the size of the
accumulator if the oil is to be supplied (a) in about 5 s and (b) in about 5 min?

Solution: Stages of pre-charging, charging and delivery are shown in Fig. 1.16.

Figure 1.16
Let the pre-charging pressure be p1 (85 bar). Gas is compressed by incoming oil from pressure 85 to 150
bar. When the bladder is compressed to 150 bar, the volume of oil inside the accumulator is 6.7 L.
Therefore, we can write
V3 − V1 = 6.7
Consider the adiabatic condition with  = 1.25.
(a) In about 5 s:
p1V1 = p2V2

 6.7 
 85(V1 )  = 150   V1  
 5 
 85(V1 )1.25 = 150  (V1  1.34)1.25
1.25
85  V  1.34 
 =  1
150  V1 
 V  1.34 
1/1.25
 85 
 1 =  
 V1  150 
 V1 = 3.144 LPS

Capacity of accumulator = 3.144  5 = 15.72 L

(b) In about 5 min:

Capacity of accumulator = 3.144  5  60 = 943.2 L

Example 1.12
A circuit has been designed to crush a car body into bale using a 152 mm diameter hydraulic cylinder.
The hydraulic is to extend 2.54 m during a period of 10 s. The time between crushing strokes is 5 min.
The following accumulator gas absolute pressures are given:p1( gas pre-charge pressure) = 84 bar (abs),
p2(gas charge pressure when the pump is turned ON) = 210 bar (abs) = pressure relief value setting,
p3(minimum pressure required to actuate load) = 126 bar (abs).
(a) Calculate the required size of the accumulator.
(b) What are the pump hydraulic kW power and flow requirements with and without accumulator?
Solution: Stages of pre-charging, charging and delivery are shown in Fig. 1.17.

p1= 84 bar p2=210 bar p3 = 126 bar

Figure 1.17
Let the pre-charging pressure be p1 (85 bar). Gas is compressed by incoming oil from pressure 84 to 210
bar and accumulator is discharged till the pressure reaches 126 bar.
(a) Without accumulator:Let the compression and expansion of gas follow isothermal law:
p1V1 = p2V2 = p3V3
Here Vc is the volume of hydraulic cylinder. It can accommodate (V3 − V2) amount of oil
Vc = (V3 − V2)
 p3V3 = p2V2
pV 210  V2
 V3 = 2 2   1.67V2 (1.13)
p2 126
 
 Vc = d 2 I  (0.152)2  2.54  0.0461m3  (V3  V2 ) (1.14)
4 4
Using Eq. (1.13) in Eq. (1.14) and solving, we get
V2 = 0.0688 m3
V3 = 0.155 m3
p V 210  0.0688
V1 = 2 2   0.172 m3  172 L
p1 840
(b) With accumulator:The pump charges accumulator in every 2.5 min. In other words, two times in
five minutes.
Flow supplied by the pump
2(V3  V2 ) 2(46.1)
Qp = =  0.307 LPS
30 300
Neglecting all losses, power supplied to the pumpis
ppump = p2  Qpump
(210  105 )(0.307  103 )
=  6.45 kW
1000
Without accumulator: The pump extends cylinder in 10 s. Flow supplied by the pump is
46.1
Qp =  0.461 LPS
10
Neglecting all losses, power supplied to the pump is
ppump = p2  Qpump
(126  105 )(461  105 )
=  58.1 kW
1000
It can be seen that flow and power requirement by the pump is more without accumulator.
Example 1.13
What size of accumulator is necessary to supply 10000 cm3 of fluid is a hydraulic system of maximum
pressure of 200 bar to 100 bar minimum. Assuming N2 gas per-charged pressure of 80 bar. Find
adiabatic and isothermal solution.
Solution: Let
V1 = Volume of accumulator (cm3)
V2 = Volume of gas at high pressure (cm3)
p2 = Maximum pressure, bar = 200 bar
p = Minimum pressure, bar = 100 bar
p1 = Per-charged pressure, bar = 80 bar

Let V1be the volume of gas in the accumulator at pre-charged 80 bar and V2be the volume of gas in the
accumulator at 200 bar. Now

V1 =V2+10000 cm3
 V =V – 10000
2 1
(a) Adiabatic process:We have p1V1  p2V2 . Now   1.25 . So
(80)V1  (200)(V1  10000)

80  V1  10000 
  
200  V1 
1.25
 V  10000 
 0.4   1 
 V1 
V  10000
 1  (0.4)1/1.25  (0.4)0.8  0.4804
V1
 V1  10000  0.4804V1
 V1  0.4804 V1 10000
 0.5195 V1  10000


V1  19249.3 cm 3
Size of accumulator = 19249.3 cm3
(b) Isothermal process:We have
 p1V1  p2V2
 80    V1    200  (V1 –  10000)
80 V1  10000
 
200 V1
V1  10000
 0.4 
V1
 V1  10000  0.4V1
 V1  0.4V1 10000
 0.6 V1 10000
V1  16666.7 cm3

Size of accumulator =16666.7 cm3

 Objective-Type Questions
Fill in the Blanks

1. A hydraulic accumulator is a device that stores the potential energy of an ______ held under pressure
by an external source against some dynamic force.
2. The main disadvantage of a weight-loaded or gravity accumulator is its extremely ______ size and
______ weight.
3. A spring-loaded accumulator stores energy in the form of a ______ spring.
4. Pulsation damping is typically an ______ condition because both storage and discharge have to be
accomplished in a very short time.
5. The nitrogen pre-charge pressure in an accumulator is based on the expected maximum rise in the
circulating hydraulic oil ______.
6. An accumulator permits _____ to be absorbed and stored in a hydraulic system.
7. Air or _____ should never be used in gas-charged accumulators.

State True or False

1. A gas-loaded accumulator is popularly used in industries.

2. In a bladder accumulator, the bladder is filled with oxygen until the designed pre-charge pressure is
achieved.
3. An accumulator can be used as a compensator for both internal and external leakages.
4. One of the important applications of accumulators is the elimination of hydraulic shock.
5. An accumulator can be used as a fail–safe device.

Review Questions

1. Define an accumulator and explain its function.

2. What are the different types of accumulators?
3. Mention some of the industrial applications of an accumulator. Explain any one of them with an
example.
4. Why are accumulators used?
5. Define and derive an expression for the volumetric capacity of bladder-type accumulators.
6. Explain the construction and operation of piston-type accumulators.
7. Explain the construction and operation of bladder-type accumulators.
8. Explain the construction and operation of diaphragm-type accumulators.
9. Discuss in detail the application of hydraulic accumulators as energy storage elements. Draw a
hydraulic circuit for this application.
10. Discuss in detail the application of hydraulic accumulators for protection against shocks.
11. Discuss in detail the application of hydraulic accumulators in protecting against thermal expansion.
12. Discuss in detail the application of hydraulic accumulators for internal leakage compensation and the
application of constant pressure.
13 What is the difference between separator and non-separator types of accumulators.
14 Name three different types of separator-type accumulators.
15. What are the advantages of bladder accumulators over piston accumulators?
Answers
Fill in the Blanks

1. Incompressible fluid
2. Large, heavy
3. Compressed
4. Adiabatic
5. Temperature
6. Energy
7. Pure oxygen

State True or False

1. True
2. False
3. True
4. True
5. True
 Lecture 30

ACCESSORIES USED IN FLUID POWER SYSTEMS

Learning Objectives
Upon completion of this chapter, the student should be able to:

 Differentiate between internal leakage and external leakage.

 Explain various types of seals used in fluid power.
 Explain the working of a durometer hardness tester.
 List various functions of a reservoir.
 Describe various types of reservoirs used in fluid power.
 Explain the design considerations for reservoirs used in fluid power.
 Carry out the heat transfer calculation of reservoirs.
 Differentiate between a strainer and a filter.
 Describe various types of filters used in fluid power applications.
 Define the beta ratio efficiency of a filter.
 Explain the importance of a heat exchanger.
 Size a heat exchanger.

1.1 Introduction
Any hydraulic system is associated with a major problem, that is, leakage. This reduces efficiency and
increases the power losses. Hence, sealing devices play a vital role in a hydraulic system by increasing the
efficiency and decreasing the power losses. Leakage can be overcome by proper maintenance of the
system and proper selection of seals and sealing at the design stage.
Leakage in a hydraulic system can be classified as follows:

1. Internal leakage:This occurs in hydraulic components built with operating clearances. Moving parts
need to be lubricated and leakage path may be designed solely for this purpose. Internal leakage does not
cause loss of fluid because the fluid returns to the reservoir. This leakage increases the clearances
between mating parts due to wear. If the entire system leakage becomes large enough, the actuators do not
operate properly.
2. External leakage:External leakage represents loss of fluid from the system. It also represents a safety
hazard. Improper assembly of pipe fittings is the most common cause of external leakage. Over-tightened
fittings may become damages or vibrations can cause properly tightened fittings to become loose. Failure
to connect drain lines, excessive operating pressure and contamination might cause the fluid to externally
leak.

1.2 Functions of Seals

Seals are used in hydraulic systems to prevent excessive internal and external leakage and to keep out
contamination.Various functions of seals include the following:

1. They prevent leakage – both internal and external.

2. They prevent dust and other particles from entering into the system.
3. They maintain pressure.
4. They enhance the service life and reliability of the hydraulic system.
1.2.1 Classification of Hydraulic Seals
Hydraulic seals can be classified as follows:

1. According to the method of sealing:

 Positive sealing: A positive seal prevents even a minute amount of oil from getting past.
A positive seal does not allow any leakage whatsoever (external or internal).
 Non-positive sealing:A non-positive seal allows a small amount of internal leakage, such
as the clearance of the piston to provide a lubrication film.

2. According to the relative motion existing between the seals and other parts:

 Static seals: These are used between mating parts that do not move relative toone
another. Typical examples are flange gaskets and seals, o-rings, etc. These are relatively
simple. They are essentially non-wearing and usually trouble-free if assembled properly.
 Dynamic seals: These are assembled between mating parts that move relative to each
other. Hence, dynamic seals are subject to wear because one of the mating parts rubs
against the seal.

3. According to geometrical cross-section:

 O-ring seal:O-ring is the most widely used seal for hydraulic systems. It is a molded synthetic
rubber seal that has a round cross-section in its free state (Fig. 1.1). O-ring can be used for the
most static and dynamic conditions. It gives effective sealing through a wide range of pressures,
temperatures and movements with the added advantages of sealing pressure in both directions and
providing low running friction on moving parts.

Figure 1.1 O-ring.

The action of the O-ring packing in the rectangular groove, in the V-groove and in the rectangular groove
with backup washers at various pressures are shown in Fig. 1.2. It can readily be seen that without backup
washers, as the pressure increases, the ring is forced or extruded into the clearance space. When the
backup ring washers are used, however, this is prevented and packing life is thus extended.
 ZERO PRESSURE

35 bar PRESSURE

70 bar PRESSURE

105 bar PRESSURE

210 bar PRESSURE

RECTANGULAR VEE GROVE NON-EXTRUSION

GROVE RINGS

Figure 1.2 Relative position of O-ring packings in different grooves at increasing pressure.

 V-ring seal and U-ring seal: V- and U-ring seals are compression-type seals used in virtually in
all types of reciprocating motion applications (Fig. 1.3). These include piston rods and piston
seals in pneumatic and hydraulic cylinder, press rank, jacks and seals on plungers and piston in
reciprocating pumps. They are also readily suited to certain slow rotary applications such as valve
stems. These packings (which can be molded into U-shapes as well as V-shapes) are frequently
installed in multiple quantities for more effective sealing.

(a) (b)
Figure 1.3(a)V-ring seal and (b) U-ring seal.

There are three important designs of V packings. They are shown in Fig. 1.4.Figure 1.4(a) shows an
outward packed installation where the female support is an integral part of the nose on the gland ring.
Figure 1.4(b) illustrates an installation of V packing on end of ram where a male ring is a part of the
retaining gland ring. For inside-packed, double-acting cylinder, Fig. 1.4(c) illustrates a typical design.
Here the gland rings are threaded and the male and female rings are separate units.
 Packing
Space

(a) (b) (c)

Figure 1.4 V packings:(a) An outside packed V-ring installation;(b) installation of V packing on the end
of the ram;(c) V packing for double-acting cylinder.

 T-ring seal:T-ring seal isa dynamic seal that is extensively used to seal cylinder-pistons, piston
rods and other reciprocating parts (Fig. 1.5). It is made of synthetic rubber molded in the shape of
the cross-section Tandreinforced by backup rings on either side as shown in Fig. 1.5. The sealing
edge is rounded and seals very much like an O-ring.

Figure 1.5T-ring seal.

 Piston cup packings: Piston cup packings are designed specifically for pistons in reciprocating
pumps and pneumatic and hydraulic cylinders. They offer the best service life for this type of
application, require a minimum recess space and minimum recess machining, and can be installed
easily and quickly. In fastening the fabricated cup packing on the end of the piston, it is
recommended that some provision be made to prevent the full pressure load from being taken on
the bottom of the cup. The packing shown in Fig. 1.6 is single acting, while that shown in Fig. 1.7
is double acting. Piston shoulder K should be 0.127mm less than the nominal thickness of the
packing. The tolerance on K is +0.00 to –0.0.762mm. Figure 1.8 shows U cup packings installed
in a piston assembly. Note other seals in cylinder.
 K K

Figure 1.6 Correct method for supporting a cup packing – single acting.

K
B

Figure 1.7 Correct method for supporting a cup packing –double acting.

Figure 1.8 The use of U cup packings in piston assembly.

 Piston rings: Piston rings are seals that are universally used for cylinder pistons. Metallic piston
rings are made of cast iron or steel and are usually plated or given an outer coating of materials
such as zinc phosphate or manganese phosphate to prevent rusting and corrosion. Piston rings
offer substantially less opposition to motion than synthetic rubber (elastomer) seals. They have a
number of non-metallic piston rings made out of tetrafluoroethylene, a chemically inert, tough,
waxy solid. Their extremely low coefficient of friction (0.04) permits them to be run completely
dry and at the same time prevents scoring of the cylinder walls. This type of piston ring is an ideal
solution to many applications where the presence of lubrication can be detrimental or even
dangerous. For instance, in an oxygen compressor, just a trace of oil is a fire or explosion hazard.

 Wiper rings and Scrapper rings: They are seals designed to prevent foreign abrasive or
corrosive materials from entering a cylinder. They are not designed to seal against pressure. They
provide assurance against rod scoring and add materiality to packing life. Figure 1.9 shows a
number of ways in which wiper rings can be assembled into a cylinder. The wiper ring is molded
from a synthetic rubber, which is stiff enough to wipe all dust or dirt from the rod yet pliable
enough to maintain a snug fit. The rings are easily installed with a snap fit into a machined
groove in the gland. This eliminates the need for and expense of a separate retainer ring.Figure
1.10 shows the application of synthetic scrapper rings. It has been found that wiper rings or
scrapper rings made of TFE(Tetrafluorethylene) will not adhere to the piston rod even during
extended inoperative periods, and will not score piston rods made of steel or chrome plated steel.
TFE is unaffected by temperature from –75 to –250 and is not affected by grease, paint, or
other coatings often used for protective packaging of cylinders and valves.

Snap Ring Retainer End Plate Retainer

Gland Retainer Stamped Retainer

Snap-in Assembly In-bearing Assembly

End Plate Assembly

End Cap Assembly

Figure 1.9 Assemblies for wiper rings.

 Snap Ring Retainer In-bearing Assembly

End-Plate Assembly
End Plate Retainer

Stamped Retainer End - Cap Retainer

Figure 1.10 Assemblies for scraper rings.

4. According to the type of seal material used: Hydraulic seals may be classified according to
the type of seal material used. Seals are manufactured from a variety of natural and synthetic
materials. Earlier leather, cork and impregnated fibers were used in hydraulic systems. But
nowadays, these are replaced by plastic and synthetic rubber materials. Synthetic rubbers
(elastomers) are compatible with oil. Elastomers can be made in various compositions to
meet various operating conditions:

 Neoprene (chloroprene).
 Buna-N.
 Silicone (Teflon).
 Tetrafluoroethylene.
 Viton.

Natural rubber is rarely used as a seal material because it swells and deteriorates with time in the presence
of oil. In contrast, synthetic rubber materials are compatible with most oils. The most common types of
materials used for seals are leather, Buna-N, silicone, neoprene, tetrafluoroethylene, viton and of course
metals.Let us discuss them below:

 Leather: This material is rugged and inexpensive. However, it tends to squeezewhen dry and
cannot operate above 90C which is inadequate for many hydraulic systems. Leather does not
operate well at cold temperatures to about −50C .
 Buna-N: This material is rugged and inexpensive and wears well. It has a rather wide operating
temperature range (−45–110C) during which it maintains its good sealing characteristics.
 Silicone: This elastomer has an extremely wide temperature range (−65–232C). Hence, it is
widely used for rotating shaft seals and static seals where a wide operating temperature is
expected. Silicone is not used for reciprocating seal applications because it has a low tear
resistance.
  Neoprene: This material has a temperature range of 50–120C. It is unsuitable above 120C
because it has a tendency to vulcanize.
 Tetrafluoroethylene: This material is the most widely used plastic for seals of hydraulic
systems. It is a tough, chemically inert, waxy solid, which can be processed only by compacting
and sintering. It has an excellent resistance to chemical breakdown up to temperatures of 370C.
It also has an extremely low coefficient of friction. One major drawback is its tendency to flow
under pressure, forming thin, feathery films. This tendency to flow can be greatly reduced by the
use of filler materials such as graphite, metal wires, glass fibers and asbestos.
 Viton: This material contains about 65% fluorine. It has become almost a standard material for
elastomer-type seals for use at elevated temperatures up to 240C. Its minimum operating
temperature is 28C.

1.3 Durometer Hardness Tester

The physical properties frequently used to describe the behavior of elastomers are as follows: hardness,
coefficient of friction, volume change, compression set, tensile strength, elongation modulus, tear
strength, squeeze stretch, coefficient of thermal expansion and permeability. Among these physical
properties, hardness is the most important because it has a direct relationship to service performance.
A durometer is an instrument used to measure the indentation hardness of rubber and rubber-like
materials. As shown, the hardness scale has a range from 0 to 100. The durometer measures 100 when
pressed firmly on flat glass. High durometer readings indicate a great resistance to denting and thus a hard
material. A durometer hardness of 70 is the most common value.
A hardness of 80 is usually specified for rotating motion to eliminate the tendency toward side motion
and bunching in the groove. The values between 50 and 60 are used for static seals on rough surfaces.
Hard seal materials (values between 80 and 90) have less breakaway friction than softer materials, which
have a greater tendency to deform and flow into surface irregularities. As a result, harder materials are
used for dynamic seals.

1.4 Reservoirs
The functions of a fluid reservoir in a power hydraulic system are as follows:

1. To provide a chamber in which any change in the volume of fluid in a hydraulic circuit can be
accommodated. When the cylinder extends, there is an increased volume of fluid in the circuit
and consequently there is a decrease in the reservoir level.
2. To provide a filling point for the system.
3. To serve as a storage space for the hydraulic fluid used in the system.
4. It is used as the location where the fluid is conditioned.
5. To provide a volume of fluid which is relatively stationery to allow entrained air to separate out
and heavy contaminants to settle. The reservoir is where sludge, water and metal slips settle.
6. It is a place where the entrained air picked up by the oil is allowed to escape.
7. To accomplish the dissipation of heat by its proper design and to provide a radiating and
convective surface to allow the fluid to cool.

A reservoir is constructed with steel plates. The inside surface is painted with a sealer to prevent rust due
to condensed moisture. At the bottom, it contains a drain plug to allow the complete drainage of the tank
when required. A removable head can be provided for easy access during cleaning. A vented breather cap
is also included that contains an air filtering screen. This allows the tank to breathe as the oil level
changes due to system demand requirements.
 A baffle plate extends lengthwise across the center of the tank. The purpose of the baffle plate is to
separate the pump inlet line from the return line to prevent the same fluid from recirculating continuously
within the tank. The functions of a baffle plate are as follows:

1. To permit foreign substances to settle to bottom.

2. To allow entrained air to escape from oil.
3. To prevent localized turbulence in the reservoir.
4. To promote heat dissipation through reservoir walls.

The return line should enter the reservoir on the side of the baffle plate that is opposite to the pump
suction line.

1.4.1 Features of a Hydraulic Reservoir

Schematic diagram of hydraulic reservoir is shown in Fig.1.11. There are many components mounted on
reservoir and each one of them having specific features.Following are the features of a hydraulic
reservoir:

1. Filler cap (breather cap): It should be airtight when closed but may contain the air vent that
filters air entering the reservoir to provide a gravity push for proper oil flow.
2. Oil level gauge: It shows the level of oil in the reservoir without having to open the reservoir.

Motor and pump

Filler with Return flow
filter

Filling level
indicator (Max.) Intake pipe

Servicing
aperture

Filling level
indicator (Min.)
Oilreturnchamber Suction chamber

Drain screw

Baffle plate

Figure 1.11Hydraulic reservoir.

3. Baffle plate: It is located lengthwise through the center of the tank and is two-third the height of the oil
level. It is used to separate the outlet to the pump from the return line. This ensures a circuitous flow
instead of the same fluid being recirculated. The baffle prevents local turbulence in the tank and allows
foreign material to settle, get rid of entrapped air and increase heat dissipation.

4. Suction and return lines: They are designed to enter the reservoir at points where air turbulence is the
least. They can enter the reservoir at the top or at the sides, but their ends should be near the bottom of the
tank. If the return line is above the oil level, the returning oil can foam and draw in air.

5. Intake filter: It is usuallya screen that is attached to the suction pipe to filter the hydraulic
oil.
6. Drain plug: It allows alloil to be drained from the reservoir. Some drain plugs are magnetic
to help remove metal chips from the oil.
7. Strainers and filters: Strainers and filters are designed to remove foreign particles from the
hydraulic fluid. Strainers and filters are discussed in detail in Section 1.6.

1.4.2 Types of Reservoirs

Industrial reservoirs come in a variety of styles. Some of them are the following:

1. Non-pressurized: The reservoir may be vented to atmosphere using an air filter or a separating
diaphragm. The type most commonly used in industry, normally, has an air breather filter, although in
very dirty environments, diaphragms or air bags are used.
2. Pressurized: A pressurized reservoir usually operates between 0.35 and 1.4 bar and has to be provided
with some method of pressure control; this may be a small air compressor maintaining a set charge
pressure. In motor circuits where there is a little change in fluid volume in the reservoir, a simple relief
valve may be used to limit the air pressure that alters with changes in temperature. The advantages of a
pressurized reservoir are that it provides boost pressure to the main pump and prevents the ingress of
atmospheric dirt.

1.4.3 Sizing of the Reservoir

The reservoir capacity should be adequate to cater for changes in fluid volume within the system, and
with sufficient surface area to provide system cooling. An oversize reservoir can present some
disadvantages such as increased cost, size and longer warming-up periods when starting from cold. There
are many empirical rules for sizing reservoirs.
The sizing of a reservoir is based on the following criteria:

1. The minimum reservoir capacity should be twice the pump delivery per minute. This must be
regarded as an absolute minimum and may not be sufficient to allow for the volume changes in
the system.
2. The reservoir capacity should be three to four times the pump delivery per minute. This may well
be too high a volume for mobile application.
3. The reservoir capacity should be 2–15 L per installed horse power. This may result in very large
reservoirs when high-pressure systems are used.
4. It must make allowance for dirt and chips to settle and for air to escape.
5. It must be able to hold all the oil.
 6. It must maintain the oil level high enough to prevent the whirlpool effect.
7. It should have a large surface area to dissipate heat generated in the system.
8. It should have an adequate air space to allow for the thermal expansion of oil.
All the above rules are based on conventional-shaped reservoirs. Special shapes require special
considerations.When heat dissipation from the reservoir is a critical factor, it can be calculated by the
following basic formula:
H  h A T  3.6 (1.1)
where H is the heat transfer (W), h is the heat transfer coefficient, A is the surface area in m2 and T is
the temperature differential (C).For a vertical plate of height L,
 T 
1/4

h  1.42   (1.2)
 L 
For a horizontal plate of width W,
 T 
1/4

h  1.32   (1.3)
W 
These formulas apply to natural radiations. Normal air circulation round the reservoir increases the
cooling considerably. For maximum heat radiations, the reservoir should be of minimum height and
maximum length(see Fig. 1.12). Figure 1.12(a) shows minimum height and is best design from heat
transfer point of view and figure shown in Fig. 1.12(b) has poor heat transfer.The equations neglect the
cooling effect of the pipe work valves and actuators which may have a surface area comparable with that
of the fluid reservoir.

The reservoir should not have any horizontal lips or angles on the vertical face as this interferes with the
natural air convection. The cooling efficiency can be increased by using a finned design (Fig. 1.13); the
fins should be vertical not horizontal. To assist the free circulation of external air and hence cooling, the
reservoir should be mounted clear of the ground.

(a) (b)
Figure 1.12(a)Best design for heat transfer; (b) design for poor heat transfer.
 Avoid pointing outward angles
and flanges

Free air convection restricted by

the flange

Cooling fins to be vertical

Figure 1.13Effect of fins and flanges.

The operating temperature of a fluid greatly affects its life. Table 1.1 gives an indication of operating
temperatures for various types of fluids. These are typical values only and the exact value for a specific
hydraulic fluid should be ascertained from the fluid supplier.
Table 1.1 Operating temperatures for various types of fluids
Temperature
Mineral Oil Water in Oil (60/40) Water Glycol Phosphate Ester
(C) (C) (C) (C)
Maximum local
100 65 65 150
temperature
Maximum
temperature for
65 40 40 95
continuous
operation
Maximum
temperature for 40 25 25 65
optimum fluid life

1.4.4 Reservoir Design and Construction

The reservoir must be equipped with a filling point and an air vent point. These are often combined as
filler breather unit complete with a filling mesh. Combined units of this nature tend to have a slow filling
rate and the filling mesh is often deliberately punctured to speed up the inflow. This defeats its purpose
and allows large dirt into the reservoir. It is also very easy to leave the air-filter cap off after filling
thereby permitting contaminants to enter. It is better to have a separate filling point complete with a quick
release coupling and integral filler unit, in which case all the fluid is pumped into the reservoir through
the filter, spin-on air breather are available with a fine filter range: 25 m absolute is typical ( 25 = 75).

The pump suction line should be fitted with an adequately sized strainer. The strainer should be located so
that there is a well distributed flow and its lowest point should be at least 75 mm above the bottom of the
reservoir (to prevent any debris on the bottom of the tank being pulled into the suction line). The top of
the strainer should be at least 150 mm below the lowest fluid level to prevent a vortex being formed and
air drawn into the suction line.

System return lines and drain lines should terminate below the minimum fluid level to prevent aeration of
the fluid. The main returns should be fitted with diffusers that reduce the return oil velocity and prevent
turbulence. Where diffusers are not used, the end of return lines should be cut at 45%. Return outlets
should be carefully positioned to minimize interaction between the return flow and the reservoir
boundaries. If the return pipes have an anti-syphon hole, aeration may be caused by the jet of fluid
emanating from them during normal operation. This can be reduced by fitting deflector plates.
The reservoir must be fitted with some form of level indicator, generally a sight glass that should have the
minimum and maximum levels clearly marked. A float switch can be incorporated to give an alarm or
shut the pump down if the oil level falls below a certain value. This is very important in large systems
where there is a possibility of a pipe failure or other sudden leak. Shutting the pump down protects the
pump from cavitation and reduces the spillage of fluid.
Baffles are fitted in the reservoir to separate the return lines from the suction lines. They create a long
flow path, which reduces surging effects, encourages dirt separation and improves cooling. A fine wire
mesh baffle between 60 and 200 mesh size (250–75 m aperture), set at an angle of 20–40to horizontal,
with the top edge terminating below the fluid surface will considerably aid the separation of entrained air.
Wherever the hydraulic fluid is an oil and water emulsion, baffles should not be used as they tend to
separate emulsion. With these fluids, good circulation in the reservoir is important to maintain emulsion.
Figure 1.14 shows a reservoir designed to include most of these features. Although it is not the best shape
for heat dissipation, it has other merits. If the fluid temperature inside the reservoir varies outside
specified limits, temperature switches can be used to give a warning, switch in coolers or heaters, shut
down pumps, prevent startup, etc. Wherever systems operate outdoors in cold temperatures or, for
example, servo systems, which in order to preserve accuracy need to work at a constant temperature,
heaters may be incorporated. These are a special type of immersion heaters having a low wattage relative
to the surface area (maximum 6 W/m2).

Lid with airtight gasket Lid with airtight Breather

gasket
Gause baffle

Quick
release
Slight
coupling
glass

Return
check
Return
Suction line entry
strainer port

Baffles Drain tap

Sloping base

Figure 1.14Reservoir design and construction.

1.5 Fluid Conditioners
In the case of large reservoirs and systems where online filtration is impossible, separate clean-up
filtration loops should be fitted. These may include an oil cooler. There are two types of oil coolers in use:
1. Water tube coolers: Water tube oil coolers consist of a series of interconnected copper tubes through
which the cooling water passes surrounded by a jacket through which the hydraulic fluid passes. It is quiet
in operation and can be arranged so that the oil pressure is higher than the water pressure; consequently,
any leakage is more likely to be of oil into the water that is less serious than the contamination of the
hydraulic fluid. When a water tube cooler is used, there is considerable flow of water involved and a
separate water cooling tower and a circulating water supply may be necessary. Usually, the water supply
is thermostatically controlled so that it is only switched ON when required.
2. Air blast coolers:An air blast cooler is similar in construction to a vehicle radiator with a powered air
fan. It should be situated in a cool area so that cold air is blown over the radiator. An air blast cooler tends
to be noisy but on small installations is preferable to water coolers owing to running and installation
costs. Air blast coolers are now available to fit between the pump and the electric motor as part of the bell
housing and coupling. Such coolers do not need a separate electric motor drive, but it is necessary to take
into account the extra power needed when sizing the pump drive.

1.5.1 Centralized Hydraulic System

The forerunner of modern gas, electricity and water authorities were a large number of local and
municipal undertakings meeting the demands of large towns and industrially customers. In the late 19th
and early 20th century, there existed several public hydraulic power companies providing water power in
a similar manner.
The earliest system was in dockyards driving machinery of cranes, dock gates and sluices, commencing
with an installation at hull docks in 1876. During that time, there were sizable undertakings in most parts
of the world.
The change to hydraulic oil as a working medium fluid made such large installation impractical, but there
has recently been a renaissance of centralized systems operating on a smaller scale. The idea of a
hydraulic ring main running around a factory in a manner similar to the pneumatic ring mains which are
in everyday use has many attractions. The principal difference, apart from the higher pressures involved
and the obvious seriousness of leaks, is that a return pipe has to be provided as well as supply. Their most
frequent use is in a factory or process plant where a group of related machines is powered from a central
source.

1.5.2 Individual versus Centralized Systems

There is still much controversy over the use of centralized hydraulic systems as opposed to individual
power packs. The features of both are being compared. In general, what is an advantage for one is a
disadvantage for the other. Both have their merits and every application must be assessed on its own
particular requirement.

1.5.2.1 Individual Power-Pack Systems

Individual power packs are provided for each machine and components mounted are specific to the
operation. They are usually supplied as modular units.

The advantages of individual power-pack systems are as follows:

1. They are completely independent of each other.

2. Different grades or types of fluids can be used as appropriate to each system.
3. Each can operate at different pressures.
4. If one circuit fails, others are still operative.
5. Power packs can be adjacent to the machine.

The disadvantages of individual power-pack systems are as follows:

 1. More power packs and components to maintain.
2. Increased cost.
3. More floor space required.
4. Greater total power.

1.5.2.2 Centralized Hydraulic Systems

In centralized hydraulic system, reservoir will cater to many machines. This is like a hydraulic ring which
runs around a factory in a manner similar to pneumatic ring.

The advantages of centralized hydraulic systems are as follows:

 Single oil reservoir.

 Standby pumps can be designed into the power pack.
 Reduced cost.
 Single unit to be maintained.
 Less space required.
 Fluid conditioning can be incorporated either offline or in the return line at much lower cost than
when individual power packs are used.
 Total power-pack capacity may be less than that for individual power packs.

The disadvantages of centralized hydraulic systems are as follows:

 If there is a failure in the power pack, all the systems fail (unless standby facility included).
 Longer pipe runs are involved than with individual power packs.
 If more than one operating pressure is involved, pressure-reducing valves have to be fitted to the
appropriate circuits.
 A large volume of fluid in the reservoir can be a considerable fire hazard.
 There may be interaction between the circuits.
 Lecture 31

ACCESSORIES USED IN FLUID POWER SYSTEMS [CONTINUED]

1.6 Filters and Strainers

For proper operation and long service life of a hydraulic system, oil cleanliness is of prime importance.
Hydraulic components are very sensitive to contamination. The cause of majority of hydraulic system
failures can be traced back to contamination. Hence, filtration of oil leads to proper operation and long
service life of a hydraulic system.
Strainers and filters are designed to remove foreign particles from the hydraulic fluid. They can be
differentiated by the following definitions:

1. Filters: They are devices whose primary function is the retention, by some fine porous medium, of
insoluble contaminants from fluid. Filters are used to pick up smaller contaminant particles because they
are able to accumulate them better than a strainer. Generally, a filter consists of fabricated steel housing
with an inlet and an outlet. The filter elements are held in position by springs or other retaining devices.
Because the filter element is not capable of being cleaned, that is, when the filter becomes dirty, it is
discarded and replaced by a new one. Particle sizes removed by filters are measured in microns. The
smallest sized particle that can be removed is as small as 1 µm. A strainer is a device whose function is to
remove large particles from a fluid using a wire screen. The smallest sized particle that can be removed
by a strainer is as small as 0.15 mm or 150 µm.
2. Hydraulic strainers: A strainer is a coarse filter. Fluid flows more or less straight through it. A
strainer is constructed of a fine wire mesh screen or of screening consisting of a specially processed wire
of varying thickness wrapped around metal frames. It does not provide as fine a screening action as filters
do, but offers less resistance to flow and is used in pump suction lines where pressure drop must be kept
to a minimum. A strainer should be as large as possible or wherever this is not practical, two or more may
be used in parallel.

1.6.1 Causes of Contamination

The causes of contamination are as follows:

o Contaminants left in the system during assembly or subsequent maintenance work.

o Contaminants generated when running the system such as wear particles, sludge and varnish due
to fluid oxidation and rust and water due to condensation.
o Contaminants introduced into the system from outside. These include using the wrong fluid when
topping up and dirt particles introduced by contaminated tools or repaired components.

1.6.2 Types of Filters

Filters may be classified as follows:

1. According to the filtering methods:

 Mechanical filters: This type normally contains a metal or cloth screen or a series of metal disks
separated by thin spacers. Mechanical filters are capable of removing only relatively coarse
particles from the fluid.
 Absorption filters: These filters are porous and permeable materials such as paper, wood pulp,
diatomaceous earth, cloth, cellulose and asbestos. Paper filters are impregnated with a resin to
provide added strength. In this type of filters, the particles are actually absorbed as the fluid
permeates the material. Hence, these filters are used for extremely small particle filtration.
  Adsorbent filters: Adsorption is a surface phenomenon and refers to the tendency of particles to
cling to the surface of the filters. Thus, the capacity of such a filter depends on the amount of
surface area available. Adsorbent materials used include activated clay and chemically treated
paper.

2. According to the size of pores in the material:

 Surface filters: These are nothing but simple screens used to clean oil passing through their
pores. The screen thickness is very thin and dirty unwanted particles are collected at the top
surface of the screen when the oil passes, for example, strainer.
 Depth filters: These contain a thick-walled filter medium through which the oil is made to flow
and the undesirable foreign particles are retained. Much finer particles are arrested and the
capacity is much higher than surface filters.

3. According to the location of filters:

 Intake or inline filters (suction strainers): These are provided first before the pump to protect
the pump against contaminations in the oil as shown in Fig. 1.15. These filters are designed to
give a low pressure drop,otherwise the pump will not be able to draw the fluid from the tank. To
achieve low pressure drop across the filters, a coarse mesh is used. These filters cannot filter out
small particles.

Figure 1.15Suction filter.

Advantages of suction filters:

(a) A suction filter protects the pump from dirt in the reservoir. Because the suction filter is outside the
reservoir, an indicator telling when the filter element is dirty can be used.
(b) The filter element can be serviced without dismantling the suction line or reservoir (easy to maintain).

Disadvantages of suction filters:

(a) A suction filter may starve the pump if not sized properly.

 Pressure line filters (high-pressure filters): These are placed immediately after the pump to
protect valves and actuators and can be a finer and smaller mesh (Fig. 1.16). They should be able
to withstand the full system pressure. Most filters are pressure line filters.

Figure 1.16Pressure filter.

Advantages of a pressure line filter:

(a) A pressure filter can filter very fine contaminants because the system pressure is available to push
the fluid through the element.
(b) A pressure filter can protect a specific component from the harm of deteriorating particles
generated from an upstream component.

Disadvantages of a pressure line filter:

(a) The housing of a pressure filter must be designed for high pressure because it operates at full
system pressure. This makes the filter expensive.
(b) If pressure differential and fluid velocity are high enough, dirt can be pushed through the element
or the element may tear or collapse.
  Return line filters (low-pressure filters): These filters filter the oil returning from the pressure-
relief valve or from the system, that is, the actuator to the tank (Fig. 1.17). They are generally
placed just before the tank. They may have a relatively high pressure drop and hence can be a fine
mesh. These filters have to withstand low pressure only and also protect the tank and pump from
contamination.

Figure 1.17Return line filter.

Advantages of a return line filter:

(a)A return line filter catches the dirt in the system before it enters the reservoir.
(b)The filter housing does not operate under full system pressure and is therefore less expensive
than a pressure filter.

Disadvantages of a return line filter:

(a) There is no direct protection for circuit components.

(b) In return line full flow filters, flow surges from discharging cylinders, actuators and accumulators
must be considered when sizing.

1. Depending on the amount of oil filtered by a filter:

 Full flow filters: In this type, complete oil is filtered. Full flow of oil must enter the filter element
at its inlet and must be expelled through the outlet after crossing the filter element fully(Fig.
1.18). This is an efficient filter. However,it incurs large pressure drops. This pressure drop
increases as the filter gets blocked by contamination.
 Figure 1.18Full flow filter.
 Proportional filters (bypass filters): In some hydraulic system applications, only a portion of oil
is passed through the filter instead of entire volume and the main flow is directly passed without
filtration through a restricted passage (Fig. 1.19).

Figure 1.19Proportional filter.

1.6.3 Beta Ratio of Filters

Filters are rated according to the smallest size of particles they can trap. Filter ratings are identified by
nominal and absolute values in micrometers. A filter with a nominal rating of 10 μm is supposed to trap
up to 95% of the entering particles greater than 10 μm in size. The absolute rating represents the size of
the largest pore or opening in the filter and thus indicates the largest size particle that could go through.
Hence, absolute rating of a 10 μm nominal size filter would be greater than 10 μm.
A better parameter for establishing how well a filter traps particles is called the beta ratio or beta rating.
The beta ratio is determined during laboratory testing of a filter receiving a steady-state flow containing a
fine dust of selected particle size. The test begins with a clean filter and ends when pressure drop across
the filter reaches a specified value indicating that the filter has reached the saturation point. This occurs
when contaminant capacity has been reached.
By mathematical definition, the beta ratio equals the number of upstream particles of size greater than
Nμm divided by the number of downstream particles having size greater than Nμm where N is the
selected particle size for the given filter. The ratio is represented by the following equation:
No. of upstream particles of size >N μm
Beta ratio = (1.4)
No. of downstream particles of size >N μm 
A beta ratio of 1 would mean that no particle above specified N are trapped by the filter. A beta ratio of
50 means that 50 particles are trapped for every one that gets through. Most filters have a beta ratio
greater than 75:
No. of upstream particles  No. of downstre am particles
Beta efficiency =
No. of upstream particles
Thus,
1
Beta efficiency = 1 − (1.5)
Beta ratio
1.7 Heat Exchangers
The heating up of hydraulic oil beyond tolerable limits in an otherwise well-designed hydraulic systemis
usually a phenomenon associated with high-pressure, high-flow systems cycling at high frequencies. The
input power in such systems is usually more than 40 kW.

Heat is generated in hydraulic systems because no component can operate at 100% efficiency. Significant
sources of heat include the pump, pressure-relief valves and flow control valves. Heat can cause the
hydraulic fluid temperature to exceed its normal operating range of 35–70C. Excessive temperature
hastens the oxidation of the hydraulic oil and causes it to become too thin. This promotes deterioration of
seals and packing and accelerates wear between closely fitting parts of hydraulic components of valves,
pumps and actuators.

The steady-state temperature of fluid of a hydraulic system depends on the heat-generation rate and the
heat-dissipation rate of the system. If the fluid operating temperature in a hydraulic system becomes
excessive, it means that the heat-generation rate is too large relative to the heat-dissipation rate. Assuming
that the system is reasonably efficient, the solution is to increase the heat-dissipation rate. This is
accomplished by the use of coolers, which are commonly called “heat exchangers.”
It is basically a problem associated with fluid power systems using constant delivery pumps in which, for
most part of the cycle, the fluid is dumped to the tank through the relief valves at high pressures resulting
in wasted power. The consequent heating of oil should not be a cause for concern if oil temperatures do
not exceed 30C above ambient even after 8 h of continuous operation.

Injection molding machines and huge hydraulic presses are typical examples for high-pressure, high-flow
systems. If the frequency of the operating cycle is also high, then heat builds up because the high
operating cycle does not permit heat dissipation. The consequent temperature raise shall be between 40
and 60C above ambient. In places where the ambient temperatures are above 30C, this heating up of oil
would be a cause for concern. Electrical valves begin to malfunction and leakage past the seals and spool
valves due to viscosity changes would affect the system performance. A poorly designed hydraulic
system is another cause for heating up of oil. The glow ratings of all valves and conductors must be
adequate to handle the pump flow. In a double-acting cylinder with a large piston area to annular area
ratio, valves must be selected to handle the discharge out of the rod end of the cylinder and not based on
the flow into the cap end. Heat exchangers are designed primarily to overcome this problem. If installed
at an appropriate location, which is the tank return line, heat exchangers help the system to dissipate heat
and maintain oil temperatures within normal limits.

In some applications, the fluid must be heated to produce a satisfactory value of viscosity. This is typical
when, for example, mobile hydraulic equipment is to operate below 0C. In these cases, the heat
exchangers are called “heaters.” However, for most hydraulic systems, the natural heat-generation rate is
sufficient to produce high enough temperatures after an initial warm-up period.

Basically, there are two types of heat exchangers: liquid-to-liquid and liquid-to-air type. Liquid-to-liquid
types are of shell and tube construction consisting of a bundle of small tubes held inside a shell. The
coolant flows through the small tubes, while the hydraulic oil passes around and between these tubes. The
tubes can be either of the straight-type or of U-type. Straight-type units have higher thermal efficiency
and are less expensive. U-types are best suited for high-temperature and high-pressure applications. They
can accommodate thermal expansion but the tube banks are difficult to clean. The heat exchangers can be
of single pass or double pass and can be of parallel-flow or counter-flow type. The double-pass counter-
flow type provides maximum heat transfer for a given size.

For hydraulic applications, the commonly used coolant is water. Standard liquid-to-liquid units can
handle pressures up to 15 bar and temperatures up to 150C although the actual temperature difference
between oil and water should not exceed 90C. The mechanism of action of liquid-to-liquid heat
exchangers is one of evaporation and condensation. The tubes are basically an enclosure containing a
fluid that can be vaporized and a material that provides capillary action. In what is basically an isothermal
process, heat at the input end causes the fluid to evaporate. Vapor travels through the tube to the
condenser or output end. Here the vapor condenses giving up its latent heat and returns to the fluid state
and travels back to the system through the evaporator end. Clean and soft water should be used to prevent
corrosion and scaling in the tubes. If the water is hard and has excessive salt, it can lead to clogging of the
insides of the narrow tube due to scale and dirt deposits. Liquid-to-air heat exchangers transfer heat from
the hydraulic fluid to the atmosphere, just like an automobile radiator. The air passes over-finned tubes
made of either copper or aluminum in which the hot hydraulic fluid circulates.

Heat exchangers are available as of the shelf components in various sizes and configurations. They are
available with temperature control valves, water strainers and bypass check valves. Bypass valves protect
heat exchangers by diverting the excess oil to the tank during surge and peak pressures.

1.7.1 Sizing of Heat Exchangers

The selection of a suitable heat exchanger involves determining the total heat equivalent to wasted energy
or the heat load. This can be assessed by analyzing the duty cycle of the hydraulic machine. The total time
period of a cycle must be broken up into its phases consisting of idling, approach, work, return, etc. and
the wasted energy calculated for each.

The sum of the energy less the energy dissipated through the reservoirs and flow lines by convection and
radiation constitutes the net energy that the heat exchanger must dissipate or the rate of heat transfer. The
maximum oil temperature at the inlet point to the heat exchanger can now be determined by using the
equation
H  mCp (T1  T0 ) (1.6)
Here H is the heat transfer rate in kJ/s;Cp is the specific heat at constant pressure that for hydraulic oil =
1.97 kJ/kgK;T1 is the oil temperature at the inlet to the heat exchanger, which typically lies between 55
and 65C;T0 is the oil temperature at the outlet, which is the desired oil temperature that the heat
exchanger must maintain. A suitable value may be assumed forT0which is consistent with the system
requirement. Also m is the mass flow rate determined by the equation
m    q (kg / s) (1.7)

where  is the density of hydraulic oil in kg/m3 and q is the oil flow rate in m3/s. If the difference between
T1 and T0 is large, then it justifies the need for a heat exchanger. If the difference is only marginal, the heat
exchanger may be dispensed with. By sizing the surface area of the reservoir, so that it can transfer
enough heat from oil to the atmosphere by conduction, convection or radiation, the net wasted energy that
the heat exchanger must dissipate can be reduced, thus reducing the size of heat exchanger.
After ascertaining the need for the heat exchanger, the size of heat exchanger in terms of quantity of water
required to dissipate the heat and maintain the desired temperature must be determined based on the
equation
 (860)( Pw )
Q (1.8)
T1  Tw

wherePw is the wasted energy in kW,Q is the water flow rate through the heat exchanger in L/min, T1 is the
temperature of the oil and Tw is the water temperature. When the flow capacity as determined from the
equation is much larger than the capacity of available heat exchangers, then two smaller heat exchangers
of equal sizes can be used in parallel. Standard heat exchangers would have the oil-to-water ratio of either
1:1 or 2:1.This means that for every liter of oil circulated, one or half a liter of water must be circulated to
achieve the desired oil temperature. The size and therefore the cost of a heat exchanger depend largely on
the initial temperature difference between the inlet oil and water. If this difference decreases, the cost
decreases. The pressure drop that the hydraulic system can permit is another factor that has a direct
bearing on the size and cost of the heat exchanger. Ideal allowable pressure drops should be between 3.5
and 5 bar.

If it becomes necessary to install a heat exchanger in an existing system, then the waste energy may safely
be assumed equal to 20% of the connected power. The value of T1 may be obtained directly by measuring
the maximum temperature of the oil in the tank and heat exchanger size, based on Eq. (1.8) above. Shell
and tube heat exchangers can be mounted either vertically or horizontally.

Example 1.1
In a hydraulic system operating at 200 bar, the pump delivery is 25 LPM and input power to the pump
drive is 10 kW. The system cycle is such that the pump is unloaded at 60% of the operating time. The
overall efficiency of the systems when it is on load is 65%. If the ambient temperature is 15C and the
maximum permissible fluid temperature in the reservoir is 50C, calculate a suitable size for the fluid
reservoir assuming that
(a) Normal air circulation around the fluid reservoir doubles the cooling owing to the natural radiation.
(b) The fluid reservoir is of square section of side a with a length of 2a.

Solution: Heat dissipation from the vertical plate:

H v  hv A T  3.6
1/ 4
 35 
where T = 50 – 15 = 35C and A = 6a2. Also hv  1.42    3.45 (a)1/ 4
 a 

So

H v  3.45 (a)1/4 6a2  353.6 (W) = 2608 (a)7/4 (W)

Heat dissipation from the horizontal top plate:
H H  hH A T  3.6
where  T = 50 – 15 = 35C and A = 6a . Also
2

1/ 4
 35 
hH  1.32    3.21 (a)1/ 4
 a 
So

H H  3.21 (a)1/4 2a2 35  3.6 = 809 (a)7/4 W

Heat dissipation owing to the natural radiation:
H v  H H  2608 (a)7/4  809 (a)7/4 =3417 (a)7/4
Heat dissipation with normal air circulation may be taken as twice that owing to natural radiation and is
equal to 6834 (a)7/4 W.
Heat input to the system during “on load” part of cycle is
10 × (1 − 0.65) = 3.5 kW

But the system is only on load for 40% of the time; thus the average heat energy input to the fluid is given
by
Average input = 0.4 × 3.5 = 1.4 kW = 1400 W
For thermal equilibrium, the heat energy entering the system must be equal to the heat energy dissipated
from the system; therefore,
6834 (a)7/4  1400
Solving, we get a = 0.404 m = 40.4 cm.
Assume the tank material measurement to be 0.4 m wide, 0.4 m high and 0.8 m long; then the volume of
the fluid contained is given by
Q = 0.4 × 0.4 × 0.8= 0.128 m3 = 128 L
In practice, the tank has to be higher than 0.4 m as there must be clearance volume above the oil. Size the
reservoir from the rule of thumb formula, that is, the reservoir capacity is equal to three to four times the
pump delivery per minute.
Reservoir capacity = −75 to 100 L
This value is similar to the value calculated.
If a very large fluid reservoir is needed to dissipate the heat energy, it may be advantageous to use a fluid
cooler.

Example 1.2
Determine the beta ratio of a filter when, during test operation, 30000 particles greater than 20 m enter
the filter and 1050 of these particles pass through the filter. What is the beta efficiency?

Solution: We have
No. of upstream particles of size  N μm 30000
Beta ratio    28.6
No. of downstream paricles of size  N μm  1050
No. of upstream particles  No. of downstream particles 30000  1050
Beta efficiency =   96.5%
No. of upstream particles 30000
Beta efficiency could also be calculated as
1 1
Beta efficiency = 1 − 1  96.5%
Beta ratio 28.6

Example 1.3
A hydraulic machine has the following duty cycle: Idle at 15 bar for 2 s, clamp workpiece at 100 bar for 5
s, approach at 15 bar for 2 s, perform work at 300 bar for 3 s, declamp, return at 15 bar for 2 s.The pump
flow is 100 LPM, the total surface area of the oil reservoir is 2.5 m2 and the hydraulic pipeline is
25 mm × 2500 mm. Calculate the net wasted energy that needs to be dissipated and recommend a suitable
heat exchanger if necessary. Assume the following values: Ambient temperature = 20C, volumetric
efficiency of the pump = 0.85, density of oil = 860 kg/m3, 1 kWh = 3.6 × 106 J.
Solution: Power dissipated in kW is given by the equation
pQ
×η
600
wherep is the pressure in bar, Q is the flow in LPM and η is the volumetric efficiency of the pump.
Power dissipated during the idle cycle while passing oil through valves and pipelines is
100
15 × × 0.85 = 2.94 kW
600
Because this phase lasts for 30 s, the energy consumed is
30
2.94 × 0.0245 kWh or 0.0245 (3.6×106)= 8.82 J
3600
100
Power dissipated during clamping is 100 × × 0.85 = 19.6 kW
600
Because this phase lasts for 5 s, the energy consumed is
15
19.6 × = 0.027 kWh
3600
= 0.027 × (3.6 × 106)
= 9.72×104 J
15
Power dissipated during approach is 100 × × 0.85 = 2.94 kW
600
Because this phase lasts for 2 s, the energy consumed is
2
2.94 × = 0.001 kWh
3600
=0.001 × (3.6 × 106)
= 3.6 × 103 J
Power dissipated during work phase is
300
100 × × 0.85 = 58.8 kW
600
Because this phase lasts for 3 s, the energy consumed is
3
58.8 × = 0.049 kWh
3600
= 0.049 × (3.6×106)
= 17.64 × 104 J
Power dissipated during return is
15
100 × × 0.85 = 2.94 kW
600
Because this phase lasts for 2 s, the energy consumed is
2
2.94 × = 0.001 kWh
3600
= 0.001 × (3.6 × 106)
= 3.6 × 103 J
Total power dissipated in 42 s = 2.1×105 J.In terms of average wasted power, this will be
105
2.1 × = 0.058 kWh
3.6  106
3600
= 0.058 ×
42
= 5 kW.
Available hydraulic power is
30
300 × × 0.85 = 58.8 kW
3600
Wasted power is 8.5% of available power.
Now
H
(T1 − T0) = × Cp (1.9)
m
We have
105
H = 2.1 × = 5 kJ/s
1000  42
m = 860 × 0.001= 0.86 kg/s
Substituting the above values in Eq. (1.9), we get
5
(T1−T0) = × 1.97 = 2.95
0.86
Because this difference is negligible, there is no need for a heat exchanger. Heat dissipated by the oil
reservoir and hydraulic pipelines can be calculated as follows: Heat dissipated by the oil reservoir
K
T  A  kW
3600

where ΔT is the difference between the maximum oil temperature and the ambient temperature in C, A is
the surface area of the reservoir in m2 and K the average rate of convection from the reservoir is 6–10
kJ/cm2 h, depending upon the condition of the surroundings. For poor air circulation, assume a value
equal to 6. The surface area of hydraulic pipelines is given by pdl, where d is the outside diameter of the
pipe and l is the length in appropriate units.

Example 1.4
Oil at 49C and 69 bar is flowing through a pressure-relief valve at 38 LPM. What is the downstream oil
temperature?

Solution: First we calculate the power lost/wasted:

Power lost = p (bar) × Q (LPM)
= (69 × 105 N/m2) (38 × 103 m3/min) × 1/60 (s)
= 4370 W = 4.37 kW
Next we calculate the oil flow rate in units of kg/s and the temperature increase.
Oil flow rate (kg/s) = 895 × Oil flow rate (m3/s)
103
= 895 × 38 × = 0.6 kg/s
60
Now
Heat generation rate (kW)
 kJ 
Oil specific heat  °C   Oil flow rate (kg / s)
Temperature ( C ) =  kg 
4.37
  4°C
1.8  0.6
Downstream oil temperature = 49 + 4 = 53 C
Example 1.5
The hydrostatic transmission receives 6 kW from the engine at the pump. The transmission output
delivers 3.7 kW to the rear wheel output drive. Assuming that the difference is lost to heat, compute the
total heat loss over the period of 4 h of operation.

Solution: , Energy loss is given by the difference between the energy supplied(to pump) and energy
taken out( at the actuator), mathematically, we get
Heat energy loss = Operation time (Pump input power – Actuator output power)
= 4 h (6 − 3.7) = 9.2 kWh
The temperature increase resulting from the heat generated in the fluid computed in C/kg of fluid is
attributed to discharging fluid across such a component as pressure-relief valves and from the mechanical
friction of moving parts. In most hydraulic systems, mechanical friction accounts for less than 20% of the
input power.
The formula for computing temperature increase due to heat generation by a fluid passing through
restriction is
Heat generated (kW)
Temperature increase (C) 
 kJ 
Oil specific weight  C  × Oil flow rate ( kg/s)
 kg 
where the specific heat of oil is given as 1.8 kJ/kgC. . When the flow rate is given in m3 /s and the mass
density of the oil is taken as 895 kg/m3 , the mass flow rate of oil is computed from
Mass flow rate (kg/s) = 895 kg/m3  Oil flow rate (m3/s)

Example 1.6
The pressure drop across a sticking control valve is observed to be 68.9 bar. If the fluid has a specific
gravity of 0.895 and a flow rate of 0.19 LPS, estimate the rise in temperature of the fluid that can be
attributed to the control valve.

Solution: The heat generated by the pressure drop across the control valve is

Heat loss generated = 68.9 × 105 × 0.19 × 10–3 = 1309 W/s

The mass flow rate of fluid through the valve is computed as
Mass flow rate kg/s = 895 kg/m3 × 0.19 × 103 m3/s = 0.17 kg/s
Solving for the temperature rise in C of the fluid we get
Heat generated (kW)
Temperature increase ( C) 
 kJ 
Oil specific weight  C   Oil flow rate ( kg/s)
 kg 
1309
  4.28C
0.17  1.8  1000
A heat exchanger relieves the hydraulic fluid of excess heat to lower its operating temperature. In gross
terms, the amount of heat to be removed and transferred to the cooling medium equals the difference
between the input to the hydraulic pump and the output of all system actuators. This assumes, of course,
that the existing ambient temperature is appropriate for the system operation and the environmental
conditions do not add or subtract heat from the fluid. This is seldom the case. In extreme environments,
both cold and hot heat exchangers may be employed to counter act primarily environmental
circumstances rather than operating conditions to maintain the temperature of oil within operable limits.
For example, in a cold region, heat is frequently added to the fluid to decrease viscosity, whereas locating
pumps, transmission lines and actuators near furnaces require that heat be subtracted from the fluid to
increase viscosity and reduce the temperature. This is a different problem than lowering the temperature
of fluids that are heated by working cycle itself, for example, by being discharged across a relief valve.

Example 1.7
A hydraulic machine has the following duty cycle: Idle at 12 bar for 30 s, clamp workpiece at 98 bar for 6
s, approach at 16 bar for 2 s, perform work at 300 bar for 3 s, declamp, return at 15 bar for 2 s.The pump
flow is 100 LPM, the total surface area of the oil reservoir is 2.5 m2 and the hydraulic pipeline is 25 mm
in diameter and 2500 mm in length. Calculate the net wasted energy that needs to be dissipated and
recommend a suitable heat exchanger if necessary. The room temperature is 22C. The volumetric
efficiency of pump = 0.86. The density of the oil used = 860 kg/m3.

Solution: Power dissipated in kW

PQ 12  100
  2.33 kW
600  η 600  0.86
Energy consumed during 30 s is
2.33  30
 0.0194 kWh
3600
Power dissipated during clamping is
98  100
 18.99 kW
600  0.86
Because clamping takes place in 5 s, the energy consumed is
18.99  6
 0.032 kWh
3600
Power dissipated during approach is
100  16
 3.1 kW
600  0.86
Because approach takes place in 2 s, the energy consumed is
3.1  2
 0.0017 kWh
3600
Power dissipated during forward (work) is
100  300
 58.4 kW
600  0.86
Because work takes place in 3 s, the energy consumed is
58.4  3
 0.0485 kWh
3600
Power dissipated during return is
100  15
 2.91kW
600  0.86
Because return takes place in 2 s, the energy consumed is
 2.91  2
 0.0016 kWh
3600
Total power dissipated in 59 s = 0.1032 kWh. We can express this in kW as
0.058  3600
 6.29 kW
59
Also
Mass flow rate = 860  0.001 = 0.86 kg/s
We have
Heat generation rate (kW)
Temperature (C) 
 kJ 
Oil specific heat  C   Oil flow rate (kg / s)
 kg 
6.29
  4.06 C
1.8  0.86
Temperature rise is small; therefore, there is no need for a heat exchanger.

Example 1.8
A hydraulic pump operates at 140 bar and delivers oil at 0.001 m3/s to a hydraulic actuator. Oil discharges
through a pressure relief valve during 60% of the cycle time. The pump has an overall efficiency of 82%
and 15% of power is lost due to frictional pressure losses in the hydraulic lines. What heat exchanger
rating is required to dissipate all the generated heat?

Solution: We have
Pump power loss  Pump power input  Pump power output
Power output
Pump power loss   Power output
Overall efficiency
1 
Pump power loss    1 pump power output
 η0 
 1   140  10  0.001 
5
   1     3.073 kW
 82   1000 
 140  105  0.001 
 (0.60)     8.4 kW
 1000 
Also
 140  105  0.001 
Line average loss  {0.60}  0.15     1.26 kW
 1000 
Therefore

Total loss = 3.073 + 8.4 + 1.26 = 12.77 kW

Select heat exchanger rating of 12.77 kW.

Example 1.9
What would be an adequate size of a reservoir for a hydraulic system using 0.0005 m3/s pump?

Solution: Size of the reservoir is three to four times the capacity of the pump, that is
Size of reservoir = 4  capacity of pump (LPM)
= 4  0.0005  4  30 (LPM)  120 L tank is required
Example 1.10
A pump delivers oil to a hydraulic motor at 20 LPM at a pressure of 15 MPa. If the motor delivers 4 kW
and 80% of the power loss is due to internal leakage, which heats the oil, calculate the heat-generation
rate in kJ/min.

Solution: We have
0.02
Pump power   150000  5 kW
60
Motor delivers 4 kW; therefore loss is 1 kW. Now
Power loss due to leakage  0.8 1  0.8 kW
Power loss due to leakage  0.8  60  48 kJ / min

Example 1.11
A certain static O-ring has a diameter of 11 mm and is given an initial squeeze of 10%. The swell of the
seal is equal to 20% increase in squeeze while the compression set is 10%. Calculate the final squeeze
percentage of the seal.

Solution: We have
Final squeeze = Initial squeeze – Compression set + Swell
= 11 (0.10−0.10 +.20) = 2.2 mm
So
2.2
Percentage of final squeeze =  100  20%
11
Objective-Type Questions
Fill in the Blanks

1. Seals are used in hydraulic systems to prevent excessive internal and external leakage and to keep out
________.
2. ________rings are seals designed to prevent foreign abrasive or corrosive materials from entering a
cylinder.
3.________ is the most widely used plastic for seals of hydraulic systems.
4. ________ almost a standard material for elastomer-type seals for use at elevated temperatures up to
240C.
5. ________is an instrument used to measure the indentation hardness of rubber and rubber-like materials.
6. A vented ________ allows the tank to breathe as the oil level changes due to system demand
requirements.
7. The pressurized reservoir usually operates at between 0.35 and ________ bar.
8. The reservoir capacity should be ________ times the pump delivery per minute. This may well be too
high a volume for mobile application.
9. A hydraulic strainer is a ________ filter.
10. ________ is a surface phenomenon and refers to the tendency of particles to cling to the surface of the
filters.
11. ________ filters are porous and permeable materials such as paper, wood pulp, diatomaceous earth,
cloth, cellulose and asbestos.
12. Mostly filters have a beta ratio ________ than 75.
13. For hydraulic applications, the commonly used coolant in a heat exchanger is ________.

State True or False

1. Internal leakage does not cause loss of fluid because the fluid returns to the reservoir.
2. A non-positive seal allows a small amount of internal leakage.
3. Dynamic seals are subject to less wear compared to static seals.
4. V- and U-ring seals are compression-type seals used in virtually all types of rotary motion applications.
5. T-ring seals are static seals.
6. Natural rubber is commonly used as a seal material.
7. Standard liquid-to-liquid units can handle pressures up to 15 bar and temperatures up to 150°C
although the actual temperature difference between oil and water should not exceed 90C.
Review Questions

1. Explain the two types of leakages in a hydraulic system. In what way do they affect the performance of
a fluid system?
2. What is a seal and what are its functions?
3. How are hydraulic seals classified? What is meant by positive sealing and non-positive sealing?
4. Distinguish between a static seal and a dynamic seal.
5. How are seals classified based on geometrical cross-section?
6. Explain the different types of sealing materials commonly used.
7. What are the primary and secondary functions of a reservoir system?
8. Explain the important elements of a reservoir system and explain the function of each.
9. What is a filter and how is it classified?
10. What are surface and depth filters?
11. What are the important locations of filters? Explain the advantages and disadvantages of each
location.
12. Why should the temperature of a working fluid be properly maintained?
13. What is the purpose of seals in a hydraulic system and how are they classified?
14. List out the most commonly used types of seal configuration.
15. What is the difference between a strainer and a filter?
16. Name various filter media.
17. List out the basic types of filtering methods used in a fluid system.
18. List various locations where filters are installed in fluid power systems.
19. What are the main criteria in the design of a hydraulic system?
1. What is the purpose of a baffle plate in the fluid power pack?
.
Answers
Fill in the Blanks

1. Contamination
2. Wiper
3. Tetrafluoroethylene
4. Viton
5. A durometer
6. Breather cap
7. 1.4 bar
8. Three–four times
9. Coarse
10. Adsorption
11. Absorption
12. Greater
13. Water

State Tue or False

1 True
2. True
3. False
4. False
5. False
6. False
7. True
 Lecture 32

MAINTENANCE OF FLUID POWER SYSTEMS

Learning Objectives

Upon completion of this chapter, the student should be able to:

List the most common causes of hydraulic system breakdown.
Explain the importance of cleanliness of hydraulic systems.
Explain the problems caused by air in hydraulic systems.
List the causes and remedy for excessive noise, incorrect flow, pressure and faulty operations.
Describe the various general safety rules for electricity and electronics.
List possible faults in solenoid valves.
Explain the method for maintaining and disposing of fluids.

1.1 Introduction

The working medium in hydraulic systems is a fluid. Till the early 20th century, water was used as a
fluid. Water as a working fluid had many drawbacks, such as low freezing point, corrosive (rust
formation) nature and poor lubrication characteristics. Gradually, various oil-based fluids that had the
desirable properties were developed for use in hydraulic systems.
In a hydraulic system, a hydraulic fluid has to perform various functions, such as follows:
 To transmit power, which is the primary function?
 To lubricate various moving parts, so as to avoid metal-to-metal contact, and reduce wear and
noise.
 To carry the heat generated in the system due to friction between moving parts and moving fluid,
and to dissipate to the environment either through a suitable heat exchanger or through the
reservoir.

To perform these functions and make the system work efficiently, a hydraulic fluid must be clean and
should possess certain properties.A hydraulic system is fairly easy to maintain: the fluid provides a
lubricant and protects against overload. But like any other mechanism, it must be operated properly. You
can damage a hydraulic system by too much speed, too much heat, too much pressure or too much
contamination.

The following is a list of most common causes of hydraulic system breakdown:

 Clogged or dirty oil filters.
 Inadequate supply of oil in the reservoir.
 Leaking seals.
 Loose inlet lines that cause the pump to take in air.
 Incorrect type of oil.
 Excessive oil temperature.
 Excessive oil pressure.

Most of these and similar kinds of problems can be eliminated if a plant-preventive maintenance
program is undertaken. This starts with the fluid power designer in the selection of high-quality,
properly sized components. It is important for the total system to provide easy access to components
requiring periodic inspection such as filters, strainers, sight gauges, drain and fill plugs, flow meters, and
pressure and temperature gauges.

1
Over half of all hydraulic system problems have been traced directly to the oil. The test kit may be used
on the spot to determine whether fluid quality permits continued use. Test that can be performed include
the determination of viscosity, water content and particulate contamination level. Viscosity is measured
using a visage viscosity comparator. Water content is determined by the hot-plate method. Contamination
is eliminated by filtering a measured amount of hydraulic fluid, examining the particles caught on
the filters under microscope and comparing what is seen with the series of photos indicating
contamination levels.

For preventive maintenance techniques to be truly effective, it is necessary to have a good report and
record system. This report should include the following:

 The types of symptoms encountered, how they were detected and the date.
 The description of the maintenance performed. This should include the
replacement of parts, the amount of downtime and the date.
 Records of dates when oil was tested added or changed. Dates of filter changes
should also be recorded.

Proper maintenance reduces hydraulic troubles. By caring for the system using a regular
maintenance program, we can eliminate common problems and anticipate special ones.

1.2 The Importance of Cleanliness

Cleanliness is the first requirement when it comes to servicing hydraulic systems. Keep dirt and
other contaminants out of the system. Small particles can score valves, seize pumps, clog orifices
and cause expensive repair jobs.
How to keep the hydraulic system clean? Let us put it this way:

 Keep the oil clean.

 Keep the system clean.
 Keep your work area clean.
 Be careful when you change or add oil.

1.3 Importance of Oil and Filter Changes

We cannot get peak performance out of a hydraulic system that is not clean. Despite all
the precautions taken when working with the hydraulic system, some contaminants get into the
system anyway. Good hydraulic oils hold these contaminants in suspension and filters collect
them as the oil passes through. Good hydraulic oil contains many additives that work to keep
contaminants from damaging or plugging the system. However, these additives lose their
effectiveness after a period of time. Therefore, oil should be changed at the recommended
intervals to make sure that the additives do their job. The system filters can absorb only a
limited amount of dirt particles and other contaminants from the oil. After that the filters stop
working. At this point, the filters should be cleaned or replaced with new ones so that the cleaning
process can be maintained.

2
1.3.1 Draining the System

Periodic draining of the entire hydraulic system is very important. This is the only positive way to
completely remove contaminants, oxidized fluid and other substances from the system. The machine
operator’s manual tells the method to be used, and the frequency, depending on conditions.

1.3.2 Cleaning and Flushing the System

In some hydraulic systems, there might be deposits left in the system. It is advisable to clean and
flush the system after draining the oil out. After draining the system, clean any sediment from the
reservoir and clean or replace the filter elements. Flush out the old oil remaining in the system after
draining, particularly if the oil is badly contaminated. Drain out the flushing oil and refill the system
with clean hydraulic oil of the recommended type. Be sure to clean or replace the system filters
before refilling the system.

1.3.3 Filling the System

Before filling the system, be sure the area around the filler cap is clean. Fill the reservoir to the
specified level with the recommended hydraulic oil. Use only clean oil and funnels or containers, and
then be sure to replace the filler cap before operating the equipment.

1.3.4 Preventing Leaks

There are internal and external leakages. Internal leakage does not result in actual loss of oil but it
does reduce the efficiency of the system. External leakage does result in direct loss of oil and can
have other undesirable effects as well. A hydraulic system should always be monitored for leaks and
remedial actions should be taken immediately.

1.3.5 Preventing Overheating

Heat causes hydraulic oil to breakdown faster and lose its effectiveness. This is why cooling of the oil
is needed. In many systems, enough heat is dissipated through the lines, the components and the
reservoir to keep the oil fairly cool. But on high-pressure, high-speed circuits, oil coolers are needed to
dissipate the extra heat.

To help prevent overheating, keep the oil at the proper level; clean dirt and mud from lines, reservoirs
and coolers; check for dented and kinks lines; and keep relief valves adjusted properly. Also be
careful to not over speed or overload the system and never hold the control valve in power position
longer than necessary.

1.4 Problems Caused By Gases in Hydraulic Fluids

Gases can be present in a hydraulic fluid (or any other fluid) in three ways: free air, entrained gas and
dissolved air.

1.4.1 Free Air

Air can exist in a free pocket located at some high point of a hydraulic system (such as the highest
elevation of a given pipeline). This free air either existed in the system when it was initially filled or
was formed due to air bubbles in the hydraulic fluid rising into the free pocket. Free air can cause the
hydraulic fluid to possess a much lower stiffness (bulk modulus), resulting in a spongy and unstable
operation of hydraulic actuators.

3
1.4.2 Entrained Gas

Entrained gas (gas bubbles within the hydraulic fluid) is created in two ways. Air bubbles can be
created when the flowing hydraulic fluid sweeps air out of a free pocket and carries it along the fluid
stream. Entrained gas can also be created when the pressure drops below the vapor pressure of the
hydraulic fluid. When this happens, the bubbles of hydraulic fluid are created within the fluid stream.
Entrained gas can cause cavitation problems in pumps and valves. These gases can greatly reduce the
effective bulk modulus of hydraulic fluids, resulting in spongy and unstable operation of hydraulic
actuators.

Vapor pressure is defined as the pressure at which a liquid starts to boil and thus begins changing into a
vapor. The vapor pressure of a hydraulic fluid (or any other liquid) increases with an increase in
temperature. Petroleum-based and fire-resistant phosphate ester fluids have very low vapor pressures.
Cavitation occurs because the vapor bubbles collapse as they are exposed to the high pressure at the
outlet port of the pump, creating extremely high local fluid velocities. This high -velocity fluid
impacts internal metal surfaces of the pump. The resulting high impact forces cause flaking or pit ting the
surfaces of internal components such as gears, vanes, etc. Cavitation also interferes with the
lubrication of mating moving surfaces and thus produces increased wear.

One indication of cavitation is a loud noise emanating from the pump. The rapid collapsing of gas bubbles
produces vibrations of pump components, which are transmitted into pump noise. Cavitation also causes a
decrease in the pump flow rate because the pumping chambers do not completely fill with the hydraulic
fluid. As a result, the system pressure becomes erratic.

1.4.3 Dissolved Air

Dissolved air is in the solution and thus cannot be seen and does not add to the volume of the
hydraulic fluid. Hydraulic fluids can hold an amazingly large amount of air in the solution. A
hydraulic fluid, as received at atmospheric pressure, typically contains about 6% of dissolved air by
volume that increases to 10% when pumped.

Dissolved air creates no problem in hydraulic systems as long as the air remains dissolved. However,
if the dissolved air comes out of the solution, it forms bubbles in the hydraulic fluid and thus becomes
entrained air.

The following will help control or eliminate pump cavitation by keeping the suction pressure above the
vapor pressure of the fluid:

 Keep suction velocities below 1.5 m/s.

 Keep pump inlet lines as short as possible.
 Minimize the number of fittings in the pump inlet line.
 Mount the pump as close as possible to the reservoir.
 Use low-pressure drop-pump inlet filters or strainers.
 Use a properly designed reservoir that can remove entrained air from the fluid
before it enters the pump inlet line.
 Use proper oil as recommended by the manufacturer.
 Keep the oil from exceeding the recommended maximum temperature level.

4
1.5 Troubleshooting Guides

The following troubleshooting guides are arranged in five main categories. The heading of each is a
symptom that indicates some malfunction in the system. The causes and remedies are given in Tables
1.1–1.5.

1.5.1 Fluid Maintenance

Fluid maintenance can be done in the following ways:
 Before opening a drum, clean the top and the bung
 Use only clean containers and hoses to transfer the hydraulic fluid.
 Provide a 200-mesh screen in the reservoir filter pipe.
 Store drums indoor or under a roof.

1.5.2 In-Operation Care of Hydraulic Fluid

This can be done in the following ways:
 Keep the system tight and repair all leaks immediately.
 Use proper air and fluid filtration.
 Establish fluid change intervals.
 Keep the reservoir filled properly to take the advantage of its heat-dissipating characteristics
and prevent moisture from condensing on inside walls.

Table 1.1 Excessive noise

Symptom Cause Remedy
Pump noisy Cavitation Any or all of the following:
Replace dirty filters.
Wash strainers.
Clean the clogged inlet line.
Clean the reservoir breather vent.
Change the system fluid.
Change to proper pump drive motor speed.
Overhaul or replace the pump.
Check fluid temperature.

Air in fluid Any or all of the following:

Tighten leaky inlet connections.
Fill the reservoir to proper level.
Bleed air from the system.
Replace the pump shaft seal.

Coupling All of the following:

misaligned Align unit.
Check the condition of seals, bearings and couplings.
Pump worn or Overhaul or replace defective parts
damaged
Motor noisy Coupling All of the following:
misaligned Align unit.
Check the condition of seals, bearings and couplings.

5
 Motor or Overhaul or replace defective parts
coupling worn
or
Relief valve Setting too Install and adjust pressure gauge
noisy damaged
low or too
close toheat
Table 1.2 Excessive
Symptom another Causevalve Remedy
Pump heated setting
Fluid heated See symptom “fluid heated”
Cavitation Any or all of the following:
Replace dirty filters.
Wash strainers.
Clean the clogged inlet line.
Clean the reservoir breather vent.
Change the system fluid.
Change to proper pump drive motor speed.
Overhaul or replace the pump.
Check fluid temperature.

Air in fluid Any or all of the following:

Tighten leaky inlet connections.
Fill the reservoir to proper level.
Bleed air from the system.
Replace the pump shaft seal.

Excessive load All of the following:

Align unit.
Check the condition of seals, bearings and
couplings.
Locate and correct mechanical binding.
Check for workload in excess of circuit
design.

Pump worn or Overhaul or replace defective parts

damaged
Relief or unloading Install and adjust pressure gauge
valve set
Motor heated too high
Fluid heated See symptom “fluid heated”
Relief or unloading Install and adjust pressure gauge
valve set
too high loading
Excessive All of the following:
Align unit.

Locate and correct mechanical binding.

seals, bearings and couplings.
Check for workload in excess of circuit
design.
Motor or coupling Overhaul or replace defective parts
worn or
Relief valve damaged
Fluid heated See symptom “fluid heated”
heated Valve setting Install and adjust pressure gauge
incorrect
6
 Worn or damaged Overhaul or replace defective
valve parts
Fluid heated System pressure too Install and adjust pressure gauge
high
Unloading valve set Install and adjust pressure gauge
too high
Fluid dirty or low Change filters.
supply Check system fluid
viscosity, change if
necessary.
Fill the reservoir to proper level.
Incorrect fluid Change filters.
viscosity Check system fluid
viscosity, change if
necessary.
Fill the reservoir to proper level.

Faulty fluid cooling Clean the cooler and/or

system strainer.
Replace the cooler control valve.
Repair or replace the cooler.

Worn pump, valve, Overhaul or replace defective

motor, parts
cylinder or other
component
Table 1.3 Incorrect flow
Symptom Cause Remedy
No flow Pump not receiving fluid Any or all of the following:
Replace dirty filters.
Clean the clogged inlet line.
Clean the reservoir breather vent.
Change the system fluid.
Overhaul or replace the pump.

Pump drive motor not operating Overhaul

7
 Pump to drive coupling sheared Check for the damaged pump
Replace and align coupling.
Pump drive motor turning in the Reverse rotation
wrong
direction control set in the wrong
Directional Any or all of the following:
direction Check the position of manually
operated controls.
Check the electrical circuit on
solenoid- operated controls.
Repair or replace pilot pressure
pump.

Entire flow passing over the relief Adjust part

valve
Damaged pump Check for the damaged pump
Replace and align coupling.
Incorrectly assembled pump Overhaul or replace part
Excessive flow Flow control set too high Adjust part
Yoke actuating device inoperative Overhaul or replace part
(variable
displacement
Rotation pumps)(RPM) of pump
per minute Replace with correct unit
drive
incorrect size pump used for
Improper Replace with correct unit
replacement
Low flow Flow control set too low Adjust part
Relief or unloading valve set too low Adjust part
Flow bypassing through the partially Overhaul or replace part or any
open or all of the following:
valve Check the position of manually
operated controls
Check the electrical circuit on
solenoid- operated controls.
Repair or replace the pilot
pressure pump.

External leak in the system Bleed air from the system.

Yoke actuating device inoperative Overhaul or replace part

(variable displacement pump)
RPM of pump drive motor incorrect Replace with correct unit

Worn pump, valve motor, cylinder Overhaul or replace part

or other

8
Table 1.4 Incorrect pressure

Symptom Cause Remedy

No pressure No flop See “incorrect flow”, symptom
“no flow”
Low pressure Pressure relief path exists See “incorrect flow,” symptom
“no flow” and “low flow”
Pressure-reducing valve set too low Adjust part
Pressure-reducing valve damaged Overhaul or replace part
Damaged pump, motor or cylinder Overhaul or replace part
Erratic pressure Air in fluid Tighten leaky
connections.
Fill the reservoir to
proper level.
Bleed air from the
system.
Worn relief valve Overhaul or replace part
Contamination in fluid Replace dirty filters and system
fluid
Accumulator defective or had lost charge Check the gas valve for
leakage.
Change to correct
pressure.
Overhaul if defective.
Worn pump, motor or cylinder Overhaul or replace part
Excessive Pressure-reducing, relief or unloading valve Adjust part
pressure misadjusted
Yoke actuating device inoperative (variable Overhaul or replace part
displacement pumps)
Pressure-reducing, relief or unloading valve Overhaul or replace part
worn or damaged

9
Table 1.5 Faulty operation
Symptom Cause Remedy
No movement No flow or pressure See “incorrect flow”
Limit or sequence device Overhaul or replace part
inoperative or misadjusted
Mechanical bind Locate bind and repair
No command signal to the servo Repair command console or
amplifier interconnecting wires
Inoperative or misadjusted Adjust, repair or replace part
servo amplifier
Inoperative servo valve Overhaul or replace part
Worn or damaged cylinder or Overhaul or replace part
motor
Slow movement Low flow See “incorrect flow”
Fluid viscosity to high Check fluid
temperature.
Check system fluid
viscosity, change if
necessary.
Insufficient control pressure for See “incorrect pressure”
valves
No lubrication of machine ways Lubricate
or linkage
Misadjusted or malfunctioning Adjust, repair or replace part
servo amplifier
Sticking servo valve Clean and adjust or
replace part.
Check the condition of
system fluid and filters.
Worn or damaged cylinder or Overhaul or replace part
motor
Erratic movement Erratic pressure See “incorrect pressure”
Air in fluid See “excessive noise”
No lubrication of machine ways Lubricate
or linkage
Erratic command signal Repair command console or
interconnecting wires
Misadjustment of Adjust, repair or replace part
malfunctioning servo amplifier
Malfunctioning feedback Overhaul or replace part
transducer
Sticking servo valve Clean and adjust or
replace part.
Check the condition of
system fluid and filters.
Worn or damaged cylinder or Overhaul or replace part
motor
Excessive speed or movement Excessive flow See “incorrect flow”
Feedback transducer Overhaul or replace part

10
1.6 General Safety Rules for Electricity and Electronics

Following are the general safety rules for electricity and electronics:

 Use approved tools, equipment and protective devices.

 Avoid wearing rings, bracelets and similar meal items when working around
exposed electric circuits.
 Never assume that a circuit is OFF. Double check it with an instrument that is
supposed to be surely operational.
 Some situations require a “buddy system” to guarantee that power would not be turned ON
 Never tamper with or try to override safety devices such as interlock (a type of
switch that automatically removes power when a door is opened or a panel
removes).
 Keep tools and test equipment clean and in good working condition. Replace
insulated probes and leads at the first sign of deterioration.
 Some devices, such as capacitors, can store a lethal charge. They may store this
charge for long periods of time. It must be certain that these devices are
discharged before working around them.
 Do not remove grounds and do not use adapters that defeat the equipment ground.
 Use protective clothing and safety glasses when handling high vacuum
devices such as picture tubes and cathode ray tubes.
 Do not work on equipment before knowing proper procedures and having
awareness of any potential safety hazards.

1.6.1 Solenoid Valves

Pneumatics will continue to dominate the power section and retain its positions in the control section. On
the other hand, it is impossible to deny the advances made by electronic controls, systems and
components due to the following advantages:

 Low power consumption.

 Short switching times.
 Higher contact ratings.
 Long service life.
 Maintenance-free operation.

1.6.1.1 Possible Faults in Solenoid Valves

Following are the possible faults:

 Directed short (at power supply, electrical bus and load): A direct short is when too much
current is sent back to the power supply overloading it, generally blowing a fuse.
 Cross short: A cross short is created by one or more wires (cables) bypassing the load causing a
direct short to occur.
 High resistance connections (too many connections at the terminal eye).
 Low voltage or over voltage at the solenoid.
 Corrosion.
 Partially or fully blocked hoses.

15
  Wire connections are open internally
 Lack of source pressure (at the compressor or on the service unit).
 Sticking spool.
 Diaphragm not working.
 Exhaust ports blocked.
 Gaskets mounted incorrectly.
 Faults caused by wear or external influences.
 Caution: Short circuiting of the power supply is not recommended without the installation of a
“circuit breaker” to protect the equipment and the user.

Causes and remedy for troubleshooting for direct shorts and faults in relay coil is given in Tables 1.6
and 1.7.

Table 1.6 Troubleshooting for direct shorts

Fault Cause Remedy
When the push button is Relay coil K1 has been shorted Pull the ground cable connected
pressed, solenoid Y1 is not directly to the ground bypassing to solenoid Y1, retry the circuit.
activated and the circuit breaker the load (relay coil K 1) If the power supply continues to
must be reset. Solenoid Y1 has been shorted short, the location of the direct
directly to ground bypassing the short is at relay coil K1. If not,
load (solenoid coil). This causes the direct short is at solenoid
the relay coil to buzz (noise like Y1.
a bee) and the circuit breaker
must be reset.
When proximity limit switch a1 Relay coil K2 has been shorted Pull the ground cable connected
and pressure switch a2 are directly to ground, bypassing to solenoid Y3. Retry the
activated, solenoid Y3 is not the load (relay load). circuit. If power supply
activated and the circuit breaker Solenoid Y3 has been shorted continues to short, the location
must be reset. directly to ground, bypassing of the direct short is at relay coil
the load (solenoid). The circuit K2. If not, the direct short is at
breaker must be reset. solenoid Y3.

16
 Table 1.7 Faults in relay coils

Fault Cause Remedy

When powered, the relay coil One or more of the wires (leads) Use the voltmeter to check the
does not function. have an infinite resistance. potential difference across each
Open (infinite resistance) in the cable and the push button when
coil. switch is open, then closed. If
Low voltage: Below the problem is with any of these
specification. components
Relay coil is not energized by The electrical limit switch is not Visually examine the electrical
electrical limit switch (or being activated. limit switch to make sure that
proximity limit switch). the roller is fully activated. If
not, reposition the sensor so that
physical contact is achieved (or
see LED).
Use the voltmeter to test the
difference in potential across
the limit switch (24 V when
open, 0 V when closed); replace
if not functioning or remove the
limit switch from the circuit and
use the ohmmeter to measure
the resistance of the limit switch
(infinite pressure when open,
approximately 0 when closed).
One of the cables (wires) is Use the multimeter to check the
either not connected or there is difference in potential across
infinite resistance in the cable each cable (wire) in the
(wire). corresponding ring. Then
remove the suspect cable(s) and
use the ohmmeter to confirm
your findings, replace the cables
if required.
The relay coil itself is If the voltmeter identifies low
malfunctioning, that is, low voltage, then check the power
voltage, an open (infinite supply and original source.
resistance) circuit, loose Replace or modify the source as
connection, high-resistance required.
connection. If an “open” infinite resistance,
loose or high connection is
suspected, use the ohmmeter to
determine the exact location of
the problem and repair/replace
as required.

15
1.7 Maintaining and Disposing of Fluids
Controlling pollution and conserving natural resources are important goals to achieve for the benefit of
society. Thus, it is important to minimize the generation of waste hydraulic fluids and to dispose them
in an environmentally friendly manner. The following are some recommendations that should be
adhered to strictly for properly maintaining and disposing hydraulic fluids:

 Select the optimum fluid for the application involved. This includes the consideration of the
system operating pressures and temperatures as well as the desired fluid properties.

 Utilize a well-designed filtration system to reduce contamination and increase the useful life
of the fluid. Filtration should be continued and filters should be changed at regular intervals.

 3. Follow a proper storage procedure for the unused fluid supply. For example, outdoor
storage is not recommended, especially if the fluid is stored in drums as it is affected by
increment weather and resulting weakening of drum seams may occur and cause
leakage and contamination.

 Fluids from the storage containers to the hydraulic systems should be transported carefully as
the chances of contamination depend to a large extent on handling. The transfer containers
should be covered when not in use.

 Operating fluids should be checked regularly for viscosity, acidity, bulk modulus, specific
gravity, water content, additive levels and particle contamination.

 The entire hydraulic system, including pumps, piping, filters, actuators and reservoir, should
be maintained according to the manufacturer’s specifications.

 Corrective action should be taken to reduce or eliminate leakage from operating hydraulic
systems. Typically leakage occurs due to worn seals or loose fittings. A preventive
maintenance program should be implemented to ensure ideal operating conditions and reduce
contamination, leakage, etc.

 Fluids must be disposed properly because a hydraulic fluid is considered to be a waste

material when it has deteriorated to the point where it is no longer suitable for use in
hydraulic systems. The various environmental government agencies also suggest against
mixing hazardous wastes with waste hydraulic fluids being disposed. It is also not allowed to
burn these waste fluids in non-industrial boilers.

 Pollution control and conservation of natural resources are critical environmental issues for
society. Properly maintaining and disposing of fluids not only protects the environment but
also conserves our natural resources.

16
Objective-Type Questions
Fill in the Blanks

1. The primary function of a hydraulic fluid is to transmit .

2. Over half of all hydraulic system problems have been traced directly to the .
3. Entrained gas can also occur when the pressure drops below the of the hydraulic fluid.
4. Cavitation occurs because the vapor bubbles collapse as they are exposed to the
pressure at the outlet port of the pump, creating extremely high local fluid velocities.
5. Oxidation is caused by the chemical reaction of oxygen from the air with particles of .

State True or False

1. Dissolved air creates no problem in hydraulic systems as long as the air remains dissolved.
2. Most of fire-resistant fluids are compatible with most natural or synthetic rubber seals.
3. The neutralization number is a measure of the relative acidity.
4. A 10 µm filter is one capable of removing contaminants as small as 10 µm in size.
5. Free air can cause the hydraulic fluid to possess a much lower stiffness.

Review Questions

1. Name five reasons for the overheating of the fluid in a hydraulic system.
2. Name four causes of low or erratic pressure.
3. What three devices are commonly used in the troubleshooting of hydraulic circuits?
4. Name five of the most common causes of hydraulic system breakdown.

5.List eight recommendations that should be followed for properly maintaining

and disposing hydraulic fluid.
6.Name two items that should be included in reports dealing with a maintenance procedure.

7. Name the three ways in which a hydraulic fluid becomes contaminated.

8. Name five things that can cause a noisy pump.
9.Name four causes of low or erratic pressure.
10.Name four causes of no pressure.
11.If an actuator fails to move, name five possible causes.
12.If an actuator has slow or erratic motion, name five possible causes.
13. Why is loss of pressure in a hydraulic system not a symptom of pump malfunction?

15
Answers
Fill in the Blanks

1. Power
2. Oil
3. Vapor pressure
4. High
5. Oil

State True or False

1. True
2. False
3. True
4. True
5. True

16
 Lecture 33

INTRODUCTION TO PNEUMATICS

Learning Objectives

Upon completion of this chapter, Student should be able to

Explain the meaning of Pneumatics

Describe the various properties desired of a air medium in pneumatic system
Explain the advantages and disadvantages of compressed air
Identify and appreciate the application of pneumatic systems in various Industries
Describe the various gas laws
List the basic components required for a pneumatic systems
Describe the various power transmission systems
Compare hydraulic, pneumatic and mechanical systems

1.1 PNEUMATICS AND ITS MEANING.

The English word pneumatic and its associate noun pneumatics are derived from the Greek
“pneuma” meaning breath or air. Originally coined to give a name to the science of the motions
and properties of air. Compressed air is a vital utility- just like water, gas and electricity used in
countless ways to benefit everyday life. Pneumatics is application of compressed air (pressurized
air) to power machine or control or regulate machines. Simply put, Pneumatics may be defined
as branch of engineering science which deals with the study of the behavior and application of
compressed air. Pneumatics can also be defined as the branch of fluid power technology that
deals with generation, transmission and control of power using pressurized air. Gas in a
pneumatic system behaves like a spring since it is compressible.

Any gas can be used in pneumatic system but air is the most usual, for obvious reasons.
Exceptions are most likely to occur on aircraft and space vehicles where an inert gas such as
nitrogen is preferred or the gas is one which is generated on board. Pure nitrogen may be used if
there is a danger of combustion in a work environment. In Pneumatic control, compressed air is
used as the working medium, normally at a pressure from 6 bar to 8 bar. Using Pneumatic
Control, maximum force up to 50 kN can be developed. Actuation of the controls can be
manual, Pneumatic or Electrical actuation. Signal medium such as compressed air at pressure of
1-2 bar can be used [Pilot operated Pneumatics] or Electrical signals [D.C or A.C source- 24V –
230V] can be used [Electro pneumatics]

1.2 CHOICE OF WORKING MEDIUM AND SYSTEM.

The choice of medium depends on the application. Some of the general, broad rules followed in
the selection of a working medium are listed below.

 When the system requirement is high speed, medium pressure (usually 6 to 8 bar) and
less accuracy of position, then pneumatic system is preferred.
 If the system requirement is high pressure and high precision, a fluid system with oil
is good.
 When the power requirement is high like in forging presses, sheet metal press, it is
impossible to use air system. Oil hydraulics is the only choice
 Air is used where quick response of actuator is required.
 If temperate variation range in the system is large, then use of air system may run into
condensation problems and oil is preferred.
 If the application requires only a medium pressure and high positional accuracy is
required then hydro –pneumatic system is preferred
 Air is non-explosive, it is preferred where fire/electric hazard are expected. Oil
systems are more prone to fire and electrical hazards and are not recommended in
such applications.
 Because air contains oxygen (about 20%) and is not sufficient alone to provide
adequate lubrication of moving parts and seals, oil is usually introduced into the air
stream near the actuator to provide this lubrication preventing excessive wear and
oxidation.

In a practical sense, compressed air is a medium that carries potential energy. However it can be
expensive to produce, and from a simple energy efficiency point of view compressed air may not
appear advantageous at first. Considering that it takes about 6 kW of electrical energy to generate
0.75 kW output on an air motor, compressed air has an efficiency rating of only 12%. In spite of
that compressed air is used due to its other advantages.

Table 1.1: The advantages and disadvantages of compressed air.

Advantages of compressed air Disadvantages of compressed air

Air is available in unlimited quantities Compressive air is relatively expensive
Compressed air is easily conveyed in means of conveying energy
pipelines even over longer distances The higher costs are, however. Largely
compensated by the cheaper elements.
Simpler and more compact equipment
Compressed air can be stored Compressed air requires good
conditioning. No dirt or moisture residues
may be contained in it. Dirt and dust
leads to wear on tools and equipment
Compressed air need not be returned. It It is not possible to achieve uniform and
can be vented to atmosphere after it has constant piston speeds( air is
performed work compressible)
Compressed air is insensitive to Compressed air is economical ony up to
temperature fluctuation. This ensures certain force expenditure. Owing to the
reliable operation even in extreme commonly used pressure of 7 bar and
temperature conditions limit is about 20 to 50 kN, depending on
the travel and the speed. If the force
which is required exceeds this level,
hydraulics is preferred
Compressed air is clean. This is The exhaust is loud. As the result of
especially important in food, intensive development work on materials
pharmaceutical, textile, beverage for silencing purposes, this problems has
industries however now largely been solved
Operating elements for compressed air The oil mist mixed with the air for
operation are of simple and inexpensive lubricating the equipment escapes with
construction. the exhaust to atmosphere.
Compressed air is fast. Thus, high Air due to its low conductivity , cannot
operational speed can be attained. dissipate heat as much as hydraulic fluid
Speeds and forces of the pneumatics Air cannot seal the fine gaps between the
elements can be infinitely adjusted moving parts unlike hydraulic system
Tools and operating elements are Air is not a good lubricating medium
overload proof. Straight line movement unlike hydraulic fluid.
can be produced directly
Differences between hydraulic and pneumatic systems.

One of the main differences between the two systems is that in pneumatics, air is compressible.
In hydraulics, liquids are not. Other two distinct differences are given below.

Pneumatic Systems

These systems have two main features:

• Pneumatic systems use compressed gas such as air or nitrogen to perform work
processes.

• Pneumatic systems are open systems, exhausting the compressed air to atmosphere after
use.

Hydraulic Systems

These systems also have two main features:

a) Hydraulic systems use liquids such as oil and water to perform work processes.
b) Hydraulic systems are closed systems, recirculating the oil or water after use.

1.3 APPLICATIONS OF PNEUMATICS

Pneumatic systems are used in many applications. New uses for pneumatics are constantly being
discovered. In construction, it is indispensible source of power for such tools as air drills, hammers,
wrenches, and even air cushion supported structures, not to mention the many vehicles using air
suspension , braking and pneumatic tires.

In manufacturing, air is used to power high speed clamping, drilling, grinding , and assembly using
pneumatic wrenches and riveting machines. Plant air is also used to power hoists and cushion support to
transport loads through the plant.

Many recent advances in air – cushion support are used in the military and commercial marine transport
industry.

Some of the Industrial applications of pneumatics are listed in the Table 1.2
 Table 1.2: Industrial applications of Pneumatics

Material Manufacturing Other applications

Handling
Clamping Drilling Aircraft
Shifting Turning Cement plants
positioning Milling chemical plants
Orienting Sawing Coal mines
Feeding Finishing Cotton mills
Ejection Forming Dairies
Braking Quality Control Forge shops
Bonding Stamping Machine tools
Locking Embossing Door or chute control
Packaging Filling Turning and inverting parts
Feeding
Sorting
stacking

1.4 PROPERTIES OF AIR

1.4.1 Composition: Air is one of the three states of matter. It has characteristics similar to those
of liquids in that it has no definite shape but conforms to the shape of its container and readily
transmits pressure. Gases differ from liquids in that they have no definite volume. That is ,
regardless of the size or shape of the containing vessel, a gas will completely fill it. Gases are
highly compressible, while liquids are only slightly so. Also, gases are lighter than equal number
of liquids, making gases less dense than liquids.

Air is a mechanical mixture of gases containing by volume, approximately 78 % of nitrogen and

21 % of oxygen, and about 1 % of other gases, including argon and carbon dioxide. Water being
the most important remaining ingredient as far as pneumatics is concerned. The dilution of the
oxygen by nitrogen makes air much less chemically active than pure oxygen but it is still capable
of causing spontaneous combustion or explosion , particularly if oil vapor at an elevated
temperature is present, as may occur in an air receiver.

Air is colorless, odorless, tasteless, and compressible and has weight. Air has a great affinity
with water and unless specifically dried, contains considerable quantities of water vapour,
sometimes as much as 1% by weight. Life on earth depends on air for survival and man harness
its forces to do useful work. Table 1.3 gives the physical properties of air
 Table 1.3: Properties of air

Property Value
Molecular weight 28.96 kg/kmol
Density of air at 15 and 1 bar 1.21 kg/m3
Boiling point at 1 bar 191 to -194
Freezing point at 1 bar -212 to -216
Gas constant 286.9 J/kg K

1.4.2 Free air and Standard air

In pneumatics, the existence of the following two conditions of atmospheric air is well accepted

• Free air: Air at the atmospheric condition at the point where the compressor is
located is defined as free air. Free air will vary with atmospheric conditions like
altitude, pressure and temperature.

• Standard air: It is also called normal air. It is defined as the air at sea level
conditions (1.01324 bar as per ISO –R554 and 20 and Relative humidity of 36%).
The condition of normal atmosphere is used as a basis for getting average values for
compressor delivery volumes, efficiencies and operating characteristics.

1.4.3 Atmospheric pressure, Gauge pressure and Absolute pressure

Air has mass and exerts a pressure on the surface of the earth. A barometer consisting of an
inverted tube close at the top will support a column of mercury at exactly 760 mm at sea level
when measured at standard conditions. Pressure above one atmosphere ( ~ 1 bar) are positive,
whereas the pressure below one atmosphere cause a vacuum to be formed. Both positive
pressures and vacuum pressures have useful purposes in pneumatics. Vacuum measurement is
usually given a mm of mercury and then converted into the holding force for such devices such
as suction pads and cylinders with a specified diameter.

Atmospheric pressure: The earth is surrounded by air. Since air has weight it can exert a
pressure on the earth’s surface. The weight of the column of air on one square meter of earth’s
surface is known as atmospheric pressure or reference pressure.
The atmospheric pressure varies slightly from day to day. In pneumatic circuit calculations,
standard atmospheric pressure is taken as 101.325 kPa.(14.7 psia)(760 mm of Hg). The
atmospheric pressure is measured using barometer.

Atmospheric pressure = Density x Acceleration due to gravity x height of barometer column

(usually mercury)

For a mercury we can use ,

Gauge Pressure: In pneumatic application, pressure is measured using pressure gage and
pressure gauges are calibrated to indicate the pressure above that of the Atmospheric pressure.
Gauge pressure refers to pressure indicated by pressure gauge.

Absolute pressure: refers to the true or total pressure. Absolute pressure = Atmospheric
pressure + Gauge pressure. Calculations involving formulae associated with the Gas laws must
be made with absolute pressure. Figure 1.1 shows the difference between the gauge and absolute
pressure. Let’s examine the two pressure levels P1 and P2.

Relative to a prefect vacuum, they are

p1= 0.7 bar ( absolute) ( a pressure less than a atmospheric pressure)

p2= 2 bar ( absolute) ( a pressure greater than a atmospheric pressure)

Relative to the atmosphere, they are

p1= -0.3 bar (Gauge) ( Suction) ( or vacuum)

p2 = 1bar (Gauge)

As can be seen from Figure 1.1, the following rule can be used in pressure conversion
calculations
Absolute pressure = Gauge pressure +Atmospheric pressure

It should be noted that vacuum or suction pressures exits in certain location of fluid power
systems (for example, in the inlet or suction lines of pumps). Therefore, it is important to
understand the meaning of pressures below atmospheric pressure. One way to generate a suction
pressure is to remove some of fluid from a closed vessel initially containing fluid at atmospheric
pressure.

1 bar Gauge pressure

ATOMSPHERIC PRESSURE ZERO GAUGE PRESSURE

-0.3 bar Gauge pressure

2 bar absolute
pressure

1 bar absolute
0.7 bar absolute
pressure
pressure ABSOULTE ZERO PRESSURE
(Complete Vacuum)

Figure 1.1 Difference between absolute and gauge pressure.

1.4.4 Variation of pressure with altitude

According to Barometric law, the atmospheric pressure decreases exponentially with the increase
in altitude. The relation is shown graphically in the Figure 1.2. Variation of pressure with respect
to altitude is linear up to 6000 m and pressure drops about 11 kPa per 1000 m change in altitude.
 Figure 1.2 Pressure variations in atmosphere.

1.5 GAS LAWS

Early experiments were conducted concerning the behavior of air and similar gases. These
experiments were conducted by scientists such as Boyle, Charles and Gay-Lussac. The results of
their experiments indicated that gases behaviors follow the law known as ideal gas laws.

1.5.1 Boyle’s Law

Robert Boyle (1627-1691), an English scientist, was among the first to experiment with the
pressure volume relationship of gas at constant temperature.

Statement: If a given mass of a gas is compressed or expanded at a constant temperature, then

the absolute pressure is inversely proportional to the volume.

Example 1.1: .50 mm diameter piston of the pneumatic cylinder of Figure 1.3 retracts 130 mm
from its present position. ( ( ) ) due to the external load on the
rod. If the part at the blind end of the cylinder is blocked, find the new pressure, assuming
temperature remains constant.
 Retraction

Blocked

Figure 1.3

Given Data:

D= diameter of piston = 50mm =5cm

Stroke= L = 130 mm =13 cm

( )

Solution

( )

Final volume = ( ) ( ( ) )

Since the temperature is constant, we can use Boyle’s Law

Thus, ( ) ( )

Example 1.2: . Four cubic m of nitrogen are under a pressure of 7 bar ( gauge) the nitrogen is
allowed to expand to a volume of 6 cubic m . What is the new gauge pressure ?

Given Data:

( )
Solution

Since the temperature is constant, we can use Boyle’s Law

Thus, ( ) ( )

Example 1.3: . Piston compresses air at atmospheric pressure to 1/7th the volume as illustrated in
the Figure 1.4 Assuming constant temperature, what is the gauge pressure of the resulting air?

Figure 1.4

Solution

Since the temperature is constant, we can use Boyle’s Law

 ( )

( )

1.5.2. Charles law

Boyle’s law assumes conditions of constant temperature. In actual situations this is rarely the
case. Temperature changes continually and affects the volume of a given mass of gas.

Jacques Charles (1746 to 1823),a French physicist, provided much of the foundations for modern
kinetic theory of gases. Through experiments, he found that all gases expand and contract
proportionally to the change in the absolute temperature, providing the pressure remains
constant.

Statement: If a given mass of a gas is heated or cooled at a constant pressure, then the volume is
directly proportional to the absolute temperature.

Example 1. 4: .The cylinder of Figure 1.4 as an initial position where ( )

) as controlled by the load on the rod. The air temperature is 30 . The load on the rod
is held constant to maintain constant air pressure, but the air temperature has increased to 65 .
Find the new volume of air the blank end of the cylinder.

Given Data:

( ) ,

Solution

Since the pressure is constant, From Charles law, we have

Solving we get,
Example 1.5: A sample of H2(g) occupies a volume of 69.37 cm³ at a pressure of exactly 1 atm
when immersed in a mixture of ice and water. When the gas (at the same pressure) is immersed
in boiling benzene, its volume expands to 89.71 cm3. What is the boiling point of benzene?

Given Data:

( ) ,

Solution

Since the pressure is constant, From Charles law, we have

Solving we get, , yields the desired result. (The ice-water mixture must be at
273.15 K, the freezing point of water.)

Example 1.6: A cylinder of gas under a pressure of 125 bar at 70 is left out in the sun in
tropics and heats up to a temperature of 130 . What is the new pressure within the cylinder.

Given Data:

( ) ,

Solution

Since the pressure is constant, From Charles law, we have

Solving we get, ( ) ( )
1.5.3 Gay-Lussac’s Law

A third gas law may be derived as a corollary to Boyle's and Charles's laws. Suppose we double
the thermodynamic temperature of a sample of gas. According to Charles’s law, the volume
should double. Now, how much pressure would be required at the higher temperature to return
the gas to its original volume? According to Boyle’s law, we would have to double the pressure
to halve the volume. Thus, if the volume of gas is to remain the same, doubling the temperature
will require doubling the pressure. This law was first stated by the Frenchman Joseph Gay-
Lussac (1778 to 1850).

Statement: At constant pressure, the absolute pressure of an ideal gas will vary directly with the
absolute temperature.

Example 1.7: .The cylinder of Figure ( same as above figure no) has a locked position (
). ( ) if temperature increases to 70 What is the new
pressure in the blank end.

Given Data:

( )

Solution

Since the volume is constant, by applying Gay –Lussac’s law, we get,

( ) ( )

Solving we get, ( ) ( )
Example 1.8:. A compressed air receiver has a volume of 0.5 m3 is filled with compressed air at
7 bar (gauge) and at a temperature of 40 . The temperature then cools to 20 . What is the final
pressure?

Given data , ( ) ( )

Since the volume is constant we can apply, Gay-Lussac law

Solving we get,

Thus, ( ) ( )

Example 1.9:.

A container is designed to hold a pressure of 2.5 atm. The volume of the container is 20.0 cm 3,
and it is filled with air at room temperature (20°C) and normal atmospheric pressure. Would it be
safe to throw the container into a fire where temperatures of 600°C would be reached?

Given data , ( ) ( )

Since the volume is constant we can apply, Gay-Lussac law

Solving we get,

Thus, ( ) ( )
This concept works in reverse, as well. For instance, if we subject a gas to lower temperatures
than their initial state, the external atmosphere can actually force the container to shrink

1.5.4. General gas equation

For any given mass of gas undergoing changes of pressure, temperature and volume, the general
gas equation can be used. By combining Boyle’s law and Gay-Lussac’s law we get,

Example 1.10: .Gas at 80 bar (gauge) and 50 is contained in the 1290 cylinder of Figure
1.5. A piston compresses the volume to 1000 while the gas is heated to 120 . what is the
final pressure of the cylinder.

Given Data:

( )

Solution

Since the volume is constant

Figure 1.5

( ) ( )

Using General gas law

Solving we get, ( ) ( )

Example 1.11: The empirical formula of benzene is CH. When heated to 100°C in a flask whose
volume was 247.2 ml, a sample of benzene vaporized and drove all air from the flask. When the
benzene was condensed to a liquid, its mass was found to be 0.616 g. The barometric pressure
was 742 mmHg. Calculate (a) the molar mass and (b) the molecular formula of benzene

Solution

Molar mass is mass divided by amount of substance. The latter quantity can be obtained from the
volume, temperature, and pressure of benzene vapor

Part (a)

Using General gas law

Solving we get,

Part (b)

The empirical formula CH would imply a molar mass of (12.0 +1.008) g mol-1 or 13.02 g mol-1,
The experimentally determined molar mass is 6 times larger.

So molecular formula must be C6H6

Example 1.12: .Two cubic meter of a gas at 5 bar and 300 K are compressed to a volume of 1
cubic m and then heated to a temperature of 420 K. what is the new gauge pressure.

Given Data:

( )

Solution

Using General gas law

Solving we get, ( ) ( )

1.6 BASIC COMPONENTS OF PNEUMATIC SYSTEMS

Pneumatic system carries power by employing compressed gas generally air as a fluid for
transmitting the energy from an energy-generating source to an energy – use point to accomplish
useful work. Figure 1.6 shows the simple circuit of a pneumatic system with basic components.

Power Opens when set

Supply pressure is reached
Load (W)

Pressure 1 – Off 2 – Raise 3- Lower

switch 1
Motor 3 2
Air cooler
Storage B
reservoir
Air Filter A

Air compressor
A
Direction
Control A
Air from
Valve
Atmosphere
Air Actuator
Air to Atmosphere

Figure 1.6 Components of Pneumatic System

Functions of components

 Pneumatic actuator converts the fluid power into mechanical power to do useful work
 Compressor is used to compress the fresh air drawn from the atmosphere.
 Storage reservoir is used to store a given volume of compressed air.
 Valves are used to control the direction, flow rate and pressure of compressed air.
 External power supply (Motor) is used to drive the compressor.
 Piping system carries the pressurized air from one location to another.

Air is drawn from the atmosphere through air filter and raised to required pressure by an air
compressor. As the pressure rises, the temperature also rises and hence air cooler is provided to
cool the air with some preliminary treatment to remove the moisture.

Then the treatment pressurized air 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
reached the required level, respectively.

The cylinder movement is controlled by pneumatic valve. one side of the pneumatic valve is
connected to the compressed air and silencers for the exhaust air and the other side of the valve is
connected to port A and Port B of the cylinder.

Position of the valve is as follows

1. Raise: To lift the weight , the compressed air supply is connected to port A and the port B is
connected to the exhaust line, by moving the valve position to the “ Raise”

2. Lower: To bring the weight down, the compressed air line is connected to port B and port A is
connected to exhaust air line , by moving the valve position to the “lower”

3. Off: The weight can be stopped at a particular position by moving the valve to position to
“Off” position. This disconnects the port A and port B from the pressurized line and the retrieval
line, which locks the air in the cylinder.

Advantages of Pneumatic system

o Low inertia effect of pneumatic components due to low density of air.

o Pneumatic Systems are light in weight.
o Operating elements are cheaper and easy to operate
o Power losses are less due to low viscosity of air
o High output to weight ratio
 o Pneumatic systems offers a safe power source in explosive environment
o Leakage is less and does not influence the systems. Moreover, leakage is not harmful

Disadvantages of Pneumatic systems

o Suitable only for low pressure and hence low force applications
o Compressed air actuators are economical up to 50 kN only.
o Generation of the compressed air is expensive compared to electricity
o Exhaust air noise is unpleasant and silence has to be used.
o Rigidity of the system is poor
o Weight to pressure ratio is large
o Less precise. It is not possible to achieve uniform speed due to compressibility of air
o Pneumatic systems is vulnerable to dirt and contamination

1.7 COMPARISON BETWEEN HYDRAULIC AND PNEUMATIC SYSTEM.

Usually hydraulic and pneumatic systems and equipment do not compete. They are so dissimilar
that there are few problems of selection between then which cannot be readily be resolved, all
factors considered, with a clear preponderance in favour of one or the other. But what of the case
where one of the two resources of power is not at hand , and compressed air is used to do
something for which oil might be better adopted, and vice versa. Certainly, availability is one of
the important factors of selection by this may be outweighed by other factors. In numerous
instances, for example, air is preferred to meet certain unalterable conditions. That is, hot spots
where there is an open furnace or other potential ignition hazard or in operations where motion is
required at extremely high speeds. It is often found more efficient to use a combined circuit in
which oil is used in one part and air in another on same machine or process. Comparison
between hydraulics and pneumatics is given in Table 1.4

Table 1.4 Comparison between Hydraulic and Pneumatic systems

Sl. No Hydraulic system Pneumatic system

It employs a pressurized liquid it employs a compressed gas
1
as fluid usually air as a fluid
Oil hydraulics system operates at Pneumatics systems usually
2
pressures upto 700 bar. operate at 5 to 10 bar.
Generally designed for closed Pneumatic systems are usually
3
systems designed as open system
System get slow down of leakage Leakage does not affect the system
4
occurs much more
5 Valve operations are difficult Easy to operate the valves
 6 Heavier in weight Light in weight
Pumps are used to provide Compressors are used to provide
7
pressurized liquids compressed gas
8 System is unsafe to fire hazards System is free from fire hazards
Automatic lubrication is provided Special arrangements for
9
lubrication needed.

1.8 COMPARISON OF DIFFERENT POWER SYSTEMS

There are three basic methods of transmitting power electrical, mechanical, and fluid power.
Most applications actually use a combination of the three methods to obtain the most efficient
overall system. To properly determine which method to use, it is important to know the salient
features of each type. For example, fluid systems can transmit power more economically over
greater distances than can are mechanical types. However, fluid systems are restricted to shorter
distances than are electrical systems.

1.12.1 Electrical Power transmission

Electrical energy in the form of current is transmitted and distributed through wires and cables.
The energy medium is controlled using switches, pushbuttons, relays, contactors, timers, sensors,
pressure switches etc. Final actuator in this system is electric motor which converts electrical
energy into mechanical energy in the form of rotary motion to perform useful work. Electrical
systems are suitable for power transmission over long distances. The limitations of electric
power include magnetic saturation, which may limit the torque capacity of the motor and
material limitation, which may limit the speed and heat dissipation problems. Switching contacts
may arc or corrode. Electric arc is a fire hazard in explosive environments. The response time of
the electro mechanical solenoid is too slow for today’s controllers. The switching time of control
elements is usually greater than 10 milliseconds. Electrical systems need to provide for heat
dissipation as most systems which generate heat by pressure or friction.

1.12.2 Mechanical Power transmission

Mechanical power is transmitted by employing a variety of kinematic mechanisms such as belts,

chains, pulleys, sprockets, gear trains, bar linkages and cams. They are suitable for the
transmission of motion and force over relatively short distances. The disadvantages of
mechanical power transmission include lubrication problems, limited speed and torque control
capabilities, uneven force distribution, and relatively large space requirement

1.12.3 Hydraulic Power transmission

In hydraulic transmission of energy, a pump is used to raise the pressure of oil and energy stored
in oil is transmitted through pipes and hoses to perform useful work. They are suitable for power
transmission over intermediate distances; they can be employed over greater distances than
mechanical types but not as electrical systems

Hydraulic systems are mechanically stiff, and can be designed to give fast operative and move
very heavy loads. They can easily generate linear motion using liner actuators (also called
cylinders). Speed control is easy and precise motion of the actuator is possible.

The disadvantages of hydraulic system include fluid leakage, containments and fire hazards with
flammable hydraulic fluids.

1.12.4 Pneumatic Power transmission

All gases are readily compressible and it is this property which differentiates them most from
liquids as a power transmission medium. In pneumatic transmission of energy, a compressor is
used as the power source to raise the pressure of the air to the required level quite slowly. They
are suitable for power transmission over intermediate distances. Pneumatic systems use simple
equipment has small transmission lines, and do not present a fire hazard.

The disadvantages of pneumatic system include a high fluid compressibility and a small power to
size ratio of components. Pneumatic systems are unsuitable for uniform motion. Operating
pressure of pneumatics is around 6 to 8 bar. And hence are capable of generating only medium
forces. The switching time of control elements is usually greater than 5 milli seconds and the
speed of the control signal is 10 to 50 m/s. Table 1.5 give the comparison of all the systems.

Table 1.5 : Comparison of Electrical, mechanical, pneumatic and hydraulic transmission

systems

Property Electrical/Mechanical Pneumatic Hydraulic

Energy IC engines, electrical energy Electrical energy is I C Engines
is used to drive motors used to drive Electric Motor
compressor and other Air Turbine are used to drive
equipments hydraulic pumps.

Medium . There is no medium, Compressed air/gas in Pressurized liquid in Pipes

Energy is transferred Pipes and hoses and hoses
through Levers, Gears,
Shafts
Energy storage Batteries Reservoir, air tank Accumulators
Regulations Variable frequency drives Pneumatic valves Hydraulic valves

Transmitters Transmitted through Transmitted through Transmitted through hydraulic

mechanical components pneumatic cylinders , cylinders, and hydraulic rotary
like levers, gears, cams, rotary drives and rotary actuators.
screw cts actuators
Distribution Good Limited (say up to Good (say up to 100 m)
system efficiency 1000m)
Operating speed Low Limited (up to 1.5 m/s) Limited (up to 0.5 m/s)
Positioning Precision in terms of few . Precision in terms of Precision in terms of few
accuracy micron can be achieved few mm ( usually 0.1 micron can be achieved
mm) can be achieved
Stability Good stability is possible . Low stability is due Good stability is possible due
using mechanical elements to High compressibility to low compressibility
of air
Forces Mechanical elements break Protected against Protected against overload
down if overloaded. Poor overload with system with high system pressure of
overloading capacity pressure of 6 to 8 bar, 600 bar, very large forces can
forces up to 50 kN can be generated.
be generated.
Cost of energy Lowest Highest Medium
Linear actuators Short stroke length using Is possible using Is possible using hydraulic
mechanical/electrical pneumatic actuators actuators(cylinders), and it
transmission elements (cylinders), it can can produce heavy force
produce medium force.
Rotary actuators AC , DC, Servo motors and Pneumatic rotary Hydraulic motors and vane
steeper motors can be used actuators can be used motors can be used
Controllable force Possible with solenoid and medium force can be High force can be controlled
DC motors, Needs cooling controlled easily
and hence complicated
Work environment Danger because of electric Noise Dangerous, unsightly and fire
shock hazardous because of leakage.
Objective Type Questions

1. When the power requirement is ------- like in forging presses, sheet metal press oil hydraulic
system is preferred
2. Pneumatic systems have --------output to weight ratio, whereas electrical systems have -------
output to weight ratio
3. Positioning accuracy of pneumatic actuator is --------------- compared to hydraulic systems

4. Compressed air actuators are economical up to ----- force only.

5. Low inertia effect of pneumatic components due to ----- density of air.

State True or False

1. Pneumatic systems are used for high pressure and low speed applications

2. Pneumatics is very useful in hazardous environment

3. Compressed air is expensive

4. According to Barometric law, the atmospheric pressure increases exponentially with the
increase in altitude

5. If a given mass of a gas is compressed or expanded at a constant temperature, then the

absolute pressure is directly proportional to the volume
Review Questions

1. Define Pneumatics

2. List the broad rules followed in the selection of a working medium.

3. List the advantages and disadvantages of compressed air.

4. Why air is used as fluid medium in pneumatic systems

5. List seven reasons for considering pneumatics instead of hydraulic system.

6. Name five characteristics of pneumatic systems

7. List twenty applications of pneumatics

8. Differentiate between Free air and standard air

9. Differentiate between Absolute pressure and atmosphere pressure

10. Discuss various pressure ranges used in pneumatic applications

11. State the following perfect gas laws

a) Boyle’s Law b) Charles Law c) Gay-Lussac law d) General gas law

12. Name six basic components used in a pneumatic systems.

13. With a simple sketch, explain the functions and working of basic components required for a
pneumatic system.

14. List five advantages and five disadvantages of pneumatics

15. Differentiate between hydraulics and pneumatics

16. Compare and contrast between hydraulic, pneumatic and electrical power transmission
systems.
Answers

Fill in the Blanks

1. High
2. High/low
3. Low
4. 50 kN
5. Low

State True or False

1. False
2. True
3. True
4. False
5. False
 Lecture 34

PREPARATION OF COMPRESSED AIR.

Learning Objectives

Upon completion of this chapter, Student should be able to

Explain the various stages of air preparation

Describe the working of various compressors
List the advantages and disadvantages of various compressors
Carry out thermodynamic analysis of compressors
Compare various types of compressors
List various ways to control compressor
Understand the selection criteria for compressor
List various hazardous of compressed air.

1.1 AIR PREPARATION

Pneumatic control systems operate on a supply of compressed air, which must be made available
in sufficient quantity and at a pressure to suit the capacity of the system. The operational
reliability and service life of a pneumatic system depend to a large extent on the preparation of
the compressed air. Impurities in the compressed air such as scale, rust and dust as well as the
liquid constituents in the air which deposit as condensate can cause a great deal of damage in
pneumatic systems. These contaminants accelerate wear on sliding surfaces and sealing
elements, adversely affecting the functioning and service life of pneumatic components. As a
result of switching the compressors on and off, pressure fluctuations occur which have an
unfavourable effect on the functioning of the system. In order to eliminate these effects,
compressed air preparation should be given utmost importance. There are four distinct stages of
air preparation they are:

Stage 1 : This consist of air intake system

Stage 2: This stage consist of compressors, with drives controls, inter-cooling, compressor
cooling, waste heat recovery and air inlet filtration

Stage 3: This stage includes Conditioning equipment, consisting of air receivers, after coolers,
separators, traps ( also frequency called drain traps or drains) , filters and air dryers

Stage 4: This stage consist of air distribution subsystems, including main trunk lines, drops to
specific usage, valving, additional filters and traps(drains) , air hoses, possible supplement air
conditioning equipment, connectors, often pressure regulators and lubricator.

Stage 1 : An Intake filter removes larger particles which can damage the air compressor.

a) Location: The intake for a compressor will located either outdoors or indoors, whichever
provides the better air quality. Elevation of the compressor relative to sea level is required to
determine the atmospheric pressure and density of intake air. Air quality is judged by its
temperature, humidity and cleanliness. We must ensure that air intage is free of moisture or
pollution.

b) Intake Temperature: The density of air varies inversely with its temperature : an increase in
delivery of approximately 1 percent is gained for -20 reduction of intake temperature.

c) Intake pipe material: The inside of intake piping must be smooth and not subject to rusting
or oxidation. Rust that flakes off will enter and damage the compressor.. Acceptable intake air
piping materials include plastic, cooper, stainless steel, aluminium or galvanized steel. On
metallic piping, mechanical couplings will be used. Welded joint must be avoided since weld
beads can break free, enter and damage the compressor.

d) Critical pipe length: resonance of intake piping will reciprocating air compressor is
prevented by avoiding certain pipe lengths. These are called critical pipe lengths, and are a
function of the air temperature and the speed of the compressor in revolutions per minute.
Critical pipe lengths must be verified with equipment manufacturers.

e) Intake air filter: The selection of filter type is based on whether air compressor to be used is
lubricated or non lubricated, and on the quality of ambient air.
  Viscous impingement filters have an efficiency of 85 to 90 percent of particle size larger
than 10 microns. This type of filter is acceptable for lubricated reciprocating compressor
operating under normal conditions
 Oil bath filters have an efficiency of 96 to 98 percent of particle sized larger than 10
microns. This type of filter is more expensive, and for the most part no longer
recommended by compressor manufacturers, but may be considered for lubricated
reciprocating compressor operating under heavy duty conditions.

 Dry filters have an efficiency of 99 percent of particles larger than 10 microns. Because
of their high filtration efficiency, these filters are the best selection for rotary and
reciprocating compressors. They must be used for non-lubricated compressors and
whenever air must be kept oil free.

 Two stage dry filters , to provide 99 percent efficiency of particles larger than 0.3 micron,
will be used for centrifugal units

 With all types of filters, a means of monitoring the air pressure drop through the element
must be provided, which indicates element contaminations.

Stage 2: In this stage air is compressed using compressor. This book is not meant to be a
comprehensive analysis of all types of air compression system that can be designed. Instead, it
will concentrate on those most often found in industry and on thermodynamic analysis in those
systems. It will explore positive displacement types in great detail and dynamic compressor in
brief.

Stage 3: In this stage outlet temperature at the compressor is reduced, solid contaminants
usually large than 100 micron are removed, and air is dried to reduce to its humidity. The units
used in the primary stage are after cooler, main line filter and dryer.
Stage 4: In this stage moisture and fine dirt particles are removed. In this stage pressure is
regulated to suit individual machine‟s requirement and introduces the fine mist of oil to the
compressed air to aid lubrication. The units used in secondary air treatment are filter , regulator
and lubricator ( Called FRL or service units)

Figure 1.1 shows all four stages of air preparation. Figure 1.2 illustrates a typical compressed air
system.
Stage 1 Stage 2 Stage 3
Stage 4

Figure 1.1 Four stages of air preparation

Figure 1.2 An Industrial compressed air system.
1.2 AIR COMPRESSORS: HISTORY AND ITS CLASSIFICATION

The first air compressor were human lungs; by blowing on cinders man started his fires. Then
with birth of metallurgy man began to melt metal and high temperatures were needed. A more
powerful compressor was required.

One of the earliest recorded uses of compressed gas (air) dates back to 3rd century B.C. This
early use of compressed air was the “water organ.” The invention of the “water organ” is
commonly credited to Ctesibius of Alexandria. Ctesibius also developed the positive
displacement cylinder and piston to move water. The water organ consisted of a water pump, a
chamber partly filled with air and water, a row of pipes on top (organ pipes) of various diameters
and lengths plus connecting tubing and valves. By pumping water into the water/air chamber the
air becomes compressed. This concept was further improved by Hero of Alexandria (also noted
for describing the principles of expanding steam to convert steam power to shaft power).

The first mechanical compressor, the hand-operated bellows, emerged in 1500 B.C. In the 1850s,
while trying to find a replacement for the water wheel at their family‟s woollen mill, Philander
and Francis Roots devised what has come to be known as the Roots blower. Their design
consisted of a pair of figure-eight impellers rotating in opposite directions. While some
Europeans were simultaneously experimenting with this design, the Roots brothers perfected the
design and put it into large-scale production.

In 1808 John Dumball envisioned a multi-stage axial compressor. Unfortunately his idea
consisted only of moving blades without stationary airfoils to turn the flow into each succeeding
stage. Not until 1872 did Dr. Franz Stolze combine the ideas of John Barber and John Dumball
to develop the first axial compressor driven by an axial turbine. Due to a lack of funds, he did not
build his machine until 1900. Dr. Stolze‟s design consisted of a multi-stage axial flow
compressor, a single combustion chamber, a multistage axial turbine, and a regenerator utilizing
exhaust gases to heat the compressor discharge gas.

A Compressor is a machine that compresses the air or another type of gas from a low inlet
pressure (usually atmospheric pressure) to a higher desired pressure level. Compressor increases
the pressure of the air by reducing its volume. Work required for increasing pressure of air is
available from the prime mover driving the compressor. Generally, electric motor, internal
combustion engine or steam engine, turbine etc. are used as prime movers. Compressors are
similar to fans and blowers but differ in terms of pressure ratios. Fan is said to have pressure
ratio up to 1.1 and blowers have pressure ratio between 1.1 to 4 while compressors have pressure
ratios more than 4.

Compressors can be classified in the following different ways.

(a) Based on principle of operation: Based on the principle of operation compressors can
be classified as.
(i) Positive displacement compressor.
(ii) Non-positive displacement compressors.
In positive displacement compressors the compression is realized by displacement of solid
boundary and preventing fluid by solid boundary from flowing back in the direction of pressure
gradient. Due to solid wall displacement these are capable of providing quite large pressure
ratios. Positive displacement compressors can be further classified based on the type of
mechanism used for compression. These can be
(i) Reciprocating type positive displacement compressors
(ii) Rotary type positive displacement compressors.

Reciprocating compressors generally, employ piston-cylinder arrangement where displacement

of piston in cylinder causes rise in pressure. Reciprocating compressors are capable of giving
large pressure ratios but the mass handling capacity is limited or small. Reciprocating
compressors may also be single acting compressor or double acting compressor. Single acting
compressor has one delivery stroke per revolution while in double acting there are two delivery
strokes per revolution of crank shaft. Rotary compressors employing positive displacement have
a rotary part whose boundary causes positive displacement of fluid and thereby compression.
Rotary compressors of this type are available in the names as given below;
(i) Roots blower
(ii) Vane type compressors
Rotary compressors of above type are capable of running at higher speed and can handle large
mass flow rate than reciprocating compressors of positive displacement type.

Non-positive displacement compressors also called as steady flow compressors use dynamic
action of solid boundary for realizing pressure rise. Here fluid is not contained in definite
volume and subsequent volume reduction does not occur as in case of positive displacement
compressors. Non-positive displacement compressor may be of „axial flow type‟ or „centrifugal
type‟ depending upon type of flow in compressor.

(b) Based on number of stages: Compressors may also be classified on the basis of number of
stages. Generally, the number of stages depends upon the maximum delivery pressure.
Compressors can be single stage or multistage. Normally maximum compression ratio of 5 is
realized in single stage compressors. For compression ratio more than 5 the multistage
compressors are used.

Type values of maximum delivery pressures generally available from different type of
compressor are,
(i) Single stage Compressor, for delivery pressure upto 5 bar.
(ii) Two stage Compressor, for delivery pressure between 5 to 35 bar
(iii) Three stage Compressor, for delivery pressure between 35 to 85 bar.
(iv) Four stage compressor, for delivery pressure more than 85 bar
(c) Based on Capacity of compressors: Compressors can also be classified depending upon the
capacity of Compressor or air delivered per unit time. Typical values of capacity for different
compressors are given as;
(i) Low capacity compressors, having air delivery capacity of 0.15 m3/s or less
(ii) Medium capacity compressors, having air delivery capacity between 0.15 to 5 m3/s.
(iii) High capacity compressors, having air delivery capacity more than 5 m3/s
(d) Based on highest pressure developed: Depending upon the maximum pressure available
from compressor they can be classified as low pressure, medium pressure, high pressure and
super high pressure compressors. Typical values of maximum pressure developed for different
compressors are as under:
(i) Low pressure compressor, having maximum pressure upto 1 bar
(ii) Medium pressure compressor, having maximum pressure from 1 bar to 8 bar
(iii) High pressure compressor, having maximum pressure from 8 to 10 bar
(iv) Super high pressure compressor, having maximum pressure more than 10 bar.
Detailed classification is given in the Figure 1.3. Air compressors are generally positive
displacement units and either of reciprocating piston type or the rotary screw or rotary vane
types. These three types are explained in detail.

Compressors

Positive displacement types Dynamic displacement type

(Turbo compressors)
1. Centrifugal compressor
2. Axial flow compressors

Reciprocating types Rotary type

1.Piston compressors 1. Twin screw compressors

2. Labyrinth compressor 2. Rotary vane compressors
3. Diaphragm compressor 3. Lobe type compressors
4. Liquid ring compressors

Figure 1.3 Classification of Compressors

Piston type of compressors are used commonly in Industries. Therfore only detailed discussion
on piston type of compressor is presented in this chapter.
1.2.1 RECIPROCATING COMPRESSORS

Reciprocating compressors have been the most widely used for industrial plant air systems. The two
major types are single acting and double acting, both of which are available as one or two stage
compressors. The Single acting cylinder performs compression on one side of the piston during one
direction of the power stroke. Two stage compressions reach the final output pressure in two separate
compression cycles, or stages, in series.

The double acting compressor is configured to provide a compression stroke as the piston moves in either
direction. This is accomplished by mounting a cross head on the crank arm which is then connected to a
double acting piston by a piston rod. Distance pieces connect the cylinder to the crankcase. They are
sealed to prevent mixing of crank shaft lubricant with the air, but vented so as to prevent pressure built
up.

1.2.1.1 PISTON COMPRESSORS

Piston type compressors are the oldest and most commonly used compressor in the pneumatic industry
because of its flexibility, high pressure capability, ability to rapidly dissipate heat of compression and oil
free. They are built for either stationary or portable services.

A. SINGLE CYLINDER COMPRESSOR

Piston compressors are available as single or double acting, oil lubricated or oil free with different
number of cylinders in different configurations. With the exception of really small compressors with
vertical cylinders, the V configuration is the most common for small compressors. On double acting, large
compressors the L type with vertical low pressure cylinder and horizontal high pressure cylinder, offer
immense benefits and is why this the most common design. The construction and working of a piston
type reciprocating compressor is very much similar to that of an internal combustion engine.

a) Construction: Piston type compressor consists of cylinder, cylinder head, and piston with piston
rings, inlet and outlet spring loaded valves, connecting rod, crank crankshaft and bearings.

b) Operation

Compression is accomplished by the reciprocating movement of a piston within a cylinder. This motion
alternately fills the cylinder and then compresses the air. A connecting rod transforms the rotary motion
of the crankshaft into the reciprocating motion of piston in the cylinder. Depending on the application, the
rotating crank (or eccentric) is driven at constant speed by a suitable prime mover (usually electric
motor). Schematic diagram of single cylinder compressor is shown in Figure 1.4

Inlet stroke: -suction or inlet stroke begins with piston at top dead centre (a position providing a
minimum or clearance volume). During the downward stroke, piston motion reduces the pressure inside
the cylinder below the atmospheric pressure. The inlet valve then opens against the pressures of its spring
and allows air to flow into the cylinder. The air is drawn into the cylinder until the piston reaches to a
maximum volume position (bottom dead centre).The discharge valve remains closed during this stroke

Outlet stroke: During compression stroke piston moves in the opposite direction (Bottom dead centre
to top dead centre), decreasing the volume of the air. As the piston starts moving upwards, the inlet valve
is closed and pressure starts to increase continuously until the pressure inside the cylinder is above the
pressure of the delivery side which is connected to the receiver. Then the outlet valve opens and air is
delivered during the remaining upward motion of the piston to the receiver.

Inlet Outlet
air air
Cooling
fins

Figure 1.4 Single cylinder compressors

B. ANALYSIS OF SINGLE CYLINDER SINGLE STAGE AIR COMPRESSOR

A typical indicator diagram for reciprocating compressor with three different types of
compression is shown in the Figure 1.5. Clearance volume is neglected.
 Figure 1.5 Types of compression

Constant pressure line 4-1 represents the suction stroke. The air is then compressed adiabatically
(process line 12”,) and is then forced out of the cylinder at constant pressure (process 2”3). Area
12”34 represents the work. If the compression is carried out isothermally, then it follows the
curve 12‟ which has less slope than both isentropic and polytrophic processes. This work done
that is area 12‟34 in isothermal process is considerably less than that due to adiabatic
compression. Thus compressor will have higher efficiency if compression follows isothermal
process. It is not possible in practice as to achieve isothermal process, as the compressor must run
very slowly. In practice compressors run at high speeds which results in polytropic process. The
cold water spray and multi stage compression are used for approximating to isothermal
compression while still running the compressor at high speeds.

C.WORK DONE IN A SINGLE STAGE COMPRESSOR NEGLECTING CLEARANCE.

Figure 1.6 shows the PV diagram of the air in the cylinder of an air compressor. Constant
pressure line ab represents the suction stroke. The air is then compressed adiabatically (process
line bc,) and is then forced out of the cylinder at constant pressure (process cd). Area abcd
represents the work.
 Figure 1.6 PV diagram

There are three types of compression processes possible in compressor they are

Isothermal compression. Compression of air takes place at constant temperature

( )--------- (1.1)

Where

Adiabatic compression. There is no flow of heat energy into or out of the gas during expansion or
compression.

( )----- (1.2)

[( ) ]

Polytrophic compression This process lies between Isothermal and adiabatic. In pneumatics, most
compression/expansions are neither adiabatic (Very fast) nor isothermal (Very slow). It is polytrophic

( )
 [( ) ]

Efficiency of compressor In a reciprocating compressor the work is minimum when compression

follows the isothermal process. The ratio of isothermal work done to the actual work done is called
isothermal efficiency.

D.WORK DONE IN A SINGLE STAGE COMPRESSOR CONSIDERING CLEARANCE.

In practical design of compressors, some clearance is required between the cylinder and piston to
prevent hitting of piston to crown of the cylinder. Figure 1.7 shows a PV diagram of single stage
compressor with clearance.

Figure 1.7 PV diagram with clearance

Thus when the compressed air is delivered during the delivery stroke, some amount of air
corresponding to clearance volume at a pressure will be left over in the cylinder. During the
next suction stroke this air expands back to initial pressure and volume . Thus before the
fresh air enters the cylinder some air corresponding to volume will be already there in the
cylinder. This the volume inhaled during the suction stroke will be which is less the
swept volume

The work done on the air delivered is not affected by the clearance volume as the work required
to compress the clearance volume is theoretically regained during its expansion from .
Thus the work done is given by

( )
[( ) ]

E. Volumetric efficiency

Free air delivery It is the amount of atmospheric air that can be sucked by the compressor at suction or
inlet condition of compressor at one atmospheric pressure, 20 , 100 percent dry air and compressor
motor running at 100 % of the rated value. FAD is an important purchasing parameter and it measures the
capacity of a compressor in terms of air flow it can handle. FAD is used to compare different
compressors. It is important to note that induced mass per cycle must equal the delivered mass per cycle
as per law of conservation of mass, although the induced and delivered volumes will be different.

( )
[ ( ) ]

Where ( )

Subscript “a” refers to free air or ambient conditions and subscript “1” refer to the condition before
compression.

F. Analysis of Air capacity rating of compressors

Air compressors are rated in terms of m3/min of free air, defined as air at actual atmospheric conditions.
Where standard atmospheric condition are 101000 Pa (absolute) and 20
In Industry we still use British system for air rating of compressors. Air compressors are rated in terms of
CFM of free air, defined as air at actual atmospheric conditions. CFM of free air is called SCFM when the
compressor inlet air is at standard atmospheric condition of 17.7 (psia) 1 bar and 68

( )
( ( )
( )
Using general gas law

( )( )

Example 1.1: A compressor delivers 4 m3 of the free air per minute at a pressure of 7 bar gauge.
Assuming that the compression follows the law , determine the theoretical work
done.

Given data

( )

( ) ( )

Solution

( )

( )

( )

( )
Solving we get Work done = 14.98 N.m/minute = 0.2496 N.m/s = 0.25 Watts
=25 kW

Example 1.2: A single stage air compressor running at 80 RPM, compress air from a pressure of 1 bar
and temperature of 15 to a pressure of 5 bar (see Figure 1.8) The clearance volume is 5 % of swept
volume which is 0.42 Assuming that the compression and expansion to follow the law
,determine the power required to drive the compressor

5 bar
p

1bar

Figure 1.8

Given data

( )

( )

Solution

( )
Volumetric efficiency referred to the suction conditions.

[ ( ) ] [ ( ) ]

( ) ( )

( )

( )

C. MULTI STAGE PISTON COMPRESSOR.

As per general gas laws, if the pressure increases temperature also increases. For example : if the exit
pressure of compressor is 5 bar in a single acting compressor, the compressor air temperature can rise to
over 200 and the motor power needed to drive the compressor rises. Therefore single stage
compressors are not used for high pressures. Multistage compressors are used when high pressures are
required, because better cooling between stages can effectively increase the efficiency and reduce the
input power requirements.

Single stage machines compress the air to pressure of about 6 bars and in exceptional cases to 10 bars,
two stage machines normally discharge pressure up to 15 bars. Discharge pressures in the range of 250
bars can be obtained with high pressure reciprocating compressor of three and four stages.
In single stage compressor, entire compression of air takes place in single stroke of the piston. In multi
stage compressor, compression takes in stages. For maximum compressor efficiency, it is desirable to
cool air after one stage using inter- stage cooler. In two stage compressor, initial compression takes place
in the low pressure cylinder. Air from this stage (low pressure cylinder) is passed through the inter cooler
to reduce the temperature. Then the cooled air is compressed in the high pressure cylinder.

Working:

Figure 1.11 shows the two stage (inline type) reciprocating air compressor. When the prime mover
connected to crank shaft rotates, crank rotates and the piston in the first stage reciprocates. It sucks the air
through the suction filter and inlet valve. The air, compressed to a certain degree passes from the left
cylinder to right cylinder through the intermediate cooler. The compression ratio in the first stage is
determined by the degree of cooling required.

Intercooler
Outlet
Inlet

Second stage
(high pressure)

First stage
(low pressure)
Valve

Driven by same
motor

Figure 1.11 Multi stage piston air compressor with intercooler

Figure 1.12 shows various parts of three stage (V type) reciprocating air compressor with receiver (air
tank). The pressure switch is connected to the electric motor. When the desired pressure in the air tank is
reached it stops the motor and hence the compressor. The safety valve opens when the pressure in air tank
exceeds the set safe pressure.

Second Stage
Cylinder
Intake Filter
Intake Filter

First Stage Third Stage

Cylinder Cylinder
Guard
Safety valve
Electric motor
base
Air Outlet
valve

Pressure Guage Pressure Switch

Air Tank

Water Outlet
valve
Stand

Figure 1.12 Various parts of three stage compressor

The drain valve drains the condensate produced at the condenser and the receiver. Cylinders and
intercoolers are either air cooled (with fins) or water cooled (with water jackets in the cylinder). Air
cooled compressor are used for low pressure applications and water cooled compressors are used for high
pressure applications.

Range: Used of pressures up to 4-30 bar and low delivery volumes (< 10000 m3/h). For pressures
exceeding 30 bar multi stage compressors are required. The multi stage compressors are available with
pressure up to 250-350 bar.

Advantages of piston type compressor

1. Piston type compressors are available in wide range of capacity and pressure
2. Very high air pressure (250 bar) and air volume flow rate is possible with multi-staging.
 3. Better mechanical balancing is possible by multistage compressor by proper cylinder
arrangement.
4. High overall efficiency compared to other compressor

Disadvantages of piston type compressor

1. Reciprocating piston compressors generate inertia forces that shake the machine. Therefore , a
rigid frame, fixed to solid foundation is often required
2. Reciprocating piston machines deliver a pulsating flow of air. Properly sized pulsation damping
chambers or receiver tanks are required.
3. They are suited for small volumes of air at high pressures.

B. ANALYSIS OF MULTI SINGLE STAGE AIR COMPRESSOR

The volumetric efficiency of a reciprocating compressor is a function of a clearance ratio, the

pressure ratio and index of expansion. As the pressure ratio is increased, the volumetric efficiency
of a compressor having a fixed clearance decreases and finally a stage may be reached when the
volumetric efficiency may be zero as see from Figure 1.13

Figure 1.13 Multi stage compressions

It is seen that for a given intake pressure, the volume of air taken into the compressor cylinder decreases
with increase in delivery pressure. At some delivery pressure the compression line intersects the line of
clearance volume ( point 3”) indicating that there is no delivery of air.

At this stage compression and re-expansion of same air takes place over and over again without any
delivery of compressed air. As a result it is seen that the maximum pressure ratio attainable with a
reciprocating compressor is limited by the clearance volume of the compressor. As clearance volume
cannot be reduced beyond a certain limit the only alternative is to resort to multi-staging.

Work done in a two stage air compressor

Figure 1.14 Multi stage compressions

Schematic diagram of Two stage air compressor with intercooler is shown in Figure 1.14 The air is first
compressed in the LP cylinder to intermediate pressure p2. It is then passed through an intercooler where
air is cooled at constant pressure before it is compressed in the HP cylinder. If the air is cooled back to
initial temperature, then the inter cooling is said to be perfect.

The PV diagram for two stage compressor is shown in the Figure 1.15
 Figure 1.15 PV Diagram for two stage air compressor

Work done per cycle in LP cylinder

[( ) ]

Work done per cycle in HP cylinder

[( ) ]

If the intercooling is perfect then

[( ) ( ) ]

Condition for minimum power in two stage compressor with perfect intercooling is given by

For a N stage compressor with perfect intercooling , compressing air from

[( ) ]
Example 1.8: A two stage air compressor takes in air at a rate of Intake pressure is
1 bar and 16 . Final pressure is 7 bar the intermediate pressure is ideal with perfect intercooling.
(See Figure 1.16) The compression takes place according to law The
compressor runs at 600 RPM. Neglecting clearance determine a)The intermediate pressure b)
Volume of each cylinder c) cylinder power

Figure 1.16
Given data

Solution

Part a

For perfect intercooling

√ √

Part b
 ⁄

( ) ( )

Volume of HP cylinder =

Part c

Minimum power required

[( ) ]

[( ) ]

1.3 COMPARISON OF DIFFERENT COMPRESSOR

Flow rate, efficiency and the pressure rise within the compressor are the three most parameters used in
defining the performance of a compressor and in its selection. Positive displacement compressors are
generally suitable for small flow rates while centrifugal and axial compressors are more commonly
applied for medium and large flow applications respectively. The advantages of centrifugal compressors
are that they are reliable, compact and robust , have better resistance to foreign object damage and are less
affected by performance degradation due to fouling. Positive displacement machines have wider
operating domain when compared to other compressor types. Centrifugal compressors are most
commonly applied in petrochemical or process industries in the flow rates ranging from 30 m3/min to
3000 m3/min. Typical comparison is given in the Table 1.2

Table 1.2 comparison of different compressors

Item Reciprocating Rotary vane Rotary screw Centrifugal
Efficiency at full load High Medium-high High High
Efficiency at part load High due to staging Poor: below Poor: below 60% Poor: below 60%
60% of full of full load of full load
load
Efficiency at no High (10%-25%) Medium High Poor High-medium
load(power as % of (30%-40%) (255-60%) (20%-30%)
full load)
Noise level Noisy Quiet Quiet it enclosed Quiet
Size Large Compact Compact Compact
Oil carry over Moderate Low-medium Low Low
Vibration High Less Less Less
Maintenance Many wearing parts Few wearing Very few wearing Sensitive to dust in
parts parts air
Capacity Low-high Low-medium Low-high Medium-high
Pressure Medium- very high Low-medium Medium-high Medium-high

1.4 CONTROL OF COMPRESSOR

1.4.1. Compressor drives

Alternating current (AC) electric motor are by far the most common drivers used for industrial plant air
compression. Large electric motors are available in two basic types: Induction motor and synchronous
motor. Nearly all industrial motors are three phase ac powered. Both the induction and synchronous
motors rely upon the production of a revolving magnetic field (RMF) in the field winding.

Induction motors are used in 90 percent of industrial applications and are designed in two types: squirrel
cage and wire wound rotor. The primary differences are the starting torque, current and amount of slip.
Squirrel cage motors are commonly used.

Normally, gas turbine, diesel or Otto cycle engine power is not economic for stationary, continuous
service compressor installation, except in special circumstances.
1.4.2 Control of compressors

There is a growing variety of control systems available for compressed air installations. These most often
concern electric driver controls and compressor controls. Compressor controls are described below.

Plant air compressor systems normally are designed to operate at a fixed pressure and to deliver a variable
volume. The Compressor is sized to deliver the maximum capacity and a control system is employed to
reduce the compressor output to match the system demand.

Compressor may incorporate several different control systems to match the compressor volume and
pressure to the demand. All of these controls monitor the system pressure as instantaneous indicator of the
status of the match between the compressor output and system demand. Usually the control system will
recognize and be designed to deliver air pressures between a design minimum and a design maximum
damped system pressure. The damping is required to eliminate the effect of pressure pulses produced by
most compressors. Pressure differentials of 0.1 to 0.5 bar between the minimum and maximum are
specified in practice, the actual differential being a function of user requirements. This differential is
known as the control range.

Energy consumption represents 80 percent of total cost for compressed air. therefore we must choose
regulations systems carefully. There are two main groups of such regulation systems

1. Continuous capacity regulation: This method involves continuous control of drive motor or valve
according to variation in pressure as shown in Figure 1.34. The result is normally a small pressure
variations (0.1 to 0.5 bar), depending on the regulation system‟s amplification and its speed.

0.75
Consumption

0.5

0.2

Figure 1.34: Continuous capacity regulation

1. Load/unload regulation: This method involves the acceptance of variation in pressure between two
values as shown in Figure 1.35. This takes place by completely stopping the flow at the higher pressure
(off loading) and resume the flow rate (loading) when the pressure has dropped to the lowest valve.
Pressure variation depend on the permitted number of load/unload cycles per time unit, but normally lie
within the range of 0.3 to 1 bar.

7.6

7.4
Pressure in bar

7.2

7.0

50 100 150 200 250 300 350 400 450 500

50
Time in seconds

Figure 1.35: Load/unload regulation

1.4.2.1 Regulation principles for displacement compressors

a) Start/Stop and Load/unload controls

The simplest control mechanism turns the compressor on or off in response to system pressure. Schematic
diagram of start /stop and unload/load control is shown in Figure 1.36 When the present system high
pressure is reached, the compressed is turned off. When the system pressure falls to the preset minimum,
the compressor is turned on. Compressors less than 5-10 kW are often controlled by completely stopping
the electric motor when the pressure reaches an upper limit valve and restarting it when the pressure
passes the lower limit value. The method demands a large system volume or large pressure difference
between the start and stop pressure, to minimise the load on the electric motor. This is an effective
regulation method under the condition that the number of starts per time unit is kept low.
 Pressure
To electrical supply
switch

Electric motor

Compressor

Figure 1.36: Load/unload regulation

b) Pressure Relief valve

The method used Pressure relief valve (PRV). This valve releases excess pressure into the atmosphere
when the preset pressure is reached. The preset pressure can be set by adjusting the spring tension of the
spring. Now a day, servo valve is used. The pressure can be easily controlled and the valve can also act
as off-loading when starting a compressor under pressure. Schematic diagram of control of compressor
using PRV is shown in Figure 1.37
To atmosphere

Compressor

Figure 1.37: Regulation using pressure relief valve

c)By pass regulation

In this method, pressure relieved air is cooled and returned to the compressor intake. This method is often
used on process compressors where gas is unsuitable or too valuable to release into the atmosphere.
Schematic diagram of control of compressor using bypass regulation is shown in Figure 1.38

Heat Exchanger

Compressor

Figure 1.38: Bypass regulation

d) Throttling the intake

Throttling is an easy method to reduce the flow. Schematic diagram of control of compressor using
throttle intake regulation is shown in Figure 1.39. By increasing the pressure ratio across the compressor,
depending on the induced under pressure in the intake, the method is however limited to a small
regulation range. Liquid injected compressors, which have a large permitted pressure ratio, can however
be regulated down to 10 % of the maximum capacity. This method makes relatively high energy
demands, due to the high pressure ratio.
 Throttle valve
Compressor

Figure 1.39: Throttle intake control regulation

e) Pressure relief with throttled intake.

Schematic diagram of control of compressor using throttle intake and pressure regulation is shown in
Figure 1.40.The most common regulation method currently used that unites a maximum regulation
range(0-100%) with low energy consumption, only 15-20% of full load power with an off-loaded
compressor (zero flow). The intake valve is closed, but with a small opening remaining, at the same time
as a blow off valve opens and relieves the outgoing air from the compressor

The compressor element then works with a vacuum in the intake and low counter pressure. It is important
that the pressure relief is carried out quickly and that is relieved volume is small to avoid unnecessary
losses during the transition from loaded to unloaded. The system demands a system volume (air receiver)
, the size of which is determined by the acceptable difference between loading and off loading pressure
and by the permitted number of unloading cycles per hour.

Pressure
switch
To atmosphere
Throttle valve

Electric motor

Compressor

Figure 1.40: Throttle intake and pressure relief control regulation

f) Speed regulation

A combustion engine, turbine or frequency controlled electric motor controls the compressor‟s speed and
thereby the flow. It is an efficient method to attain an equal outgoing pressure and low energy
consumption.

Pressure
switch

Speed regulator

Electric motor

Compressor

Figure 1.41: Speed regulation

Schematic diagram of speed control of compressor is shown in Figure 1.41.The regulation range varies
with the type of compressor, but is greatest for liquid injected compressor. Frequently speed regulations
and pressure relief are combined, with or without a throttled intake at low degrees of loading.

g) Variable discharge port

The capacity of screw compressors can be regulated by moving the position of the discharge port in the
housing, in the screw‟s lengthways direction, towards the intake. However, the method demands high
power consumption with sub-loads and is relative unusual.

g) Suction valve unloading

Piston compressors can be effectively relieved by mechanically forcing the intake valves to the open
position. Air is then pumped out and in under the position of the piston, with minimal energy losses as
result often lower than 10% of the loaded shaft power. On double acting compressors there is generally
multi-stage off loading, where one cylinder at a time is balance to better adapt the capacity to demand. An
odd method used on process compressor is to allow the valve to be open during a part of the piston stroke
and thereby receive a continuous flow control.
Objective Type Questions

1. -----------------types of reciprocating compressors are most commonly used compressors.

1. Compare to positive displacement type compressor, dynamic compressor are much -------in
size and produce much ----- vibration.
3. If the air compressor has a duty of -------, and the air compressor will be running for 10
minutes, then it should run for a combined maximum of 6 minutes ON and 4 minutes OFF.
4. It is not possible in practice as to achieve isothermal process, as the compressor must run very
--------. In practice compressors run at high speeds which results in -------- process

5. In ------------------- control regulation, pressure relieved air is cooled and returned to the compressor
intake

6.In a single acting reciprocating compressor, the suction, compression and delivery of air takes
place in __________ of the piston

7. Intercooling in mutli stage compressor is done to -----------the work of compression

8. The ratio of work done per cycle to the stroke volume of the compressor is known as ---------

9. The volume of air delivered by the compressor is called ………………..

10. In a centrifugal compressor, an increase in speed at a given pressure ratio causes increase in
flow and --------- in efficiency

11.A large clearance Volume in a reciprocating compressor results in ----------------volume flow

rate

12.When the temperature of air leaving the intercooler, in a two stage compression with
intercooler, is __________ the original atmospheric air temperature, then the intercooling is
known as perfect or complete intercooling
State True or False

1. A dynamic compressors works with a constant pressure.

2. Positive displacement compressor is selected for larger volume of gas and higher pressure
ratios. Dynamic compressor is selected for lower volume of gas fluid and smaller pressure ratios.

3. Compressor will have higher efficiency if compression follows isothermal process.

4. Running on the same operating speed, the two lobes blower can deliver large air flow and
volume than conventional three lobes type

5. Continuous capacity regulation is the most common type of control and regulations used in
Compressor.

6. The total heat rejected in a reciprocating air compressor is equal to the sum of the heat rejected
during polytropic compression per kg of air and heat rejected in the intercooler per kg of air

7. In a four stage compressor, if the pressure at the first and third stage are 1 bar and 16 bar, then
the delivery pressure at the fourth stage will be 64 bar

8. The volumetric efficiency for reciprocating air compressors is about 60 to 70 %

9. The minimum work required for a two stage reciprocating air compressor is double the work
required for each stage

10. The clearance volume in the compressor is kept minimum because it effects on volumetric
efficiency.

11. Work done by a two-stage reciprocating air compressor per cycle is equal to the workdone in
LP. cylinder and H.P. cylinder

12. The actual volume of air delivered by a compressor, When reduced to the normal temperature
and pressure conditions is called compressor capacity

13.An axial compressor gives optimum performance at high speeds and large volume flows
Review Questions

1. Explain the different stages of preparation of compressed air.

2. Explain the effect of type of compression in reciprocating air compressor

3. Define isothermal efficiency and derive an expression for the same

4 Explain the effect of clearance volume in single cylinder single stage compressor

5. Define volumetric efficiency of an air compressor and derive an expression for the same

6. Explain the effect of increasing delivery pressure on the volume of air delivered

7. Derive an expression for the intermediate pressure which gives minimum power in a two stage
compressor with perfect inter cooling

8. What is the advantage of multi stage compressor

9. Differentiate between positive and dynamic displacement compressor

10. Name three types of positive displacement compressor

11. Explain the working principle of screw compressor. What are its advantages and
disadvantages?

12. What is a diaphragm compressor? List its types and advantages

13. Explain on/off regulation of compressor with a neat sketch

14. Explain pressure relief and by pass regulation of compressor control with neat sketches.

15. List all factors to be considered in selection of a compressor for a give application.
Answers

Fill in the Blanks

1. Piston
2. smaller/less
3. 60/40
4. Slowly/polytropic
5. Bypass
6. Two strokes
7. minimise
8. Mean effective pressure.
9. Compressor capacity
10. decrease
11. reduced
12. equal to

State True or False

1. True
2. False
3. True
4. False
5. False
6. True
7. True
8. False.
9. True
10. True
11. True
12 False
13. True
 Lecture 35

COOLING AND DRYING OF COMPRESSED AIR.

Learning Objectives

Upon completion of this chapter, Student should be able to

Explain the importance of secondary treatment of compressed air

List the various functions of an after cooler
Describe the functions of air and water coolers
Explain the theory of air dryers
Describe various types of air dryers used in pneumatic Industry
List the various functions of Air receiver
Differentiate Air receiver and Air accumulators
Size the Air receiver and compressor

1.1 IMPORTANCE OF SECONDARY TREATMENT

Compressed air is an essential power source that is widely used throughout industry. This safe, powerful
and reliable utility is the most important part of production process. However, compressed air will contain
water, dirt, wear particles and even degraded lubricating oil which all mix together to form an unwanted
condensate. This condensate often acidic, rapidly wears tools and pneumatic machinery, blocks valves
and orifices causing high maintenance and costly air leaks. It also corrodes piping systems and can bring
production process to an extremely expensive standstill.

The quality of air required throughout a typical compressed air system can vary. It is highly
recommended that the compressed air is treated prior to entry into the distribution system as well as at
each usage point or application. This approach to system design provides the most cost effective solution
to system purification as it not only removes the contamination already in the distribution system, it
ensures that only the most critical areas receive air treated to the highest level. In many instances the
compressed air system will be supplying air to more than one application and although the purification
equipment specified in the compressor room would remain unchanged, the point of use protection will
vary depending upon the air quality requirements of each application. In many cases this action alone is
not enough, as modern production systems and processes demand an even higher level of air quality.
Where required, “point of use” filtration, refrigeration or desiccant air dryers can provide the correct air
quality, without the need for drying the complete compressed air installation, which can be both costly
and totally unnecessary.

The three desirable qualities of compressed air are:

a) Compressed air must be cleaned: Dirty or contaminated air may cause seals to wear. Dirt can
wedge into clearance between moving parts or block air passages which may cause faulty
operation or component failure
b) Compressed air must be cooled: Heat is undesirable due to the fact that if this hot air is passed
directly into the pipes, they would elongate die to the heat. Contraction would occur when
compressor is shut down. This recurring process would cause the joint to leak and reduce
efficiently. Therefore, flexibility must be built in. Instead of discharging air from the compressor
outlet directly into the air receiver for storage, the air is passed through the after cooler
c) Compressed air must be dried: water in compressed air lines can wash away lubricant from
pneumatic tool parts causing rapid wear increased air consumption, and increased maintenance
costs. Moisture can freeze at the exhaust of tools and interfere with their efficient operation. In
applications like paint spraying, air agitation of liquid etc. moisture can cause rejections and scrap
work. There are several ways to remove moisture from compressed air before it can damage.
Generally, the least expensive is after cooling.

1.2 AFTER COOLER

Air compression process may be designed to either to be adiabatic or to involve heat transfer, depending
on the purpose for which the gas is compressed. If the compressed air is to be used promptly in engine,
adiabatic compression may be required. In much application, however, air is stored in a tank for use as
needed. The air in the tank loses heat to the surroundings and reaches room temperature when finally
used. In this case the overall effect of compression and storage is to increase pressure of gas without
change of temperature. In can be shown that if the gas is cooled during compression, instead of after the
process, the work required will be less than for adiabatic compression. A further advantage of cooling is
the reduction of volume and the consequent reduction of pipe line losses. For this reason, since cooling
during compression is not very effective, after coolers are often used to cool the gas leaving the
compressor.
The compressed air discharged from an air compressor is hot. Compressed air at these temperatures
contains large quantities of water in vapour form. After coolers are heat exchangers for cooling the
discharge from a air compressor. They use either air or water and are an effective means of removing
moisture from compressed air.

After coolers control the amount of water vapour in a compressed air system by condensing the water
vapour into liquid form. In a distribution or process manufacturing system, liquid water can cause
significant damage to the equipment that uses compressed air. An after cooler is necessary to ensure the
proper functionality of pneumatic or air handling devices that are a part of process manufacturing systems

About 75 % of the moisture can be removed using after cooler. A moisture separator installed at the
discharge of the after cooler removes most of the liquid moisture and solids from the compressed air.
Utilizing centrifugal force, moisture and solids collect at the bottom of the moisture separator. An
automatic drain should be used to remove the moisture and solids

1.2.1 Functions of compressed air after coolers

 Cool air discharged from air compressors via the heat exchanger
 Reduce risk of fire (Hot compressed air pipes can be a source of ignition)
 Reduce compressed air moisture level
 Increase system capacity
 Protect downstream equipment from excessive heat

Coolers are usually sized with a CTD (Cold Temperature Difference) of 2.7°C, 5.5°C, 8.3°C, or
11°C. This means that the compressed air temperature at the outlet of the after cooler will be equal to
the cooling medium temperature plus the CTD when sized at the specified inlet air temperature and
flow.

1.2.2 Types of after coolers.

There are two basic types of air after coolers:

1. Air-cooled
2. Water-cooled.
Compressor manufacturers may include after coolers within the compressor package. In general these
compressors are referred to as integral after coolers. A stand-alone or freestanding after cooler is a
separate unit installed downstream of the compressor.

1.2.2.1 Air-Cooled After cooler

Air-Cooled After coolers provide economical cooling by using ambient air to cool the hot compressed air
from an air compressor. They cool the hot compressed air leaving the compressor at a temperature of
approximately 100°C to 150°c to the desired inlet temperature of an air dryer which is approximately
35°c to 50°c. As the compressed air cools, about 75% of the water vapour present condenses into liquid
water which should be immediately removed from the system with a separator. Air-Cooled After coolers
can be sized to cool the hot compressed air to within -15°c to -5°F of the ambient air temperature. They
are available in capacities from 500 LPM to100000LPM

1.2.2.2 Water-Cooled Pipe Line after cooler

The most common style for compressed air service is a Shell and Tube Heat Exchanger. The pipe line
after cooler consists of a shell with a bundle of tubes fitted inside. Typically the compressed air flows
through the tubes in one direction as water flows on the shell side in the opposite direction. Heat from the
compressed air is transferred to the water. Water vapor forms as the compressed air cools. The moisture is
removed by the moisture separator and drain valve. The tube bundles can be fixed or removable. Fixed
tube bundles cost less but are more difficult to maintain than bundles that can be removed for cleaning or
service.

The disadvantages of a water-cooled after cooler include high water usage and difficult heat recovery.
Advantages to using a water-cooled after cooler include better heat transfer and no required electricity

1.3 DRYING OF COMPRESSED AIR

Function: is to lower the dew point of the compressed air by removing the moisture from it. For simple
applications, to remove excess humidity, we need simple after cooler, an air receiver, and a filter with
condensate traps. However, to get high quality compressed air additional means of dehydration must be
provided using dryer.

1.3.1 TYPES OF AIR DRYERS

Generally four basic types of air dryers are used in Industries.

1. Absorption type dryer

2. Adsorption type dryer
3. Refrigeration dryer
4. Membrane dryer

1.3.1.1 Absorption type dryer

Absorption drying is a purely chemical process. The moisture in the compressed air forms a compound
with drying agent like phosphoric pentaoxide in the tank. This causes the drying agent to break down. It is
then discharged in the form of a fluid at the base of the tank. Schematic diagram of absorption dryer is
shown in Figure 1.1

Oil vapour and oil particles are also separated in the absorption dryer. Large quantities of oil have an
effect on the efficiency of the dryer. Therefore it is advisable to include a fine filter in front of the dryer.

Dry air outlet

Flux

Condensate

Moist air inlet

Condensate drain

Figure 1.1 Absorption dryer

Advantages of Absorption dryer

1. Simple to install
2. Low mechanical wear because there is no moving parts
3. No external energy requirement
Disadvantages of Absorption dryer

1 Maintenance cost is high

2. Low efficiency

3. Consumable cost is high

1.3.1.2 Adsorption type dryer

Adsorption is a physical process of moisture removal on the porous surface of certain granular materials.
Gaseous molecules are attracted to certain solid surfaces by van der walls forces and this causes the
adsorption. The degree of attraction or adsorption depends on properties of gaseous molecules and
desiccant. Most commonly used desiccants re activated alumina, molecular sieves and silica gel.

Figure 1.2 shows the various parts of adsorption dryer. Wet incoming compressed air after passing
through a pre-filter is directed to the adsorption chamber containing the desiccant. Water vapour in the
compressed air is absorbed by the desiccant. Thereafter dry air is allowed to pass to the application
through the after filter.

Adsorption dryers usually have two desiccant filled chambers with interconnecting piping and switching
valves. The valves permit removal of the collected moisture from one chamber while the other chamber is
used to purify the compressed air. The twin tower design facilitates simultaneous compressed air drying
and saturated desiccant regeneration for non-stop production. A contaminated desiccant bed can be
regenerated by either elevating its temperature or by decreasing its pressure and purging.

The capacity of the desiccant bed is limited owing to abrasion and contamination of the adsorption
medium by oil and other substances. Under normal conditions, it is required to replace the drying agent
once in 2 to 3 years.
 Figure 1.2 Adsorption type dryer

1.3.1.3 Refrigerated dryer

The layout of a typical refrigerated air dryer is shown in Figure 1.3 It is composed of a heat exchanger
(stage1) and a refrigerating unit (Stage2) to reduce the temperature of the compressed air. The incoming
warm and humid air is first passed through the air –to-air heat exchanger, and then through the
refrigerating unit to reduce the temperature of the compressed to as low as +2 . This drying method is
based on the principle that if the compressed air is cooled to a temperature below the dew point,
condensation talks place and water is precipitated. Almost all the water and oil particles get condensed,
and collected in the water traps provided at appropriate points. The cooled compressed air is then filtered
to remove from it the suspended solid particles and most of the oil mist. The pressure dew point of 2 is
possible with this type, which is sufficient enough for the smooth operation of the most of the industrial
and process applications.
 Air -air heat exchanger
Dry air outlet

Moist air inlet

Separator

Cooling agent

Separator
Refrigeration plant

Stage 1 Stage 2

Figure 1.3 Refrigerated dryer

In most cases, the type of dryer needed is determined by the pressure dew point required in the systems.
Table 1.1 gives the summary of advantages and disadvantages of the dryers.

Table 1.1 Comparison of three types of dryer

Type Advantages Disadvantages

Absorption Pressure dew point + 16 Inlet temperature must not exceed 30
Low capital cost Drying agents are consumables and
therefore must be regularly replenished.
Highly corrosive chemical are used.
They are not environmental friendly
Refrigeration + 3 pressure dew point Output dew point will vary with
Input temperature can be as high as 16 approach temperature at the inlet and
cleanliness of heat exchanger
Adsorption Achievable pressure dew point of -40 High capital cost
 High operating cost
Use of micro filters adds cost to prevent
the residue from chemicals.

1.3.1.4 Membrane dryer

Membrane dryers are yet another type of dryer to remove moisture from compressed air. It consists of
three stages.

Stage 1: Contains a filter which removes the water and contaminants down to 5 micron.

Stage 2: High efficiency coalescing filter removes oil and sub micron particles down to 0.01 micron

Stage 3: membrane module removes the remaining moisture in the vapour form

In this of dryer, pre-cleaned compressed air is passed through a bundle of hollow fibres in the membrane
module. The hollow fibres constitute a membrane layer specially designed to attract the water vapour
inside. This water vapour diffuses through the very thin selective layer until it reaches the outside of the
membrane due to partial pressure difference between inside and outside of the membrane. The permeated
water vapour is then swept away by a small amount of dry air fed back along the length of the membrane
fibre through a purging valve.

Advantages of Membrane dryer

1. Membrane dryers typically maintain a pressure dew point of 0

2. Membrane dryers are simple and compact
3. Dryers run almost noiseless
4. There is no need for regeneration because membranes never gets saturated
5. They do not require electric supply
6. Low operating cost

3.3.2 Theory of drying

Air taken from the atmosphere contains moisture which in normal circumstances is precipitated
as condensate within the system through which it passes, namely in the compressor after cooler,
the air receiver, collecting points in the piping and the filter of the service unit ahead of the air
consumers.

Compressed air will always contain as much water as it is capable of absorbing at the lowest
temperature assumed by the air on its passage from the compressor to the consumption point.
Typical values of water vapour saturation capacity of an air at selected atmospheric temperatures
is given in Table 1.2

Table 1.2 Water vapour saturation capacity of air at selected atmospheric temperatures

Temperature -10 0 5 10 15 20 30 50 70 90

Water 2.1 4.9 7 9.5 13 17 30 83 198 424

vapour, g/

For example, at 20 one cubic meter of compressed air will still contain 17 grams of moisture.
Existing in the form of water vapour, this moisture is not separated in the filter of the service unit
either; rather it is entrained by the air into all the downstream control and operating components.
Due to the centrifugal action taking place in the filter and increased flow velocity resulting there
from, the air stream is cooled a certain amount relative to the ambient temperature, which does
cause a small portion of condensate to be separated in the filter.

Since the control and operating elements of the pneumatic systems will normally be at ambient
temperature, no further condensate will be precipitated at these points. Therefore, the remaining
moisture passes out with the external air released to the atmosphere. As observed above, the low
residual moisture content of the air will hardly constitute a potential hazard to standard
pneumatic control and operating components.

In the case of specialised applications and used of compressed air, however, as in spray painting,
intricate low-pressure control systems, the chemical and pharmaceutical industries, food
industry, pneumatic instruments and pneumatic conveying, the situation is different. Everywhere
that the compressed air comes into direct contact with the process medium in such instances,
simple conditioning of the air by the means described usually will not be sufficient. It is then
necessary to provide additional means of dehydrating and filtering the compressed air.

1.3.2.1 Humidity and relative humidity

Water vapour is constantly evaporating from lakes, rivers and seas and is absorbed by the
atmosphere and carried across vase distances by winds, finally being deposited in the form of
rain, mist, etc. Atmospheric air therefore, is nature’s way of transmitting large quantity of water
vapour all over the earth.

Relative humidity(RH): it is ratio of amount of water present in a given quantity of air, to the
maximum possible amount which it can contain under the same conditions of pressure and
temperature and ratio is usually expressed as percentage. The amount of moisture condensing out
of compressed air is a function of the relative humidity of the intake air and temperature.

h
h
h

In other words, relative humidity is the amount of water vapour present in a given volume of air,
whereas the humidity at saturation is the total amount of water vapour which that the same
volume of air can absorb at the given temperature. Table 1.3 gives the mass of water in kg per
100 m3 of free saturated air. Table 1.4 gives the amount of condensate in g/m3 of air at various
temperature and Relative humidity

Table 1.3 Mass of water in kg per 100 m3 of free saturated air.

Temperature Gauge pressure (bar)

0 2 4 6 8
0 0.48 0.17 0.10 0.07 .05
20 1.73 0.576 0.346 0.247 0.192
40 5.10 1.7 1.02 .728 .567
60 12.95 4.32 2.59 1.85 1.44
 80 29.04 9.68 5.81 4.15 3.23
100 56.00 19.33 11.76 8.40 6.53
120 0.00 36.73 22.04 15.74 12.24
140 0.00 0 37.74 29.96 20.97

Mass of water in in kg per 100 m3 of free saturated air

Table 1.4 Amount of condensate in g/m3 of air at various temperature and RH

Temp Percentage relative humidity (RH)

10 20 30 40 50 60 70 80 90 100
-12 0.179 0.354 0.533 0.709 0.888 1.066 1.2503 1.421 1.600 1.780
0 0.483 0.965 1.451 1.933 2.426 2.906 3.387 3.867 4.348 4.830
10 0.934 1.865 2.790 3.730 4.670 5.606 6.520 7.460 8.400 9.337
15 1.313 2.617 3.816 5.063 6.386 7.795 9.029 10.158 11.631 17.957
21 1.826 3.661 5.469 7.300 9.131 11.946 12.793 14.600 16.431 18.698
27 2.494 4.980 7.516 10.069 12.521 15.012 17.582 20.024 22.757 25.634
32 3.307 6.614 10.061 13.548 16.835 20.276 23.486 27.0044 30.451 33.721
35 3.936 7.872 11.808 15.744 19.681 23.617 27.554 31.489 35.426 39.248
37.8 4.531 9.039 13.571 18.102 22.611 27.141 31.673 36.489 39.900 45.248
43.3 6.018 12.037 18.056 24.075 30.094 36.112 42.131 48.150 54.160 60.371
49 7.895 15.790 23.686 31.580 39.476 47.370 55.267 63.166 78.910 78.928
55 10.161 20.322 30.583 40.650 50.805 61.200 71.127 81.3 91.504 101.656

The condensate, as the precipitated water in the compressed air line is termed, causes the
damage if it is not removed properly. Corrosion in pipes and tubes, corrosion in control and
working elements and corrosion in machine parts. If the condensate gets into the pneumatic
equipment, proper functioning may be prevented. Solid particles such as dust, rust, and scale can
also have an adverse effect on the function of the various items of pneumatic equipment.

Oil residues from the compressor can produce together with the compressed air a mixture of oil
mist and air (gas mixture) which can cause explosions at higher temperatures (above 353k)
Problem 1.1 : A compressor delivers 400 m3 of free air per hour at a pressure of 6 bar gauge and
a temperature of 40 . Atmospheric air at compressor intake has a relative humidity of 80 % and
a temperature of 20 . Determine the amount of water that can be extracted from the compressor
plant per hour.

Solution: Refer to Table 1.3

At 20 and zero bar gauge pressure, 100 m3 of free saturated air contains 1.73 kg of water.
From the definition of RH

Amount of water actually present in air = 1.384 kg

Since 400 m3is delivered, water content of air entering the compressor = 1.384 =5.536 kg

From the Table 1.3, corresponding to 40 , and 6 bar compressor output pressure, amount of
3
water per 100 m of free saturated air is given by 0.728

Since 400 m3is delivered, water content of air leaving the compressor = 0.728

=2.912 kg

Therefore the amount of water extracted from the compressor plant per hour is

5.536-2.912 = 2.62 kg

1.3.2.2 Dew point temperature

The temperature at which air is fully saturated with moisture (that is 100 % humidity) is the dew
point. Simply put, dew point is the temperature where condensation begins. Cooling below dew
point will cause condensation of the water vapour. Lower the dew point, the less moisture the air
is able to absorb or hold. For example 1 m3 of air has 17 grams of water at 20 and at -10
water vapour it is 2.1 grams. The capacity of holding water in air is a function of volume and
temperature it does not depend on pressure. But still it is necessary to consider the working
pressure of the systems when comparing different facility for the dehydration of air. This brings
in the term pressure dew point.

a) Pressure dew point: Temperature representing the dew point at the respective operating
pressure of the dryer is known as pressure dew point. The air is a compressible gas and the dew
point temperature changes with the pressure. More precisely it is not the pressure but volume that
matters. When the gas is pressurized, the volume is reduced and the air has less capacity to hold
moisture. We can say with the increasing pressure and reduced volume, the dew point
temperature also increases. In drying air by refrigeration, pressure dew point defines the lowest
air temperature attainable in the dryer at the operating pressure of the system.

b) Atmospheric dew point:

As discussed above, Compression and expansion of air affects its dew point. Generally
speaking, compression increases dew point, and expansion (i.e. de-compression) lowers dew
point. For example, consider compressed air leaving a dryer at 15 bar with a pressure dew point
of -40 ºC @ 15bar. If the pressure is eventually reduced to 7.5bar, the pressure dew point will
fall to -45 ºC @ 7.5 psig. If the air is further expanded to 5 bar, the pressure dew point becomes
-60º C @ 0.4 bar. For this reason, the phrase pressure dew point (PDP) is commonly used. This
term usually refers to the dew point of the compressed air at full line pressure. Conversely the
phrase atmospheric dew point refers to what the dew point would be if fully depressurized to
atmospheric conditions. Figure 1.4 shows the relationship between atmospheric dew point versus
pressure dew point for various pressures ranging from 0 MPa to 1.5 MPa
 Figure 1.4 Atmospheric dew point versus Pressure dew point

Problem 1.2 : Find the atmospheric dew point where pressure is 0.7 MPa and pressure due point
is 5

Solution

Refer to Figure 1.4, Corresponding to 0.7 MPa and pressure dew point of 5 we get
atmospheric dew point as -20
 0.7
MPa

Pressure dew
point ( 5 )

Atmospheric dew point ( -20 )

Figure 1.5

Problem 1.3 : Find the amount of condensate per shift in a plant, if air is compressed to 6 bar
(gauge) receiver pressure. Assume the initial condition of air at sea level at 21 and 60 %
Relative humidity (RH). Assume 35 temperature of compressed air in the receiver. Flow rate
of the compressor is given as 20

Solution:

Refer to Table 1.4

Given that the initial condition of air at sea level at 21 and 60 % Relative humidity (RH).

1 of air has 11.946 grams of the water vapour

Compression ratio reveals how many of ambient air is to be used to produce 1 of

compressed air at that pressure.

It means 7 of free air is required. From the Table 1.4 each of air contains 60 % RH and
21 , 11.946 grams of moisture.
Hence the amount of water in 6.9 is

7 11.946 = 83.622 grams of water

Let us assume 35 temperature of compressed air in the receiver.

From the table, 1 of air at 35 and 100 % RH amount of water is 39.248 grams.

Therefore, amount of water condensed and separated

= 83.622-39.248 =43.374 grams

Therefore, there will be of water for each of ambient air

Flow rate of the compressor is given as 20

Amount of water for 20 = 6.2 20 = 124 grams in one minute

Amount of water for one hour = 124 60 = 7440 grams

Amount of water in 8 hours shift = 7440 8 = 59520 grams 60 kg.

Problem 1.4 : Find the amount of condensate in one hour if 22 kW compressor operates under
the following condition a) Air at 60% relative humidity and 30 ambient temperature is
pressurised to 7 kg/cm2(7 bar). It is then cooled to 25 . Compressor output is 3 Nm3/min at 7
kg/cm2(7 bar)

Solution

Refer the nomogram given in the Figure 1.6, locate point 1 which corresponds to inlet
temperature of the compressor and erect a perpendicular line to meet 60%RH line. And then
draw the horizontal line to cut 7 bar pressure line. We get pressure dew point temperature as
60 .( )Since the air is cooled to 25 erect a vertical line to cut 7 bar pressure
line. ( ) From the nomogram water liquid collected is 20.7-3.2 = 17.5 g/Nm3
Which amounts to 17.5x3x60=3150 grams per hour. More than 3 litres of water is produced each
hour.

Figure 1.6: Pressure dew point nomogram.

Problem 1.5 : Using nomogram, Find the amount of water vapour saturation capacity of an air
at 20 and compare with Table 1.2
 Figure 1.7: Dew point chart (saturation chart)

For nomogram, at 20 one cubic meter of compressed air will still contain 16 grams of
moisture. It closely matches with typical values of water vapour saturation capacity of an air at
20 given in Table 1.2
1.4 STORAGE OF COMPRESSED AIR

1.4.1 AIR RECEIVER

Receivers perform several functions in compressed air systems. Firstly, they provide a larger system
capacity, which increases the cycle time of compressor control systems. This makes less difficult the
elimination of unstable and overcorrecting control cycles.

The receiver also dampens pulsations from reciprocating compressors, acts as a reservoir to prevent
excessively temporary pressure drop during sudden short-term demand, and can be used to smooth air
flow through dryers, separators and other air conditioning equipment. Because the air entering the
receiver is reduced in velocity and cooled, some of the moisture may condensate and fall to the bottom of
the receiver where it can be removed by a valve or preferably, a trap. Such a receiver can reduce further
the amount of moisture which must be removed by a subsequent drying stage. The receiver always
equipped with a pressure relief valve.

From compressor To system

Safety valve

Removable access
cover (Manhole) Pressure Temperature

Temperature and pressure

signal to electrical control

Drain cock

Figure 1.8 Components of Air receiver

Figure 1.8 shows essential features of a receiver. They are usually of cylindrical construction fabricated
out of steel. Receiver is basically a pressure vessel and attracts the safety of testing requirement as per
factory act. A safety valve is necessary to release the excess pressure of air stored. A pressure gauge and
temperature gauges are provided and usually coupled with pressure switches to control on-off of the
compressor and for remote alarms.

A drain cock allows removal of condensed water. Access via a manhole allows cleaning. Obviously,
removal of manhole cover is hazardous with a pressurized receiver and safety routines must be defined
and followed to prevent accidents.

Installation of accumulator within a pneumatic system will depend on the specific air consumers and will
only be necessary when large volume of air are consumed in short periods, that is intermittent peak load.

Figure 1.9 shows diagram of compressed air installation with air receiver and accumulator.

Slope 1-2 %
Accumulator
Air Receiver

Compressor

Condensate trap

Figure 1.9 Diagram of compressed air distribution system with branch line with accumulator

1.4.2 Analysis sizing of Air Receivers

The receiver size in cubic feet normally should be atleast 12 seconds of compressor capacity in small
units, to not less than 8 seconds of compressor capacity for larger units. Empirical rule suggest that the
receiver volume should be 1/10 of FAD per minute to 1/6 FAD per minute for small compressor.
Sometimes small compressors are mounted upon a receiver and the receivers serve as a basic mounting
frame for the assembly of the compressors and their accessories. Under these and some other
circumstances, the only pressure relief valve frequently located upon the receiver. When this mounting
procedure is employed, care must be taken to assure that no other valve is between the compressor and
the receiver, and that support members or frames are not welded into the receiver tank seam welds.

1.4.2.1 Empirical relations to size the compressor

The sizing of air receivers requires taking into account parameters such as system pressure and flow rate
requirements, compressor output capability, and the type of duty of operations. Basically a receiver is an
air reservoir. The receiver must be capable of handing transient demand.
Case 1 : No air is supplied to the receiver during the time interval in which air is being
drawn off
In such cases we can find the capacity of receiver as

[ ]
[ ]

Case 2 : Air is supplied to the receiver during the time interval in which air is being drawn
off
Then, The air receiver size can be determined by using the following empirical equation
[ ]
[ ]
( )
( )
( )
( )
( )
( )

Case 3 : Compressor with offloading/loading regulation The following relation applies when
dimensioning the receiver’s volume. Note that this relation only applies for compressors with off
loading/loading regulation
 [ ]

( )
( )
( )
( )
(
( )

1.4.2.2 Requirement on Air receiver according to Factory act 1973 section 39

Air receiver are classified as pressure vessels and become subject to periodical inspection and test under
the factory acts. Every owner of an air receiver must be acquainted with the requirement of factory act
relating to receiver, and a summary of these rules is given below-

 Every air receiver and its fittings shall be of sound construction

 Each air receiver under pressure shall be protected by a suitable safety valve adjusted to prevent
the pressure exceeding the maximum working pressure
 Safety valve should be constructed so as to permit the air to escape without increasing the
pressure beyond 10 percent above the blow off pressure with the compressor running at full
capacity
 It must be fitted with an accurate pressure gauge
 I t must be fitted with a suitable appliances for draining the receiver
 It must be provided with a manhole , hand hole or other means to allow thorough cleaning of the
interior
 Where there is more than one receiver in the factory bear a distinguishing mark which shall
easily be visible
 Every receiver shall be thoroughly cleaned and examined at least once every twenty four months
by a competent authority.
 All welded receivers must be hydraulically tested twice the working pressure
 Each receiver must be permanently marked with the following
 a) Maker’s identification number
b) Date of test
c) Specification number
d) Hydraulic test pressure
e) Maximum working pressure

1.4.2.3 Analysis of power requirement to drive compressor

Another important design consideration is to determine the power required to drive an air compressor to
meet system pressure and flow rate requirements. The following empirical relationship can be used to find
the theoretical power requirement.

(( ) )

( )
( )
( )
To find the actual power, the theoretical power is divided by the overall compressor efficiency.

(( ) )

Problem 1.4 : Air is used at a rate of 1 from a receiver at 40 and 1000 kPa (gauge). If the
atmosphere pressure is 101 kPa (abs) and the atmospheric temperature is 20 . How many of
free air (standard ) must the compressor provide?

Solution

( ) ( )

( )
Using General gas law

Solving we get

Problem 1.5 : a. Calculate the required size of the receiver that must supply air to pneumatic system
consuming for 10 minutes between 828 kPa and 690 kPa before the compressor resumes
operation b. what size is required if the compressor is running and delivering at

Solution:
The air receiver size can be determined by using the following equation
[ ]
[ ]
Part a
( )
( )

( )

( )

( )
( )

[ ]
[ ]
Solving we get
Part b
The required size of the compressor when the compressor is running and delivering air at
[ ]
[ ]
Solving we get
Objective Type Questions

1. About ------ of the moisture can be removed using after cooler

2. Adsorption is a --------- process of moisture removal on the porous surface of certain granular
materials.
3. Absorption drying is a purely ------- process. The moisture in the compressed air forms a compound
with drying agent like phosphoric pentaoxide in the tank
4. -------------- is to lower the dew point of the compressed air by removing the moisture from it
5. Temperature representing the dew point at the respective operating pressure of the dryer is
known as ---------- dew point.

State True or False

1. In adsorption process gaseous molecules are attracted to certain solid surfaces by van der walls forces

2.. High Pressure dew point values indicate small amounts of water vapour in the compressed air.
3. It is important to remember that atmospheric dew point can be compared with PDP when comparing
different dryers.

4. Installation of accumulator within a pneumatic system will depend on the specific air consumers and
will only be necessary for intermittent peak load.

5. Membrane dryers do not require electric supply

Review Questions

1. State the adverse effects of moisture content compressed air

2. What is the function of an after cooler?

3. What are the different methods of drying compressed air

4. Explain the working of absorption dryer with a neat sketch

5. Explain the working of adsorption dryer with a neat sketch

6. Explain the working of regenerative dryer with a neat sketch

7. Why two drying chambers are used in adsorption dryer

8. Explain the functional and constructional features of a refrigerated dryer

9. List the advantages and disadvantages of absorption dryer

10. List the advantages and disadvantages of membrane dryer

11. List the advantages and disadvantages of refrigeration dryer

12. List five functions of Air receiver

13. Why must receiver tank be drained periodically?

14. Name three fittings used on all air receiver

15. What are the important maintenance activities to be carried out on air receiver

16. What are thumb rules we follow in selecting air receiver

Answers

Fill in the Blanks

1. 70-85%
2. physical
3.chemical
4. After cooler
5. Pressure

State True or False

1. True
2. False
3. False
4. True
5. True
 Lecture 36

CONDITIONING AND DISTRIBUTION OF COMPRESSED AIR.

Learning Objectives

Upon completion of this chapter, Student should be able to

Explain the importance of fluid conditioners

List the major functions of filter and selection criteria
List application of the seven qualities of air as per ISO
Describe the function of various types of air regulators
List the function of FRL unit
Explain the various compressed air net work system
List the factors to be considered in selection of components for pneumatic network
Size the pipe diameter, pressure drop for a given pneumatic network

1.1 FLUID CONDITIONERS

Operating instructions issued for pneumatic components almost always contain a note
recommending the installation of an air filter, pressure regulator and lubricator upstream of the
component. This is to ensure that only air which has been suitably conditioned will reach the
consumer.

Air filter, pressure regulator and lubricator are now built as packaged combination known as
service units. Other than the impurities that might be entrained with the intake air and delivered
by the compressor air might pick up contaminants such as dust, scale or rust particles in the
distribution main leading to the take-off point. Provided that air main has been properly installed,
the major part of these impurities will collect in the condensate drain tanks. Minute particles
remain suspended in the air stream however and would damage the working parts of pneumatic
components by their abrasive action were they are removed beforehand. Furthermore the air flow
in the main pulsated, due, for one thing, to the compressor running intermittently as controlled by
pressure in air receiver. The consumer, on the other hand, need to work with a uniform air
pressure. Finally, lubrication is required for the moving parts of the pneumatic equipment.

The atmospheric air that is compressed in the compressor is obviously not clean because the
atmospheric air contains many contaminants line dirt , smoke water vapour etc. this
contaminated air lead to excessive wear and failure of pneumatic components. Therefore fluid
conditioners are used to supply clean dry and contamination free compressed air.

The purpose of the fluid conditioners is to make the compressed air more acceptable and suitable
fluid medium for the pneumatic system as well as the operating personal. The following five
fluid conditioners are used in pneumatic systems

1. Air Filters

2. Air Regulators

3. Air Lubricator

4.1.1 AIR FILTERS

The purpose of the air filter is to clean the compressed air of all impurities and any condensate it
contains.

a) Function of air filters

 To remove all foreign matter and allow dry and clean air flow without restriction to
regulator and then to the lubricator
 To condensate and remove water from the air
 To arrest fine particles and all solid contaminants from air

Filters are available in wide range starting from a fine mesh wire cloth (which strains heavy
foreign particles) to elements made of synthetic material (which removes very small particles)

Usually in line filter elements can remove contaminants in the 5-50 micron range.
b) Source of contamination.

Contaminants in a compressed air system can generally be attributed to the following:

 The quality of air being drawn into the compressor: Air compressors draw in a large
volume of air from the surrounding atmosphere containing large numbers of airborne
contaminants.
 The type and operation of the air compressor: The air compressor itself can also add
contamination, from wear particles to coolants and lubricants.
 Compressed air storage devices and distribution systems: The air receiver and system piping
are designed to store and distribute the compressed air. As a consequence, they will also store
the large amounts of contaminants drawn into the system.

Additionally, piping and air receivers will also cool the moist compressed air forming condensate
which causes damage and corrosion.

c) Types of contamination in a compressed air system

 Atmospheric dirt: Atmospheric air in an industrial environment typically contains 140

million per m3 of dirt particles. 80% of these particles are less than 2 microns in size and are
too small to be captured by the compressor intake filter, therefore passing directly into the
compressed air system
 Water vapour, condensed water and water aerosols: Atmospheric air contains water vapour
(water in a gaseous form). The ability of compressed air to hold water vapour is dependent
upon it's temperature. The higher the temperature, the more water vapour that can be held by
the air. During compression, the air temperature is increased significantly, which allows it to
easily retain the incoming moisture. After the compression stage, air is normally cooled to a
usable temperature. This reduces the airs ability to retain water vapour, resulting in a
proportion of the water vapour being condensed into liquid water which is removed by a
condensate drain fitted to the compressor after-cooler. The air leaving the after-cooler is now
100% saturated with water vapour and any further cooling of the air will result in more water
vapour condensing into liquid water. Condensation occurs at various stages throughout the
 system as the air is cooled further by the air receiver, piping and the expansion of valves,
cylinders, tools and machinery. The condensed water and water aerosols cause corrosion to
the storage and distribution system, damage production equipment and the end product. It
also reduces production efficiency and increases maintenance costs. Water in any form must
be removed to enable the system to run correctly and efficiently.
 Rust and pipe scale: Rust and pipe scale can be found in air receivers and the piping of “wet
systems” (systems without adequate purification equipment) or systems which were operated
“wet” prior to purification being installed. Over time, this contamination breaks away to
cause damage or blockage in production which can also contaminate final product and
processes.
 Micro-organisms: Bacteria and viruses will also be drawn into the compressed air system
through the compressor intake and warm, moist air provides an ideal environment for the
growth of micro-organisms. If only a few micro-organisms were to enter a clean
environment, a sterile process or production system, enormous damage could be caused that
not only diminishes product quality, but may even render a product entirely unfit for use and
subject to recall.
 Liquid oil and oil aerosols: Most air compressors use oil in the compression stage for
sealing, lubrication and cooling. During operation, lubricating oil is carried over into the
compressed air system as liquid oil and aerosols. This oil mixes with water vapour in the air
and is often very acidic, causing damage to the compressed air storage and distribution
system, production equipment and final product.
 Oil vapour: In addition to dirt and water vapour, atmospheric air also contains oil in the
form of unburned hydrocarbons. The unburned hydrocarbons drawn into the compressor
intake as well as vaporized oil from the compression stage of a lubricated compressor will
carry over into a compressed air system where it can cool and condense, causing the same
contamination issues as liquid oil.
d) Factor affecting selection of filters

While selecting the filters, the following factors should be taken into account.

 Size of particles to be filtered from the system

 Capacity of the filter
 Accessibility and maintainability
 Life of the filter
 Ability to drain the condensate

e) Construction

The construction of typical cartridge type filter along with graphical symbols is shown in Figure
1.1. It consists of filter cartridge, Deflector, bowl, water drain valve. Filter bowl is usually made
of plastic and transparent. For pressure more than 10 bar, bowl may be made of brass.

Figure 1.1 Construction of a Air filter.

f) Operation

Air enters the inlet port of the air filter through angled louvers. This causes the air to spin as it
enters the bowl. The centrifugal action of the rotating air causes the larger pieces of dirt and
water particles to be thrown against the inner wall of the filter bowl. These contaminants then
flow down into the bottom of the filter bowl.

A baffle prevents turbulent air from splashing water on to the filter element. The air, which has
been pre-cleaned in this way, then passes through the filter element, where the fine dirt particles
are filtered out. The size of the dirt particles which can be filtered out depends on mesh size of
filter element (usually 5-50 microns). The compressed air then exits through the outer port.

The pressure difference between inlet and outlet will indicate the degree to which the filter
element is clogged. Commercially available filters have many additional features like automatic
drain facility, coalescing type filter element, service life indicator etc.

g) Seven Quality levels of air required in production systems.

Figure 1.2 illustrates different levels of purity for various applications. Air from a compressor
passes through an after cooler with an auto drain to remove condensate. As the air cools further
in the air receiver more condensate is removed by an auto drain, installed on the bottom.
Additional drains may be fitted to all low points on the pipeline. The system divides into three
main parts:- Branches (1 and 2) provide air direct from the air receiver. Branches (3 – 6) use air
conditioned by a refrigerated type of dryer. Branch 7 incorporates an additional dryer of the
adsorption type. Standard filters in sub branches 1 and 2, equipped with auto drains remove
condensate; sub-branch 2 being higher purity because of the micro filter. Sub branches 3 – 5, use
refrigerated dry air, thus, branch 3 requires no auto drain, branch 4 needs no pre filtering and
branch 5 gives an improved level of air purity using a micro filter and sub micro filter, the
moisture having been removed by a refrigerated type of air dryer. Sub branch 6 incorporates an
odour removal filter. An adsorption type dryer eliminates all risk of condensation at low
temperatures in sub branch 7. Typical applications are listed in Table 1.1
 Figure 1.2 Schematic Definition of 7 Degrees of Filtration

Table 1.1 Definition and typical applications of the seven qualities of air.
No. Removal of Application Typical examples
1 Dust particles > 5 micron Where some solid Workshop air for clamping
Liquid oil to 99% impurities humidify and blowing and simple
Saturated humidity to 96% oil can be accepted pneumatic drives
2 Dust particles > 0.3 micron Where removal of dust General industrial equipment,
Oil mist to 99.9% and oil dominates, but a pneumatic controls and
Saturated humidity to 99% certain amount of drives, seamless metallic
condensation can be joints, air tools and air
risked motors
3 Humidity to atmosphere dew Where removal of Similar to (1) as the air is dry
point of -17 humidity is imperative additional spray painting
 Dew point but traces of fine dust
Saturated humidity to 99% and oil are acceptable
4 Dust particles > 0.3 micron Where no humidity, fine Process control, measuring
Oil mist to 99.9% dust and oil vapour are equipment , high quality
Humidity up to an atmospheric acceptable spray painting, cooling of
dew point of -17 foundry and injection
moulding dies
5 Dust particles > 0.3 micron Where pure air , Pneumatic precision
Oil mist to 99.9999% practically free from any measuring devices,
Humidity up to an atmospheric impurity is required electrostatic spray painting,
dew point of -17 cleaning and drying of
electronic assemblies
6 As in (5) with odour removal Where absolutely pure Pharmacy , food industry for
air, as under (5) but packaging , air transport,
odour free brewing and breathing air
7 All impurities as in (6) but with Where risk of Drying electronic
atmospheric dew point of greater condensation during components, storage of
than -30 expansion and low pharmaceuticals, marine
temperature must be measuring equipment, air
avoided, transport of powder.

h) Main Line Filter

A large capacity filter should be installed after the air receiver to remove contamination, oil
vapours from the compressor and water from the air. This filter must have a minimum pressure
drop and the capability to remove oil vapour from the compressor in order to avoid
emulsification with condensation in the line. It has no deflector, which requires a certain
minimum pressure drop to function properly A built-in or an attached auto drain will ensure a
regular discharge of accumulated water.
The filter is generally a quick change cartridge type. Figure 1.3 shows schematic diagram of
Main line filter.

Figure 1.3 Typical main line filter

1.1.2 AIR REGULATOR

a) Function: The function of the air pressure regulator is to maintain working pressure virtually
constant regardless of fluctuations of the line pressure and air consumption. When the pressure
is too low, it results in poor efficiencies and when the pressure is too high, energy is wasted and
equipment’s performance decay faster.

In pneumatic system, pressure fluctuations occur due to variation in supply pressure or load
pressure. It is therefore essential to regulate the pressure to match the requirement of load
regardless of variation in supply pressure or load pressure.
b) Where to regulate

Generally pressure is regulated in pneumatic system at two places.

 At the receiver tank

 In the load circuits

Pressure regulation at the receiver tank is required as a safety measure for the system. In the load
circuits, pressure regulator is used to regulate the pressure for downstream components such as
valves and actuators.

c) Types of Pressure regulator

There are two types of Pressure regulators

i) Diaphragm type regulator

ii) Piston type regulator

Diaphragm type regulator is commonly used in Industrial pneumatic system. There are two
types of diaphragm type regulator

i) Non- reliving or non-venting type.

ii) Relieving or venting type

Relieving or venting type is commonly used and is explained below.

1.1.2.1 Relieving or Venting Type Pressure regulator

A Relieving type pressure regulator is shown in Figure 1.4, Outlet pressure is sensed by a
diaphragm preloaded with a adjustable pressure setting spring. The compressed air , which flows
through a controlled cross section at the valve seat, acts on the other side of the diaphragm. The
diaphragm has large surface area exposed to secondary (outlet) pressure and is quite sensitive to
its fluctuations. The movement of diaphragm regulates the pressure.
 Figure 1.4 venting type pressure regulator

If the outlet pressure is low: whenever the more compressed air is consumed on secondary side
or load side, then load pressure reduces. Therefore less force acts on diaphragm. The opposing
higher spring force pushes the diaphragm in such a way as to move the valve disc more and
permitting more air to flow to secondary side and thus increasing the pressure again.

If the outlet pressure is high: whenever the less compressed air is consumed on secondary side
or load side, then load pressure increases. Therefore more force acts on diaphragm. The opposing
higher spring force pulls down the diaphragm in such a way as to move the valve disc less and
permitting air to flow to vent hole and thus decreasing the pressure again

1.1.2.2 Non-Relieving or Non-Venting Type Pressure regulator

In this case compressed air cannot escape to the atmosphere in the event of high backpressure
acting on the diaphragm, as there is no exit path provided in the diaphragm for the trapped air.
Figure 1.5 shows the non –relieving venting type pressure regulator.
 Figure 1.5 Non-venting type pressure regulators

1.1.3 AIR LUBRICATOR

Function: The function of air lubricator is to add a controlled amount of oil with air to ensure
proper lubrication of internal moving parts of pneumatic components. Lubricants are used to

 To reduce the wear of the moving parts

 Reduce the frictional losses
 Protect the equipment form corrosion

The lubricator adds the lubricating oil in the form of fine mist to reduce the friction and wear of
moving parts of pneumatic components such as valves, packing used in air actuators

Excessive lubrication is undesirable. Excessive lubrication may results in

 malfunctioning of components,
 seizing and sticking of components after prolonged downtime
 environmental pollution

Operation: The operation is similar to the principle of the carburettor. Schematic diagram is
shown in Figure 1.6. As air enters the lubricator its velocity is increased by a venture ring. The
pressure at the venture ring will be lower than the atmospheric pressure and the pressure on the
oil is atmospheric. Due to this pressure difference between the upper chamber and lower
chamber, oil will be drawn up in a riser tube. Oil droplets mix with the incoming air and form a
fine mist. The needle valve is used adjust the pressure differential between across the oil jet and
hence the oil flow rate. The air – oil mixture is forced to swirl as it leaves the central cylinder so
that large particles of oil is goes back to bowl and only the mist goes to outlet.

Figure 1.6 Air lubricator

The lubricator starts to operate only when there is sufficient flow of air. If too little air is drawn
off, the flow velocity at the nozzle is not sufficient to produce an adequate vacuum and hence to
draw oil out of the vessel. Only thin mineral oil may be used in pneumatic system lubricator.
Viscosity ratings are normally 10-50 Centistokes or SAE 10 . Table 1.2 give the normally used
oil. The list is purely alphabetic and not in order of preference.
 Table 1.2 Typical oils used in air lubricator

Suitable oil grades/Trade name Viscosity at 20

ARAL OEL TU 500 23.6 cSt
Avia Avilub RSL 3 34 cSt
BP Energol HL 40 27 cSt
ESSO SPINESSO 34, Nutto H5, H10 23 cSt
Mobil Vac HLP 9, Velocite oil no 6 25.3 cSt
Shell TELLUS OEL 15, OL 10 22 cSt
TEXACO Rando oil AAA 25 cSt
VALVOLINE RITZOL R-60 26 cSt
Vedol Andarin 38 20.5 cSt
Aral , Vitamol, GF10, DE10, CM5, CM10 21 cSt

1.1.4 Filter Regulator Lubricator Unit (FRL Unit) /Service Unit

Compressor
Clean, dehydrated, Clean, dehydrated,
compressed air regulated, l ubricated
Motor compressed air for
Clean, dehydrated, regulated at desired
pressure for spray cylinders, valves, tools,
compressed air (97%) motors, etc
Pressure vessel with pressure variations guns, food packing etc
with stored
compressed air

Emulsion made of Polluted compressed

Lubricating oil &condensate air, oil, water &
solid matter

Filter Regulator Lubricator

Figure 1.7 Installation of FRL unit

In most pneumatic systems, the compressed air is first filtered and then regulated to the specific
pressure and made to pass through a lubricator for lubricating the oil. Thus usually a filter,
regulator and lubricator are placed in the inlet line to each air circuit. They may be installed as
separate units, but more often they are used in the form of a combined unit. Figure 1.6 shows the
schematic arrangement of installation of Filter, Regulator and Lubricator unit .

The combination of filter, regulator and lubricator is called FRL unit or service unit. Figure 1.7
(a) gives the three dimensional view of FRL unit. Figure 1.7(b) gives detailed symbol of FRL
unit. Figure 1.7(c) gives simplified symbol of FRL unit.

Figure 1.7 a) Three dimensional view of FRL unit b) detained symbol c) simplified symbol of FRL

1.2 AIR DISTRIBUTION SYSTEM

The main objective of air distribution system is to provide a distribution channel for compressed
air without any leak and keep the pressure drop within permissible limits. The air distribution
system consists of conductors and fittings which interconnect various components of a
pneumatic system. Figure 1.8 shows a typical air distribution system. It consists of compressor,
water cooled after cooler, Air receiver, dryer and ring main system. The air main takes the shape
of a ring. Air from main header is drawn by sub headers. Sub headers may have its own
accumulators.
 Sub Header

Bend
Compressor
outlet valve

Header
Water cooler
Reducer
Drop line

Riser Quick connector

Compressor
T-pipe

Bend
Discharge pipe

Air Receiver
Shut-off valve
Dryer
Drain valve

Figure 1.8 : Typical Air distribution system ( Ring type)

The air distribution should take into account the following parameters

1. Choice of fluid conductor

2. Flow resistance
3. Correct sizing of pipes
4. Correct sizing of fittings.
5. Pipe layout
Objective Type Questions

1. Air filter, pressure regulator and lubricator are now built as packaged combination known as
FRL unit or ---------- units.
2. The pressure difference between inlet and outlet will indicate the degree to which the air filter
element is ----------

3. In pneumatic system, pressure fluctuations occur due to variation in ---------- pressure or load
pressure.
4. The main objective of air distribution system is to provide a distribution channel for
compressed air without any leak and keep the --------- within permissible limits.
5. Equivalent pipe length is length of straight pipe of the same -------- size giving the same
pressure drop

State True or False

1. Usually in line filter elements can remove contaminants in the 0.005-0.0005 micron range

2. A manifold type pneumatic network has the advantages that, being in the form of closed
circuit, the velocity of the air the main will be reduced and the pressure drop will be less.
3. Two Quality levels of air required in pneumatic production and distribution systems.

4. In Non-Venting Type Pressure regulator case compressed air cannot escape to the atmosphere
in the event of high backpressure acting on the diaphragm, as there is no exit path provided in
the diaphragm for the trapped air.

5. A single, large air compressor is more efficient and less costly than the several smaller units if
the demand is fairly constant
Review Questions

1. State the importance of fluid conditioning

2. Describe the function of air filter.

3. With help of neat sketch explain the working of air filter.

4. State clearly nine qualities of filtered air requirement and its application

5. Describe the function of an air pressure regulator

6. With the help of neat sketch explain the working of air regulator

7. Difference between venting and non-venting type of pressure regulator.

8. Describe the function of an air lubricator

9. With the help of neat sketch explain the working of air filter.

10. List commonly used oil in an air lubricator

11. State the advantage of main ring pneumatic net work

12. List five important considerations in pipe layout in pneumatic network

13. With the help of neat sketch, explain ring and manifold type of pneumatic network

14. List the guidelines for selection of pneumatic components and compressor

15. Discuss the three ways to remove the water from the air in the air distribution system
Answers

Fill in the Blanks

1. service
2. clogged
3. supply
4. pressure drop
5. diameter

State True or False

1. False
2. False
3. False
4. True
5. True
 Lecture 37

PNEUMATICS ACTUATORS

Learning Objectives

Upon completion of this chapter, Student should be able to

Explain the meaning of Pneumatic Actuator

Classify the various types of Pneumatic actuators
Explain the working of various pneumatic actuators
Understand the importance of cushioning
Study the seals used in the Pneumatic actuators
Understand the working of rodless cylinders
List advantages and disadvantages of various cylinder mounting
Study the effect of buckling in cylinders
Explain the various lever systems used with pneumatic cylinders
List the various applications of different lever systems using actuators
Explain the working of limited angle rotary actuators.
Explain the working and application of air motors

1.1 PNEUMATICS ACTUATORS

Pneumatic actuators are the devices used for converting pressure energy of compressed air into the
mechanical energy to perform useful work. In other words, Actuators are used to perform the task of
exerting the required force at the end of the stroke or used to create displacement by the movement
of the piston. The pressurised air from the compressor is supplied to reservoir. The pressurised air
from storage is supplied to pneumatic actuator to do work.

The air cylinder is a simple and efficient device for providing linear thrust or straight line motions
with a rapid speed of response. Friction losses are low, seldom exceeds 5 % with a cylinder in good
condition, and cylinders are particularly suitable for single purpose applications and /or where rapid
movement is required. They are also suitable for use under conditions which preclude the
employment of hydraulic cylinders that is at high ambient temperature of up to 200 to 250

Their chief limitation is that the elastic nature of the compressed air makes them unsuitable for
powering movement where absolutely steady forces or motions are required applied against a
fluctuating load, or where extreme accuracy of feed is necessary. The air cylinder is also inherently
limited in thrust output by the relatively low supply pressure so that production of high output forces
can only be achieved by a large size of the cylinders.

1.2 TYPES OF PNEUMATICS ACTUATORS

Pneumatic cylinders can be used to get linear, rotary and oscillatory motion. There are three types of
pneumatic actuator: they are

i) Linear Actuator or Pneumatic cylinders

ii) Rotary Actuator or Air motors
iii) Limited angle Actuators

1.2.1 Types of Pneumatic cylinders /Linear actuators

Pneumatic cylinders are devices for converting the air pressure into linear mechanical force and
motion. The pneumatic cylinders are basically used for single purpose application such as clamping,
stamping, transferring, branching, allocating, ejecting, metering, tilting, bending, turning and many
other applications.

The different classification scheme of the pneumatic cylinders are given below

1. Based on application for which air cylinders are used

i) Light duty air cylinders

ii) Medium duty air cylinders

iii) Heavy duty air cylinders

2. Based on the cylinder action

i) Single acting cylinder

ii) Double acting cylinder

 Single rod type double acting cylinder

 Double rod type double acting cylinder

3. Based on cylinder’s movement

i) Rotating type air cylinder

ii) Non rotating type air cylinder

4. Based on the cylinder’s design

i) Telescopic cylinder
 ii) Tandem cylinder

iii) Rod less cylinder

 Cable cylinder,
 Sealing band Cylinder with slotted cylinder barrel
 Cylinder with Magnetically Coupled Slide

iv) Impact cylinder

v) Duplex cylinders
vi) Cylinders with sensors

1.2.1.1 Based on application for which air cylinders are used

Air cylinders can be classified according to their intended use, as light duty, medium duty or heavy
duty types. In the main this merely governs the strength of the cylinder, and thus typical choice of
material of construction and the form of construction. Comparison is given in Table 1.1. It should be
noted that classification by duty does not necessarily affect the output performance of the cylinder, as
bore size for bore size; identical cylinder diameter will give the same thrust on the same line
pressure, regardless of whether the cylinder is rated for light, medium or heavy duty. This form of
rating , however, normally precludes the use of light classification for cylinders of large size ( and
thus high thrust) ; and medium classification for cylinders of even large size and very high thrust
outputs.

All plastic construction has the advantage of being inherently free from corrosion and similar
troubles but, in general is limited to smaller cylinder sizes and light duty applications. As originally
introduced they were intended to provide low cost cylinders for light duty work , and where rigidity
of the unit was not an important factor. The development of all-plastic cylinders for higher duties
tends to nullify any cost advantage and the types has not, as yet, achieved any particular prominence,
although the potentialities remain for corrosion- resistant duties.

Force limitation with air cylinders are purely matter of size and cost. Since line pressures available
are usually very much lower than pressure common in hydraulic circuits, air cylinder must be very
much larger in diameter than the hydraulic cylinders for the same thrust performance. Where a very
high force is required the cost of the suitable size of air cylinder may work out at more than the cost
of a complete hydraulic system to do the same job. In addition the cost of the compressed air feed
such cylinders could also be prohibitive.
Table 1.1: Materials of construction for light, medium and heavy duty cylinders

Components Type of cylinder

Light duty Medium duty Heavy duty
Cylinder tubes Hard drawn seamless Hard drawn seamless Hard drawn seamless
aluminium or brass tubes brass tubes tubing , brass , bronze,
Plastics Aluminium , brass, iron iron or steel casting
or steel castings
End covers Aluminium alloy castings Aluminium brass, High tensile castings
Fabricated aluminium , bronze, iron or steel
brass , bronze castings, fabricated brass,
bronze,
Pistons Aluminium alloy castings Aluminium alloy Aluminium alloy
castings, Brass, cast iron castings, Brass, cast iron
Piston rods EN 8 or similar steel EN 8 steel, ground and Ground and polished
ground and polished or polished or chrome stainless steel
chrome plated plated. Ground and
polished stainless steel
Mounting Aluminium alloy casting Aluminium,brass,iron High tensile castings or
brackets castings fabricated

1.2.1.2 Based on the cylinder action

Based on cylinder action we can classify the cylinders as single acting and double acting. Single
acting cylinders have single air inlet line. Double acting cylinders have two air inlet lines.
Advantages of double acting cylinders over single acting cylinders are

1. In single acting cylinder, compressed air is fed only on one side. Hence this cylinder can
produce work only in one direction. But the compressed air moves the piston in two
directions in double acting cylinder, so they work in both directions
2. In a single acting cylinder, the stroke length is limited by the compressed length of the spring.
But in principle , the stroke length is unlimited in a double acting cylinder
3. While the piston moves forward in a single acting cylinder, air has to overcome the pressure
of the spring and hence some power is lost before the actual stroke of the piston starts. But
this problem is not present in a double acting cylinder.
A) Single acting cylinders.

Single acting cylinder has one working port. Forward motion of the piston is obtained by supplying
compressed air to working port. Return motion of piston is obtained by spring placed on the rod side
of the cylinder. Schematic diagram of single acting cylinder is shown in Figure 1.1

Single acting cylinders are used where force is required to be exerted only in one direction. Such as
clamping, feeding, sorting, locking, ejecting, braking etc.,

Single acting cylinder is usually available in short stroke lengths [maximum length up to 80 mm] due
to the natural length of the spring. Single Acting Cylinder exert force only in one direction. Single
acting cylinders require only about half the air volume consumed by a double acting cylinder for one
operating cycle.

Vent

(By spring)

Vent

Figure 1.1 Construction features of single acting cylinder

There are varying designs of single acting cylinders including:

1. Diaphragm cylinder
2. Rolling diaphragm cylinder
3. Gravity return single acting cylinder
4. Spring return single acting cylinder

i) Diaphragm cylinder

This is the simplest form of single acting cylinder. In diaphragm cylinder , piston is replaced by a
diaphragm is replaced by a diaphragm of hard rubber, plastic or metal clamped between the two
halves of a metal casing expanded to form a wide, flat enclosure. Schematic diagram of diaphragm
cylinder is shown in Figure 1.2.The operating stem which takes place of the piston rod in diaphragm
cylinder can also be designed as a surface element so as to act directly as a clamping surface for
example. Only short operating strokes can be executed by a diaphragm cylinder, up to a maximum of
50 mm. This makes the diaphragm type of cylinder particularly adaptable to clamping operations.
Return stroke is accomplished by a spring built into the assembly or by the tension of diaphragm
itself in the case of very short stroke. Diaphragm cylinders are used for short stoke application like
clamping, riveting, lifting, embossing and riveting

P = Air inlet port

Symbol

Diaphragm

Stem

Figure 1.2 Construction features of diaphragm cylinder

ii) Rolling diaphragm cylinder

They are similar to diaphragm cylinders. Schematic diagram of Rolling diaphragm cylinder is shown
in Figure 1.3.They too contain a diaphragm instead of piston, which is this instance rolls out along
the inner walls of the cylinder when air pressure is applied to the device, thereby causing the
operating stem to move outwards. Compared with the standard diaphragm type, a rolling diaphragm
cylinder is capable of executing appreciably longer operating strokes (averaging from 50 mm to
800mm) . Separate guiding of stem is not normally provided in these designs, since the component
being actuated by the cylinder usually cannot break out of set limits of motion. Any off-center
displacement is compensated by the rolling diaphragm with no loss of power. Materials used for
rolling diaphragms in present –day designs ensure good durability under normal operating
conditions. On the other hand, even very small cracks or cuts in the diaphragm will generally lead to
early failure because if high stresses are imposed on the flexible material as it unrolls at each stroke.
If the actuator needs to be dismantled for any reason, it must accordingly be inspected carefully for
any burrs or sharp edges inside. Metal cuttings also constitute a hazard if they are able to enter the
cylinder housing.
 P P

Symbol

Figure 1.3 Construction features of rolling diaphragm cylinder

iii) Gravity Return Single Acting Cylinder

Load

Figure 1.4 Gravity return Single Acting Cylinder

Figure 1.4 shows gravity return type single acting cylinders. In a push type (a), the cylinder extends
to lift a weight against the force of gravity by applying oil pressure at the blank end. The oil is passed
through blank end port or pressure port. The rod end port or vent port is open to atmosphere so that
air can flow freely in and out of the rod end of the cylinder. To retract the cylinder, the pressure is
simply removed from the piston by connecting the pressure port to the tank. This allows the weight
of the load to push the fluid out of the cylinder back to tank.
In pull type gravity return type single acting cylinder the cylinder (b) lifts the weight by retracting.
The blank end port is the pressure port and blind end port is now the vent port. This cylinder will
automatically extend whenever the pressure port is connected to the tank.

iv) Spring Return Single Acting Cylinder

Spring return single acting cylinder is shown in Figure 1.5 in part (a) push type the pressure is sent
through pressure port situated at blank end of the cylinder. When the pressure is released, the spring
automatically returns the cylinder to the fully retracted position. The vent port is open to atmosphere
so that air can flow freely in and out of the rod end of the cylinder.

Part (b) shows a spring return single acting cylinder. In this design cylinder retracts when the
pressure port is connected to the pump flow and extend whenever the pressure port is connected to
the tank. Here pressure port is situated at rod end of the cylinder.

Figure 1.5 Push and Pull type Single Acting Cylinder

B) Double acting cylinders.

Schematic diagram of double acting cylinder is shown in Figure 1.6. Double Acting Cylinders are
equipped with two working ports- one on the piston side and the other on the rod side. To achieve
forward motion of the cylinder, compressed air is admitted on the piston side and the rod side is
connected to exhaust. During return motion supply air admitted at the rod side while the piston side
volume is connected to the exhaust. Force is exerted by the piston both during forward and return
motion of cylinder. Double acting cylinders are available in diameters from few mm to around 300
mm and stroke lengths of few mm up to 2 meters
 Figure 1.6 Double acting cylinder

Construction of Double acting cylinder

The construction features of double acting cylinder are shown in Figure 1.7. The construction of
double acting cylinder is similar to that of a single cylinder. However, there is no return spring. In
double acting cylinder, air pressure can be applied to either side ( supply and exhaust) of the piston,
thereby providing a pneumatic force in both directions. The double acting cylinders are mostly
commonly used in the application where larger stroke length is required.

Inlet Piston Retract

Point seal Rod seal port
End
seal
Wiper
seal
Rod

Base cap
(end cap)
Bearing

Barrel
piston Weld Bearing
and seal cap

Figure 1.7 Construction features of double acting cylinder

The seven parts of the double acting cylinder are

1. Base cap with port connection

2. Bearing cap with port connection
3. Cylinder barrel
4. Piston
5. Piston rod
6. Scrapper rings
7. Seals
The base cap and bearing cap are made of cast material, aluminium or malleable cast iron. The two
caps can be fastened to the cylinder barrel by tie rods, threads or flanges.

Cylinder barrel is usually made of seamless drawn steel tube to increase the life of the sealing
components, the bearing surfaces of the cylinder are precision machined,. For special applications,
the cylinder barrel can be made of aluminium, brass or steel tube with hard chromed bearing surface.
These special designs are used where operation is infrequent or where there are corrosive influences.

The piston rod It is preferably made from heat treated steel. A certain percentage of chrome in the
steel protects against rusting. Generally the threads are rolled to reduce the danger of fracture.

Piston seals are provided in between piston and barrel to avoid leakage. A sealing ring is fitted in the
bearing cap to seal the piston rod. The bearing bush guides the piston rod and may be made of
sintered bronze or plastic coated metal.

In front of this bearing bush is a scrapper ring.(wiper ring). It prevents dust and dirt particles from
entering the cylinder space. Bellows are therefore not normally required.

The materials for the double cup packing sealing are

Perbunan, for -20 to + 80

Viton, for -20 to +190

Teflon for -80 to +200

O rings are normally used for static sealing.

Construction of Double acting cylinder

There are two types of double acting cylinders.

i) Double acting cylinder with piston rod on one side.

ii) Double acting cylinder with piston rod on both sides

i) Double acting cylinder with piston rod on one side.

Figure 1.8 shows the operation of a double acting cylinder with piston rod on one side. To extend the
cylinder, pump flow is sent to the blank end port as in Figure 1.8 (a). Fluid from the rod end port
returns to the reservoir. To retract the cylinder, the pump flow is sent to the rod end port and fluid
from the blank end port returns to the tank as in Figure 1.8 (b).
 Figure 1.8 Double Acting Cylinder with piston rod on one side

ii) Double acting cylinder with piston rod on both sides

Figure 1.9 Double Acting Cylinder with piston rod on both side

A double acting cylinder with piston rod on both sides (Figure 1.9) is a cylinder with rod extending
from both ends. This cylinder can be used in an application where work can be done by both ends of
the cylinder, thereby making the cylinder more productive. Double rod cylinders can withstand
higher side loads because they have an extra bearing one on each rod to withstand the loading.
Double rod cylinders are used when there is bending load and accurate alignment and maximum
strength is required. A further advantage is that rod is precisely located and may be used to guide the
machine member coupled to it, dispensing with external guides or bearing in many cases, most
standard production models are available either in single rod or double rod configuration A
disadvantage of double rod configuration is that there is a reduction in maximum thrust due to the
blanking effect of the rod cross section on the piston area and a slightly larger size of cylinder is
required for a given duty. The thus will be the same on the ingoing stroke as that of a single rod
double acting cylinder.

1.2.1.3 Based on the cylinder action

Rotating type of cylinders are used in applications where cylinder body is connected to a rotating
member and air connection to the cylinder in a stationary housing. They are not widely used.

Non Rotating type of cylinders are widely used Industries. Cylinder body is connected air connection
are mounted stationary housing and piston rod moves and exerts force.

1.2.1.4 Based on the cylinder’s design

In industry , differentiation is made between special design of regular cylinder and the special duty
cylinders designed for a special purpose that are known by designation of their own. Special design
cylinders are basically natural variations of single or double acting cylinders. Variations in special
designs derived from standard production of cylinders and merely exchanging selected parts for
others of different shapes or material. Special duty cylinders on the other hand are from the start
designed to non-standard conditions of service or application. Following section deals with some of
commonly used special design and special duty cylinders.
 A) Telescopic Cylinder

Extend
port Seals

Stage 3 A Retract port via

flexible house
B
Stage 2 Y

Rod
Stage 1 X

Pressure
Port Inner
Outer pistion 2
pistion 1
a)Three stages b)Retracted
Extended position c) Displacement type telescopic cylinder (Two
position positions)

Figure 1.10 Double Acting Cylinder with piston rod on one side

Telescopic cylinder (shown in Figure 1.10 (a) and (b)) is used when long stroke length and short
retracted length are required. They extend in stages, each stage consisting of a sleeve that fits inside
of the previous stage. Figure 1.10 (c) shows the construction of a typical double acting telescopic
cylinder with two pistons (Two stages).

Extension stroke: When the pressure is applied at port A, air flow through port X and Y and
pressure is applied on both sides of Piston 1. But difference in areas causes the piston 1 to move to
the right. Once the piston 1 fully extends, Inner Piston 2 will extend.

Retraction stroke: To retract, air is applied to port B. Air pressure will act on the annulus of the
inner piston 2 and moves inner piston 2 to the left. When the inner piston moves to left and started to
close port X, air from port B goes to annular side of the piston 1 via port Y and pushes the piston 1 to
the left.

Figure shows the construction of a typical double acting telescopic cylinder with three pistons (three
stages)

Forward stroke: when the pressurised air enters the port p, larger ram of diameter A moves first.
Since the diameter of Ram A is relatively large, this ram produces large force at the beginning of the
lift of the load. ( usually in many application, initial inertial is high and larger force is required in the
beginning, once initial inertia is overcome, smaller force is required to keep moving the weight).
When ram A reaches the end of the stroke, ram B begins to move, providing smaller force. When
ram B reaches its end position, Ram C will move outward to complete the stroke.
Retraction stroke: When the pressurised air enters the port T, then it acts on the annular area of
Ram A and ram A is retrieved. Once the Ram A is retrieved, pressure continues to act on annular
area of Ram B and retrieves Ram B. In similar way, the Ram C is also retrieved.

B) Tandem Cylinder

Schematic diagram of Tandem cylinder is shown in Figure 1.12. Tandem cylinders are two separate
double acting air cylinders arranged in line to one cylinder body so that the power generated by the
two is added together, thereby approximately doubling the piston output. A tandem cylinder is used
in applications where a large amount of force is required from a small-diameter cylinder. Basically, a
tandem cylinder is simply two or more separate cylinders stacked end to end in a unit and with all the
pistons mounted on a common piton rod. Pressure is applied to both pistons, resulting in increased
force because of the larger area. The drawback is that these cylinders must be longer than a standard
cylinder of larger flow rate than a standard cylinder to achieve an equal speed because flow must go
to both pistons

Figure 1.11 Double Acting Cylinder with piston rod on one side

Tandem cylinders are used where large output force is required with appreciable saving in bulk and
weight. Tandem cylinders are employed where a small diameter of the assembly is required.
c ) Rodless Cylinder

A rod less air cylinder differs from a basic air cylinder in that no piston rod extends outside the
cylinder body. Instead, the internal piston is connected to an external carriage, by means of a
magnetic or mechanical coupling system

There are three types of rod less cylinders, they are

i) Cable Cylinder
ii) Sealing band Cylinder with slotted cylinder barrel
iii) Cylinder with Magnetically Coupled Slide
i) Cable cylinder:
It is used for very long strokes, up to 2000mm. It consists of nylon jacketed cable which
enters the cylinder barrel and is attached to one end of internal cylinder and exits through
the gland seal and enters into the other end of the internal cylinder through the another
gland seal as shown in the Figure1.12. When compressed air enters the cylinder the piston
moves from end-to-end. The cables which are attached to either side of the piston and
extend out the ends of the cylinder move as well. Depending on the direction of the piston
both the carriage and any on-carriage tooling moves towards one end of the air cylinder
or the other.

LOAD

Gland seal

Die cast aluminium disc

Figure 1.12 Cable cylinder

ii) Sealing band Cylinder with slotted cylinder barrel

Schematic diagram of sealing band cylinder with slotted cylinder barrel is shown in the
Figure 1.13. Common components of a band cylinder are:

a. End caps
b. cylinder barrel
c. cylinder piston
d. carriage
e. mechanism for connecting carriage to piston
f. sealing bands / strips

Outer sealing band carriage

Carriage
X

Inner Seal

X Piston
Cylinder Section X-X

Figure 1.12 Sealing band cylinder with slotted cylinder barrel

As the carriage moves, the two band sealing strips are alternately opened in front and then closed
behind of the moving carriage, regardless of the direction of travel. The seals on the pistons inside
the cylinder barrel press the inner band seal tight against the barrel of cylinder, preventing air from
leaking out.

The carriage on top of the band cylinder will have a wiper assembly at either end which will both
remove any debris from the carriage path, and press the top seal tightly against the outside of the slot
in the cylinder barrel, stopping any compressed air from escaping there.

iii) Cylinder with Magnetically Coupled Slide

LOAD

Port Port

Figure 1.12 Schematic diagram of cylinder with Magnetically Coupled Slide

Figure 1.12 shows the schematic diagram of magnetic piston cylinder. Piston has powerful magnet
which bonds the piston inside the cylinder with carriage outside which also contain powerful magnet.
The magnetic cylinders are available upto the size of about 40 mm diameter and stroke lengths from
50mm to 4000 mm. They can operate at the speed of about 3000 mm/sec. The major advantages of
this type of cylinders are

i) There is no leakage
ii) There is no direct contact of moving elements therefore the wear is less
iii) The orientation of the carriage can be changed easily,
 D) Impact cylinders

Impact cylinders are used for high energy applications. Schematic diagram of impact cylinder is
shown in Figure 1.13. These comprise, basically a normal pneumatic cylinder allied to a reservoir
where by the speed of operation of the cylinder may be raised by some 15 times and the energy
rating increases some 200 times without using larger valves or higher air supply pressures. Impact
cylinders find particular application for high energy rate forming where, typically, an 200mm bore
impact cylinder may accomplish a similar duty to that previously requiring a 50 Ton press.

If normal cylinders are used for forming operations, the thrust forces of the compressed air are
limited. A cylinder producing high kinetic energy is the impact cylinder. In accordance with formula
for kinetic energy (KE), the obvious means of obtaining high impact energy is by increasing the
velocity.

Rear end cap Rear barrel Bleed plug Piston Front barrel Front end cover

Centerpiece Blank plug Piston seat Piston rod

Figure 1.13 Schematic diagram of Impact cylinder

If the forming stroke is large, the velocity diminishes rapidly and hence also the impact energy, This
type of cylinder is therefore not suitable for large forming strokes. They are used for stamping,
punching, cutting, riveting, beading, embossing etc.
Sequence of operation is shown in the Figure 1.14. To the top end of conventional cylinder is added
a reservoir opening into the cylinder proper via a poppet valve (centre piece) controlled by the piston
movement. Ratio is the piston area to poppet valve (centre piece) area is of the order of 9:1 so that
pressure in the reservoir is balanced by a pressure of approximately 1/9th in the exhaust end of the
cylinder.

To charge the cylinder the reservoir is connected to the line with the pressure building up to the line
pressure. Movement of the piston is opposed by exhaust pressure until this falls to 1/9 th of the line
pressure. Forces acting on the top and bottom of piston are then in balance and the piston starts to
move away from the poppet seat (centre piece). Immediately the poppet valve is open and the
reservoir pressure is applied over the entire whole of the piston area resulting in very rapid
acceleration of the piston up to the maximum speed. The energy released by the air suddenly allowed
to expand from the reservoir is thus converted into kinetic energy by the piston assembly which
delivers an impact blow.

Figure 1.14 Sequence of operation of Impact cylinder

E) Duplex cylinder or opposite thrust or multi position cylinder

A special duty tandem arrangement is also used in duplex cylinder, although in this case the (two)
pistons are mounted on separate connecting rods, one operating the other. Each piston is thus capable
of independent motion via its own separate air supply control Thus a duplex cylinder may be used
for tow motion duties- example clamping a work piece in position y motion of one piston, followed
by a shearing, punching, pressing or similar operation powered by the other piston.
Opposed thrust or multi position cylinders are similarly a combination assembly of at least two
double acting cylinders in one with the pistons and rods in opposed arrangement. This results in a
four position cylinders as shown in Figure 1.15 (b) The characteristic of such opposed thrust
cylinders is the availability of more than two definite fixed operating positions. Theoretically it is
possible for a multiple number of pistons and rods to be combined into the one cylinder assembly so
as to obtain an actuator with six or eight position. Three position cylinders as illustrated in Figure
1.15(a) can be obtained as standardized units. Designs with up to 12 operating positions are possible.

Application

- Filling shelves from a conveyor

- Lever actuation
- Sorting device ( accept – reject- rework)

Figure 1.15 Duplex cylinder (a) three position b) four position

F) Position sensor for cylinders

In automation application, it is often required for a signal to be generated when the cylinder piston
reaches a particular position along its stroke, so that the control system can initiate the next phase of
the operation. This position may be at either end of the stroke or some point intermediate between
the ends. There are several ways in which this can be done. Schematic diagram of cylinders with
position sensor is shown in Figure 1.16
  The piston rod trips a micro-switch or pneumatic valve
 Pressure threshold sensors respond to a drop in exhaust pressure when the piston stops
moving
 Magnetic sensors mounted directly on the cylinder barrel sense the magnetic field created by
a permanent magnet incorporated in the piston and trigger reed switch.
 Hall effect sensors triggered by a magnetic piston
 Pneumatic reed valves. Triggered by a magnetic piston
 Miscellaneous such as photoelectric, inductive and capacitive detectors

Magnetic trip switches are the traditional method for position sensing and are still widely used and
reliable. Pressure threshold sensor respond less to actual position than to piston velocity, so they are
only suitable for detecting the end of the piston travel, they have work unreliably with slow moving
pistons. Both of these are gradually being superseded by the two types of magnetic sensors.

Limit switch

Pressure sensor

Embedded magnet Signal pickup

Figure 1.16 Cylinder with sensors (a) Mechanical b) pressure c) magnetic

The other type of sensors which are used are electronic sensor with magnetic detection. They are
directly mounted on a magnetic cylinder tube. A permanent magnet is embedded in the piston. This
creates a magnetic field. When the piston moves, the magnet actuates the electronic system of the
sensor and provides the desired signal. These electronic position sensors work at 10-24 volts. The
maximum current is around 150mA. The leakage current is around 10 mA at 24 Volts and internal
voltage drop is less than 0.5 Volts for 100 mA. They are capable of working between -10 to +60
1.3 Standard metric cylinders

BS: 5785 1980 gives tables (Table 1.2) of preferred sizes for the cylinder bore and rod diameter of
metric cylinders. Most cylinder manufacturers have based their standard range of metric cylinders on
these recommendations, offering two rod sizes for each cylinder bore.

A number of combinations have a piston rod to piston diameter ratio in the region of 0.7, which gives
an annulus area of approximately one-half the full bore area. This area ratio is of use in regenerative
circuits to give similar values of speed and thrust on both the extension and retraction strokes.

1.3.1 Graphical Symbols for cylinders.

There are several symbol systems and conventions in use around the world for pneumatic cylinders.
Most official recognized by standard bodies, commonly used is ISO 1219-1. Table 1.3 gives the
symbols for most commonly cylinders in industry.

Table: 1.2 Standard cylinder sizes

Piston 40 50 63 80 100 125 140 160 180 200 220 250 280 320
Diameter(mm)

Piston Rod small 20 28 36 45 56 70 90 100 110 125 140 160 180 200
Diameter(mm) large 28 36 45 56 70 90 100 110 125 140 160 180 200 220
 Table 1.3 Graphical symbols of cylinders

Sl Graphical Symbols Explanation

No

1 Single acting cylinder with unspecified return: Air pushes

the piston in one direction and the piston is return is
unspecified. External dock or lever may push
2
Single acting cylinder with spring return. Air pushes the
piston in one direction and piston returns by spring on rod
side
3
Double acting cylinder –single piston rod: the force
exerted by compressed air moves the piston in both
direction.
4.
Double acting cylinder –double piston rodIt has piston
rods extending from both ends of the cylinder. It produces
equal force and speed on both sides of the cylinder
1.
Telescopic cylinder –double acting is used where space is
constraint. It is used for long stroke application like in
pneumatic cranes, dump trucks, lift fork trucks, dipper
wagon
7.
Double acting cylinder – fixed cushion on one side,
Cushioning is used in the end position to prevent sudden
impact which otherwise may damage parts.
8
Double acting cylinder – variable cushion on one side–
fixed cushion on one side, cushioning is variable in one
direction by adjusting the orifice opening.
9
Double acting cylinder – variable cushion on both sides–
fixed cushion on one side, cushioning is variablein both
direction.

5.4 Cylinder mountings.

The way in which the cylinder is mounted influences service life, maintenance frequency and
success of the entire installation. Poor mounting design can cause excessive side loads and stresses
which will bring about early failure of some vital component. There are three main categories of
cylinder mounting. The selection of these mountings depends on the application and machine
configuration.
 1. Fixed Centreline mountings
2. Pivoted centreline mountings
3. Fixed non centreline mountings

Blind end Flange Rod end trunnion End lug Mount

Blind end trunnion Side lug Mount

Rod end Flange

Centerline lugs Clevis Integral key Mount

Tie rod Mount Central Trunnion Flush Mount

a) Fixed centerline mountings a) Pivoted centerline mountings a) Fixed noncenterline mountings

Figure 1.17 Types of mounting a) Fixed centreline b) Pivoted centreline c) Fixed noncenterline

Figure 1.17 shows all three types of mountings.

Fixed Centreline mountings: In this mounting, the cylinder is supported along its centre line. The
mounting bolts are thus subjected to shear or simple stress. This mounting needs accurate alignment.
Misalignment is not tolerable.

Pivot centreline mounting: Many applications need rotational degree of freedom for a cylinder as it
reciprocates. The pivot mounting can be clevis type or trunnion type. This mounting permits
rotational freedom in one plane. If universal joint is used, greater degrees of freedom are possible.

Fixed non centreline mounting: This mounting of cylinder introduces torque under loaded
condition. The cylinder may rotate or bend about its mounting bolt when loaded. The stress level on
the cylinder is higher as compared to the centre line mounting.

Following points should be considered while mounting the cylinder

1. Cylinders with centreline mountings tend to lean under load.

2. Cylinder with non-centreline mounting generally require strong machine frames to resist
bending moments
 3. If the motion of the machine part acted on by the cylinder rod movement is essentially linear,
a fixed mounted cylinder should be used.
4. If the cylinder has a long stroke, a pivoted mounted cylinder may be required to prevent the
piston rod buckling. Where long stroke and fixed mounting are necessary , support is needed
to prevent vibration and excessive sag
5. The mounting selection depends on the resulting force (compression or tension) in the
cylinder rod. The blind end or cap flange mounting is best for compressive loads. The rod end
or head flange mounting is best where the rod is in tension
6. Alignment problem are always critical. If misalignment can occur between the cylinder and
machine part it moves, it is necessary to compensate for this in the selection of cylinder
mounting. For example, a simple centreline pivot mounting will compensate for
misalignment if it occurs in only one plane. Where misalignment can occur in more than one
plane, the cylinder must be fitted with a universal ( ball and socket) pivot joint. It is important
that both ends of the pivot mounted cylinder should be supplied with flexible connections.

1.4.1 Piston rod buckling

The piston rod in a pneumatic cylinder will act as a strut when it is subjected to a compressive load
or it exerts a thrust. Therefore the rod must be of sufficient diameter to prevent buckling. Euler’s
strut theory is used to calculate a suitable piston rod diameter to withstand buckling. Euler’s formula
states that

Where K = buckling load (kg),

E = modulus of elasticity (kg/ ) (2.1 × kg/ for steel),

I = second moment of area of the piston rod ( )( for a solid rod of diameter d cm), an L =
free (equivalent) buckling length (cm) depending on the method of fixing the cylinder and piston rod.
The values of L for various configuration is shown in Figure 1.19

The maximum safe working thrust or load F on the piston rod is given by

F= /S,
 l Deflected strut
Deflected
strut l
Center Trunnion
L=l

Rear Pivot
Rear Pivot and center Trunnion mounted, Guided pivoted load

l
Deflected
strut l Deflected strut
Rear flange Front flange
L=2l

b) One end rigidly fixed , free load

l
Deflected
strut l Deflected strut
Rear flange Front flange
L=l/2

c) one end rigidly fixed, guided load

Deflected
strut
l

l
Deflected strut
Rear flange Front flange
L=l/√

d) One end rigidly fixed, pivoted and guided load.

Figure 1.19 Relationship between piston rod, free buckling length and method of fixing

Where S is a factor of safety which is usually taken as 3.1. The free or equivalent buckling length L
depends on the method of fixing the piston rod end and the cylinder, and on the maximum distance
between the fixing points, i.e. the cylinder fully extended. In cases where the cylinder is rigidly fixed
or pivoted at both ends there is a possibility of excessive side loading occurring. The effect of side
loading can be reduced by using a stop tube inside the cylinder body to increase the minimum
distance between the nose and the piston bearings. Schematic diagram is shown in Figure 1.20. The
longer the stop tube, the lower will be the reaction force on the piston owing to the given value of
side load. Obviously the stop tube reduces the effective cylinder stroke

Reaction to
side load
Nose bearing Side load

Piston tube Stop tube

Figure 1.20 Use of stop tube to minimize side loading.

1.5 Cylinder seals

Seals are used in cylinders to prevent the losses caused by leakage and to make the effective use of
the compressed air energy medium. Important characteristics needed for seals are

1. Long life
2. Low friction
3. Resistance to heat
4. Stability of form
5. Higher range of working pressure
6. Higher Range of temperature
7. Mechanical strength

1.1.1 Classification

1. Static seals

2. Dynamic seals

Static seals are used to provide a sealing between the stationary parts of a cylinder. For example, end
cap and barrel. O ring is most commonly used static seal. O rings are used for small cylinders.

Dynamic seals are used provided for surfaces which are moving. Dynamic seals are used provided
for surfaces which are moving. Cup seals and Z seals are commonly used dynamics seals.
There are a variety of seals required within a pneumatic cylinder. Single acting cylinders use less
number of seals. Double acting seals use at least five different types of seals as shown in Figure 1.21

Figure 1.21 Different types of seals used in pneumatic cylinders

1. Cushion seals
2. Wear ring
3. Piston seals
4. Barrel seals
5. Piston rod/wiper seal

Cushion seals: Cushioning protects a cylinder and its load by absorbing energy at the end of the
stroke. When the piston moves to the left of pneumatic cylinder, the air on the left side of the piston
in the left chamber must be exhausted to allow full travel of the piston and rod. In a cushioned
cylinder, this air cannot escape from the port by virtue of the cushion seals which seals against the
piston rod. The only escape path is through the cushion orifice, which is normally a small hole.
When the piston reaches the cushion seal, the piston travel is slow down due to cushioning of the air.
Thus the cushion seals perform a dual role of a seal and non-return valve.

Wear ring is a open band fixed around the piston. It is made from a hard plastic material normally
Teflon compounded with polyphenylene sulphide or good quality bearing bronze to provide best
wear resistance and excellent bearing support. Wear ring also guards the rod against scoring by
piston.
Piston seal: An O-ring piston seal is used for small bore sizes. For medium and large bore double
acting cylinders cup seals are used. They are cheap and easy to fit but may be easily damaged by dirt.

Barrel seal: O-ring piston seal is used as barrel seal. It is used in the near the end caps and it is tight
fit in the grooves location

Piston rod seal/ Wiper seal.

A piston rod seals, also known as wiper seal, is used for harsh environment. This seals acts as
pressure seal and wiper seal. The external body of this seal is a pressure-tight fit within the bearing
housing. Cleaning action of the seal removes abrasive particles that can settle on the rod during the
outward stroke of the cylinder or due to some other operations

5.6 End cushioning in pneumatic cylinders

The inherent capability of all air cylinders to perform rapid reciprocating motion also supplies a
disadvantage in that considerable kinetic energy is dissipated in the form of shock at the completion
of the stoke. This can set up severe stresses in cylinders itself or end covers, or on frame work of the
machines to which it is attached. This can be overcome by providing cushioning to produce gradual
deceleration of the piston as it approaches the end of its stroke. Schematic diagram is shown in
Figure 1.22

Cushion spear

Cushion Retraction stroke

Port

Cushion adjusting restrictor

Figure 1.22 Operation of cylinder cushions.

Need for cushioning when the pressurised air is supplied at the inlet port of the cylinder, piston
accelerates and travels inside the cylinder. Piston has to be slowed down at the end of the stroke to
prevent excessive impact on the end caps. These shock loads arise not only from the fluid pressure,
but also from the kinetic energy of the moving parts of the cylinder and load. These end travel shock
loads can be reduced by decelerating the piston at the end of stroke by cushioning.
For the prevention of shock due to stopping loads at the end of the piston stroke, cushion devices are
used. Cushions may be applied at either end or both ends. They operate on the principle that as the
cylinder piston approaches at the end of stroke exhaust fluid is forced to go through an adjustable
needle valve which is set to control the escaping fluid at the given rate. This allows the deceleration
characteristics to be adjusted for different loads. When the cylinder piston is actuated, fluid enters the
cylinder port and flows through the little check valve so that entire piston area can be utilized to
produce force and motion.

There are two types of cushioning is possible in pneumatic cylinder

1. Fixed cushioning
2. Adjustable cushioning

Fixed cushioning: This type of cushioning is used for small bore cylinder. These cylinders make use
of synthetic rubber buffers to give a simple fixed cushion effect. These shock absorbent disks placed
into the end-covers suction the impact of the piston. Schematic diagram is shown in Figure 1.23

Figure 1.23 Operation of cylinder cushions

Adjustable cushioning: As a rule, cushions are applied to cylinders whose piston speed exceeds 0.1
m/s. Cushion can be applied at one end or both ends of the cylinder. Adjustable cushioning is
possible with two methods

1. Using the cushion seal

2. Using the piston with the plunger

Using the cushion seal: Cushioning using cushion seal was explained earlier in cylinder seal section
1.1.1.In a cushioned cylinder, this air cannot escape from the port by virtue of the cushion seals
which seals against the piston rod. The only escape path is through the cushion orifice, which is
normally a small hole. When the piston reaches the cushion seal, the piston travel is slow down due
to cushioning of the air
Using the piston with plunger and cap: In this type exhaust air is unrestricted until the plunger
enters the cap. The exhaust flow route is through deceleration valve which reduces the end of travel
speed. The needle valve is adjustable to allow the deceleration rate. Schematic diagram of the
construction of cylinder cushion is shown in Figure 1.24

Construction and working:

Double O-ring
Cushion Assembly
packing on piston
Tube
Stainless steel
cylinder tube

End Cover

Piston Rod
Bush
Piston

Figure 1.24 construction of cylinder cushions

a) 1. Exhaust flow passes freely out of the

cylinder.

b)
1. Check valve allows free
flow to piston to extend 2. Plunger enters the cap

3. No flow takes restricted

path causing the piston to
4. Rate of deceleration can be
decelerate
adjusted here.

Figure 1.25 Operation of cylinder cushions a) normal position b) end position

A typical cylinder cushioning operation arrangement is shown in the figure 1.25(a) and 1.25(b)

As the piston approaches the end of its stroke, the plunger enters the end cap port and thus blocks the
free flow. Now the fluid is trapped between the piston and end cap. This fluid can escape only by
passing through the adjustable restrictor, as shown in the Figure 1.25(b). This fluid flow through the
restricted flow path causes the piston to decelerate. The rate of deceleration of the piston can be
controlled by adjustable needle valve. A non-return valve or check valve is provided to allow free
flow of fluid to the cylinder quickly during the return stroke.

1.7 CYLINDER FORCE, VELOCITY AND POWER

The output force (F) and piston velocity (V) of double acting cylinders are not the same for extension
and retraction strokes.

a)

During extension, entire piston

area Ap is subjected to fluid
pressure

b)

During retraction, annulus area

Ap-Ar is subjected to fluid
pressure

Figure 1.26 Effective areas during extension and retraction strokes

During the extension stroke shown in Figure 1.26(a), the fluid pressure acts on the entire circular
piston area Ap. During the retraction stroke, the fluid enters the rod end side and the fluid pressure
acts on the smaller annular area between rod and cylinder bore (Ap- Ar) as shown by the shaded area
in Figure 1.26 (b). Ar is the area of the piston rod. Due to the difference in the cross sectional area,
the velocity of piston changes. Since Ap is greater than (Ap-Ar), the retraction velocity (Vret) is
greater than the extension velocity (Ve) for the same flow rate.
During the extension stroke, fluid pressure acts on the entire piston area (A r), while during retraction
stroke, the fluid pressure acts on the annular area (Ap-Ar). This difference in area accounts for
difference in output forces during extension and retraction strokes. Since (Ar) is greater than (Ap-Ar),
the extension force is greater than the retraction force for the same operating pressure.

Force and Velocity during Extension stroke

----------------------(1)

-------------------------(2)

Force and Velocity during Retraction stroke

---------------------(3)

-----------------------------(4)

Power developed by a pneumatic cylinder ( both in extension and retraction)

-----------(5)

In metric units, the kW power developed for either extension or retraction stroke is

( ) --------(6)

Power during extension

Power during retraction

=

Comparing equations (A) and (B), we can conclude that the powers during extension and retraction
strokes are same.
1.8 ACCELERATION AND DECELERATION OF CYLINDER LOADS

Acceleration

To calculate the acceleration of cylinder loads, the equations of motion must be understood.

Let

u = initial velocity

v = velocity after a time t

s = distance moved during time t

a = acceleration during time t.

The standard equations of motion are:

--------------------(9)

-----------------(10)

-----------------(11)

and

The force F to accelerate a weight W horizontally with an acceleration a is given by

Force = mass × acceleration

F = (W/g) a

Where g is the acceleration due to gravity and is ⁄ . The force P required to overcome
friction is given by P = µW, where µ is the coefficient of friction.

Note: Dynamic cylinder thrust

In dynamic applications the load inertia, seal friction, load friction, etc. must be allowed for in
calculating the dynamic thrust.

As a first approximation, the dynamic thrust can be taken as 0.9 times the static thrust. (It must be
realized that this is only an approximation and can be considerably in error, dependent on load
conditions and associated circuitry.)
Cylinder seal friction varies with seal and cylinder design. The pressure required to overcome seal
friction is not readily available from the majority of cylinder manufacturers. The seal friction
breakout pressure can be taken as 5 bar for calculation purposes. It will reduce when the piston starts
to move. The pressure required to overcome seal friction will reduce as the cylinder bore size
increases and will vary according to seal design.

Example 1: A pneumatic cylinder is required to move a 1000 N load 150mm in 0.5s. What is
the output power?

Solution

Velocity,

⁄ ⁄ =0.3m/s

Power,

=300W = 0.3 kW

Example 2: A pneumatic cylinder is required to extend at a minimum speed of 0.75 m/s in a

system with a flow rate of 50 LPM. What cylinder size is required?

Solution

⁄ ⁄

Solving we get

Example 3: An 8 cm diameter pneumatic cylinder has a 4 cm diameter rod. If the cylinder

receives flow at 100 LPM and 6 bar, find the (a) Extension and retraction speeds (b) Extension
and retraction load carrying capacities.

Solution

Qin=100 LPM=100/(1000× =1/600 (m3/s)

dp= diameter of cylinder= 8 cm = 8 x 10-2 m

dr = diameter of piston rod= 4cm = 4x10-2 m

p = 6 bar =6x105 N/rn2 or Pa

(a) Vext= = =0.3315m/s

⁄
(b) Vret= ( ) ( )

( )
(c)
*( ) ( ) +
(d) ( )

1.11 Rotary Actuators

Rotary Actuators are used to achieve angular motion. Rotary actuators are devices which produce
high torque output and have a limited rotary movement. Standard rotations are 90 , 180 , and 270 .
Rotary actuators are mainly available in three designs.

i) Vane type limited rotation motors

 Single vane rotation motor

 Double vane rotation motor
ii) Rotary Actuator of Rack and Pinion Type
iii) Helix spine rotary actuator

1.11.1 Vane type actuators

Where the torque and motion is all produced in a rotary sense, the construction limits the rotation to
less than one rotation.

Piston type actuators are essentially linear actuators mechanically connected to translate the linear
force to produce an output torque and rotational movement. These devices are capable of providing
an output motion of one revolution or more but not continuous rotation.

Both type give bi-directional output motion, and most produce the same torque in both senses. Also
output torque is generally constant throughout the stroke. There is no linkages and lost motion
associated with cylinder- crank rod arrangement.
While the most often used actuators for pneumatic drives are cylinders for translational movements,
there are many applications that require a turning or twisting movement of up to 360 degrees.
Examples are turning components over in a drilling jig, providing a wrist action on a pick-and-place
device or operating process valves. They are used in bench grinders, agitators, mixers, feeders,
hoists, vibrators, pipe threaders etc.

i) Single Vane limited rotation actuators

The single vane actuator consists of a cylindrical housing, through which passes a central shaft to
which the vane is rigidly attached. The housing has shoe or a stopper fixed to internal diameter of
housing as shown in the Figure 1.43(a), thus dividing the interior space into two chambers.
Pressurised air enters through port A and rotates the vane in the clockwise direction and air in the
other chamber moves out of the port B. Similarly, when the air pressure is applied to the port B, the
vane rotates in anti-clockwise direction and air in the other chamber moves out of the port A. Design
geometry normally limits the rotary movement of a single vane actuator to about 280 maximum

ii) Double vane limited rotation actuators

It is possible to modify the design to have two vanes fixed to the output shaft 180 apart and two
fixed stoppers in the casing providing two separate operating halves each with two chambers as
shown in Figure 1.43(b). This gives twice the maximum torque output of a single vane device for the
same supply pressure. Obviously the maximum angle of rotation is reduced and because of second
stopper only 100 is usually possible.

Figure 1.43 Vane actuators a) single vane b) double vane

 iii) ANALYSIS OF TORQUE CAPACIT OF SINGLE VANE LIMITED ROTATION ACTUATOR

RR  Outer radius of the output shaft (m)

RV  Outer radius of the vane (m)
L  Width of the vane (m)
p  Hydraulic pressure (Pa)
F  Hydraulic force acting on the vane (N)
A  Surface area of vane in contact with oil (m2 )
T  Torque capacity (N m)

The force on the vane equals the pressure times the vane surface area: ( RV  RR )
L
F  pA  p( RV  RR ) L
The torque equals the vane force times the mean radius of the vane:
R  RR
T  p( RV  RR ) L V
2
On rearranging, we have
T  p(R2V  R2R )L ----- (1)
A second equation for torque can be developed by noting the following relationship for volumetric
displacement VD .:
VD  π ( R2V  R2R ) L ----- (2)
Combining equation 1 and 2 yields
p  VD
T
2π ------- (3)

For a two vane actuator the theoretical torque is twice that for a single vane. For the given design and
style of vane actuator the torque rating is directly proportional to the maximum supply pressure. The
volume displacement of a single vane actuator is given by

Where is rotary movement in radians

From this speed of rotation (rad/s) can be calculated for a supplied flow rate Q(mL/s) with the
width and both diameters expressed in cm as

Although the total volume in a two vane actuator will be the same for the same body size, its speed
will be halved for the same flow rate because two chambers must be filled. If necessary, speed can be
controlled by throttling or by fitting orifice plugs controlling inflow or outflow. The most critical
feature of the vane actuator is the length requiring sealing around the vane between the end faces and
the internal bore of the casing. Since this a moving seal there is usual compromise between good
sealing with low leakage and resulting higher friction. The sealing surface with the bore is also at the
largest radius and operating at the higher sliding speed. Seals are usually pressure activated and may
give a nonlinear torque relation with the pressure. In addition to the vane seal, further seals are
required on the shaft where it emerges from the body of the actuator and between the shaft and the
fixed stopper. The problem of leakage may also be evident where the actuator has to be locked with
the load held by a pressurized fluid column as in a linear cylinder. The lock will not be positive due
to internal leakage unless provision is made to supply extra fluid to compensate for the leakage. The
shaft support may be plain bearing, roller bearing or needle roller type. Friction is responsible for the
difference between the starting torque and dynamic torque. Starting torque can be estimated as 80%
of the dynamic torque. Overall efficiency of vane actuator is between 70 % to 90%.

1.11.2 Rotary Actuator of Rack and Pinion Type

Schematic diagram of rotary actuator of rack and pinion type is shown in Figure 1.44. They are
special duty rotary actuators. It has a high torque and small installation dimensions. The actuator has
double pistons, which transmit the turning moment to the output shaft. The toothed piston rods act on
the output shaft in a rack-and-pinion type arrangement. Each piston and toothed rod is of integral
construction. The rack-and pinion type arrangement gives an even turning moment throughout the
rotation movement. The drive shaft is robustly supported in bushings of self-lubricating type. There
are key-ways on the output end of the shaft, while the opposite end of the shaft has a stub that can be
used to accommodate end-position indication, or to facilitate hand operation of the actuator. The
turning limits of the rotary actuator should be determined by external stop lugs, in order to protect
the unit from the effects of excessive load inertia. Compressed air is fed into the piston chambers via
a connection plate and drilled galleries in the central part and end covers. This rotary actuator has a
cylinder block of natural anodized aluminum, with end covers of black anodized aluminum. The unit
is available in 5 different sizes, covering a turning-moment range of 20 to 200 Nm. As standard, all
sizes are available with a turning angle of either 90° or 180°. Three dimensional view of Rack and
pinion type is shown in Figure 1.45
 Input rack Stroke adjuster

Output pinion

Figure 1.44 Rotary Actuator of Rack and Pinion Type (single rack)

Figure 1.45 Three dimensional view of Rotary Actuator of Rack and Pinion Type

Torque can be doubled by adding another actuator as shown in the Figure 1.46
 Adjustable Single acting Pinion connected
cushion cylinder to output shaft Stroke adjuster

Rack

Figure 1.46 Rotary Actuator of Rack and Pinion Type (two rack)

5.11.3 Helix spine rotary actuator

Figure 1.47 shows a simplified cutaway view of a spiral-shaft rotary actuator. Thespiral-shaft rotary
actuator has a keyed, non-rotating piston with a hollow rod. The hollow rod has a set of internal
spiral grooves that mesh with the spiral shaft. The spiral-grooved shaft only has rotational movement
and extends through the housing as an output shaft. With fluid piped to the CW port, the output shaft
turns clockwise. With fluid piped to the CCW port, the output shaft turns counter clockwise

Keyed Non rotating

Port - CW piston Port - CCW

Output shaft

Hollow rod Spiral shaft

Figure 1.47 Helix spine rotary actuator

Objective Type Questions

1. Single acting cylinders can produce work in -------------- direction

2. In---------------------- type of cylinder, the force on the piston rod is almost doubled.
3. Telescopic cylinders are normally used for ----------------- stroke lengths
4. In first order lever system, fixed hinge point is located ----------- the cylinder and loading point
1. Cylinder with -------mounting generally require strong machine frames to resist bending moments

6. The single acting cylinder converts the compressed air energy into ------in the form of force and
linear movement in one direction only.

7. Pneumatic ------ element convert the energy in the compressed air into force and motion. The
pneumatic drive elements can move in a linear, reciprocating or rotating motion.

8. Typically, the piston can have diameters of as much as ---- mm

9.------- acting cylinders are used in the assembling and packing automated lines to move, lift, feed,
eject, press or push objects or to clamp parts. Practically, they are suitable for oil- free operation.

10. The compressed air is applied only on the bottom side of the piston that is why the cylinder can
move loads or perform mechanical work in a forward motion only and that the effective force is
reduced by the ---------

11.The working speed of piston is in the range of 50 to ----- mm/s

12 In -----------type of cylinder , it is equipped with a compressible chamber with flexible sides that
can be expanded to draw air in and compressed to force the air out

13.An alternative construction is a single acting cylinder, spring ------- with a spring in the piston
area causing the piston to extend. Such pistons are used in the automotive industry and these are
mounted in the air brakes for vehicles and trains

14.Another special form of single-acting cylinders is -------return spring in which the piston’s return
stroke is caused by external forces or by its own weight.

11.Short stroke cylinders are used when short strokes are required together with high ------
State True or False
1. Telescopic cylinder is used when long stroke length and short retracted length are required.

2.. Compared to first class lever, Second-class lever also results in a smaller load stroke for a given
cylinder stroke

3 For a second-class lever system the cylinder rod pin lies between the load road pin and fixed-hinge
pin of the lever.

4. In first order lever system, the loading point is in between the cylinder and the hinge point.

1. In pneumatic cylinders dynamic thrust can be taken as 0.1 times the static thrust

Review Questions

1. What is the function of a pneumatic actuator?

2. How can you classify the pneumatic actuators?

3. How do hydraulic actuators differ from pneumatic actuators?

4. What is the function of a pneumatic cylinder?

1. Explain the working of double acting double rod cylinder with a neat sketch

6. Explain the working of tandem and telescopic cylinders with a neat sketch

7. Mention few applications of pneumatic cylinders

8. Differentiate between single acting and double acting cylinder

9. What are the main advantages of magnetic cylinder?

Answers

Fill in the Blanks

1. only one
2. Tandem
3. long
4. in-between
1. non-centreline
6. mechanical energy
7. drive
8. 100mm
9. single
10. return spring
11. 500
12. diaphragm
13.extend
14. without
11. forces

State True or False

1. True
2. True
3. False
4. False
1. False
 Lecture 38

PNEUMATIC CONTROL VLAVES

Learning Objectives

Upon completion of this chapter, Student should be able to

Define the function of a valve

Classify the valves
Identify the DCVs as per ISO designation
Explain the various types of Directional control valves
Explain the various method of valve actuation
Describe the function of various Non return valves
Understand the working of quick exhaust valves
Differentiate pressure control valve and sequence valve

1.1 VALVES

Valve are defined as devices to control or regulate the commencement, termination and direction and
also the pressure or rate of flow of a fluid under pressure which is delivered by a compressor or
vacuum pump or is stored in a vessel.

Values of one sort or another, perform three main function in pneumatic installation

 They control the supply of air to power units, example cylinders

 They provide signal which govern the sequence of operation
 They act as interlock and safety devices

The type of valve used is of little importance in a pneumatic control for most part. What is important
is the function that can be initiated with the valves, its mode of actuation and line connection size,
the last named characteristics also determining the flow size of the valve. Valves used in pneumatics
mainly have a control function that is when they act on some process, operation or quantity to be
stopped. A control function requires control energy, it being desirable to achieve the greatest possible
effect with the least effort. The form of control energy will be dictated by the valve’s mode of
actuation and may be manual, mechanical, electrical hydraulic or pneumatic.

Valve available for pneumatic control can be classified into four principal groups according to their
function:
 1. Direction control valve
2. Non return valves
3. Flow control valves
4. Pressure control valves

1.2 DIRECTION CONTROL VALVES

Pneumatic systems like hydraulic system also require control valves to direct and regulate the flow
of fluid from the compressor to the various devices like air actuators and air motors. In order to
control the movement of air actuators, compressed air has to be regulated, controlled and reversed
with a predetermined sequence. Pressure and flow rates of the compressed air to be controlled to
obtain the desired level of force and speed of air actuators.

The function of directional control valve is to control the direction of flow in the pneumatic circuit.
DCVs are used to start, stop and regulate the direction of air flow and to help in the distribution of air
in the required line.

6.2.1 TYPES OF DIRECTION CONTROL VALVES

Directional valves control the way the air passes and are used principally for controlling
commencement, termination and direction of air flow. The different classification scheme of the
pneumatic cylinders are given below

1. Based on construction

i) Poppet or seat valves

- Ball seat valve

- Disc seat valve

- Diaphragm Valves

ii) Sliding spool valves

- Longitudinal slide valve

- Suspended spool valves

- Rotary spool valves

2. Based on the Number of ports

 i) Two way valves

ii) Three way valves

iii) Four way valves

3. Based on methods of actuation

i) Mechanical

ii) Electrical

iii) Pneumatic

4. Based on Size of the port

Size refers to a valve’s port size. The port sizes are designated as M5, G1/8, and G1/4 etc. M refer to
Metric thread, G refer to British standard pipe (BSP) thread.

5. Based on mounting styles

i) Sub base

ii) Manifold

iii) In-line

iv) Valve island

6.2.1.1 ISO DESIGNATION OF DIRECTION CONTROL VALVES

Valves are represented by symbols because actual construction is quite complex. A symbol specifies
function of the valve, method of actuation, no of ports and ways. Pneumatic symbols have been
standardised in ISO 1219-1:2006. (Fluid power systems and components – Graphic symbols and
circuit diagram). Another standard ISO 1219-2:1995 establishes the rules for drawing diagrams of
fluid power systems using symbols from ISO 1219-1. Port designations are described in ISO 5599.

Port markings: As per the ISO 5599, ports are designated using a number system. Earlier, a letter
system was used to designate a port. Table 1.1 gives port markings.
Port Old (Letter) system ISO (Number) System Remarks
Pressure port P 1 Supply port
Working port A 2 3/2 DCV
Working ports A, B 4, 2 4/2 or 5/2 DCV
Exhaust port R 3 3/2 DCV
Exhaust ports R, S 5,3 %/2 DCV
Pilot ports Z or Y 12 Pilot line (flow 1-2)
Pilot ports Z 14 Pilot line (flow 1-4)
Pilot ports Z or Y 10 Pilot line (no flow)
Internal pilot ports Pz, Py 81, 91 Auxiliary pilot line

Table 1.1: Port Markings of Direction Control Valve

Ports and position: DCVs are described by the number of port connections or ways they control.
For example: Two way, three – way, four way valves. Table 1 shows the Port markings of DCVs and
Table 1.2 shows commonly used DCVs with old and new designations.

Table 1.2: Port designation of DCV

Port and position
2/2 Directional control
2(A)
valve
Port

1(P) Positionn

3/2 Directional control

2(A) valve
(normally closed)

1(P) 3(R)

2(A) 3/2 Directional control

valve
(normally open)
1(P) 3(R)

4/2 Directional control

4(A) 2(B) valve

1(P) 3(R)
 4(A) 2(B) 5/2 Directional control
valve

5(R) 3(S)
1(P)
5/3 Directional control
valve
4(A) 2(B)

5(R) 3(S)
1(P)

1.2.1.2 POPPET DIRECTION CONTROL VALVES

There are two different types of poppet valves, namely ball seat valve and disc seat valve.

A.Ball seat valve.

In a poppet valve, discs, cones or balls are used to control flow. Figure 1.1 shows the construction of
a simple 2/2 normally closed valve. If the push button is pressed, ball will lift off from its seat and
allows the air to flow from port P to port B. When the push button is released, spring force and air
pressure keeps the ball back and closes air flow from port P to port B. Valve position are shown in
Figure 1.1(a) 1.1 (b) 1.1(C)

(c) Symbol

Figure 1.1 Two/Two Ball seat Poppet valve

B. Disc seat poppet valve
Figure 1.2 shows the construction of a disc type 3/2 way DCV. When push button is released, ports 1
and 3 are connected via hollow pushbutton stem. If the push button is pressed, port 3 is first blocked
by the moving valve stem and then valve disc is pushed down so as to open the valve thus
connecting port 1 and 3. When the push button is released, spring and air pressure from port 1 closes
the valve.. Comparison between Ball seat and disc seat valve is given in Table 1.3

Figure 1.2 Disc seat poppet valve

Advantages of poppet valves are as follows

i) Response of poppet valve is very fast- short stroke to provide maximum flow opening
ii) They give larger opening (larger flow) of valves for a small stroke
iii) The valve seats are usually simple elastic seals so wear is minimum
iv) They are insensitive to dust and dirt and they are robust, seats are self cleaning
v) Maintenance is easy and economical.
vi) They are inexpensive
vii) They give longer service life: short stroke and few wearing parts give minimum wear and
maximum life capabilities

Disadvantages of poppet valves are as follows

i) The actuating force is relatively high, as it is necessary to overcome the force of the built
in reset spring and the air pressure.
ii) They are noisy if flow fluctuation is large.

Table 1.3 Comparison of Ball seat and Disc seat valves

Ball seat valves Disc seat valve
They are inexpensive Offer large area and lift required is very small
They are relatively small in size Time response is good
Insensitive to dirt and dust Insensitive to dirt and dust
Can be operated manually or mechanically Can be actuated manually , mechanically,
electrically or pneumatically

C.Diaphragm valves

The diaphragm between the actuator and valve body hermetically isolates the fluid from the actuator.
The valves are maintenance-free and extremely robust and can be retrofitted with a comprehensive
range of accessories, e.g. electrical position feedback, stroke limitation or manual override. Figure
1.4 shows unactuated and actuated position of diaphragm valves.

a) Unactuated b) actuated

Figure 1.4 Diaphragm valve: unactuated position, actuated position

Closed position: When de-energized, the valve is closed by spring action
Open position: If the actuator is pressurized by the control pressure, it simultaneously lifts the
control piston and the valve spindle to open the valve.

6.2.1.3 SPOOL DIRECTION CONTROL VALVES

A. Hand operated 3/2 DCV

The cross sectional views of 3/2 DCV (normally closed) based on spool design is shown below.
When the valve is not actuated, port 2 and 3 are connected and port 1 is blocked. When the valve is
actuated then port 2 and 1 are connected and port 3 is blocked.
 2

1 2
3

1 3
2

Spool

1 3

Figure 1.5 3/2 Directional control valve (Normally closed)

Figure 1.5 shows schematic diagram of 3/2 spring operated valve. There are three ports common
port, normally open port and normally closed. When the valve is not actuated, there is flow from NO
port to common port. When the valve is actuated there is flow from NC to common port.

B.Pneumatically actuated 3/2 DCV

The cross – sectional views of pneumatically actuated NC type 3/2 DCV in normal position and
actuated positions are shown in the Figure 1.7

1 3 2
(12)

1 3
2

Pilot air (12)

Spool

1 3

Figure 1.7 3/2 Directional control valve (pneumatically operated)

In normal position, the working port (2) is closed to the pressure port (1) and open to the exhaust port
(3). When the compressed air is applied through the pilot port (12), the spool is moved against the
spring. In the actuated position, the working port (2) is open to the pressure port(1) and closed to the
exhaust port(3). Thus, the application of the compressed air to the port 12 causes the pressure port
(1) to be connected to the working port (2).
Pneumatically actuated valves have following advantages

i. Great flexibility for use in simple as well as complex control system

ii. Adaptability for use in safety circuits.
iii. Various control functions can be easily incorporated as and when required
iv. Feedback signals from sensors can be applied conveniently for the purpose of controlling the
pilot ports of these main valves. This means existing pneumatically actuated control circuits
can be modified easily to incorporate any additional control requirement.

C.Pneumatically actuated 4/2 DCV

The valve shown in Figure 1.9 is a 4/2 way valve pneumatically operated DCV. Switch over is
effected by direct application of pressure. If compressed air is applied to pilot spool through control
port 12, it connects port 1 with 2 and 4 is exhausted through port 3. If the pilot pressure is applied to
port 14, then 1 is connected with 4 and line 2 exhausted through port 3. On disconnecting the
compressed air from the control line, the pilot spool remains in its current position until spool
receives a signal from the other control side.

4(A) 2(B) 4(A) 2(B)

1(P) 3(R) 1(P) 3(R)

Figure 1.9 Schematic diagram of 4/2 way valve

D. Suspended Disc Direction Control Valves
This valve is quite similar to 4/2 way spool valve. Schematic diagram is shown in Figure 1.11. In this
design disc is used instead of a spool. This suspended disc can be moved by pilot pressure or by
solenoid or by mechanical means. In this design, main disc connects port 1 to either port 4 or 2. The
secondary seat discs seal the exhaust port 3 whichever is not functional. These values are generally
provided with manual override to manually move the cylinder.

4 2
4( 2(B
A) )

1(P) 3(R

3 1 3 )
4 2
4(A 2(B)
)

1(P) 3(R)

3 1 3

Figure 1.11 4/2 Directional control valve (suspended disc type)

Figure 1.12 below shows 5/2 way valve which uses suspended disk instead of spool. In spool type
valve, spool controls the opening and closing of ports. In this type, suspended disc controls the
opening and closing of ports. This suspended disc can be moved by pilot pressure at port 14 or port
12. When the pilot pressure acts through port 14. The ports 1 - 2 and 4 - 5 are connected and 3 is
blocked. When the air is given to pilot line 12, then 2 - 3 and 4 -1 are connected and 5 is blocked

Figure 1.12 5/2 Directional control valve (suspended disc type)

Advantages

i) They have short actuation movement

ii) They are quick to operate because of small switching movement
iii) If signals are applied at both ports, first signal will be dominant

Disadvantages

i) Construction of the valve is complex

ii) Expensive

E.Rotary valves

The rotary spool directional control valve (Figure 1.13) has a round core with one or more
passages or recesses in it. The core is mounted within a stationary sleeve. As the core is rotated
within the stationary sleeve, the passages or recesses connect or block the ports in the sleeve. The
ports in the sleeve are connected to the appropriate lines of the fluid system.

Figure 1.13 Parts of a rotary spool directional control valve.

Figure 1.14 shows the construction of a rotary spool directional control valve. We connect different
ports by rotating the handle. By rotating the handle, core gets connected to different holes to give the
required configuration of the valve. This type of the valve can be directly mounted on panel using
bolt.

Figure 1.15 shows three different position of the core when the handle is rotated. Left most envelope
of DCV connects P to B and A to T. Middle envelope of DCV blocks all ports. Right most envelope
of DCV connects P to A and T to B.
 Figure 1.15 Three different positions of 4/3 way rotary spool directional control valve.

Table 1.4 shows schematically the different position of core and sleeve for various middle position of
4/3 way Direction control valve.

Table 1.4 Different position of core and sleeve for various mid position of 4/3 DCV
6.2.1.5 METHODS OF ACTUATION.
The methods of actuation of pneumatic directional control valves depend upon the requirements of
the task. (Table 1.5) The types of actuation vary;

 manually actuated
 mechanically actuated
 pneumatically actuated
 electrical
 combined actuation

The symbols of the methods of actuation are detailed in DIN ISO 1219. When applied to a
directional control valve, consideration must be given to the method of initial actuation of the valve
and also the method of return actuation. Normally these are two separate methods. They are both
shown on the symbol on either side of the position boxes. There may also be additional methods of
actuation such as manual overrides, which are separately indicated.

Table 1.5 Methods of actuation

Type of actuation Type of control Symbol

Manual General

Pushbutton

Detent lever operated

Foot pedal

Mechanical Spring return

Spring centered
 Roller operated

Idle roller

Pneumatic Direct

Indirect, pilot operated

Electrical Single solenoid

Double solenoid

Combined Double solenoid with pilot

operated

1.2.1.7 BASED ON MOUNTING STYLES

Directional control valves can be mounted in two ways; inline and subplate.

Inline means that there are threaded connections in the valve itself. Fittings are screwed directly into
the valve. This method has several disadvantages. Each time the valve is disconnected there is the
possibility of damaging the valve by stripping the threads. The threads will also wear each time the
unit is disconnected, causing contamination and an increased possibility of leakage. In the subplate
method, the bottoms of the valves have unthreaded connections. The valve is then attached to a
subplate that has matching connections.

The subplate has the threaded connection to which the fittings are attached. Sealing at the valve
/subplate interface is accompanied through the use of o-rings, which fit into small recesses around
the DCV ports. The subplate methods results in less leakage, less contamination, and a smaller
probability of doing damage to the valve during assembly and disassembly. Valve replacement is
simpler and less time – consuming task.
 Figure 1.34 Manifold for three valves

1.2.2 NON RETURN VALVES

Non return valves permit flow of air in one direction only, the other direction through the valve being
at all times blocked to the air flow. Mostly the valves are designed so that the check is additionally
loaded by the downstream air pressure, thus supporting the non-return action.

Among the various types of non-return valves available, those preferentially employed in pneumatic
controls are as follows

i) Check valve
ii) Shuttle valve
iii) Restrictor check valve
iv) Quick exhaust valve
v) Two pressure valve

A. Check valve

The simplest type of non-return valve is the check valve (Figure 1.35 (a)) , which completely
blocks air flow in one direction while permitting flow in the opposite direction with minimum
pressure loss across the valve. As soon as the inlet pressure in the direction of free flow develops
a force greater than that of the internal spring, the check is lifted clear of the valve seat. The
check in such valve may be plug, ball, plate or diaphragm.
 Figure 1.35 Check valve

B. Shuttle valve

It is also known as a double control valve or double check valve. A shuttle valve has two inlets and
one outlet. At any one time, flow is shut off in the direction of whichever inlet is unloaded and is
open from the loaded inlet to the outlet (Figure 1.36). A shuttle valve may be installed, for example,
when a power unit (cylinder) or control unit (valve) is to be actuated from two points, which may be
remote from one other.

Figure 1.36 Shuttle valve

C. Restrictor check valve

It also termed speed control valve for pneumatic applications are actually hybrid type of unit. By
reason of their throttling function they are flow control valves and they are indeed used as flow
control valves in pneumatics. Incorporation of check function also makes them non –return valves
and it is as such that they are generally classified.

Usually the throttle of a restrictor check valve is adjustable so as to permit regulations of air flow
through the valve. Throttling function is effective only in one direction of flow, while in the other
direction free flow is provided through the check.(Figure 1.37). When restrictor check valves are
used to control the speed of pneumatic cylinders, differentiation is made between supply-air and
exhaust air-throttling.

Figure 1.37 Functional diagram of restrictor check valve.

D. Quick Exhaust Valves

A quick exhaust valve is a typical shuttle valve. The quick exhaust valve is used to exhaust the
cylinder air quickly to atmosphere. Schematic diagram of quick exhaust valve is shown in Figure
1.38. In many applications especially with single acting cylinders, it is a common practice to increase
the piston speed during retraction of the cylinder to save the cycle time. The higher speed of the
piston is possible by reducing the resistance to flow of the exhausting air during the motion of
cylinder. The resistance can be reduced by expelling the exhausting air to the atmosphere quickly by
using Quick exhaust valve.
 2 2

1 3 1 3

Figure 1.38 Functional diagram of quick exhaust valve.

The construction and operation of a quick exhaust valve is shown in Figure 1.38. It consist of a
movable disc (also called flexible ring) and three ports namely, Supply port 1, which is connected to
the output of the final control element (Directional control valve). The Output port, 2 of this valve is
directly fitted on to the working port of cylinder. The exhaust port, 3 is left open to the atmosphere

Forward Motion: During forward movement of piston, compressed air is directly admitted behind
the piston through ports 1 and 2 Port 3 is closed due to the supply pressure acting on the diaphragm.
Port 3 is usually provided with a silencer to minimise the noise due to exhaust.

Return Motion: During return movement of piston, exhaust air from cylinder is directly exhausted
to atmosphere through opening 3 (usually larger and fitted with silencer) .Port 2 is sealed by the
diaphragm. Thus exhaust air is not required to pass through long and narrow passages in the working
line and final control valve

Typical applications of quick exhaust valves for single acting and double acting cylinders are shown
in Figure 1.39
 2
2
1 1
3 3
Quick return Quick return valve
2
valve
4 2

1 3 5 3
1

Figure 1.39 Application of quick exhaust valve.

E. Two Pressure Valve

This valve is the pneumatic AND valve. It is also derivate of Non Return Valve. A two pressure
valve requires two pressurised inputs to allow an output from itself. The cross sectional views of two
pressure valve in two positions are given in Figure 1.40 As shown in the figure, this valve has two
inputs 12 and 14 and one output 2. If the compressed air is applied to either 12 or input 14, the spool
moves to block the flow, and no signal appears at output 2. If signals are applied to both the inputs
12 and 14, the compressed air flows through the valve, and the signal appears at output 2.

No output
No output

Figure 1.40 Two pressure valve.

1.2.3 FLOW CONTROL VALVES

Function of a flow control valve is self –evident from its name. A flow control valve regulates the
rate of air flow. The control action is limited to the air flow passing through the valve when it is
open, maintaining a set volume per unit of time. Figure 1.41(a) shows a variable restrictor type flow
control valve (manifold type). Figure 1.41(b) shows a variable restriction type flow control valve
(inline type). Figure 1.42 shows another design of Flow control valve, in which flow can be set by
turning the knob.

Figure 1.41 Flow control valve a) manifold b) inline

Figure 1.42 Flow control valve (adjustable)

1.2.4 PRESSURE CONTROL VALVE.

Compared with hydraulic systems, few pressure control valves are brought into use in pneumatics.
Pressure control valves control the pressure of the air flowing through the valve or confined in the
system controlled by the valve.

There are three types of pressure control valves

1. Pressure limiting valve

 2. Pressure sequence valve
3. Pressure regulator or pressure reducing valve

A.Pressure limiting valve.

Prevents the pressure in a system from rising above a permissible maximum. Construction feature of
pressure limiting valve is shown in Figure 1.43. It is a standard feature of compressed air production
plant but is hardly ever used in pneumatic controls. These valves perform a safety relief function by
opening to the atmosphere if a predetermined pressure is exceeded in the system, thus releasing the
excess pressure. As soon as the pressure is thus relieved to the desired figure, the valve closed again
by spring force.

Figure 1.43 Pressure limiting valve

B.Pressure sequence valve

Function of the sequence valve is very similar to that of a pressure limiting valve. It is however used
for a different purpose. Outlet of the pressure sequence valve remains closed until pressure upstream
of it builds up to a predetermined value. Only then the valve opens to permit the air from inlet to
outlet. Sequence valve must be incorporated into a pneumatic control where a certain minimum
pressure must be available for a given function and operation is not be initiated at any pressure lower
than that. There are also used in systems containing priority air consumers, when other consumers
are not to be supplied with air until ample pressure is assured.
C.Pressure reducing valve or regulator

Pressure regulators, commonly called pressure-reducing valves, maintain constant output pressure in
compressed-air systems regardless of variations in input pressure or output flow. Regulators are a
special class of valve containing integral loading, sensing, actuating, and control components.
Available in many configurations, they can be broadly classified as general purpose, special purpose,
or precision. Three dimensional view of pressure reducing valve is shown in Figure 1.44

General-purpose or utility regulators have flow and regulation characteristics that meet the
requirements of most industrial compressed-air applications. Such regulators provide long service
life and relative ease of maintenance at competitive prices. Precision regulators are for applications
where regulated pressure must be controlled with close tolerances. Such regulators are used when the
outcome of a process or the results of a test depend on accurate pressure control.

Special-purpose regulators often have a unique configuration or special materials for use with fluids
other than compressed air. Regulator construction can range from simple to complex, depending on
the intended application and the performance requirements.

However, the principle of operation and the loading, actuating, and control components are basic to
all designs. Most regulators use simple wire coil springs to control the downstream pressure. Various
size springs are used to permit regulation of the secondary pressure within specific ranges. Ideally,
the required pressure should be in the center one-third of the rated outlet pressure range. At the lower
end of the pressure range, the spring loses some sensitivity; at the high end, the spring nears its
maximum capacity.

Regulators can use either a piston or diaphragm to sense downstream pressure. Diaphragms are
generally more sensitive to pressure changes and react more quickly. They should be used where
sensitive pressure settings are required (less than 0.0025 bar). Pistons, on the other hand, are
generally more rugged and provide a larger effective sensing area in a given size regulator. The
functional difference between precision and general-purpose regulators is the degree of control
accuracy of the output pressure. Output pressure accuracy is determined by the droop due to flow
changes (regulator characteristics).

Pressure droop is most pronounced when the valve first opens. Factors contributing to droop are:
load change with spring extension, effective area change with diaphragm displacement, and
unbalance of area forces on the valve. The amount that output pressure changes with variations in
supply pressure is called the regulation characteristic and is influenced by the ratio of diaphragm area
to valve area and the degree of valve unbalance.
 Figure 1.44 Three dimensional figure of pressure regulating valve.

When selecting a pressure regulator, the important factors to consider are:

1. Normal line pressure.

2. Minimum and maximum regulated pressure required: Regulators can have a broad
adjustment range and may require a specific spring or accessory to match the requirements.
Also, minimum and maximum pressure should be within the middle third of the regulator
range.

3. Maximum flow required at regulated pressure.

4. Pipe size: Not all regulators are available in all pipe sizes; note where adapters are required.
Also, pipe size should be consistent with flow requirements.

5. Regulator adjustment frequency: A number of different adjusting methods are possible. When
selecting a regulator, consider the location, application, adjusting method, and user.

6. Degree of pressure precision required.

7. Accessories or options include gages and panel mounting.

8. Environmental or fluid conditions that could be incompatible with materials used in the
regulator.

9. Special features such as high relief or remote control.

10. The consequences of a regulator malfunction or failure: A damper or relief valve might be
needed to protect personnel or equipment. Also, dead-end service or intermittent actuation
may require positive valve shutoff, bleed units, or close control of pressure-relief points.
Filters, lubricators, relief devices, and other system options should be considered in the
selection process.
Objective Type Questions

1. Valves are defined as devices to control, or regulate the commencement and -------of air
2. On resetting valves, for example those equipped with a return spring, the -----position is the
position assumed by the moving parts of the valve when it is connected but not actuated.
3. Direct control of a valve means that valve is caused to operate directly by actuating element
without any -----------elements being operated.
4. ----------------automatically limit flow to a single direction at the point where they are installed in
an air line.
5. In pressure regulating valve inlet pressure is ----------than the outlet pressure.

6. Poppet valves give --------- stroke and few wearing parts give minimum wear

7. The quick exhaust valve is used to exhaust the cylinder air quickly to -----------------
8. compared with hydraulic systems, -----varieties of pressure control valves are used in pneumatics

9. As per ISO 1219-1:2006 designation, number 12 or 14 indicate -------------- ports

10. In rotary spool directional control valve , rotating part is called ----- and stationary part is
called-----

11. The two most common basic flow control devices used in a pneumatic system are fixed-sized
orifices and _____ valves.

12.The meter ----flow-control circuit is the preferred method to use for controlling the operating
speed of cylinders in pneumatic circuits.

State True or False

1. Restrictor check valves are non return valves which are also employed as flow control valves.

2. Quick exhaust valves are designed to decrease the position speed in the cylinder

3 spring force set on a pressure limiting valve or sequence valve corresponding to minimum
permissible or minimum desired pressure of the controlled fluid.

4. Ball seat valves ensure perfect sealing at all times in pneumatic circuit

5. Two way valves are used where a pure straightway function is required, that is when downstream
equipment does not need exhausting to the atmosphere via this valve.

6. The pressure sequence valve holds the working pressure largely constant.

7. Two pressure valve is the pneumatic OR valve

8. Shuttle valve is the pneumatic OR valve.

9. Pressure loss in manifold type valve is more than inline type valves

10. Suspended disc type valve has very long actuation movement

Review Questions

1. List the function of a pneumatic Valve?

2. How can we classify the pneumatic valves?

3. How can we classify Direction control valve( DCV)

3. How do 2/2 way differ from 4/2 way pneumatic Direction control valve

4. What are the advantages of poppet valve over ball valve

5. Explain the working of 3/2 Direction control valve with a neat sketch

6. Explain the working of 5/3 Direction control valve with a neat sketch

7. Mention few applications of 4/3 Direction control valve

8. Differentiate between Rotary valve and spool type valve

9. How do you classify Non return valves?

10. Mention few applications of Non return valves

11. Explain with the help of neat sketch the construction and working of quick exhaust valves

12. How do you classify Pressure control valves?

13. Explain the difference between pressure limiting valve and sequence valve

14. Explain the working of pressure limiting valve

15. Compare and contrast two way valve and shuttle valve. Mention its application.
Answers

Fill in the Blanks

1. direction
2. neutral
3. intermediate
4. Non return valves
5. higher
6. Shorter
7. atmosphere.
8.few
9. pilot
10. core/sleeve
11. Needle
12 Out

State True or False

1. True
2. False
3. False
4. False
5. True
6. True
7. False
8. True
9. False
10. False
 Lecture 39

SINGLE ACTUATOR CIRCUITS

Learning Objectives

Upon completion of this chapter, Student should be able to

Differentiate between pneumatic circuit and pneumatic circuit diagram

State basic rules used in design of pneumatic circuits
Explain the memory, delay, OR , AND and NOT functions
Explain the direct and indirect control of single acting cylinder
Explain the direct and indirect control of double acting cylinder
Differentiate supply and exhaust air throttling
Study various methods of checking end positions of a cylinder
Design pressure and time dependant circuits

1.1 Pneumatic circuit and pneumatic circuit diagram.

Pneumatic control systems can be designed in the form of pneumatic circuits. A pneumatic circuit is
formed by various pneumatic components, such as cylinders, directional control valves, flow control
valves, pressure regulator, signal processing elements such as shuttle valve, two pressure valve etc.
Pneumatic circuits have the following functions
 To control the entry and exit of compressed air in the cylinders.
 To use one valve to control another valve
 To control actuators or any other pneumatic devices

A pneumatic circuit diagram uses pneumatic symbols to describe its design. Some basic rules must
be followed when drawing pneumatic diagrams.

To be able to design pneumatic circuits, it is better for one to have basic knowledge on the designing
simple pneumatic circuits. With this foundation, one would be able to move on to the designing more
complicated circuits involving many more cylinders.
1.2 SINGLE ACTING CYLINDER CONTROL

1.2.1 DIRECT CONTROL OF SINGLE ACTING CYLINDER.

2 2

1 1 3
3
Figure 1.1 Direct control of a single acting cylinder

Pneumatic cylinders can be directly controlled by actuation of final directional control valve (Figure
1.1 ). These valves can be controlled manually or electrically. This circuit can be used for small
cylinders as well as cylinders which operates at low speeds where the flow rate requirements are less.
When the directional control valve is actuated by push button, the valve switches over to the open
position, communicating working source to the cylinder volume. This results in the forward motion
of the piston. When the push button is released, the reset spring of the valve restores the valve to the
initial position [closed]. The cylinder space is connected to exhaust port there by piston retracts
either due to spring or supply pressure applied from the other port.

Example 1: A small single acting cylinder is to extend and clamp a work piece when a push button
is pressed. As long as the push button is activated, the cylinder should remain in the clamped
position. If the push button is released, the clamp is to retract. Use additional start button. Schematic
diagram of the setup is shown in Figure 1.2

Figure 1.2
 Solution

The control valve used for the single acting cylinder is the 3/2 way valve. In this case, since
the cylinder is of small capacity, the operation can be directly controlled by a push button 3/2
way directional control valve with spring return.

3/2 NC -DCV 3/2 NC -DCV

2 2
12 1 12 12
12

Start valve
12 12

1 1

a) Cylinder unclamping work b) Cylinder clamping work

Figure 1.3

When start button and 3/2 NC valve is operated, cylinder moves forward to clamp the work piece.
When start button and 3/2 way valve is released cylinder comes back to the retracted position as
shown in Figure 1.3
1.2.2 INDIRECT CONTROL OF SINGLE ACTING CYLINDER

2 Start valve 2
12 12

3 1 3
1

3/2 NC -DCV

1 3 1 3

Figure 1.4 Indirect control of a single acting cylinder

This type of circuit (Figure 1.4) is suitable for large single cylinders as well as cylinders operating at
high speeds. The final pilot control valve is actuated by normally closed 3/2 push button operated
valve. The final control valves handle large quantity of air. When the push button is pressed, 3/2
normally closed valve generate a pilot signal 12 which controls the final valve thereby connecting
the working medium to piston side of the cylinder so as to advance the cylinder. When the push
button is released, pilot air from final valve is vented to atmosphere through 3/2 NC – DCV.

The signal pressure required can be around 1-1.5 bar. The working pressure passing through the
final control valve depends on the force requirement which will be around 4-6 bar. Indirect control
as permits processing of input signals. Single piloted valves are rarely used in applications where the
piston has to retract immediately on taking out the set pilot signal.

Example 2: A large single acting cylinder is to extend and clamp a work piece when a push button is
pressed. As long as the push button is activated, the cylinder should remain in the clamped position.
If the push button is released, the clamp is to retract. Use additional start button.
 Valve 3
2

Valve 2
12
12

Valve 1
12
12

a) Cylinder clamping work b) Cylinder unclamping work

Figure 1.5

The control valve used for the single acting cylinder is the 3/2 way valve. In this case, since the
cylinder is of large capacity, the operation cannot be directly controlled by a push button 3/2 way
directional control valve with spring return. Indirect control is to be used as shown in the Figure 1.5

Valve 2 is a small capacity valve which controls the large capacity valve 3. When the valve 2 is
unactuated the cylinder is in the retracted condition. When the valve 2 is actuated the cylinder is in
the extended position to clamp the work piece.

1.2.3 CONTROL OF SINGLE ACTING CYLINDER USING “OR” VALVE

Shuttle valve is also known as double control valve or double check valve. A shuttle valve has two
inlets and one outlet (Figure 1.6). At any one time, flow is shut off in the direction of whichever inlet
is unloaded and is open from the loaded inlet to the outlet. This valve is also called an OR valve. A
shuttle valve may be installed for example, when the cylinder or valve is to be actuated from two
points, which may be remote from one another.
 2 2

Figure 1.6 Shuttle valve ( OR valve)

The single acting cylinder in Figure 1.7 can be operated by two different circuits. Examples include
manual operation and relying on automatic circuit signals, that is, when either control valve  or
control valve  is operated, the cylinder will work. Therefore, the circuit in Figure 1.7 possesses the
OR function.

Figure 1.7 Control of a single acting cylinder using OR valve

1.2.4 CONTROL OF SINGLE ACTING CYLINDER USING “AND” VALVE

This valve is the pneumatic AND valve. It is also derivate of Non Return Valve. A two pressure
valve requires two pressurised inputs to allow an output from itself. The cross sectional views of two
pressure valve in two positions are given in Figure 1.8 As shown in the Figure 1.8, this valve has
two inputs 12 and 14 and one output 2. If the compressed air is applied to either 12 or input 14, the
spool moves to block the flow, and no signal appears at output 2. If signals are applied to both the
inputs 12 and 14, the compressed air flows through the valve, and the signal appears at output 2.
 Figure 1.8 control of a single acting cylinder using OR valve

Another name for an AND function is interlock control. This means control is possible only when
two conditions are satisfied. A classic example is a pneumatic system that works only when its
safety door is closed and its manual control valve is operated. The flow passage will open only when
both control valves are operated. Figure 1.9 shows the circuit diagram of an AND function circuit.
The cylinder will work only when both valve  and  are operated.

Figure 1.9 Control of a single acting cylinder using AND valve

1.2.5 CONTROL OF SINGLE ACTING CYLINDER USING “NOT” VALVE

Another name for a NOT function is inverse control. In order to hold or lock an operating conveyor
or a similar machine, the cylinder must be locked until a signal for cancelling the lock is received.
Therefore, the signal for cancelling the lock should be operated by a normally open type control
valve. However, to cancel the lock, the same signal must also cancel the locks on other devices, like
the indication signal . Figure 1.10 shows how the normally closed type control valve  can be
used to cut off the normally open type control valve  and achieve the goal of changing the signal.
 Figure 1.10 Control of a single acting cylinder using NOT valve

1.3 DIRECT CONTROL OF DOUBLE ACTING CYLINDER

The only difference between a single acting cylinder and a double acting cylinder is that a double
acting cylinder uses a 5/2 directional control valve instead of a 3/2 directional control valve (Figure
1.11). Usually, when a double acting cylinder is not operated, outlet ‘B’ and inlet ‘P’ will be
connected. In this circuit, whenever the operation button is pushed manually, the double acting
cylinder will move back and forth once

Figure 1.11 Direct control of a double acting cylinder

In order to control the speed in both directions, flow control valves are connected to the inlets on
both sides of the cylinder. The direction of the flow control valve is opposite to that of the release of
air by the flow control valve of the single acting cylinder. Compared to the throttle inlet, the flow
control valve is tougher and more stable. Connecting the circuit in this way allows the input of
sufficient air pressure and energy to drive the piston.
Example 3: Pneumatic system is to be designed to operate a door of public transport vehicles.
(Figure 1.12). Assuming that the opening and closing of the doors are controlled by two button
switches ON and OFF. When the button switch ON is pressed, the door will open. When the button
switch OFF is pushed, the doors will close.

Solution.

Figure 1.12 Operation of pneumatic system that controls the door of vehicle

Solution

Solution is given in Figure 1.13, which is self explanatory

Figure 1.13 Pneumatic circuit to control the door of vehicle

1.3.1 IN DIRECT CONTROL OF DOUBLE ACTING CYLINDER USING MEMORY
VALVE

4 2 MEMORY valve 4 2 MEMORY valve

14 12
14 12
5 3
5 3
1 1 RETURN 2
FORWARD 2 RETURN 2 FORWARD 2

1 1 1 3
1 3 3
3

SUPPLY

a) Signal from the valve “Return” b)Signal from the valve “Forward”

Figure 1.14 Indirect control of Double acting cylinder using memory valve

When the 3/2 way valve meant for Forward motion (Figure 1.14b) is pressed, the 5/2 memory valve
switches over through the signal applied to its pilot port 14. The piston travels out and remains in the
forward end position. Double piloted valve is also called as the Memory valve because now even if
this push button meant Forward is released the final 5/2 control valve remains in the actuated status
as the both the pilot ports of 5/2 valves are exposed to the atmosphere pressure and the piston
remains in the forward end position.

When the 3/2 way valve meant for return motion (Figure 1.14a) is pressed, the 5/2 way valve
switches back to initial position through the signal applied to its pilot port 12. The piston then returns
to its initial position and remains in the rear end position. Now even if the Return push button is
released the status of the cylinder will not change.
The circuit is called a memory circuit because it uses a 5/2 way double pilot memory valve. 5/2 way
valve can remember the last signal applied in terms of the position of the spool in the absence of
reset springs, thus memorising or storing the pneumatic signal. Double piloted 4/2 way valve also
can be used as memory valve

1.4 SUPPLY AIR THROTTLING AND EXHAUST AIR THROTTLING

It is always necessary to reduce the speed of cylinder from maximum speed based on selected size of
final control valve to the nominal speed depending on the application. Speed control of Pneumatic
Cylinders can be conveniently achieved by regulating the flow rate supply or exhaust air. The
volume flow rate of air can be controlled by using flow control valves which can be either two way
flow control valve or one way flow control valve
There are two types of throttling circuits for double acting cylinders:
i) Supply air throttling
ii) Exhaust air throttling

1.4.1 Supply air throttling.

This method of speed control of double acting cylinders is also called meter –in circuit (Figure
1.15a). For supply air throttling, one way flow control valves are installed so that air entering the
cylinder is throttled. The exhaust air can escape freely through the check valve of the throttle valve
on the outlet side of the cylinder. There is no air cushion on the exhaust side of the cylinder piston
with this throttling arrangement. As a result, considerable differences in stroking velocity may be
obtained even with very small variations of load on the piston rod. Any load in the direction of
operating motion will accelerate the piston above the set velocity. Therefore supply air throttling can
be used for single acting and small volume cylinders.
 1V1 1V2 1V1 1V2

1S 4 2 4 2
1S

5 3 5 3
1 1

a) Supply air throttling b)Exhaust air throttling

Figure 1.15 Throttling Circuits

1.4.2 Exhaust air throttling.
This method of speed control of double acting cylinders is also called meter-out (Figure 1.15b). In
exhaust air throttling throttle relief valves are installed between the cylinder and the main valve in
such a way that the exhaust air leaving the cylinder is throttled in both directions of the motion of the
cylinder. The supply air can pass freely through the corresponding check valves in each case. In this
case, the piston is loaded between two cushions of air while the cylinder is in motion and hence a
smooth motion of the cylinder can be obtained. The first cushion effect is due to supply air entering
the cylinder through check valve, and second cushion effect is due to the exhaust air leaving the
cylinder through the throttle valve at a slower rate. Therefore, exhaust air throttling is practically
used for the speed control of double acting cylinders. Arranging throttle valves in this way
contributes substantially to the improvement of feed behaviour.

1.5 VARIOUS METHODS OF CHECKING END POSITION OF A CYLINDER

The following methods are commonly used to know the end positions of piston in the cylinder:
a) Mechanically operated limit switches
i) Roller lever type ii) Idle return roller type
b) Reed sensors – Normally used in cylinder with magnetically coupled slide
i) With Electrical output ii) With pneumatic output
c) Electrical proximity switches
d) Pneumatic Signal generators
In this chapter we shall only discuss use of limit switches to get the end position of piston in the
cylinder.

1.5.1 Use of Limit Switches

S1 and S2 are the limit switches corresponding to home position and extended position. Although
they are located in the path of the movement of piston rod, normal practice is to represent the symbol
of the limit switches on either side of the 3/2 way control valve without put signals connected to the
pilot ports of the valve.( in this Figure 1.16 pilot signals actuations are shown for clarity) The limit
switches of Roller lever type are essentially 3/2 way ball seat or disc seat type of valves handling
pneumatic signals. These are available with direct actuation type and internally pilot actuation type
versions. Limit switches of idle return roller type are used for actuation only in one direction are used
as signal elimination device in case of signal overlap.

S1 S2 S1 S2

MEMORY valve
4 2 MEMORY valve 4 2
14 12
14 12

5 3
5 3
1 1 RETURN 2
FORWARD 2 RETURN 2 FORWARD 2

S2 1 S1 1 S2 1 3
S1 1 3 3 3

SUPPLY SUPPLY

a)Signal from the valve “Return” b) Signal from the valve “Forward”

Figure 1.16 : Use of limit switches in pneumatic circuits

1.6 PRESSURE DEPENDENT CONTROLS
Pressure sequence valve is essentially a switch on or off valve. Sequence Valve generates a
pneumatic signal if the sensing pressure [signal input] is more than the desired set pressure. This
generated output signal is used to control the movement of cylinder by using it as a set signal or reset
signal to the final control valve to obtain forward or return motion respectively. Used for applications
such as bonding cylinders, clamping cylinder etc. to ensure desired minimum pressure in the
cylinder. This is a combination valve, having two sections. One of the section is a 3/2 directional
control and the other a pressure control valve. Schematic diagram of pressure sequence vavle is
shown in Figure 1.17

12 1 2 3
12 1 2 3

Figure 1.17: Pressure dependant control valve

Sensing pressure signal is introduced at port 12. Manual adjustment of pressure setting is done with
the help of a cap screw/knob which is spring loaded. Clock wise rotation of knob results setting for
higher pressure setting and anticlockwise rotation of knob results in lower pressure setting. The right
section is basically a 3/2 directional control valve [NC] - pilot operated using pressure signal derived
from left section.

The cross sectional views and symbols of a pressure sequence valve is shown in Figure. This valve
consists of a 3/2 directional control valve and a pressure control valve. The principle of operation of
a sequence valve is that outlet of sequence valve remains closed until pressure upstream of it builds
up to a predetermined value. When a pre-set pilot pressure is reached within the valve at port 12(due
to the building up of the line pressure after the cylinder piston reaches the end of its stroke), the
spring loaded piston is unseated. The resulting pilot pressure actuates the integrated 3/2 directional
control valve of the pressure sequence valve and generates an output signal which connects port 1 to
2. Note that when the piston is seated, the piston area in the 3/2 directional valve, that is exposed to
the pilot pressure, is held to a minimum. This helps reduce the restraining force. When the pressure,
however, unseats the piston, a large piston area is exposed to pressure, and the piston is held wide
open. The adjusting screw on the top of the valve sets the pressure.

Example 11: A double acting cylinder is used to press together glued components (Estimated
pressure is around 4 bar). Upon pressing a push button, the clamping cylinder is to extend and trip
the roller valve. One the fully extended position of the cylinder has been reached and sufficient
clamping force has been developed, the cylinder is to retract to the initial position, develop a
pneumatic circuit using a pressure sequence valve.

1S3

4 2 4 2
14 12 14 12

5 3 5 3
1 1
1.5 1.5
Pressure Sequence valve
1
4 bar
2 4 bar 2

1 3 1 3
12
12

2 2 2 2
1.2 1.3 1.2 1.3

1 3 1 3 1 3 1 3

a) Cylinder extending b) Position when cylinder begins

to retract after 5 seca) Cylinder
fully extended
Figure 1.18 Pressure dependant control valve

The two position of the pneumatic circuit for the control task, when the cylinder is extending and
when the cylinder is fully extended, are shown in Figure 1.18. The pressure in the sequence valve is
set to working pressure of 4 bar, and the signal input to the pressure sequence valve is tapped from
the power line from port 4 of valve 1.1 to the cylinder to gauge the pressure on the piston side of the
cylinder. As shown in the Figure 1.18 valve 1.2 initiates the forward motion of the cylinder. While
the cylinder is moving forward, the pressure in the power line from port 4 of valve 1.1 to the cylinder
will not built up to the working pressure. Only after the cylinder is fully extended, will the maximum
pressure in the line built up resulting in sufficient pressure to glue. When the set pressure in the
sequence valve is reached, the integrated 3/2 directional control valve is actuated, generating an
output signal. This signal is used to reset the final control element 1.1 and thus causing the return
motion of the cylinder.

1.7 TIME DEPENDENT CONTROLS

Pneumatic timers are used to create time delay of signals in pilot operated circuits. Available as
normally closed timers and normally open timers. Usually pneumatic timers are on delay timers.
Delay of signals is very commonly experienced in applications such as bonding of two pieces.
Normally open pneumatic timers are also used in signal elimination. Normally open pneumatic
timers are used as safety device in two hand blocks

Time delay valve is a combination of a pneumatically actuated 3/2 direction control valve, an air
reservoir and a throttle relief valve. The time delay function is obtained by controlling the air flow
rate to or from the reservoir by using the throttle valve. Adjustment of throttle valve permits fine
control of time delay between minimum and maximum times. In pneumatic time delay valves,
typical time delays in the range 5-30 seconds are possible. The time delay can be extended with the
addition of external reservoir.
Pneumatic timer can be classified as
1. On –delay timer
2. Off – delay timer
In on-delay timer, the 3/2 DCV is actuated after a delay with reference to the application of pilot
signal and is rest immediately on the application of the pilot signal. In off delay timer, the 3/2 DCV
is actuated immediately on the application of the pilot signal and is reset only after a delay with
reference to the release of the pilot signal.
Pneumatic timers can also be classified according to type of pneumatically actuated 3/2 DCv as:
1) Time delay valve, NC type
2) Time delay valve, NO type.

Time delay valve, NC type. The constructions of an on-delay timer (NC) type in the normal and
actuated are shown in Figure 1.19 It can be seen that 3/2 DCV operates in the on delay mode
permanently. But, in some designs, the valve can be operated in the off-delay mode by connecting
the check valve in reverse direction. For this purpose, the ports of the throttle check valve should be
brought out.

Time delay valve, NO type. The construction and function of an on-delay timer (NO) type is similar
to that of an on-delay timer (NC) type except for the type of 3/2 DCV valve. In the on-delay valve
(NO) type, a 3/2 DCV (NO) type is used whereas in the on-delay timer (NC) type, a 3/2 DCV (NC)
type is used. Timing diagrams for all four type of Pneumatic delay valve is given in Table 1.1

12
3
12
3

2
2

1
1

(b) Actuated Position

(a) Normal Position

Figure 1.19
Table 1.1 Timing diagrams for all four type of Pneumatic delay valve
Timing diagram Symbol

ON OFF
2

t
1 3

ON OFF

2
t

3
1

ON OFF
2

t 1 3

ON OFF
2

t
1 3
Example 12: A double acting cylinder is used to press together glued components . Upon operation
of a press button, the clamping cylinder slowly advances. Once the fully extended position is reached
, the cylinder is to remain for a time of t = 6 seconds and then immediately retract to the initial
position. A new start cycle is only possible after the cylinder has fully retracted and after a delay of 5
seconds. During this delay the finished part is manually removed and replaced with new parts for
gluing. The retracting speed should be fast, but adjustable.

1S2 1S3

V5 V6

V4 4
14 12
5
1
V2 V3 Time delay valve

V1 Time delay valve

12 14
14 2
6 sec 12

12 1 3
5 sec
1 3
2
S1 2 S3

S2 1 3
1 3

Figure 1.20

If the push button S1 is actuated for a sufficiently long time period ( t = 5 second) then the air
reservoir of time delay valve V1 is filled and corresponding 3/2 valve is switched, following which a
signal is applied at input 1 of the dual pressure valve V2.
If the push button S1 is actuated, the AND condition at the dual pressure valve is met. A signal is
applied at the control port 12 of the control element V4. The valve V4 switches, pressure is applied
to the piston side of the cylinder 1A and the piston rod advances. After as short advancing distances,
the limit switch S2 is released, pressure is reduced in the air reservoir of the time delay valve V1 via
the roller lever valve S2, and the integrated 3/2 way valve switches back to its initial position. The
AND condition at the dual pressure valve is now no longer met. Actuation of the push button S1
becomes ineffective.
Upon reaching the advancing position, the piston rod actuates the roller lever S3. The pressure line to
the time delay valve V3 is now released and pressure in the air reservoir is increased. The rate of
pressure increase is adjustable via the integrated flow control valve. When the switching pressure has
been reached, the integrated 3/2 way valve switches and a signal is applied at the control port 12 of
the final control element V4. The valve V4 reverses and the piston rod retracts. Upon release of the
limit switch S3, the time delay valve V3 Switches to its initial position again.

The limit switch S2 is actuated, when the piston rod reaches its initial position, the pressure in the air
reservoir of the time delay V1 starts to increase until the switching pressure has been reached after t
= 5 seconds. The integrated 3/2 way valve switches. The initial status of the system is now reached
again and a new cycle can be started. The piston rod speed is set at the restrictors of the one way
flow control valves V5 and V6.
Objective Type Questions

1. For relatively small single acting and double acting cylinder ------- type of control is preferred.
2. A single acting pneumatic cylinder or a non-reversing air motor can be controlled by ---- way
valve as the signal output unit. When a four way control valve is used one outlet port is -----------
3. Double acting cylinders can be controlled by two –three way valve or ...........way valve.
4. Throttle relief valve or throttle check valve is used to control the ---------------- in pneumatic
circuits.
5. In supply air throttling, air ----------------- the cylinder is throttled

6. Shuttle valve or double check valve can be used as logic ----- Valve.

1. In ------------ pneumatic timer, the 3/2 DC valve is actuated after a delay with reference to the
application of the pilot signal and is reset immediately after the release of the pilot signal.

8. The pressure sequence valve is a combination of two valves, that is adjustable pressure ----------
valve and a 3/2 direction control valve.

9. As per ISO 5599 pilot lines ports are designated using 12 or -------------

10. The most important threads used on pneumatic valves are metric thread(M), National pipe thread
(NPT) , Unified fine thread(UNF) and -------- (BSP~G)

State True or False

1. For large single acting or double acting cylinder we prefer to use direct control

2. Supply air throttling is used only for the speed control of single acting cylinders and small volume
cylinders.

3 Exhaust air throttling is practically used in all double acting cylinder due to double cushioning
effect.

4. Double piloted 4/2 and 5/2 valves can be used as memory valves in pneumatic circuit design

5. There is no possibility of signal conflict in memory valves.

6. Two pressure valve can be used as not valve in pneumatic circuit design

7. Return speed of the double acting cylinder can be increased by means of quick exhaust valve.
8. In off time delay timer, the 3/2 DC valve is actuated immediately on the application of the pilot
signal and is reset only after a delay with reference to the release of the pilot signal.

9. There are four possible combinations of pneumatic delay timer using NO and NC control.

10. ISO 5599 systems recommend alpha numeric port designation for direction control valves

Review Questions

1. Where are three way and four way valves used?

2. List the basic five rules that are important in design of pneumatic circuits.

3. State three types of signal processing elements used in pneumatic control

4. Explain the working of NOT valve, give one application of it.

5. Mention few applications of AND and OR valve

6. What are the functions of pneumatic timer delay valves

7. How are timer delay valves classified

8. Differentiate between ON time delay and OFF time delay with help of symbols

9. Explain with the help of neat sketch the construction and working of pressure sequence valve

10. Give two applications of pressure sequence valve and time delay valve.

11. Compare and contrast two way valve and shuttle valve. Mention its application.

12 Differentiate between supply air throttling and exhaust air throttling

13. Why exhaust air throttling is practically used for speed control of the double acting cylinder.

14. What is the advantage of internal pilot valve in pneumatic valves.

15. State the difference between the final control element and signal element
Answers

Fill in the Blanks

1. direct
2. three / plugged
3. four/five
4. flow(speed)
5. entering
6. OR
7. On time delay
8. Relief
9. 14
10. British standard pipe thread (BSP~G)

State True or False

1. False
2. True
3. True
4. True
5. False
6. False
7. True
8. True
9. True
10. False
 Lecture 40

MULTI ACTUATOR CIRCUITS

Learning Objectives

Upon completion of this chapter, Student should be able to

Differentiate between single actuator and multi actuator circuit

List the various methods available for pneumatic circuit design
Explain the signal conflict in double piloted memory valve
Draw motion and displacement diagram for multi cylinders
List and explain various signal elimination methods
Explain the working of idle roller valves and its use
Design multi cylinder circuits using cascade method and step counter method

1.1 SINGLE ACTUATOR CIRCUIT VERSUS MULTI ACTUATOR CIRCUITS

In the previous chapter, we have learnt about the various means and ways to control a single actuator
circuits, both for single acting and double acting cylinders. Implementation of logic gates along with
use of pressure sequence valve and time delay was systematically presented.

Most of the practical pneumatic circuits use multi cylinders. They are operated in specific sequence
to carry out the desired task. For example, to drill a wooden component first we need to clamp and
then drill. We can only unclamp the cylinder, if and only if the drill is withdrawn away from the
workpice. Here sequencing of movement of clamp cylinders and cylinder which carries the drill is
important. This sequencing is carried out by actuation of appropriate final control valves like
directional control valves. The position of the cylinders is sensed by the sensors like limit switches,
roller or cam operated valves.

Multi cylinder pneumatics circuits can be designed in various methods. There is no universal circuit
design method that suits all types of circuits. Some methods are commonly used for compound
circuits but would be too expensive for simple circuits. There are five common methods used by
engineering and they are given below

 Classic method or Intuitive method

 Cascade method
 Step counter method
 Karnaugh–veitch method
 Combinational circuit design
In this chapter Classic method, cascade method and step counter methods are discussed. Chapter 8
deals with Boolean algebra, KV mapping method and combinational circuit methods. Double piloted
4/2 and 5/2 directional control valves are susceptible to signal conflicts. Cascading and Step counter
method are more systematic methods than intuitive methods. Signal conflict can be eliminated by
using cascade and stepper counter method.

1.2 CLASSIC METHOD OR INTUITIVE METHOD

In intuitive method, circuit design is done by use of general knowledge of pneumatics following the
sequence through intuitively. In general, steps involves

 Write down sequence and draw motion diagrams

 Draw in cylinders and control valves
 Complete circuits intuitively.

1.2.1 Coordinated and sequential motion control.

In majority of the pneumatic applications more than one cylinder is used. The movement of these
cylinders are coordinated as per the required sequence. Sensors are used for confirming the cylinder
position and the resultant actuation of the final control element. Normally limit switches are used.
The activation of limit switches of different cylinders will provide set or reset signal to the final
control valves for further controlling the movement of various cylinders. The limit switches have to
be arranged in the proper location with the help of motion diagram

1.2.2 Demonstration of Classic method

In order to develop control circuitry for multi cylinder applications, it is necessary to draw the
motion diagram to understand the sequence of actuation of various signal input switches-limit
switches and sensors. Motion diagram represents status of cylinder position -whether extended or
retracted in a particular step

Example 1 : In a press shop, stamping operation to be performed using a stamping machine. Before
stamping, workpice has to be clamped under stamping station. Then stamping tool comes and
performs stamping operation. Work piece must be unclamped only after stamping operation.
Step 1: Write the statement of the problem:
Let A be the clamping cylinder and B be the stamping cylinder as shown in the Figure xxx. First
cylinder A extends and brings under stamping station where cylinder B is located. Cylinder B then
extends and stamps the job. Cylinder A can return back only cylinder B has retracted fully.

Step 2: Draw the positional layout. (Figure 1.1)

Stamping

Cylinder
Cylinder B

Figure 1.1 Positional layout

Step3: Represent the control task using notational form

Cylinder A advancing step is designated as A+
Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-

Therefore, given sequence for clamping and stamping is A+B+B-A-

Step 4 Draw the Displacement –step diagram (Figure 1.2)

1
A+ A-
A
0

1
B-

0
Step 2 Step 3 Step 4 Step 5=1
 Figure 1.2 Displacement step diagram

Step 5 Draw the Displacement –time diagram (Figure 1.3)

1
A+ A-
A
0

1
B+ B-
B
0
t1 t2 t3 t4 t5

Time step

Figure 1.3 Displacement time diagram

Step 6: Analyse and Draw Pneumatic circuit.

Step 6.1 Analyse input and output signals.

Input Signals

Cylinder A – Limit switch at home position ao

Limit switch at home position a1
Cylinder B - Limit switch at home position bo
Limit switch at home position b1

Output Signal

Forward motion of cylinder A ( A+)

Return motion of cylinder A (A-)
Forward motion of cylinder B( B+)
Return motion of cylinder B( B+)
Step 6.2 Using the displacement time/step diagram link input signal and output signal.(Figure
1.4)
Usually start signal is also required along with a0 signal for obtaining A+ motion.
1. A+ action generates sensor signal a1, which is used for B+ motion
2. B+ action generates sensor signal b1, which is used for B- motion
3. B- action generates sensor signal b0, which is used for A- motion
4. A- action generates sensor signal a0, which is used for A+ motion
Above information (given in 6.2) is shown below graphically

a1 b0
a0 a0
1
start A+ B+ B- A-

1
A+ A-
A a0
0
a1 b1 b0
1
B+
B B-
0
Step 1 Step 2 Step 3 Step 4 Step 5=1

Position step

Figure 1.4 Input/output signal flow

Step 7 Draw the power circuit (Figure 1.5)

i) Draw the cylinders A(1.0) and B(2.0).
ii) Draw the DCVs 1.1 and 2.1 in unactuated conditions
iii) Mark the limit switch positions for cylinders A(1.0) and B(2.0).
 A(1.0) B(2.0)
a0 a1 b0 b1
0

2.1
1.1 44 2
4 2
14 14 12
12

3 5 3
5
1 1
1

Figure 1.5 Power circuit diagram

Step 8 Draw the control circuit (Figure 1.6)

A(1.0) B(2.0)B(

a0 a1 b0 b1
0
1.1 2.1
4 2
4 2 4
14 14 12
12

5 3 5 3
a0 2
1 1 2
a1 2 b1
1 3
2 1 1 3
Start 2 b0 3

1 3 3
1

Pneumatic circuit for A+ B+ B- A-

Figure 1.6 Control circuit diagram

Step 9 Analysis of pneumatic circuit

1.When the start button is pressed, the signal appears at port 14 of valve 1.1 through limit switch
signal a0.

2. Check for the presence of the signal at the other end (12) of valve 1.1. Notice that the signal is
also present at port 12 of valve 1.1. (because bo is also pressed). This results in signal conflict and
valve 1.1 is unable to move.(Figure 1.7)
 A(1.0) B(2.0)

a0 a1 b0 b1
0
1.1 2.1
44 2
4 2 12
14 14 12

a0 5 3
2 5 3
1 1 2
a1 2 b1
1 3
2 b0 2 1 3 1 3
Start
1
1 3 3
1

Figure 1.7 Signal conflict at valve 1.1

3. Let us assume for time being, bo is somehow disengaged so that valve 1.1 can switch over and
consequently cylinder A can extend. When the start button is pressed. (Figure 1.8)

A(1.0) B(2.0)
b0 b1
a0 a1
0

1.1 2.1
44 2
4 2
14 12 14 12

3 5 3
2 5
a0 1
1 b1 2
a1 2
1 3
2 1 1 3
Start 2 b0 3

1 3 3
1

Figure 1.8 Pneumatic circuit after cylinders A and B are extended

(A+ B+)
4. When cylinder A fully extends, it generates a limit switch signal a1, which is applied to port 14 of
the valve 2.1.

5. Check for the presence of the signal at the other end (12) of valve 2.1. Signal is not present at port
12 of valve 2.1 and hence there is no signal conflict

6. Signal applied to port 14 of the valve 2.1 causes the shifting of DCV 2.1 and cylinder B extends.

7. When cylinder B fully extends, it generates a limit switch signal b1, which is applied to port 12 of
valve 2.1

1. Check for the presence of the signal at the other end of 14 of valve 2.1. It can be seen that signal is
also present at the port 14 of valve 2.1(because a1 is also pressed). This results in signal conflict and
valve 2.1 is unable to move (Figure 1.9)

A(1.0) B(2.0)
b0 b1
a0 a1
0

1.1 2.1
4
4 2
4 2
14 12 14 12

3 5 3
a0 2 5
1 1 2
a1 2 b1
1 3
2 1 1
Start 2 b0 3 3

1 3 3
1

Figure 1.9 Signal conflict at valve 2.1

9. Let us assume for time being, b1 is somehow disengaged so that valve 2.1 can switch over and
consequently cylinder B can retract.(Figure 1.10)
 A(1.0) B(2.0)
b0 b1
a0 a1
0

1.1 2.1
4
4 2
4 2
14 12 14 12

3 5 3
a0 2 5
1 1 2
a1 2 b1
1 3
2 b0 2 1 1 3
Start 3

1 3 3
1

Figure 1.10 Position when cylinder B is reversing (B -)

10. When the cylinder B is fully retracted, it generates a limit switch signal b0, which is applied to
port 12 of the valve 1.1. (Figure 1.11)

A(1.0) B(2.0)
a0 a1 b0 b1
0

1.1 2.1
44 2
4 2
14 12 14 12

3 5 3
a0 2 5
1 1 2
a1 2 b1
1 3
2 1 1
Start 2 b0 3 3

1 3 3
1

Figure 1.11 Position when cylinder A has retracted fully (A-)

11. Check for the signal at the other end 14 of the valve 1.1 Notice that signal is not present at port
14 of the valve 1.1 and hence there is no signal conflict. So valve 1.1 can switch over and Cylinder A
can retract.
Example 2 : Two cylinders are used to transfer parts from a magazine onto a chute (Figure 1.12).
When a push button is pressed, the first cylinder extends. Pushing the part from the magazine and
positions it in preparation for transfer by the second cylinder onto the out feed chute. Once the part is
transferred, the first cylinder retracts, followed by the second. Confirmation of all extended and
retracted positions are required.

Figure 1.12 Positional diagram

Step 1: Write the statement of the problem:
Let A be the first cylinder (Pushing) and B be second cylinder (feeding) as shown in the Figure xxx.
First cylinder A extends and brings under stamping station where cylinder B is located. Cylinder B
then extends and stamps the job. Cylinder A can return back only cylinder B has retracted fully.

Step 2: Draw the positional layout. (Figure 1.13)

Feeding

Cylinder B
Pushing

Cylinder A

Figure 1.13 Positional diagram

Step3: Represent the control task using notational form

Cylinder A advancing step is designated as A+
Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-

Therefore, given sequence for clamping and stamping is A+B+A-B-

Step 4 Draw the Displacement –step diagram (Figure 1.14)

 1
A+ A-
AB
0

1
B-
B B+
0
Step 2 Step 3 Step 4 Step 5=1

Figure 1.14 Displacement step diagram

Step 5 Draw the Displacement –time diagram (Figure 1.15)

1
A+ A-
A
0

1
B+ B-
B
0
t1 t2 t3 t4 t5

Time step

Figure 1.15 Displacement time diagram

Step 6: Analyse and Draw Pneumatic circuit.

Step 6.1 Analyse input and output signals.

Input Signals

Cylinder A – Limit switch at home position ao

Limit switch at home position a1
Cylinder B - Limit switch at home position bo
Limit switch at home position b1

Output Signal

Forward motion of cylinder A ( A+)

Return motion of cylinder A (A-)
Forward motion of cylinder B( B+)
Return motion of cylinder B( B+)

Step 6.2 Using the displacement time/step diagram link input signal and output signal. (Figure
1.16)
Usually start signal is also required along with b0 signal for obtaining A+ motion.
1. A+ action generates sensor signal a1, which is used for B+ motion
2. B+ action generates sensor signal b1, which is used for A- motion
3. A- action generates sensor signal a0, which is used for B- motion
4. B- action generates sensor signal b0, which is used for B- motion
Above information (given in 6.2) is shown below graphically

a1 b1 a0
b0 b0
1
start A+ B+ A- B-

1
A+ A-
A a0
0
b1
a1
1
B+ B-
B
b0
0
Step 1 Step 2 Step 3 Step 4 Step 5=1

Position step

1.16 Input output signal flow

Step 7 Draw the power circuit (Figure 1.18)

i) Draw the cylinders A(1.0) and B(2.0).
ii) Draw the DCVs 1.1 and 2.1 in unactuated conditions
iii) Mark the limit switch positions for cylinders A(1.0) and B(2.0).
 A(1.0) B(2.0)
a0 a1 b0 b1
0

2.1
1.1 44 2
2
14 14 12
12

3 5 3
5
1 1
1

Step 8 Draw the control circuit (Figure 1.19)

A(1.0) B(2.0)B(
B(2.0)
a0 a1 b0 b1
0
1.1 2.1
4 2
4 2 4
12 14 4 12
14
2.2
5 3 5 3
b0 2 1.2
1.3 1
1 a0 2
a1 2
1 3 1a
2 1 1 3
Start 2 2.3 3
0
b1
1 3 3
1

Figure 1.19 Pneumatic circuit for A+B+A-B-

Step 9 Analysis of pneumatic circuit

1. When the start button is pressed, the signal appears at port 14 of valve 1.1 through limit switch
signal b0.

2. Check for the presence of the signal at the other end (12) of valve 1.1. Notice that the signal is not
present at port 12 of valve 1.1. (Because b1 is not pressed). There is no signal conflict and valve 1.1
is able to move. So A advances to forward position.

3. When cylinder A fully extends, it generates a limit switch signal a1, which is applied to port 14 of
the valve 2.1. Cylinder B advances to forward position.
5. Check for the presence of the signal at the other end (12) of valve 2.1. Signal is not present at port
12 of valve 2.1 (because a0 is not pressed, A is already in extended position now) and hence there is
no signal conflict

6. Signal applied to port 14 of the valve 2.1 causes the shifting of DCV 2.1 and cylinder B extends.

7. When cylinder B fully extends, it generates a limit switch signal b1, which is applied to port 12 of
valve 1.1 . Cylinder A returns and ao is pressed. There is no signal conflict, as ao and a1 are mutually
exclusive signals.

10. When the cylinder A is fully retracted, it generates a limit switch signal a0, which is applied to
port 12 of the valve 2.1. Cylinder B retracts.

All five sequence of operations are shown in Figure 1.20 to Figure 1.24

A+ OPERATION A(1.0) B(2.0)B(

a0 a1 B(2.0)
b0 b1
0
1.1 2.1
4 2
4 2 4
14 12 14 4 12
2.2
5 3 5 3
b0 2 1.2
1.3 1
1 a0 2
a1 2
1 3 1a
2 1 1 3
Start 2 2.3 3
0
b1
1 3 3
1

Figure 1.20 Pneumatic circuit for A+B+A-B- ( A+ operation)

B+ OPERATION A(1.0) B(2.0)B(

a0 a1 B(2.0)
b0 b1
0
1.1 2.1
4 2
4 2 4
14 12 14 4 12
2.2
5 3 5 3
b0 2 1.2
1.3 1
1 a0 2
a1 2
1 3 1a
2 1 1 3
Start 2 2.3 3
0
b1
1 3 3
1

Figure 1.21 Pneumatic circuit for A+B+A-B- ( B+ operation)

A- OPERATION A(1.0) B(2.0)B(

a1 B(2.0) b0 b1
a0
0

1.1 2.1
4 2
4 2 4
14 12 14 4 12
2.2
5 3 5 3
b0 2 1.2
1.3 1
1 a0 2
a1 2
1 3 1a
2 1 1 3
Start 2 2.3 3
0
b1
1 3 3
1

Figure 1.22 Pneumatic circuit for A+B+A-B- ( A- operation)

B- OPERATION A(1.0) B(2.0)B(

a1 B(2.0) b0 b1
a0
0

1.1 2.1
4 2
4 2 4
14 12 14 4 12
2.2
5 3 5 3
b0 2 1.2
1.3 1
1 2
a1 2
1 3 a0
2 1 1 3
Start 2 2.3 3 1a
b1 0
1 3 3
1

Figure 1.23 Pneumatic circuit for A+B+A-B- ( B- operation)

 INITIAL POSITION B(2.0)B(
A(1.0)
B(2.0)
a0 a1 b0 b1
0
1.1 2.1
4 2
4 2 4
12 14 4 12
14
2.2
5 3 5 3
b0 2 1.2
1.3 1
1 a0 2
a1 2
1 3 1a
2 1 1 3
Start 2 2.3 3
0
b1
1 3 3
1

Figure 1.24 Pneumatic circuit for A+B+A-B- ( initial position)

1.2.3 Elimination of Signal Conflict

Various methods are used to solve problem of signal conflicts in multi cylinder circuits.

a) Idle return roller

b) Reversing valves ( memory valves)
c) Modules as combination of valves

Cascading method uses the revering valves ( also known group changing valves) and Step counter
method uses modular valves. Both methods are discussed in subsequent section in this chapter.

1.2.3.1 Use of Idle Return Rollers.

An idle-return roller valve consists of a 3/2 DCV fitted with an idle return roller mechanism. The two
designs of the idle roller is shown in Figure 1.25
 Figure 1.25 Two designs of Idle return rollers

The action of the idle return roller valve can be understood using the Figure 1.26 The idle return
roller may be positioned in the control system so that when the cylinder extends, the piston passes
over the idle – roller mechanism of the valve, thus activating the valve. (Figure 1.26a ), but also
permitting the valve to be deactivated immediately when the piston moves to the extreme end
position (Figure 1.26b). As a result, the valve generates a short output pulse during the forward
motion of the cylinder. The idle return mechanism also allows the cylinder to retract without re-
activating the valve (Figure 1.26c and Figure 1.26d). Hence, in the end position or during the return
motion of the piston, the valve does not gets actuated, and no output signal is produced. For the
generation of short output pulse by the idle-return roller valve during the return motion of the
cylinder, this valve may be positioned in the opposite direction as compared to the case during the
forward motion of the cylinder.

In the previous sequence problem, we have identified that roller valves b1 and a1 are responsible for
signal conflicts. To eliminate the problem of signal conflicts the roller valve b1 and a1 to be replaced
by idle return rollers.

Drawbacks of idle –return rollers.

1. This method is not reliable

2. End position cannot be sensed accurately
3. Fast control system cannot be set up.
 a) Cylinder extending (b) Cylinder fully extended
Valve actuated Valve is released

(d) Cylinder fully retracted (c) Cylinder retracting

Valve is NOT actuated Valve is NOT actuated

Figure 1.26 Actions of Idle return rollers

Example 3 : Develop Pneumatic circuit for A+ B+ B- A- sequence. Avoid signal conflict using idle
– return roller.

Figure 1.27 shows the circuit for getting the control sequence A+ B+ B- A- using the idle –return
rollers at the position bo and a1. The roller valves at position a0 and b1 need be replaced with the
idle return rollers as these valves do not cause signal conflicts for the given sequence circuit.
 A(1.0)A( B(2.0)
1.0)
a0 a1 b0 b1
0
1.1 2.1
44 2
4 2
14 14 12
12

5 3 5 3
a0 2
1 a1 1 2
a1 2 b1
1
3
2 2 1 3 3
Start b0 1

1 3 1 3

Figure 1.27 Pneumatic circuits for A+ B+ B- A- (with idle return roller)

1.3 CASCADE METHOD

A Bi-stable memory valve or reversing valve can be used to eliminate signal conflicts. Signal
conflict is avoided by allowing the signal to be effective only at times when they are needed. Two of
the possible designs are possible.

i) Cascade method
ii) Shift register method

1.3.1 Demonstration of Cascade method

In order to develop control circuitry for multi cylinder applications, as done before in classic method,
it is necessary to draw the motion diagram to understand the sequence of actuation of various signal
input switches-limit switches and sensors. Motion diagram represents status of cylinder position -
whether extended or retracted in a particular step
Step 1: Write the statement of the problem:
First cylinder A extends and brings under stamping station where cylinder B is located. Cylinder B
then extends and stamps the job. Cylinder A can return back only cylinder B has retracted fully.

Step 2: Draw the positional layout. (Figure 1.28)

Stamping

Cylinder B
Clamping

Cylinder A

Figure 1.28 Positional diagram

Step3: Represent the control task using notational form

Cylinder A advancing step is designated as A+
Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-
Given sequence for clamping and stamping is A+B+B-A-

Step 4 Draw the Displacement –step diagram (Figure 1.29)

1
A+ A-
A
0
A
1
B+ B-
B
0
Step Step 2 Step 3 Step 4 Step 5=1

0Step 1
Position step
position step

Figure 1.29 Displacement step diagram

Step 5 Draw the Displacement –time diagram (Figure 1.30)

1
A+ A-
A
0

1
B+ B-
B
0
t1 t2 t3 t4 t5

Time step

Figure 1.30 Displacement time diagram

Step 6: Analyse and Draw Pneumatic circuit.

Step 6.1 Analyse input and output signals.

Input Signals

Cylinder A – Limit switch at home position ao

Limit switch at home position a1
Cylinder B - Limit switch at home position bo
Limit switch at home position b1
Output Signal

Forward motion of cylinder A ( A+)

Return motion of cylinder A (A-)
Forward motion of cylinder B ( B+)
Return motion of cylinder B( B+)
Step 6.2 Using the displacement time/step diagram link input signal and output signal. (Figure
1.31)
Usually start signal is also required along with a0 signal for obtaining A+ motion.
1. A+ action generates sensor signal a1, which is used for B+ motion
2. B+ action generates sensor signal b1, which is used group changing.
3. B- action generates sensor signal b0, which is used for A- motion
4. A- action generates sensor signal a0, which is used for group changing
Above information (given in 6.2) is shown below graphically

a1 b1 b0
a0 1
CHANGE GROUP
a0
A-
start

Group II to I

1
A-
A a0
0
a1 b1 b0
1
B+
B B-
0
Step 1 Step 2 Step 3 Step 4 Step 5=1

Position step

Figure 1.31 Displacement time diagram

Step 7 Draw the power circuit (Figure 1.32)

i) Divide the given circuits into groups. Grouping should be done such that there is no
signal conflict. Do not put A+ and A- in the same group. Similarly B+ and B- should
not be put in the same group. In other word A+ and A- should belong to different
group to avoid signal conflict.
In our example of A+ B+ B- A- we can group as
A+ B+ B- A-
Group 1 Group 2
ii) Choose the number of group changing valve = no of groups -1
In our example, we have 2 groups so we need one group changing valve

Connect the group changing valve as follows. From the figure it is clear that when the
control signals I and II are applied to group changing valve, the air (power) supply changes
from Group 1(G1) to Group 2 (G2)

G1

G2 G2

Group changing Valve (GCV)

I II
I I

3
5 3
1 5 1

If “I ” signal is given to DCV If “II” signal is given to DCV , Air is

, Air is available in group G1 available in group G2

Figure 1.32

iii) Arrange the limit switch and start button as given below (Figure 1.33)

2
a0
b1
1 3 b0
a1 a0 b1 b0

1 3 1 3 1 3 1 3

Figure 1.33

iv) Draw the power circuit (Figure 1.34)

 A(1.0) B(2.0)
a0 a1 b0 b1
0

1.1 2.1
4 2 44 2
14 14 12
12

5 3 5 3
1 1
1

Figure 1.34

Step 8 Draw the control circuit (Figure 1.35)

 A(1.0) B(2.0)

a0 a1 b0 b1
0

1.1 2.1
4 2
2 4
4 B+
A B-
A-
Start
+
5 3 5
3
1
1

II I

G2 a1 (line1)
a0 (line2)
b1 (line 3)
b0 (line 4)

a1 a0 b1 b0

2 2 2
2
a1 & b1 Connected to group ̅
a0 & b0 Connected to group

2
Figure 1.35 Pneumatic circuits for A+ B+ B- A-
Step 9 Analysis of pneumatic circuit
1. Assume that air is available in the line G2 to start with. (Say from last operation)
2. When the start button is pressed, Air supply from Group G2 is directed to line 2 through actuated
limit switch a0. Now the air available in line 2, actuates the Group changing valve (GCV) to switch
over to position I. This switching of the GCV causes air supply to change from G2 to G1.

3. Now the air is available in line G1. The air supply from group G1 is directed to port 14 of the
valve 1.1. As there is no possibility of signal conflict here, valve 1.1 switches over causing the A+
action.

4. Sensor a1 is actuated as the result of A+ action, allowing the air supply from the Group G1 to
reach to line 1 through a1. Now the air available reaches port 14 of valve 2.1. As there is no
possibility of signal conflict here, valve 2.1 switches over, causing B+ action automatically.

5. Sensor b1 is actuated as result of B+ action, allowing the air supply in line 3. Air from line 3
allows the air to reach port 12 of Group changing valve (also called reversing valve). As a result, the
Group changing valve switches over, causing the group supply to change from G1 to G2.

6. Now the air is available in G2. Air from G2 acts on port 12 of the Valve 2.1. As there is no
possibility of signal conflict here, valve 2.1 switches over, causing B- action automatically.

7. Sensor is actuated as the result of B- action. Now the air is available in line 4.Air from line 4
reach port 12 of the valve 1.1 , As there is no possibility of signal conflict here, valve 2.1 switches
over , causing A- action automatically.

The cascade system provides a straightforward method of designing any sequential circuit.
Following are the important points to note:

a) Present – the system must be set to the last group for start-up
b) Pressure drop- Because the air supply is cascaded, a large circuit can suffer from more
pressure drop.
c) Cost – Costly due to additional reversing valves and other hardware.
Objective Type Questions

1. Design of circuits using intuitive method is --------------- time consuming compared to step counter
method.
2. When hard ware costs are not important but circuit design time must be minimal, then ...... method
of the circuit design is used.
3. Where the hardware costs are paramount, then -------------- circuit methods are used.
4. When absolute fool proofing of circuits is required, ------------------ circuit methods are used.
5. --------------- are used to sense the end position of cylinder movements

State True or False

1. We have to draw all valves in their de-actuated , unpressurised rest position as in electrical
switching components

2. In order to gain fully controlled sequence of all cylinders in a program , it is essential to install end
position sensors at all movements end position.

3 4/2 or 5/2 double piloted valves are free from signal overlaps.

4. Step counter method is absolutely free from signal conflicts

5. Time delay and pressure delay functions cannot be used in multicylinder circuit design
Review Questions

1. Explain how signal conflict occurs using an example

2. What is the effect of signal conflict in multi actuator circuit design

3. What are the different ways to eliminate signal conflict in multi actuator circuit design

4. Explain the step displacement diagram for A+B+B-A- sequence.

5. List few disadvantages of using idle return rollers for overcoming signal conflicts

6. Explain the principle of cascade method with a suitable sequence example

7. Briefly explain the principles of step counter method with a suitable example

1. Draw a group changing cascade circuit for two groups, three groups, four groups and five groups.

9. Explain with the help of neat sketch the construction and working of pressure sequence valve

10. What are the different ways to sense the end position and movement of cylinders
Answers

Fill in the Blanks

1. More
2. Step counter
3. logic
4. step counter
5. limit switches

State True or False

1. True
2. True
3. False
4. True
5. False
 Lecture 41

ELECTRO – PNEUMATIC CONTROL

Learning Objectives

Upon completion of this chapter, Student should be able to

Explain the various steps involved in electro pneumatics

List seven basic electrical devices used in electro pneumatics
Describe the constructional details of solenoid valves
Explain the operations of control devices like limit switches, sensors, timers , counters and
pressure switches
Differentiate between capacitive and inductive proximity sensors
Differentiate between dominant on and off latching circuits
Design single actuator electro pneumatic circuits
Design a sequence circuits using two and three cylinders

1.1 INTRODUCTION

Electro pneumatics is now commonly used in many areas of Industrial low cost automation. They are
also used extensively in production, assembly, pharmaceutical, chemical and packaging systems.
There is a significant change in controls systems. Relays have increasingly been replaced by the
programmable logic controllers in order to meet the growing demand for more flexible automation.

Electro-pneumatic control consists of electrical control systems operating pneumatic power systems.
In this solenoid valves are used as interface between the electrical and pneumatic systems. Devices
like limit switches and proximity sensors are used as feedback elements.

Electro Pneumatic control integrates pneumatic and electrical technologies, is more widely used for
large applications. In Electro Pneumatics, the signal medium is the electrical signal either AC or DC
source is used. Working medium is compressed air. Operating voltages from around 12 V to 220
Volts are often used. The final control valve is activated by solenoid actuation

The resetting of the valve is either by spring [single Solenoid]or using another solenoid [Double
solenoid Valve] . More often the valve actuation/reset is achieved by pilot assisted solenoid actuation
to reduce the size and cost of the valve

Control of Electro Pneumatic system is carried out either using combination of Relays and
Contactors or with the help of Programmable Logic Controllers [PLC]. A Relay is often is used to
convert signal input from sensors and switches to number of output signals [ either normally closed
or normally open] .Signal processing can be easily achieved using relay and contactor combinations

A Programmable Logic Controller can be conveniently used to obtain the out puts as per the required
logic, time delay and sequential operation.. Finally the out put signals are supplied to the solenoids
activating the final control valves which controls the movement of various cylinders. The greatest
advantage of electro pneumatics is the integration of various types of proximity sensors [electrical]
and PLC for very effective control. As the signal speed with electrical signal, can be much higher,
cycle time can be reduced and signal can be conveyed over long distances.

In Electro pneumatic controls, mainly three important steps are involved:

 Signal input devices -Signal generation such as switches and contactor, Various types of
contact and proximity sensors
 Signal Processing – Use of combination of Contactors of Relay or using Programmable
Logic Controllers
 Signal Out puts – Out puts obtained after processing are used for activation of solenoids,
indicators or audible alarms

1.2 SEVEN BASIC ELECTRICALDEVICES

Seven basic electrical devices commonly used in the control of fluid power systems are

1. Manually actuated push button switches

2. Limit switches
3. Pressure switches
4. Solenoids
5. Relays
6. Timers
7. Temperature switches

Other devices used in electro pneumatics are

1. Proximity sensors
2. Electric counters
1.2.1 Push button switches

A push button is a switch used to close or open an electric control circuit. They are primarily used for
starting and stopping of operation of machinery. They also provide manual override when the
emergency arises. Push button switches are actuated by pushing the actuator into the housing. This
causes set of contacts to open or close.

Push buttons are of two types

i) Momentary push button

ii) Maintained contact or detent push button

Momentary push buttons return to their unactuated position when they are released. Maintained
(or mechanically latched) push buttons has a latching mechanism to hold it in the selected
position.

The contact of the push buttons, distinguished according to their functions,

i) Normally open (NO) type

ii) Normally closed (NC) type
iii) Change over (CO) type.

The cross section of various types of push buttons in the normal and actuated positions and their
symbols are given in the Figure 1.1 In the NO type, the contacts are open in the normal position,
inhibiting the energy flow through them. But in the actuated position, the contacts are closed,
permitting the energy flow through them. In the NC type, the contacts are closed in the normal
position, permitting the energy flow through them. And, the contacts are open in the actuated
position, inhibiting the energy flow through them. A changeover contact is a combination of NO and
NC contacts.

Type of devices Terminal Numbers

Normally closed contacts Normally open contacts
Push buttons and Relays 1 and 2 3 and 4
Timers and Counters 5 and 6 7 and 8
Designation of the pushbuttons

Type of contact Designation

Momentary contact type First digit indicates the function of contact.
PB station ( 2 NO +2 NC) Second digit represents a serial ordering. 3 and 4
13 23 31 41 represents NO contacts and 1 is the serial no.

13

14 24 32 42 14
First digit indicates the function of contact.
Maintained Contact type PB station Second digit represents a serial ordering. 3 and
(2NO+2 NC) 4 represents NO contacts and 1 is the serial no.
13 23 31 41
13

14
14 24 32 42
 Push button
Switching element

Normally Open (NO)

Contacts

Normal position Actuated position Symbol

Normally closed (NC)

2

Normal position Actuated position Symbol

2 4
Change Over (CO)

Normal position Actuated position Symbol

Figure 1.1 : Pushbuttons and their symbols

1.2.2 Limit switches

Any switch that is actuated due to the position of a fluid power component (usually a piston rod or
hydraulic motor shaft or the position of load is termed as limit switch. The actuation of a limit switch
provides an electrical signal that causes an appropriate system response.
Limit switches perform the same function as push button switches. Push buttons are manually
actuated whereas limit switches are mechanically actuated.
There are two types classification of Limit switches depending upon method of actuations of contacts
a) Lever actuated contacts
b) Spring loaded contacts

In lever type limit switches, the contacts are operated slowly. In spring type limit switches, the
contacts are operated rapidly. Figure 1.2 shows a simplified cross sectional view of a limit switch
and its symbol.

2 4

1
2

1
4

Figure 1.2: Cross sectional view of a limit switch

1.2.3 Pressure switches

A pressure switch is a pneumatic-electric signal converter. Pressure switches are used to sense a
change in pressure, and opens or closes an electrical switch when a predetermined pressure is
reached. Bellow or diaphragm is used to sense the change of pressure. Bellows or Diaphragm is
used to expand or contract in response to increase or decrease of pressure. Figure 1.3 shows a
diaphragm type of pressure switch. When the pressure is applied at the inlet and when the pre-set
pressure is reached, the diaphragm expands and pushes the spring loaded plunger to make/break
contact.
 Adjusting Screw

Contact set

4 4

2 2

1 1

Diagphragm
14 14

Figure 1.3: Cross sectional view of a pressure switch

1.2.4 Solenoids

Electrically actuated directional control valves form the interface between the two parts of an electro-
pneumatic control. The most important tasks of electrically actuated DCVs include.

i) Switching supply air on or off

ii) Extension and retraction of cylinder drives

Electrically actuated directional control valves are switched with the aid of solenoids. They can be
divided into two groups:

i) Spring return valves only remain in the actuated position as long as current flows through
the solenoid
ii) Double solenoid valves retain the last switched position even when no current flows
through the solenoid.

In the initial position, all solenoids of an electrically actuated DCVs are de-energised and the
solenoids are inactive. A double valve has no clear initial position, as it does not have a return spring.
The possible voltage levels for solenoids are 12 V DC, 12V AC, 12 V 50/60 Hz, 24V 50/60 Hz,
110/120V 50/60 Hz, 220/230V 50/60 Hz.

a) 3/2 Way single solenoid valve, spring return.

 3 3

1 2 1 2

Figure 1.4: Cross sectional view of a 3/2 single solenoid valve

The cross sectional view of 3/2 way single solenoid valve in the normal and actuated positions are
shown in Figure 1.4. In the normal position, port 1 is blocked and port 2 is connected to port 3 via
back slot (details shown in the circle) When the rated voltage is applied to coil, armature is pulled
towards the centre of the coil and in the process the armatures is lifted away from the valve seat. The
compressed air now flows from port 1 to port 2, and ports 3 is blocked. When the voltage to the coil
is removed, the valve returns to the normal position. Figure 1.5 shows 2/2 solenoid operated valve

3 3 Solenold
Electri Connectioncal

2 2
1 1
 Figure 1.5: Cross sectional view of a 2/2 way solenoid operated valve

b) 5/2 Way single solenoid valve, spring return.

The cross section view of 5/2 way single solenoid in the normal and actuated positions are shown in
Figure 1.6. In normal position, port 1 is connected to port 2, port 4 is connected to port 5, and port 3
is blocked. When the rated voltage is applied to coil 14, the valve is actuated through an internal pilot
valve. In actuated position, port 1 is connected to port 4 , port 2 is connected to port 3, and port 5 is
blocked. The valve returns to the normal position when the voltage to the armature coil is removed.
This type of valves is normally used as final valve to control double acting cylinders.

2 4 2 4

14 14

3 1 5 3 1 5

Figure 1.6: Cross sectional view of a 5/2 way solenoid operated valve

c) 5/2 Way single double solenoid valve

The cross section view of 5/2 way double solenoid in the normal and actuated positions are shown in
the Figure 1.7 when the rated voltage is applied to coil 14, the valve is actuated to a one switch in
position with port 1 connected to port 4, port 2 connected to port 3, and port 5 blocked. When the
rated voltage is applied to the coil 12, the valve is actuated to the other switching position with port 1
connected to port 2, port 4 connected to port 5 and port 3 blocked.
 Figure 1.7: Cross sectional view of a 5/2 way double solenoid operated valve

The symbols for the various solenoid/pilot actuated valves are given in Table 1.1

Table 1.1 Various symbols for DCVs

Symbol Details
3/2 way Single solenoid valve (spring
return )

3/2 way pilot operated single solenoid

valve( spring return)

5/2 way single solenoid Valve (spring

return)

5/2 way double solenoid valve.

5/2 way piloted operated double

solenoid valve.

1.2.5 Relays

A relay is an electro magnetically actuated switch. It is a simple electrical device used for signal
processing. Relays are designed to withstand heavy power surges and harsh environment conditions.
When a voltage is applied to the solenoid coil, an electromagnet field results. This causes the
armature to be attracted to the coil core. The armature actuates the relay contacts, either closing or
opening them, depending on the design. A return spring returns the armature to its initial position
when the current to the coil is interrupted. Cross sectional view of a relay is shown in Figure 1.8

A large number of control contacts can be incorporated in relays in contrast to the case of a push
button station. Relays are usually designated as K1, K2, and K3 etc. Relays also possess interlocking
capability that is an important safety feature in control circuits. Interlocking avoids simultaneous
switching of certain coils.
 Return Spring
Relay coil
12 14 22 24
A1
Armature

A2
11 21
Insulation

Coll core

Contact terminals

A1 A2 4 2 1

Figure 1.8: Cross sectional view of a relay

1.2.6 Timer Or Time delay relays

Timers are required in control systems to effect time delay between work operations. This is possible
by delaying the operation of the associated control element through a timer. Most of the timers we
use is Electronic timers. There are two types of time relay

i) Pull in delay ( on –delay timer)

ii) Drop –out delay (off delay timer)

In the on-delay timer, shown in Figure cc, when push button PB is pressed (ON), capacitor C is
charged through potentiometer R1 as diode D is reverse –biased. The time taken to charge the
capacitor, depends on the resistance of the potentiometer (R1) and the capacitance(C) of the
capacitor. By adjusting the resistance of the potentiometer, the required time delay can be set. When
the capacitor is charged sufficiently, coil K is energised, and its contacts are operated after the set
time delay. When the push button is released (OFF), the capacitor discharges quickly through a small
resistance (R2) as the diode by passes resistor R1, and the contacts of relay (K) return to their normal
position without any delay.

In the off-delay timer, the contacts are operated without any delay when the push button is pressed
(ON). The contacts return to the normal position after the set delay when the push button is released
(OFF).

The construction and symbols of the on-delay and off-relay timers are given in Figure1.9. Timing
diagram is shown in Table 1.2
 +24 V

4 D

R2 K
R1

0V

+24 V

4
D

R2 C K
R1

0V

Figure 1.9: Construction features of timer and its symbols

 Table 1.2: Timing diagram for on and off delay timer

Timing diagram Symbol

Voltage at relay coil On-delay timer circuit

Open t
Contact
Closed

Voltage at relay coil

Off-delay timer circuit

Closed
Contact
t
Open

1.2.7 Temperature Switch

Temperature switches automatically senses a change in temperature and opens or closes an electrical
switch when a predetermined temperature is reached. This switch can be wired either normally open
or normally closed.

Temperature switches can be used to protect a fluid power system from serious damage when a
component such as a pump or strainer or cooler begins to malfunction.

1.2.8 Reed Proximity switches

Reed switches are magnetically actuated proximity switches. Reed switches are similar to relays,
except a permanent magnet is used instead of a wire coil. Schematic diagram of reed switch is shown
in Figure 1.1. The reed switches comprise two ferromagnetic reeds placed with a gap in between and
hermetically sealed in a glass tube. The glass tube is filled with inert gas to prevent the activation of
the contacts. The surfaces of the reed contacts are plated with rhodium or iridium. Whole unit is
encapsulated in epoxy resin to prevent mechanical damage to the switch. They are also provided with
LED indicator to show its switching status.

When the magnet is away the switch is open, but when the magnet is brought near the switch is
closed. The reed switch is operated by the magnetic field of an energized coil or a permanent magnet
which induces north (N) and south (S) poles on the reeds. The reed contacts are closed by this
magnetic attractive force. When the magnetic field is removed, the reed elasticity causes the contacts
to open the circuit. The transfer type reed switch is normally ON, due to mechanical bias of the
common (COM) lead, which is between the normally closed (N.C) reed contact and the normally
open (N.O) reed contacts. When an external magnetic field is induced, the N.C blade is not affected
because it is non-magnetic but the COM lead is attracted by the N.O lead and moves. When the
magnetic field is removed, COM lead again moves to the N.C lead by mechanical.

Figure 1.10: Construction features of reed switch

The two wire reed switch consists of two reeds. One of reed is connected to positive terminal of
electric supply and other is connected to signal output. The three wire reed wire consists of three reed
contacts. One is connected to positive terminal of electric supply. Second one is connected to
negative terminal of the electric supply and third one is connected to the signal output. Symbol of the
three wire reed switch and two wire reed switch is shown in Figure 1.11

Figure 1.11: Symbol of 3 wire and 2 wire reed switch

Advantages of reed switches are

1. Reed switches are cheap.

2. They have long service life
3. They have shorter switching time ( in the order of 0.2 to 0.3 millis seconds)
4. They are compact and maintenance frees
 Disadvantages of reed switches are

1. They cannot be used in environments subjected to magnetic fields ( like resistance welding
machine)
2. Closing of contacts in reed switch is not bounce free

1.2.9 Electronic sensors

Inductive, Optical and capacitive proximity switches are electronic sensors. They normally have
three electrical contacts. One contact for supply voltage , other for ground and third for output signal.

In these sensors, no movable contact is switched. Instead, the output is either electrically connected
to supply voltage or to ground. There are two types of electronic sensors with regard to the polarity
of output voltage.

Positive switching sensors: In this output voltage is zero if no part is detected in the proximity. The
approach of a work piece or machine part leads to switch over of the output, applying the supply
voltage.

Negative switching sensors: In this the supply voltage are applied to the output if no part is detected
in the proximity. The approach of a work piece or machine part leads to switch over of the output,
switching the output voltage to 0 volts.

a) Inductive sensors

Inductive sensor use currents induced by magnetic field to detect the nearby metal objects. The
inductive sensor uses a coil or inductor to generate a high frequency magnetic field as shown in
Figure 1.12. If there is a metal object near the changing magnetic field, current will flow in the
object. This resulting current flow sets up a new magnetic field that opposes the original magnetic
field. The net effect is that it changes the inductance of the coil in the inductive sensor. By measuring
the inductance the sensor can determine when a metal have been brought nearby.

These sensors will detect any metals, when detecting multiple types of metal multiple sensors are
used. In addition to metals, graphite also can be sensed. It is important to note that these work by
setting up a high frequency field. If a target nears the field will induce eddy currents. These currents
consume power because of resistance, so energy is in the field is lost, and the signal amplitude
decreases . The detector examines filed magnitude to determine when is has decreased enough to
switch.
 Symbol

Oscillator and Output

level detector switching

Figure 1.12: Inductive sensor

The sensors can detect objects a few centimetres away from the end. But, the direction to the object
can be arbitrary as shown in Figure 1.13. The magnetic field of the unshielded sensors covers a large
volume around the head of the coil. By adding a shield (a metal jacket around the sides of the coil)
the magnetic field becomes smaller, but also more directed. Shields will often be available for
inductive sensors to improve their directionality and accuracy.

Figure 1.13: Shielded versus unshielded Inductive sensors

Advantages of proximity sensors are

1. They are self contained, rugged and extremely reliable

2. They have long service life
3. They have shorter switching time
4. They are compact and maintenance frees

Disadvantages of proximity sensors are

 1. Like reed switches , they cannot be used in environments subjected to magnetic fields ( like
resistance welding machine)

Applications of proximity sensors

The proximity sensors can be used for various applications, These include:

 Sensing of end position of linear actuators like cylinders and semi rotary actuators
 They are used to detect metallic pieces on conveyor. That is presence or absence of work
piece on conveyor
 They are used in press to detect the end position
 They are used to monitor drill breakage while drilling.
 They are also used as feed back devices in speed measuring devices

Factors influences the sensing distance

The switching distance of inductive sensors depends on the conductivity and permeability of the
metal part whose presence or absence to be detected. This distance varies with the material
composition of the target object, with mild steel takes as the material for standard reference (Table
1.3.) This is described by the reduction factor. The reduction factor is the factor by which the sensing
range of the inductive sensor is reduced based on material composition of the objected to be sensed ,
compared to steel [FE 360] as the standard reference .

Table 1.3 Reduction factors for various materials

Material Reduction factor

Stainless steel 0.80 to 0.85
Nickel steel 0.70 to 0.90
Aluminium and brass 0.35 -0.50
Copper 0.25 -0.40

Another factor which affects the sensing range of inductive sensors is the diameter of sensing coil. A
small sensor with a coil diameter 0f 18mm has a typical range of 1mm, while a large sensor with
core diameter of 75mm has a sensing range up to 50mm or even more

b) Capacitive sensors

Capacitive sensors are able to detect most materials at distances upto a few centimetres.

We know that
In the sensor the area of the plates and distance between them is fixed. But, the dielectric constant of
the space around them will vary as different material is brought near the sensor. An illustration of a
capacitive sensor is shown Figure 1.14 an oscillating field is used to determine the capacitance of
the plates. When this changes beyond selected sensitivity the sensor output is activated.

Figure 1.14: Capacitive sensors

For capacitive sensor the proximity of any material near the electrodes will increase the capacitance.
This will vary the magnitude of the oscillating signal and the detector will decide when this is great
enough to determine proximity.

These sensors work well for insulators (such as plastics) that tend to have high dielectric coefficients,
thus increasing the capacitance. But, they also work well for metals because the conductive materials
in the target appear as larger electrodes, thus increasing the capacitance as shown in Figure 1.15. In
total the capacitance changes are normally in the order of pF.

Figure 1.15: Capacitive sensors for metals and dielectrics

Advantages of proximity sensors are

1. They are widely used because of their ability to react with wide range of materials
2. They are suitable for detecting non metallic objects
3. They can be used to sense and monitor level in storage containers

Disadvantages of proximity sensors are

1. They are sensitive especially in humid environment

2. Without the compensator ring, the sensor would be very sensitive to dirt, oil and other
contaminants that might stick to the sensor.
c) Optical proximity sensors

Light sensors have been used for almost a century - originally photocells were used for applications
such as reading audio tracks on motion pictures. But modern optical sensors are much more
sophisticated

Optical sensors require both a light source (emitter) and detector. Emitters will produce light beams
in the visible and invisible spectrums using LEDs and laser diodes. Detectors are typically built with
photodiodes or phototransistors. The emitter and detector are positioned so that an object will block
or reflect a beam when present. A basic optical sensor is shown in Figure 1.16

Figure 1.16: A Basic Optical sensor

In the figure the light beam is generated on the left, focused through a lens. At the detector side the
beam is focused on the detector with a second lens. If the beam is broken the detector will indicate an
object is present. The oscillating light wave is used so that the sensor can filter out normal light in the
room. The light from the emitter is turned on and off at a set frequency. When the detector receives
the light it checks to make sure that it is at the same frequency. If light is being received at the right
frequency then the beam is not broken. The frequency of oscillation is in the KHz range, and too fast
to be noticed. A side effect of the frequency method is that the sensors can be used with lower power
at longer distances

An emitter can be set up to point directly at a detector, this is known as opposed mode. When the
beam is broken the part will be detected. This sensor needs two separate components, as shown in
Figure 1.17 This arrangement works well with opaque and reflective objects with the emitter and
detector separated by distances of up to hundreds of feet

Figure 1.17: Opposed mode optical sensor

Having the emitter and detector separate increases maintenance problems and alignment is required.
A preferred solution is to house the emitter and detector in one unit. But, this requires that light be
reflected back as shown in Figure 1.18. These sensors are well suited to larger objects up to a few
feet away.

Figure 1.18: Emitter and detector in one unit

The reflector is constructed with polarizing screens oriented at 90 deg. angles. If the light is reflected
back directly the light does not pass through the screen in front of the detector. The reflector is
designed to rotate the phase of the light by 90 deg., so it will now pass through the screen in front of
the detector.

In the figure, the emitter sends out a beam of light. If the light is returned from the reflector most of
the light beam is returned to the detector. When an object interrupts the beam between the emitter
and the reflector the beam is no longer reflected back to the detector, and the sensor becomes active.
A potential problem with this sensor is that reflective objects could return a good beam. This
problem is overcome by polarizing the light at the emitter (with a filter), and then using a polarized
filter at the detector. The reflector uses small cubic reflectors and when the light is reflected the
polarity is rotated by 90 degrees. If the light is reflected off the object the light will not be rotated by
90 degrees. So the polarizing filters on the emitter and detector are rotated by 90 degrees, as shown
in Figure 1.19 The reflector is very similar to reflectors used on bicycles

Figure 1.19: Polarized light in retroreflective sensors

For retro reflectors the reflectors are quite easy to align, but this method still requires two mounted
components. A diffuse sensors is a single unit that does not use a reflector, but uses focused light as
shown in Figure 1.20

Figure 1.20: Diffuse sensor

With diffuse reflection the light is scattered. This reduces the quantity of light returned. As a result
the light needs to be amplified using lenses

Diffuse sensors

Diffuse sensors use light focused over a given range, and a sensitivity adjustment is used to select a
distance. These sensors are the easiest to set up, but they require well controlled conditions. For
example if it is to pick up light and dark colored objects problems would result.

When using opposed mode sensors the emitter and detector must be aligned so that the emitter beam
and detector window overlap, as shown in Figure 1.21. Emitter beams normally have a cone shape
with a small angle of divergence (a few degrees of less). Detectors also have a cone shaped volume
of detection. Therefore when aligning opposed mode sensor care is required not just to point the
emitter at the detector, but also the detector at the emitter. Another factor that must be considered
with this and other sensors is that the light intensity decreases over distance, so the sensors will have
a limit to separation distance

Figure 1.21: Beam divergence and alignment

If an object is smaller than the width of the light beam it will not be able to block the beam entirely
when it is in front as shown in Figure 1.22. This will create difficulties in detection, or possibly stop
detection altogether. Solutions to this problem are to use narrower beams, or wider objects. Fiber
optic cables may be used with an opposed mode optical sensor to solve this problem, however the
maximum effective distance is reduced to a couple feet
 Figure 1.22: The relationship between beam width and object size

Separated sensors can detect reflective parts using reflection as shown in Figure 1.23. The emitter
and detector are positioned so that when a reflective surface is in position the light is returned to the
detector. When the surface is not present the light does not return

Figure 1.23: separated sensors

Other types of optical sensors can also focus on a single point using beams that converge instead of
diverge.(Figure 1.24) The emitter beam is focused at a distance so that the light intensity is greatest
at the focal distance. The detector can look at the point from another angle so that the two centerlines
of the emitter and detector intersect at the point of interest. If an object is present before or after the
focal point the detector will not see the reflected light. This technique can also be used to detect
multiple points and ranges, as shown in Figure 1.25 where the net angle of refraction by the lens
determines which detector is used. This type of approach, with many more detectors, is used for
range sensing systems
 Figure 1.24: Point detection using focused optics

Figure 1.25: Multiple point detection using optics

Some applications do not permit full sized photo optic sensors to be used. Fiber optics can be used to
separate the emitters and detectors from the application. Some vendors also sell photosensors that
have the phototransistors and LEDs separated from the electronics.

1.2.10 Electric counters

An electric counter consist of a coil, associated circuits and contacts, a reset coil, manual reset,
release button and a display window. Pressure the release button of the counter and entering the
desired count valve set the pre-determining counter. The pre-determined count valve is displayed in
the window. There are two types of counters

1. Up counter
2. Down counter
Up counter: An up counter counts electrical signal upwards from zero. For each electrical counting
pulse input to an up-counter coil, the counter value is incremented by 1. When the predetermined
valve has been reached, the relay picks up and the contact set is actuated.

Down counter: An down counter counts electrical signal downwards from preset valve. If the count
valves of zero is reached the relay picks up and the contact set is actuated. The counter can be reset
manually by pressing the reset button or electrically by applying a reset pulse to the reset coil. The
pre-determined value is maintained when the counter is reset. The symbols of up counter and down
counter is shown in Figure 1.26(a) and Figure 1.26(b)

A1 2 4 A1 2
R1 R1

A2 R2 1 A2 R2 1

Figure 1.26: a) up counter b) down counter

1.3 Electro pneumatics circuits for single actuator

Control of single cylinders using electro pneumatics

Forward stroke: The circuit is closed when push button PB closes. A magnetic field is produced in
the coil Y. The armature in the coil opens the passage for the compressed air. The compressed air
flows from 1 to 2 of the 3/2 DCV to cylinder, which travels to the final forward position.

Return stroke: When the push button PB is released, the circuit is interrupted. The magnetic field at
coil Y collapses, the 3/2 way valve switches back to its original position as shown in Figure 1.27.
The compressed air in the cylinder then exhausts through port 3 of the DCV and the cylinder travel
to the final rear position.
10.3.1 Direct Control of single acting cylinder (Figure 1.27)
1.0 1.0

1.1 1.1
2 2

12 12C
3 1 3
1

+24 V
+24 V

PB PB

12
12

0V
0V

Position when cylinder is extended Position when cylinder is retracted

retracted

Figure 1.27: Direct control of single acting cylinder

1.3.2. Indirect Control of single acting cylinder (Figure 1.28)

1.0 1.0

1.1 1.1
2 2

Y Y

3 1 3
1

+24 V
+24 V

PB K1
PB K1

K1 Y
K1 Y

0V
0V

Position when cylinder is extended Position when cylinder is retracted

Figure 1.28: Indirectretracted

control of single acting cylinder

Forward stroke: The circuit is closed when push button PB closes. Closing of Push button PB
energises a relay K1. The coil Y is energised via normally open contact K1 (indirect energising).
A magnetic field is produced in armature of the coil Y opens the passage for the compressed air. The
compressed air flows from 1 to 2 of the 3/2 DCV to cylinder, which travels to the final forward
position.

Return stroke: When the push button PB is released, the circuit is interrupted. Opening of Push
button PB de-energises a relay K1. The magnetic field at coil Y is collapses due to the opening of
contact K1 the 3/2 way valve switches back to its original position as shown in Figure 1.28. The
compressed air in the cylinder then exhausts through port 3 of the DCV and the cylinder travel to the
final rear position.
1.3.3 Direct Control of double acting cylinder (Figure 1.29)

1.0 1.0

4 2 4 2
Y Y

5 3 5 3

1 1

24 V 24 V

PB PB

Y Y

0V 0V

a) Position when cylinder is extended Position when cylinder is retracted

Figure 1.29: direct control of double acting cylinder

Forward stroke: The double acting cylinder is controlled by 5/2 way valve. When the pushbutton
PB is pressed, coil Y is energised and the directional control valve is activated by compressed air via
pilot control. The piston travels to the final forward position.

Return stroke: When the push button PB is released, the circuit is interrupted. The magnetic field at
coil Y collapses, the return spring of 5/2 becomes active and the 5/2 way valve switches back to its
original position as shown in Figure 1.29. The compressed air in the cylinder then exhausts through
port 5 of the 5/2 DCV and the cylinder travel to the final rear position.
1.3.4 Indirect Control of double acting cylinder (using 5/2 way, single solenoid)

1.0 1.0

4 2 4 2

Y Y
5 3 5 3
1 1

+24 V +24 V

PB K1 PB K1

K1 Y K1 Y

0V 0V

b) Position when cylinder is retracted

a) Position when cylinder is extended

Figure 1.30: Indirect control of double acting cylinder

Forward stroke: The circuit is closed when push button PB closes. Closing of Push button PB
energises a relay K1. The coil Y is energised via normally open contact K1 (indirect energising).
A magnetic field is produced in armature of the coil Y opens the passage for the compressed air
through internal pilot. The compressed air flows from 1 to 4 of the 5/2 DCV to cylinder, which
travels to the final forward position.

Return stroke: When the push button PB is released, the circuit is interrupted. Opening of Push
button PB de-energises a relay K1. The magnetic field at coil Y is collapses due to the opening of
contact K1 the 5/2 way valve switches back to its original position as shown in Figure 1.30. The
compressed air in the cylinder then exhausts through port 5 of the DCV and the cylinder travel to the
final rear position.
1.3.5 Indirect Control of double acting cylinder (using 5/2 way, double solenoid) (Figure 1.31)

1. 1.
0 0

1. 4 2
1. 4 2
1Y1 Y2 1
Y1 Y2
5 3
5 3
1
1

+24 V 1 2 3 4 +24 V

PB1 PB2 PB1

PB2

K2 Y1 Y2 K1 K2 Y1 Y2
K1

0V N NC N NC 0V
N NC N NC
O
3 O
4 O O
3 4

a) Position when cylinder is extended b) Position when cylinder is

retracted
Figure 1.31: Indirect control of double acting cylinder (using 5/2 way vavle)

Forward stroke: when push button PB1 is pressed, coil Y1 is energised and 5/2 way directional
control valve changes over. The piston travels out and remains in the final forward position until a
signal is applied to coil Y2. The 5/2 directional control valve will remain in the last position because
it is double solenoid valve and has no return spring.

Return stroke: When the push button PB1 is released and PB2 is pressed. Opening of Push button
PB1 de-energises a relay K1. The magnetic field at coil Y1 is collapses due to the opening of contact
K1. Closing of PB2 energises Y2 and the piston returns to its original position as a result of
changeover of the 5/2 way valve. The 5/2 way directional control valve will not switch over if there
is an active opposing signal. For example, if Y1 is switched on and a signal is given to Y2, there will
be no reaction as there would be an opposing signal
1.3.6 Control of double acting cylinder OR logic (Parallel circuit) (Figure 1.32)

4 2 4 2
Y Y
5 3 5 3
1 1
24 V 24 V

PB 1 PB2 PB 1 PB 2

Y Y

0V 0V

a) Cylinder is extended using PB1 b) Cylinder is retracted (both PB released)b)

Figure 1.32: OR logic

The piston of a double acting cylinder is to travel out when either one of two pushbutton switch is
pressed. It is to return when both are released. When push button PB1 or PB2 are pressed. Coil Y1 is
energised. The directional control valve switches over and the piston travels to the final forward
position. When both the push button switches are released, the signal is removed from Y1 and the
cylinder travels back to its original position.
1.3.7 Control of double acting cylinder AND logic (Figure 1.33)

4 2 4 2

Y Y

5 3 5 3
1 1
24 V
24 V

PB 1 PB 1

PB2
PB2

Y
Y

0V
0V

a) Cylinder is extended using PB1 b) Cylinder is retracted (both PB released)

Figure 1.33: AND logic

1.3.8 Latching circuits

Double acting cylinder is to be controlled using 5/2 directional control valve , single solenoid, spring
return. When push button PB1 is pressed, cylinder should extend and remains in that position when
PB1 is released. The cylinder is to retract completely when PB2 is pressed. In addition, the cylinder
is to remain in the retracted postion even when PB2 is released. Develop a Electro-pneumatic control
circuit with an electrical latching with a) dominant off b) dominant On

Solution

In the following pneumatic circuit a double acting cylinder is controlled by 5/2 way valve.When Y1
is energised cylinder moves forward. When Y1 is deenergised cylinder retracts to its iniatil position.

We can construct the latching circui using the following electrical components

1. Use NO pustton button for ON or Start button control

2. Use NC push button for the OFF or stop control
3. Use a relay

Latching circuit can be dominatn ON or dominant Off. Dominnat position refer to stauts of relay
coil ( circuit) when both the start and stop signals are applied simultaneously

a) Latching circuit with Dominant OFF

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, if the circuit goes to
OFF position , then such a circuit is called Dominant OFF latching circuit. Refer to Figure 1.34 ,

a) When we press START push button PB1 is pressed and released , following operations
occurs:
1. Relay coil K1 in branch 1 ( vertical) is energised. All Contact K1 closes
2. Notice that there is a NO contact of K1 in branch 2 , which is connected parallel to PB1.
This NO contact of K1 latches the start push button. Therefore even if the PB1 is
released, NO contact of K1 in branch 2 keeps coil K1 energised.
3. There is another NO contact in branch 3, which is connected to Y1. When push button
PB1 is pressed this also remain closed, as a result cylinder moves forward and remains
there until stop button PB2 is pressed.
b) When we press STOP push button PB2 is pressed momentarily and released , following
operations occurs:
1. Relay coil K1 in branch 1 ( vertical) is de-energised. All Contact K1 opens
2. NO contact of K1 in branch 2 , which is connected parallel to PB1 is now open. This NO
contact of K1 no more latches the start push button.
 3. NO contact in branch 3 is also open now, which is denergises. As a resutl cylinder moves
back to its home position and remains there until start button PB1 is pressed again.

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, K1 contacts are open
and the circuit goes to OFF position . That is why this circuit is called Dominant OFF latching
circuit.

1.0 1.0

1.1 4 2 1.1 4 2

Y1 Y1
5 3 5 3
1 1

+24 V 1 2 3 +24 V 1 2 3

PB1 K1 K1 K1 K1

PB2
PB2

Y1 Y1
K1 K1

0V NO 0V NO NC
NC

2,3 2,3

a) Circuit is in latched position b) Circuit is in unlatched position

Figure 1.33: Dominant OFF cirucit

 b) Latching circuit with Dominant ON

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, if the circuit goes to ON
position , then such a circuit is called Dominant ON latching circuit. Refer to Figure 1.34 ,

a) When we press START push button PB1 is pressed and released , following operations
occurs:
4. Relay coil K1 in branch 1 ( vertical) is energised. All Contact K1 closes
5. Notice that there is a NO contact of K1 in branch 2 , which is connected parallel to PB1
and in series with PB2. This NO contact of K1 latches the start push button. Therefore
even if the PB1 is released, NO contact of K1 in branch 2 keeps coil K1 energised.
6. There is another NO contact in branch 3, which is connected to Y1. When push button
PB1 is pressed this also remain closed, as a result cylinder moves forward and remains
there until stop button PB2 is pressed.
b) When we press STOP push button PB2 is pressed momentarily and released , following
operations occurs:
1. Relay coil K1 in branch 1 ( vertical) is de-energised. All Contact K1 opens
2. NO contact of K1 in branch 2 , which is connected parallel to PB1 is now open. This NO
contact of K1 no more latches the start push button.
3. NO contact in branch 3 is also open now, which is denergises. As a resutl cylinder moves
back to its home position and remains in home position until start button PB1 is pressed
again.

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, K1 contacts are open
and the circuit goes to OFF position . That is why this circuit is called Dominant OFF latching
circuit.
 1.0 1.0

1.1 4 2 1.1 4 2

Y1 Y1
5 3 5 3
1 1

+24 V 1 2 3 +24 V 1 2 3

PB1 K1 K1 PB1 K1 K1

PB2 PB2

Y1 Y1
K1 K1

0V NO 0V NO NC
NC

2,3 2,3

a) Circuit is in latched position b) Circuit is in unlatched position

Figure 1.34: Dominant ON circuit

1.3.9 Automatic return of a double acting cylinder (spring return) (Figure 1.35)

1.0 1.0
S2
S2
Limit switch

1.1 4 2 1.1 4 2

Y1 Y1
5 3 5 3
1 1

+24 V 1 2 3 +24 V 1 2 3

PB1 K1 K1 K1 K1

S2 S2

Y1 Y1
K1 K1

0V NO 0V NO NC
NC

2,3 2,3

a) Cylinder while extending b) Position when S2 just pressed

Figure 1.35: Automatic return of double acting cylinders using single solenoid
1.3.10 Direct control of automatic return of a double acting cylinder ( double solenoid)
(Figure 1.36)
1.0

1.0
S2
S2

1.1 4 2 1.1 4 2

Y1 Y2 Y1 Y2

5 3 5 3
1
1

+24 V 1 2 +24 V 1 2

PB1
S2 S2

Y1 Y2 Y1 Y2

0V 0V

b) Position when S2 just pressed

a) Cylinder while extending

Figure 1.36: Automatic return of double acting cylinder using double solenoid
1.3.11 Indirect control of automatic return of a double acting cylinder ( double solenoid)
(Figure 1.37)

1.0
1.0
S2
S2

1.1 4 2 1.1

Y1 Y2 Y1 Y2

5 3 5 3
1
1

+24 V 1 2 3 4 +24 V 1 2 3 4

PB1 K1 K2 K2
S2 S2 K1

K2 Y1 Y2 K1 Y2
K1 K2 Y1

0V NO 0V
NC NO NC
3,4 3,4

a) Cylinder while extending b) Position when S2 just pressed

Figure 1.37: Indirect Automatic return of double acting cylinder using double solenoid
1.3.12 Automatic return of a double acting cylinder (using proximity switch) (Figure 1.38)

1.0 1.0
S2
S2
Limit switch

1.1 4 2 1.1 4 2

Y1 Y1
5 3 5 3
1 1

+24 V 1 2 3 +24 V 1 2 3

PB1 K1 K1 K1
K1

K2 K2

Y1 K1 Y1
K1

NO 0V NO
0V NC NO NC NC NO NC

2,3 2,3
1 1

a) Cylinder while extending b) Position when S2 just pressed

Figure 1.38: Automatic return of double acting cylinder using proximity switch
1.3.13 Oscillating motion of a double acting cylinder (Forward ) (Figure 1.39)

1.0
S1 S2

1.1 4 2

Y1 Y2
5 3
1

+24 V 1 2 3 4 5 6

PB1 K1
K1 S2 K2 K3
Start

S1
Stop

K1 K2 K3 Y1 Y2

0V NO NC NO NC
NO NC
5 6
2,3

a) Cylinder while extending

Figure 1.39: Oscillating motion of double acting cylinder (forward motion)

1.3.14 Oscillating motion of a double acting cylinder (Return ) (Figure 1.40)

S1 S2

1.1

Y1 Y2

5 3
1
+24 V 1 2 3 4 5 6

PB1 K3
K1 K1 S2 K2

S1

K1 K2 K3
Y1 Y2

0V NO NC NO NC
NO NC
3,4 3,4
3,4

b) Position when S2 just pressed

Figure 1.40: Oscillating motion of double acting cylinder (return motion)

1.3.15 Control of system with timed response

Control systesm which are assinged a particular timing sequence must be equipped with electrical
time lag relays. There are control systems which are purely affected by time or combination of path
scanning and time.

These time-lag relays , which are usually electronic time lagg relays nowadays, have two basic types
of timed response. They are referred to as time-lag relays with energising delay and de-energising
dealy. Time lag-relay with energising delay and Time lag-relay with de-energising delays are shown
in Figure 1.41 and 1.42.

a) Time lag-relay with energsing delay

15
1
Input (S1)

0
16 18

1
Output

S1 15

16 18

Figure 1.41: Time lag-relay with energsing delay

 b) Time lag relay with de-energixing delay

15
1
Input (S1)

0
16 18

1
Output

15

S1

16 18

Figure 1.42: Time lag relay with de-energixing delay

 c) Control of double acting cylinder with time delay (Double solenoid) (Figure 1.43)

S2

4 2

Y1 Y2
5 3
1

+24V 1 2 3 4

K2
K1
PB1 5
S2
K1

Y1 Y2

K2
K2 5

K1

0V

2 1 5
4

Figure 1.43 Control of double acting cylinder with time delay

When manual pushbutton PB1 is pressed, relay K1 changes state and the normally open contact k1
of relay is connected to solenoid coil Y1. When the normally open contact closes , the solenoid valve
changes state,

The cylinder travels to its final forward position where it actuates limit switch S2. This limit switch
stats the time lag relay K2 ( with energising delay)

After 5 seconds the normally open contact of time lag relay energises the solenoid coil Y2 of the
directional control valve. The vavle changes over and causes the piston to travel to its final rear
position.
d) Control of double acting cylinder using timer(single solenoid) (Figure 1.44)

S2
S2

4 2
4 2
Y1
Y1
5 3
5 3
1
1

+24 V +24 V
1 2 3 4 1 2 3 4

PB1 K1 K1 PB1 K1
K1
S2 S2

T t sec

Y1 T Y1
t sec

K1 K1

0V 0V

a) Position when cylinder S2 is just pressed b) Position of the cylinder after t sec

Figure 1.44 Control of double acting cylinder with time delay

A latching circuit is used to obtain the necessary memory function. The position of the circuit when
push button PB1 is pressed and then released is given in Figure xx. The cylinder extends to its
forward-end position and actuates limit switch S2 automatically. As the return motion is to be
delayed, on –delay timer is used to obtain the necessary time delay. The required time delay should
be set on the timer. Limit switch S2 controls the timer coil T. After the set delay, the timer contact
interrupts the latching circuit, thus causing the return motion of the cylinder as shown in Figure…
1.3.17 Control of double acting cylinder using electric counter with two end sensors (Figure
1.45)

Design a electro pneumatic circuit for a double acting cylinder to perform a continuous to and fro
motion. The cylinder has to stop automatically after performing 50 cycles operations

S1 S2

1.1

Y1 Y2

5 3
1
+24 V 1 2 3 6 6
4 5

S2
PB1 K3
K1 K1 K2

PB1
S2

S1
Counter
contact

A1 R1
R1
K1 K2 K3 Y1 Y2
A2 R2
A2

0V NO NO NC NO NC
NC NO NC
5 6
2,3 1

Figure 1.45 Control circuit using timer

When push button PB1 is pressed, it energises the coil K1 in branch 1. K1 in branch 2 is latched
with PB1. Contact K1 in branch 3 energises the coil K2 in branch 3, which in turn closes contact K2
in branch 5 causing solenoid coil Y1 in branch 5 to energise and move the direction control valve.
Cylinder moves forward.

When cylinder touches the limit switch S2 in branch 7, it sends a signal pulse to counter coil (A1
andA2) in branch 7. After a desired number of cycles is reached ( 50 cycles), then counter contact C
in branch 1 opens and de-energises the K1 and cylinder stops.
1.3.18 Oscillation of double acting cylinder using end positioning with proximity switches

S1 S2

4 2

Y1 Y2
5 3
1

+24V 1 2 3 5 7 8

PB1 K1
K1
K3

K2

S1 S2

Y2

K3
K2
Y1

K1

0V

2 7 8
3

Figure 1.46 Oscillation of double acting using proximity switches

1.3.19 Control of double acting cylinder using pressure switch

Components are to be stamped using stamping machine. A double acting cylinder is used to push the
die attached down to a fixture when two push buttons are pressed simultaneously. The die is to return
to the initial position upon reaching sufficient stamping pressure as sensed by a pressure switch and
one second delay. Develop an electro pneumatic control circuit to implement the control task for the
stamping operation.

Solution is shown in the Figure 1.47, which is self explanatory

4 2

Y1 Y2
5 3
1

+24V 1 2 3 4 5 6

PB1
K1 P K1 K2

PB2

K2

K2 1 Y1 Y2

K1

0V

3 2 6
5

Figure 1.47 Control of double acting cylinder using pressure switch

1.3.20 Control of double acting cylinder using delay on and off timer and counter

Components are to be stamped using stamping machine. A double acting cylinder is used to push the
die attached down to a fixture one second after push button is pressed. The die is to return to the
initial position upon reaching sufficient stamping time of two seconds is reached. This automatic
cycle should stop after 5 cycles. Start button should reset the counter. Develop an electro pneumatic
control circuit to implement the control task for the stamping operation.

Solution is shown in the Figure 1.48, which is self explanatory

S1 S2

4 2

Y1 Y2
5 3
1

+24V 1 2 3 4 5 6 7 8 11

K1 K3
PB1
PB1 K1 K2 S2
S2

S1

K3 2
K2 1 C 5
Y2
Y1

K1

0V

3 5 8 1
4

Figure 1.48 Control of double acting cylinder using counter and delay
1.3.21 Control of double acting cylinder using delay on and off timer and counter

Components are to be stamped using stamping machine. A double acting cylinder is used to push the
die attached down to a fixture one second after push button is pressed. The die is to return to the
initial position upon reaching sufficient stamping time of two seconds is reached. This automatic
cycle should stop after 5 cycles. Start button should reset the counter. Initial position sensing is
through magnetic reed switch. Develop an electro pneumatic control circuit to implement the control
task for the stamping operation.

Solution is shown in the Figure 1.49, which is self explanatory

S1 S2

4 2

Y1 Y2
5 3
1

+24V 1 3 4 5 6 7 8 9 10 13

PB1
PB1 K2 S2
K3
S1 S2
K1

K1

Y1 K3 2 Y2 C 5
K2 1
C

K1

0V

3 7 10 2
5

Figure 1.49 Control of double acting cylinder using reed switch for initial sensing
Objective Type Questions

1. A relay is considered as an electro -------------- actuated switch

2. When both start and stop buttons are pressed simultaneously, circuits goes to OFF condition in
Dominant ------ circuit.
3. Inductive sensors cannot be used to detect ………………….. materials.
4. Push buttons are operated manually, where as limit switches are operated ----------------------
5. --------------- switches are magnetically actuated proximity switch

State True or False

1. Electro pneumatic circuits are less reliable than pure pneumatic circuits.

2. A pressure switch is electric – pneumatic signal convertor

3 A relay is electro pneumatically operated switch that operates under the control of additional
electrical circuits.

4. An electrical latching relay circuit is an example of memory function

5. Limit switches are usually operated manually.

Review Questions
1. Explain briefly the working principle of an electro magnetic relay

2. Draw the symbol for an electromagnetic relay with 2 NO and 1 NC

3. What are the different ways to implement memory function in electro pneumatic circuits?

4. Explain the step displacement diagram for A+B+B-A- sequence.

5. List few disadvantages of using electro pneumatic circuits.

6. Explain the principle of cascade method using electro pneumatics with a suitable sequence
example

7. What are the functions of sensors

8. Explain the working principle of a limit switch

9. Explain the working principle of a reed switch

10. Draw the symbols for the following

a) limit switch b) Inductive type proximity switch c) capacitive type proximity switch d) optically
operated sensor

11. Differentiate between through beam sensors and diffuse sensors

12. Compare inductive , capacitive and optical types of sensors

13. Explain the functions of on delay timers with suitable circuit.

14. Explain the functions of an off delay timers with suitable circuit.

15. Differentiate between the behaviours of on timer delay and off timer delay with the help of a
timing diagram.

16. Explain the function of a pressure switch

17. Explain the function of up counter and down counter.

18. Draw a group changing cascade circuit for two groups, three groups, and four groups

19. Explain with the help of neat sketch the construction and working of pressure sequence valve

20. What are the different ways to sense the end position and movement of cylinders
Answers

Fill in the Blanks

1. magnetic
2. off
3. non-metallic
4. automatically
5. reed

State True or False

1. False
2. False
3. False
4. True
5. False
 Lecture 42

PNEUMATIC CIRCUIT DESIGN USING PLC

Learning Objectives

Upon completion of this chapter, Student should be able to

Define PLC and its function

Explain the difference between hard wired control and PLC control
Explain the different section of PLC
List the advantages of PLC over electromagnetic relays.
Explain the functions of major components of PLC
Explain various programming approaches used in PLC
Describe the functions of memory functions, timers and counters
Convert the logic functions into ladder diagram
Design PLC circuits for single and multi actuators

1.1 Introduction

A programmable logic controller (PLC) is essentially a user friendly micro-processor based

microcomputer, consisting of hardware and software, designed to control the operation of
Industrial equipment and processes. An important advantage of the PLC is that it can be easily
programmed and reprogrammed. PLC has tremendous impact on Industrial control and
instrumentation due to its high reliability and flexibility at the design and implementation stages.
The decreasing cost of microprocessor with increasing facilities in them is acting as catalyst in
their widening scope of applications. In recent years, PLC are being used in place of
electromechanical relays or cam operated logic controllers to control fluid power systems.
Modern day PLCs are developed into a sophisticated and highly versatile control system
component capable of performing complex mathematics functions and operate at fast
microprocessor speeds. Some leading PLC manufacturers are ABB, Allen Bradley, Honeywell,
Siemens, GE Fanuc, Mitsubishi, Modicon, Omron etc.
1.2 PLC – Defined

PLC can be defined as digital electronic device that uses a programmable memory to store
instructions and to implement functions such as logic, sequencing, counting, timing and
arithmetic in order to control machine, processes and instrumentation

PLC is user –friendly digital computer used for making logic decisions and providing output. It
consists of solid state digital elements and is a replacement for hard-wired electro-mechanical
relays to control pneumatic systems.

The term „programmable logic controller‟ is defined as follows by IEC 1131 ( PLC standard)
part 1

“A digitally operating electronic system, designed for use in an industrial environment, which
uses a programmable memory for the internal storage of user- oriented instructions for
implementing specific functions such as logic , sequencing , timing , counting and arithmetic, to
control through digital or analog inputs and outputs, various types of machines or processes.
Both the PC and its associated peripherals are designed so that they can easily integrated into an
industrial control system and easily used in all their intended function”

PLC is quite similar to digital computers. They also have certain features which are specific to
logic controllers. They are

1. PLC are rugged and designed to withstand vibrations, temperature , humidity and noise
2. The interfacing for input and output is part of the controller
3. They are easily programmable and primarily use logic and switching functions

1.3 Hard-wired control systems

In hard wired control systems, relays are used. For example: In Electricalcontrol, the wiring of
control elements such as sensors, solenoids, counters etc. are through relays control. Such relay
controlled systems are also called as hard-wired control system because any modification in
control program involves rewiring of the circuit. Therefore, hardwired controls are cumbersome
and difficult to modify when production requirement changes regularly. Hard-wired control
systems are difficult to maintain because any small problem in design could be a major problem
in terms of tracing and rewiring.

Hard wired control systems consists of three division

1. Input section – Consists of push –buttons, switches and sensors. They transfer signals to the
processing section

2. Processing section –Consists of relay coils and contacts. They determined the relationship
between the inputs received and outputs required

3. Output section –Consists of solenoids, lamps, and contactor coils etc. The processed signals
are transferred to this section.

1.4 PLC Systems.

PLC systems offer number of advantages over hard wired electromechanical relay control
systems. Unlike the electromechanical relays, PLCs are not hard-wired to perform specific
functions. Thus, when system operation requirement change, a software program is readily
changed instead of having to physically rewire relays. In addition, PLCs are more reliable, faster
in operation, smaller in size, and can be readily expanded.

PLC systems consists of three division

1. Input section – Consists of push –buttons, switches and sensors which are connected to
specific input addresses in the program. They transfer address information to the processing
section

2. Processing section –The microprocessor receives the input signals from input sections and
executes the information (called instructions) in the software program and sends the processed
signals to output section

3. Output section –Takes the signal from processing section and modify the signal from the
processor to operate output devices connected to specific output addresses.
Advantages of PLCs over Electromechanical relays

The PLC replaces electromechanical relays due to their following advantages

a. PLCs are more reliable and faster in operation

b. They are compact and can be expanded easily
c. They require less electrical power
d. They are less expensive when compared to Hardwired systems of same number of control
functions
e. Hard-wired electromechanical relays lack flexibility. For example, when system
operation requirement change, then the relays have to be rewired.
f. PLCs have very few hardware failures when compared to electro-mechanical relays
g. Special functions such as time-delay actions and counters , can be easily performed using
PLCs

Comparison between Relay and PLC is presented in Table 1.1

Table 1.1 Comparison between Relay and PLC

Features Electromechanical PLC

relay
Size of the controller Bulky Compact
Programming Time consuming Easy
Flexibility Rewiring required Reprogramming required
Cost Expensive Less expensive
Maintenance Poor Minimum
Fault finding and troubleshooting Difficult Easy to identify fault and repair
1.5 MAJOR COMPONENTS OF PLC

As discussed earlier, A PLC is essentially a microcomputer consisting of hardware and software.

The major components are

1. Power Supply module

2. Input module
3. Central processing unit
4. Output modules
5. Software

a)Power supply module:

Usually input output modules require 24V DC and processor require 5V DC. Usually power
supply is integral part of PLC. Power supply units convert 120/230 V AC line voltage to
standard supply of 24 VDC or 5V DC using standard rectifier circuits

b)Input module

Input devices include push buttons, sensors, potentiometers, pressure switches. The function of
the input module is to covert high voltages from input devices to low level logic voltages that the
CPU uses internally for processing.

Input module can process both analog input and digital input. Digital inputs are more preferred in
Industry.

c)Analog input module is used to convert analog signal form analog devices like temperature
sensors, pressure sensors etc. to digital signals using ADC (Analog –to digital convertor).
Analog signal is varying voltage in the range of 0-12 V or current in the range of 5-20 mA.
These values of current or voltage is converted into integer value (say16 bit word)

Digital `is used to convert signal digital input to 5V digital signals that CPU uses internally to
execute a user program.
d)Central processing unit

The central processing unit controls and processes all operations within the PLC and hence
called brain of the PLC. The CPU can perform various arithmetic and data manipulation function
with the local and remotely located Input/output sections. Further, the processor can perform
many communication functions it needs to interface with a personal computer, remote
Input/Output, other PLCs and peripheral devices

Functions of CPU are :

1. It receives input from various sensing devices and switches

2. It executes the user program
3. It makes various decisions to control the operation of the equipment or process
4. It can perform various arithmetic and data manipulation functions
5. It delivers corresponding output signals to various load control devices such as relay coils
and solenoids

e)Output module

Output devices include contactor coils, solenoid coils, lamps, etc. Output module amplifies the
low–level logic signals generated by the CPU and pass these modified signals to the final control
elements to operate the output devices.

f) Software

PLC consists of two parts: Operating systems and user program. The PLC operating system
provides effective support ranging from the creation of project structure to the creation of user
programs. The OS system is accessed through a graphical user interface window ( also known as
Main window). The main window contains all the functions needed to set up a project , configure
the hardware , write and test programs. User program can be written in any standard PLC
programming language like ladder diagram or statement list.

While processing a PLC program, the CPU scans and executes the main program cyclically;A
program scan cycle consists of sequential operations that include input scan, program scan, and
output scan. In the input scan, the CPU updates the process image input table, in the output scan;
the CPU updates the process image output table. After the completion of each scan cycle, the
CPU returns to the beginning of the next cycle and again repeats the cycle. The time taken to
scan one program is called scan –cycle time.

1.6 PROGRAMMING OF PLC

There are various approaches for entering the program into PLC they are

1. Ladder diagram based

2. Low level based on Boolean expressions
3. Functional blocks
4. High level language

Most of the programming methods used today for PLC are based on the ladder logic diagram.
Therefore the concept of ladder diagram is explained in the following sections

The PLC programming based on the use of ladder diagram involves writing a program in a
similar manner to drawing a switching circuit. The ladder logic diagram is converted into PLC
ladder diagram by using the conventions of PLC ladder diagram constructions. This method
requires the use of simple keyboard and CRT with minimum graphic capability to display the
symbols, representing components and their inter relationship in the ladder logic diagram. The
components are of two types, contact and coils. Contacts are used to represent input switches,
relay contacts and similar elements. Coils are used to represent load such as solenoids, relays,
timers, counters etc. The programmer inputs the ladder diagram rung by rung into the PLC
memory with the CRT displaying the results for verification.

The ladder diagram has two vertical sides (also called rungs) (Figure 1.1). The left side line
represent line with a positive voltage and right side represent a line with zero voltage. Between
these two sides are the horizontal rungs for the assumed power flow. The symbols representing
the various program elements are placed on the rungs in order to realize the required control task.
 Bit address
Output address
+ 0V
Rung

Program logic Output coil

Figure 1.1 Ladder diagram

There are five program elements/operations commonly used in PLC ladder diagram they are

1. PLC Bit logic operations

2. Timer Operations
3. Counter operations
4. Comparison operations
5. Arithmetic operations.

1 PLC bit logic operations : Some important programming elements for bit logic operations are

a) NO contact
b) NC contact
c) Coil

Each of these elements can be selected from the program window. NO and NC elements should
not be confused with the hardware NO and NC contacts of switching devices.

NO Contact of PLC:

The PLC representation of NO contact is given in Figure 1.2. This contact scans for the signal
state ON (1) at the specified bit address. Power flows through NO contact if the scanned bit
address has a signal state ON (1). This contact is used for scanning the signal state of input
devices or output devices or other internal program elements.

Bit address Bit address Bit address

NO program contact NC program contact PLC coil

+24 +24

V V

PB 0 state 1 state
PLC PLC

11 01 11 01

0 1
L L

a) PLC circuit – PB open b) PLC circuit – PB

Closed
+24 +24

V V

PB K1 K1
0 0 1 1

L L
K1 K1

0V 0V
a) Relay circuit – PB open
b)Relay circuit –PB closed

Figure 1.2 PLC circuit with NO contact position using NO push button

NC Contact of PLC:

The PLC representation of NC contact is given in Figure 1.3 This contact scans for the signal
state OFF (0) at the specified bit address. Power flows through NC contact if the scanned bit
address has a signal state OFF (0). This contact is used for scanning the signal state of input
devices or output devices or other internal program elements. Figure 1.4 shows PLC circuit with
NC contact position using NO push button. Figure 1.5 shows PLC circuit with NC contact
position using NC push button.

+24 +24

V V

0 state
PB 1 state
PLC PLC

12 02 12 02

1 0
L L

a) PLC circuit – PB Closed b) PLC circuit – PB open

+24 +24

V V

PB K1
K1
0 0
1 1

L
K1 K1 L

0V 0V

a) Relay circuit – PB closed b)Relay circuit –PB open

Figure 1.3 PLC circuit with NO contact position using NC push button
 +24 +24

V V

PB 1 state
PB 0 state
PLC PLC

13 03 13 03

1 0
L L

a) PLC circuit – PB Released b) PLC circuit – PB pressed

+24 +24

V V

PB K1 K1

1 0
0 1

L
K1 K1 L

0V 0V

a) Relay circuit – PB released b) Relay circuit –PB pressed

Figure 1.4 PLC circuit with NC contact position using NO push button
 +24 +24

V V

PB 0 state
PB 1 state PLC PLC

14 04 14 04

0 L 1

a) PLC circuit – PB pressed b) PLC circuit – PB open

+24 +24

V V

PB K1 K1

0 1
1 0

L
K1 K1 L

0V 0V

a) Relay circuit – PB pressed b)Relay circuit –PB open

Figure 1.5 PLC circuit with NC contact position using NC push button

1.7 PLC TIMERS

Many control tasks require the programming of time. For example, cylinder 2 is to extend, if the
cylinder 1 is retracted- but only after a delay of few seconds. The timers of a PLC are realised in
the form of software modules and are based on the generation of digital timing. Memory space is
allocated in system memory to store the values of the delay time. The represnetion of the timer
address varies from manufacturer to manufacturer. For sake of understanding we shall as T1, T2
for timer addresses. The typical number of timers available in commerical PLC are 64, 128, 256 ,
512 or even more. To explictiy reset timer, an RLO of 1 has to be appled at the reset port.
There are two types of PLC timer

PLC on delay timer : The timer will be ON state when it recieves a start input siganl and The
signal state of output changes to 0 from 1 , when preset timing is reached. The signal state of the
output changes from 0 to 1 when preset time has been reached with reference to change of RLO
(Result of logic operation) from 0 to 1(ON) at the start input .Functional diagram is shown in
Figure 1.6

Timing diagram Symbol

ON OFF circuitOn-delay timer

Start Input circuit
Start input Output

Delay time

Reset
t
Output

Figure 1.6 : PLC On delay timer

PLC off delay timer : The timer will be ON state when it recieves a start input siganl and The
signal state of output changes to 1from 0 , when preset timing is reached. The signal state of the
output changes from 1 to 0 when preset time has been reached with reference to change of RLO
from 1 to 0(OFF) at the start input. Functional diagram is shown in Figure 1.7

Timing diagram Symbol

OFF-delay timer
Start input

Start input Output

t
Output Delay time

Reset

Figure 1.7 : PLC OFF delay timer

1.8 PLC COUNTERS

Counters are used to detect pieces numbers and events. Controllers frequently need to operate
with counters in practice. For example: a counter in circuit is required if exactly 20 identical
components are to be conveyed to a converyor belt via a sorting device.

There are two basic counter types a) Count Up b) Count down

When the input to count up counter goes true the accumulator value will increase by 1 ( no
matter how long the input is true). If the accumulator value reaches the preset value the counter
bit will be set. A count down counter will decrease the accumulator value until the preset vaule is
reached. Symbols are shown in Figure 1.8

Up counter Down counter

Count up Output Count down Output

Set Set
Preset Preset
Reset Reset

Figure 1.8 : Up and down counter

1.9 PLC Memory elements

Memory elements are used to store intermediate values. Memory function are achieved using
flags ( bit memory locations) and system memory. Specified bit memory can be set or reset
using a set coil. A latch in ladder logic uses one instruction to latch and a second instruction to
unlatch, as shown in Figure 1.9. The output with an S inside will turn the output D on when the
input A becomes true. D will stay on even if A turns off. Output D will turn off if input B
becomes true and output with a R inside becomes True.
 D

A Set coil

R
Reset coil
B

Figure 1.9 a ladder logic latch

Both set coil and reset coil can be combined in one box as shown in Figure 1.10. Following
instructions are to be followed while writing a program for memory function

 Setting up a memory location

 Resetting up a memory location

The memory address locations vary from manufacturer to manufacturer. For sake of simplicity
we shall use M1, M2 … to represent memory. Number of bit memories available in PLC for
memory are 1024, 2048 8192 and more.

If the power flows either momentarily or continuously to the set coil, the specified memory
address is set to signal state 1. If power flows momentarily or continuously to the reset coil , the
corresponding memory address is reset to signal state 0. If there is no power in the set input or
reset input, the memory address remains unaffected. The output of the memory function can be
accessed through either NO or NC program element

Set reset memory Reset set memory bloc

Output Output
Set Reset
Reset
Set

Figure 1.10 : Memort box representation

Set and reset functions are combined in one memory box as shown in Figure 1.10. They can be
further classified into two categories

a) Memory box with set priority

b) Memory box with reset priority

The functions of a memory box are similar to the memory coils. In the memory box with set
priority, the associated memory address is set when signal state 1 appears simultaneously at both
the set and reset inputs. In the memory box with reset priority, the associated memory address is
reset when signal state 1 appears simultaneously at both reset and set inputs. This concept is
similar to Dominant ON and Dominant OFF functions of electrical latching circuits discussed in
chapter lecture 41
Example 1 : Double acting cylinder is used to perform machinng operation. Pneumatic cylinder
is advanced by pressing two push buttons simultaneously. If any one of the push button is
released, cylinder comes back to start position. Draw the pneumatic circuit, PLC wiring diagram
and ladder diagram to implement this task.

Solution is shown in Figure 1.11

1.0 +
Assignment Table
B1 PB2
PLC PB1 11
12
PB2 12
1.1 O1 Y1 01
4 2

Y1 Y1
5 3
1
0
wiring diagram

11 12 O1

Ladder diagram

Figure 1.11 a) Pneumatic diagram b) wiring diagram c) ladder diagram

As shown in the PLC wiring diaram , The pushbuttons PB1 and PB2 are connected at memory address I1
and I2. I1 and I2 are connected in series in ladder diagram to relase this AND logic funtion.

When the push buttons PB1 and PB2 are pressed simultaneously, the addresses I1 and I 2 turn to state 1
from state 0 , as a result power flows thorugh the coil and there will be output at coil 01. Output at the coil
01 operated the solenoid coil and cylinder moves foraward to do the required operation.

If any one of PB1 and PB2 is pressed, then corresponding bit addresses turns to 0, since I1 and I2 are in
series , if any of them turns to 0 state , there will not be any outout at 01 and thus solenoid is deenergised
and returns back.
Example 2 : Double acting cylinder is used to perform forward and return motion. Pneumatic cylinder
is advanced by pressing push buttons PB1. Cylinder is returned by pressing push button PB2. Draw the
pneumatic circuit, PLC wiring diagram and ladder diagram to implement this task.

Solution is shown in Figure 1.12

1.0 +
Assignment Table
PB1 PB2P
PLC PB1 11
11 12
PB2 12
1.1 O1 O2 Y1 01
4 2
Y2 02
Y1 Y2 Y1 Y2
5 3
1
0
PLC wiring diagram
11 O1
1

12 O2
2

Figure 1.12 a) Pneumatic diagram b) wiring diagram c) ladder diagram PLC

PLC Wiring diagram and Ladder diagrams are shown in Figure 1.7. when the pushbutton PB1 is pressed
state of the address I1 turns to 1 and thus there will be output 01. The output of 01 operates the solenoid
Y1 and cylinder moves forward,

When the cylinder reaches the extreme forward position, and Push button PB2 is operated , the state of
address I2 turns to 1 and thus there will be output 02. The output of 02 operates the solenoid Y2 and
cylinder return back to initial position.
Example 3 : Double acting cylinder is used to perform forward and return automatically after
reaching the extreme forward position. Pneumatic cylinder is advanced by pressing push
buttons PB1. Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to implement
this task.

Solution is shown in Figure 1.13

1.0 +
S2 Assignment Table
PB1 S2
PLC PB1 11
11 13
S2 13
1.1 O1 O2 Y1 01
4 2
Y2 02
Y1 Y2 Y1 Y2
5 3
1
0
PLC wiring diagram
11 O1
1

13 O2
2

Figure 1.13 a) Pneumatic diagram b) wiring diagram c) ladder diagram

PLC Wiring diagram and Ladder diagrams are shown in Figure 1.7. when the pushbutton PB1 is pressed
state of the address I1 turns to 1 and thus there will be output 01. The output of 01 operates the solenoid
Y1 and cylinder moves forward,

When the cylinder reaches the extreme forward position, and Limit switch S2 is operated , the state of
address I3 turns to 1 and thus there will be output 02. The output of 02 operates the solenoid Y2 and
cylinder return back to initial position.
Example 4 : Double acting cylinder is used to perform pressing operation. Cylinder has to move
forward when PB1 button is pressed and return for set time of 20 seconds before it automatically
returns to intial position. Limit switch S2 is used for end sensing of the forward motion of the
cylinder. Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to implement this
task.

Solution is shown in Figure 1.14

+
PB1 S2
PLC
11 13
PLC wiring diagram
O1 O2

Y1 Y2

1.0 11 O1
S2
1

Timer T1
13
On delay timer O2
2
Start I/O O/P
1.1 Delay time – 20 S
4 2
Reset
Y1
Y1 Y2
Y2
5 3 Ladder diagram
1

Figure 1.14 a) Pneumatic diagram b) wiring diagram c) ladder diagram

When PB1 is pressed, address I1 input state goes to 1 and there is an output at O1. Due to output at O1,
the solenoid coil Y1 is operated and cylinder moves forward. When cylinder reaches end position , limit
switch S2 is operated and as a result address I3 changes to 1 and consequently starts the timer T1. The
signal state of timer T1 changes to 1 after 20 seconds is reached. At the end of 20 seconds there will be
output from Timer T1 set output O2. Coil Y2 is energised thus causing the return motion of the cylinder.
Example 5 : Double acting cylinder is used to perform continuous to and fro motion. Cylinder
has to move forward when PB1 button is pressed and once to and fro reciprocation starts it
should continue till stop button PB2 is pressed. Limit swithces are used for end position sensing.
Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to implement this task.

Solution is shown in Figure 1.15

+ 1.0

PB1 PB2 S1 S2

11 12 13 14

PLC 1.1
O1 O2
4 2

Y1 Y2
Y1 Y2 5 3
1
0
PLC wiring diagram

Memory M1
11 Set-reset Memory signal from I1 sets and
1 Set O/P Memory signal from I2 resets.

Reset
2 M1 13 O1 M1=1, I3=1, Output O1 =1, Y1 is ON

O2
14 I4=1 , output O2 =1, Y2 is ON

Figure 1.15 a) Pneumatic diagram b) wiring diagram c) ladder diagram

The start and stop operations can be implemented using memory flag with address M1 that is set by PB1
and reset by PB2. The state of the memory element M1 is scanned through an NO contact, is combined in
series with the state of sensor S1 to get start and stop controls.
Example 6 : Double acting cylinder is used to perform to and fro operation. Cylinder has to
move forward when PB1 button is pressed and continue to and fro motion till 10 cycles of
operations is performed. Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to
implement this task.

Solution is shown in Figure 1.16

+ 1.0

PB1 PB2 S1 S2

11 12 13 14

PLC 1.1
O1 O2
4 2

Y1 Y2
Y1 Y2 5 3
1
0 Pneumatic diagram
PLC wiring diagram
Memory M1
11 Set-reset
Rung 1 I1 sets flag M1, C2 resets M1. NC of C1
Set O/P
C1 Reset scans for Zero state of counter C1

Rung 2 M1 13 O1 M1=1, I3=, O1=1 Y1 is ON

14 O2
I4=, O2=1 Y2 is ON
Rung 3
COUNTER C1
14 Down Counter
Count down
11 Set O/P
10 Pre-set value =10
Reset Ladder diagram

The fully automatic operation of cylinder can be obtained as earlier using limit switch S1 and S2. Start
and stop operation can be implemented using memory flag with address M1 that is set by PB1 at I1 and
reset by NC contact of a down counter. The state of memory flag M1 scanned through an NO contact
(rung 2) is combined in series with the state sensor S1 to get start and stop controls.
Example 7 : Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to implement
A+B+B-A- sequence.

Solution is shown in Figure 1.17 and Figure 1.18

1.0 S1 S2 S3 S4
1.0

1.1 2.1
4 2 4Y1 2
Y1 Y2 Y1 Y2
5 3 5 3
1 1
+
PB1 PB2 S1 S2 S3 S4

11 12 13 14 15 16

O1 O2 O3 O4

Y1 Y2 Y3 Y4
0
Figure 1.17 PLC wiring diagram

In this sequence circuit, PB2 is used to initiate the program. Pressing PB2 causes the last memory state
M4 to set and all other memory flags M1, M2 and M3 to reset. Initially S1 and S3 are actuated and
generate outputs.

Condition 1: Pressing PB1 sets Memory flag M1 and resets Memory flag M4. Solenoid Y1 is energised.
Cylinder A extends (A+). Sensor S1 is deactivated once A travels and S2 is activated when end position is
reached.

Condition 2: When S2 is actuated, memory M2 is set and Memory flag M1 is reset. Solenoid Y3 is
energised. Cylinder B extends (B+). Sensor S3 is deactivated once B travels and S4 is activated when end
position is reached.
Condition 3: When S4 is actuated, memory M3 is set and Memory flag M2 is reset. Solenoid Y4 is
energised. Cylinder B retracts (B-). Sensor S4 is deactivated once B travels and S3 is activated when
initial position is reached

Condition 4: When S3 is actuated, memory M4 is set and Memory flag M3 is reset. Solenoid Y2 is
energised. Cylinder A retracts (A-). Sensor S2 is deactivated once B travels and S1 is activated when
initial position is reached
 Memory M1
PB1 M4 S1 Set-reset Y1
Set O/P

M2
Condition 1 2 Reset
PB2 Reset
3
Memory M2
M1 S2 Set-reset Y3
4 Set O/P

M3
Condition 2 5 3
3
Reset
PB2 Reset
6

Memory M3
M2 S4 Set-reset Y4
7
Set O/P

M4
Condition 3 8 Reset
PB2 Reset
9

Memory M4
M3 S3 Set-reset Y2
10
Set O/P
PB2
Condition 4 11
M1
Reset
12
Reset

Figure 1.18 Ladder diagram

1.11 Areas of Application of a PLC

Every system or machine has a controller, depending on the type of technology used, controller
can be divided into pneumatic, hydraulic, electrical and electronic controllers. Frequently we use
combination of different technologies. Furthermore, differentiation is made between hard wired
programmable and programmable logic controller. The first is used primarily in cases, where any
reprogramming by the user is out of the question and job size warrants the development of a
special controller. Typical application for such controllers can be found in automatic washing
machine, video cameras, and cars.

However, if the job size does not warrant the development of special controllers or if the user is
to have the facility of making simple or independent program changes, or of setting timers and
counters, then the use of universal controllers, where the program is written to an electronic
memory, is the preferred option. The PLC represents such a universal controller. It can be used
for different applications and via the program installed in its memory , provides the user with a
simple means of changing , extending and optimising control processes.

PLC are widely used in Industries due to following reasons.

 Cost of PLC automation is less and PLC is very versatile

 PLC can be commissioned and installed easily
 Programming of PLC is quite simple. Ladder programming is flexible
 They are not hard wired control. They can be programmed and reprogrammed to
accommodate frequent changes in program
 Monitoring of on line work process is easy, therefore trouble shooting and maintenance
of PLC is not a difficult task
 They can be classified as low cost automation devices
 They can be used in harsh environment where humidity and temperature are high. Their
working is not effected by vibration and shock
 They can be used to execute complex mathematical algorithms, servomotor control,
Stepping control, axis control, self – diagnosis, on line monitoring, condition monitoring,
system trouble shooting, communicating to other PLCs, data acquisition, Networking,
storage and report generation
  PLC are most suitable for low cost automation, where frequent changes to the control
requirement would be expected during their operational life like in Batch type of
production systems.

1.12 PLC standards

Previously valid PLC standards focussing mainly on PLC programming were generally used in
Europe at end of the seventies. This included non-networked PLC system, which primarily
execute logic operations on binary signals. DIN 19 239, for example, specifies programming
language which possess the corresponding language commands for these applications.

Since 1992, an international standard now exists for programmable logic controllers and
associated peripheral devices like programming and diagnostic tools, testing equipment, man to
machine interfaces.

In 1992, IEC 1131 standards were developed as an open framework for PLC architecture. The
second edition of IEC 1131 ( Known as IEC 61131) was published in 2003. The new IEC
standard consists of five parts

 Part 1 : General information

 Part 2 : Equipment requirement and tests
 Part 3 : programming languages
 Part 4 : User guidelines in preparation with IEC
 Part 5: Messaging service specification

Parts 1 to 2 of this standard were adopted unamended as European standard EN 61 131, parts 1
to 2. As such, they also hold the status of a German standard. Part 3 of new IEC deals with
programming languages and defines two graphical and two textural PLC programming language
standards. The standard also defines both graphical and textual sequential function chart
elements to organise programs for sequential and parallel control processing. It is now possible
to program PLC using following languages
  IL- Instruction list
 ST – structural text
 LD – Ladder diagram
 FBD - Functional block diagram
 SFC- Sequential function chart

The purpose of the new standard was to define and standardize the design and functionality of a
PLC and the languages required for programming to the extent where users were able to operate
using different PLC systems without any particular difficulties.

Large number o f major PLC suppliers are members of association called PLCopen which
supports IEC 1131. Allen Bradley, Klockner–Moeller, Phillips Siemens or Mitsubishi to mention
a few.
Objective Type Questions

1. The most important sections of PLC are input section, output section and ------
2. The Structure of PLC consists of power supply module, CPU, I/O modules and --------
3. User program can be written in any standard PLC programming language like statement list
and ------------------
4. The AND function combines the bit addresses of inputs and produces an RLO ( Results of
logic operation) of ..... when all the inputs are scanned for 1
5. The function of timer is to provide ------------------ between work operations

State True or False

1. Hard wired control systems are used widely when production requirements change regularly

2. Relay controls are less expensive compared to PLC controls

3 While processing a PLC program, CPU scans and executes the main program cyclically.

4. The NO and NC PLC program contact is same as the hardware NO and NC contacts.

5. The OR function combines the bit addresses of inputs and produces an RLO ( Results of logic
operation) of 1 when any one or more of inputs are scanned for 1.
Review Questions

1. What is a hard wired control? what are its disadvantages

2. List five differences between PLC control and Relay control

3. List three input devices commonly used in PLC control

4. Explain the working of functions of CPU , Input and output module and memory in PLC

5. Mention few applications of PLC

6. What are the functions of timer in PLC

7. Briefly explain the structure of PLC

8. Differentiate between ON time delay and OFF time delay with help of symbols

9. What is meant by bit logic operations in relation to a PLC

10. Give functions of following PLC program elements a) Program coil b) NC contact c) NO
contact d) Set coil e) reset coil f) Set-reset box g) reset-set box h) on delay timer i) off delay
timer j) up counter k) down counter
Answers

Fill in the Blanks

1. Program section
2. Software
3. Ladder diagram
4. 1(one)
5. delay

State True or False

1. False
2. False
3. True
4. False
5. True
 Appendix A

Standard Symbols for Hydraulic Components

Table B.1 Flow lines

Hydraulic

Pneumatic

Continuous flow

Pilot connection L

L>10E

E
Drain connection L
L<5E

d5E
Connected
d
L

Not connected

Flexible

Plugged

Restricted, affected by viscosity

Restricted, not affected by viscosity

 Table B.2 Basic Hydraulic Circuits

Miscellaneous
E D
Line, mech. connection (shaft, levers, piston
rods)
D<5E
Line, enclosure (several components in a unit)
Spring

Direction of rotation

Electric motor M

Heat engine M

Filter or strainer

Reservoir, with line above fluid level

Reservoir, with line below fluid level
Reservoir, as header

Adjustable setting

Reservoir switch

Pressure switch

Accumulator
Sring Loaded Gas Loaded

Cooler, without indicating flow line

Cooler, indicating flow lines of coolant

Heater

Pressure gauge
 Pumps and Fluid Motors

With one direction of flow

Fixed-capacity hydraulic pump

With two directions of flow

With one direction of flow

Variable-capacity hydraulic pump

With two directions of flow

With one direction of flow

Fixed-capacity hydraulic motor

With two directions of flow

With one direction of flow

Variable-capacity hydraulic motor

With two directions of flow

 Cylinders
Detailed Simplified

Cylinder, single-acting

Cylinder, returned by spring

Cylinder, double-acting with single

piston rod

Cylinder, double-acting with double

piston rod

Cylinder, with single fixed cushion

Cylinder, with double adjustable

cushion

Cylinder, telescopic single-acting

Cylinder, telescopic double-acting

 Control Methods

Control, muscular By lever

With detents By pedal

By push button
Control, Electrical

By solenoid
With 1 Winding With 2 Winding

By electrical motor M

Control, Hydraulics ( Direct Acting)

Hydraulic Pneumatic
By application of pressure

Hydraulic Pneumatic
By release of pressure

Control, Hydraulics ( Indirect Control, Pilot-Operated)

Hydraulic Pneumatic

By application of pressure

Hydraulic Pneumatic

By release of pressure

Control paths inside the unit

Control, Electrohydraulic
Solenoid – controlled Solenoid – operated
and pilot – operated or pilot – operated
 Control, Mechanical (Operating in One Direction Only)
By plunger or tracer By roller

By spring By roller

Control, servo

Pressure Control Valves

Throttling orifice Throttling orifice

(normally closed) (normally closed)

Inlet pressure control

Pressure relief valves

Inlet pressure or remote pilot

control

Proportional pressure Inlet pressure limited to a value

relief valves proportional to pilot pressure

Sequence

Without relief port Without relief port with remote

control

Pressure regulator or
reducing valve With relief port With relief port with remote
control
Differential pressure regulator (outlet pressure is reduced
by a fixed amount with respect to the inlet pressure)

Proportional pressure regulator (outlet pressure is reduced

by a fixed ratio with respect to the inlet pressure)

Flow Control Valves

Shut-off valve

Non-return valve (also called check

valve)

Non-return valve, spring-loaded

Non-return valve, pilot-operated

Non-return valve, with restriction

Flow control valve, with fixed output

Simple
Detailed

Flow control valve, with variable

output

Detailed Simple
 Direction Control valves

These squares indicate direction control valves, having

as many distinct positions as there are squares. The
pipe connections are represented as connected to the
box, representing the unoperated condition. For
operation, boxes are imagined to be displaced, so that
pipe connections correspond with ports of the box in
question.

One-flow path

Two closed ports

Directional valve, with two extreme positions and an

infinite number of intermediate conditions with varying
degrees of throttling

Detailed

Directional valve single-solenoid-controlled, pilot-

operated in both directions, spring return, four ports,
two distinct position

Simple
 Pneumatics Components

Vacuum pump

Detailed Symbol
Filter with Auto Lubricator with
Drain Drain

Filter–regulator–lubricator

Relieving Adjustable
Regulator

Simplified Symbol

Filter with water trap with manual

Air bleed

Plain with no provision

for connection
Exhaust port

Threaded for connection

Air compressor
 Appendix B
Glossary of Terms

Absolute pressure: The pressure above absolute pressure. It is the sum of atmospheric pressure
and gauge pressure.

Absolute zero pressure: The reference zero that is not the atmospheric pressure. It is the
pressure of pure vacuum.

Accumulator: A container in which fluid is stored under pressure as a source of fluid power.

Accuracy: The ability of the system to achieve a desired output.

Actuator: A device for converting hydraulic energy into mechanical energy. It can be linear or
rotary type.

Aeration: Air trapped in hydraulic fluid. Excessive aeration may cause system to operate
erratically.

Amplifier: A device used to amplify an electrical signal. The signal may be current, voltage or
power and can be either direct current or alternating current.

Annular area: Refers to effective area of the rod side of the single acting cylinder.

Atmospheric pressure: Pressure exerted by the atmosphere at any specific location on the
Earth’s surface. Atmospheric pressure at sea level under normal barometric condition is 1.0315
bar.

Baffle: Plate installed in hydraulic reservoir to separate flow of the return line from the flow to
the pump inlet.

Bar: An international standard pressure unit. 1 bar = 100 kPa.

Bleed off: To divert specific controllable portion of pump delivery directly to tank.

Brake valve: A valve used to in exhaust line of a hydraulic motor to prevent the overrunning
load and excessive pressure while decelerating or stopping the load.

Breather: A device that permits air to move in and out of the component or tank to maintain
atmospheric pressure.

Bypass: A secondary path for fluid flow.

Cartridge: Replaceable part of filter.

Cavitation: A localized gaseous condition within liquid stream that occurs where pressure is
reduced to the vaporpressure level. Cavitation can cause noise and pump wear.

Check valve: A control valve that permits fluid in only one direction.

Circuit: An arrangement of hydraulic, pneumatic or electrical components interconnected to

form a specific function within a system.

Closed circuit: A circuit arrangement in which pump output, after passing through various
components returns directly to pump inlet, instead of tank.

Closed loop: A system in which the feedback of one or more elements (hydraulic, pneumatic or
electrical) is compared to a command signal, providing error signal to control the output of the
loop.

Closed ports: Ports of hydraulic valve which are blocked and do not permit flow.

Compensator control:An automatic displacement control for variable pumps and motors. It
alters the displacement in response to system pressure changes as related to the adjusted pressure
setting.

Component:A single hydraulic, electrical, pneumatic or mechanical unit.

Compressibility:The change of volume of a unit volume of fluid when it is subjected to a unit

change of pressure. The compressibility of liquid is very small compared to air or gas.

Cooler:A heat exchanger that removes heat from the system.

Counter balance valve:A pressure control valve that maintains back pressure to prevent load
from falling.

Cracking pressure:The pressure at which a pressure-operated valve begins to pass fluid.

Cushion:A device that provides controlled resistance to motion. The cushion can be either built
into either end of hydraulic cylinder, thus restricting the output flow and providing cushion to the
load near the end of travel.

Cylinder:A device that converts fluid power into linear mechanical power.

Deadband:The region or band of no response where an error signal will not cause a
corresponding actuation of the controlled variable.

Delivery:The volume of fluid discharged by a pump in a given time. Usually expressed in liters
per minute (LPM).

Differential cylinder:Any cylinder in which the two opposed piston areas are not equal.
Directional valve:A valve whose primary function is to direct or prevent flow through selected
channels.

Displacement:The volume of the fluid delivered by pump or required by motor during one
revolution.

Dither:A low-amplitude,high-frequency signal inserted into a servo loop to minimize the effect
of column friction, hysteresis and deadband.

Double-acting cylinder:A cylinder in which hydraulic force may be applied to movable element
in either direction.

Drain:A passage or line from which leakage flow returns.

Drift:The percentage above or below the programmed operating level of a servo amplifier over a
specified operating time

Efficiency:The ratio of output to its input. Efficiency is usually expressed in percentage.

Electrohydraulic servo valve:A type of servo valve, most of which are capable of providing an
output flow directly proportional to the input electric current.

Error:The amount by which a control system misses its target.

Error signal:Algebraic sum of input signal and feedback signal.

Filter:A device used to separate and retain insoluble contaminates from a fluid.

Flow control valve:A valve whose primary function is to control or regulate flow rates.

Flow rate:The volume of fluid passing a given point in pipe or device in unit time

Four way valve:A directional valve having four flow paths.

Full flow filter:A hydraulic filter where all the flow must pass through the filter elements.

Gain:The ratio of output signal of a device to its input.

Gauge pressure:A pressure measured by a gauge or calculated using the atmosphere as zero
pressure.

Head pressure:Pressure caused by the weight of the fluid.

Heat exchanger:Device which removes heat from hydraulic system using air or liquid.

Hunting:The tendency of servo system to oscillate continuously.

Hydraulic control:A control that is actuated by hydraulically induced forces

Hydraulics:The science and application of fluid power, pertaining specifically to fluid pressure,
flow and restriction.

Hydrodynamics:Engineering science pertaining to the energy of liquid flow and pressure.

Hydrokinetics:Engineering science pertaining to energy of liquid in motion.

Hydropneumatics: Combination of hydraulic and pneumatic fluid power.

Hydrostatics:Engineering science pertaining to the energy of liquid at rest.

Hysteresis:The difference between the response to an increasing signal and that to a decreasing
signal having the same slope.

Kinetic energy:Energy that a body has by virtue of its mass and velocity.

Lag:Delay in response, usually given in degrees or in milliseconds.

Laminar flow:A flow condition where flow particles move in continuous parallel paths without
momentum or mass transfer.

Lands:Portion of a valve spool that seals flow from undesired passages while permitting flow to
desired ports.

Line:A hose, pipe or tube used to conduct hydraulic flow.

Linear actuator:Adevice for converting hydraulic energy into linear movement.

Linearity:The degree of straightness of the hysteresis plot of servo valve. How closely output
follows input.

Liter:A unit of volume. 1L= 1000 cm3.

Manifold:A fluid conductor with many connection ports.

Manual control:A control actualled by the human operator.

Manual override:A means of manually actuating an automatically controlled device.

Micron rating:The smallest size particle, measured in microns, that a filter will remove.

Motor (hydraulic):Adevice that converts hydraulic energy into rotary mechanical energy.

Null:The condition where servo valve provides zero output.

Open-centered valve:Valve in which all ports are interconnected in the center or neutral
position.
Pilot pressure:Auxiliary pressure used to actuate or control other hydraulic components.

Pilot valve:The controlling valve of two- or three-stage valve or any auxiliary valve used to
operate another valve.

Piston:Movable part of cylinder. A rod is smaller than piston.

Plunger:Movable part of cylinder. A rod is same size as piston.

Poppet:The part of a valve that blocks flow when it closes against a seat.

Port:The beginning or end of the passage in a component.

Positive displacement:The characteristics of a pump or motor in which the inlet is positively

sealed from the outlet. Since the fluid cannot readily circulate within the unit, the rate of fluid
delivery is virtually constant with rotation.

Precharge pressure:The pressure of compressed gas in an accumulator prior to the admission of

liquid.

Pressure:Force per unit area. Expressed in Pascals or heads of liquids such as meter or mm of
mercury.

Pressure differential:The difference in pressure between anytwo points in a system.

Pressure drop:The pressure differential across component or system.

Pressure override:The difference between the cracking pressure of a valve and the pressure
reached when the valve is passing its full flow.

Pressure-reducing valve:Avalve that lowers and regulates the lower output pressure.

Pressure switch: An electrical switch turned on and off by fluid pressure.

Proportional flow filter:A filter designed to pass part of flow through the filter element
proportional to the pressure drop.

Proportional valve:A valve that allows remote proportional control of pressure,flow,

acceleration and direction. It has most of the characteristics of a servo valve but it not as
responsive as servo valve.

Pump (hydraulic):A device that converts mechanical force and motion into hydraulic fluid
power.

Ram:A single-acting cylinder with a single diameter plunger rather than a piston and rod.
Regenerative circuit: A circuit arrangement for a differential cylinder in which discharge fluid
from the rod end is combined with pump delivery to be directed into the cap end.

Repeatability:Exactness with which servo motion or position can be duplicated.

Reservoir:A container for storage of liquid in a fluid power system.

Restrictor: Component designed to offer restriction to a hydraulic flow.

Return line:A line used to carry exhaust fluid from working device to reservoir.

Reversing valve:Afour-way directional valve used to reverse a double-actingcylinder or

reversible motor.

Rotary actuator:The name reserved for a hydraulic motor that has less than 360-degree rotation.

Sensitivity:The minimum input signal to a servo device required to produce detectable output
signal.

Sequence:The order of a series of operations or movement of a device.

Sequence valve: A pressure-operated valve, which at a predetermined pressure setting, diverts

flow to a secondary circuit while holding the predeterminedminimum pressure on the first
circuit.

Servo:Using feedback to obtain automatic control.

Servo mechanism:A servo loop where the output load tracks as if it were driven by input signal,
even when the output power is many times that of the input. The output power is derived from
the main or auxiliary power source and not from the servo input.

Servo system: A servo mechanism or any other closed loop system where the output position,
speed, pressure, torque or power is automatically controlled by the feedback signal as a function
of input signal.

Servo valve:A flow valve or a valve that modulates output flow and pressure as a function of the
input signal.

Signal:Acommand for a desired position, speed, torque and acceleration in servo.

Single-acting cylinder: A cylinder in which hydraulic force may act in only one direction. The
cylinder must be returned by gravity or spring or other mechanical force.

Solenoid: Electromechanical device that converts electrical energy into linear mechanical
motion.

Spool:moving part of a valve that directs the flow through the system
Strainer:Acoarse filter.

Stroke:Length of travel of a piston or plunger.

Subplate: An auxiliary ported plated for mounting hydraulic components.

Suction line: The hydraulic line connecting the inlet of pump to a reservoir.

Sump: Reservoir.

Surge pressure: Increased pressure due to dynamic condition in the system.

Swash plate: A stationary canted plate in an axial type piston pump that causes the pistons to
reciprocate as the cylinder block and pistons rotate

Synchro: Arotary electromechanical device used as AC position feedback or reference signal in

servo.

Tank: Reservoir or sump.

Throttle: Used to restrict flow. May be used as noncompensated flow control or to produce a
pressure drop as a part of compensated flow valve.

Turbulent flow: A flow condition where flow particles move in a random manner rather than in
parallel paths as in laminar flow. The usual cause of turbulence is use of sharp-edged orifice in
the control valves.

Unload: To unload pressure, by dumping the flow directly to the tank.

Unloading valve: Allows the pressure of one circuit to be unloaded when the pressure of another
circuit reaches the predetermined setting.

Valve: Apart that controls fluid flow, pressure and direction.

Vent: To connect to atmosphere.

Viscosity: Ameasure of internal resistance of fluid or resistance of a fluid to flow.

 LECTURE 1- INTRODUCTION TO HYDRAULICS AND PNEUMATICS

FREQUENTLY ASKED QUESTIONS

1. Define the term fluid power.

Fluid power is the technology that deals with the generation, control and transmission of forces
and movement with the use of pressurized fluids in a confined system.

2. Differentiate between fluid transport and fluid power systems

Fluid transport systems have their sole objective the delivery of a fluid from one location to
another to accomplish some useful purpose. Examples include pumping stations for pumping
water to homes, cross country gas lines.

Fluid power systems are designed to perform work. In fluid power systems, Work is obtained
by pressurized fluid acting directly on fluid cylinder or fluid motor. A cylinder produces a force
resulting in linear motion, whereas a fluid motor produces a torque resulting in rotary motion

3. Differentiate between hydraulics and pneumatics

Oil hydraulics employs pressurized liquid petroleum oils and synthetic oils, and pneumatics
employs compressed air which is exhausted to the atmosphere after performing the work.

3. List the six basic components used in a hydraulic systems

i) Reservoir ii) Pump iii) Prime mover iv) Valves v) actuators vi) Piping

4. List the six basic components used in a pneumatic systems

i) Compressed air tank ii) compressor iii) Prime mover iv) Valves v) actuators vi) piping
5. List ten applications of fluid power in the automotive industry

1. Power brakes, 2. Power steering, 3.Shock absorbers 4.Air conditioning 5.Automobile

transmission. 6. Agriculture 7. Aviation, 8.Fabrication industry 9.Machine tools 10. Oil industry
and Pharmaceuticals

6. Name five hydraulic applications and five pneumatic applications

Hydraulic applications Pneumatic applications

Automobile power steering, brakes, aircraft Packaging machinery, Bottle filling
landing gear, lift trucks, front end loaders Industry, artificial heart, logic control
systems and robotic materials handling
devices.

7. List five advantages and five disadvantages of hydraulics

Advantages of Hydraulic system

1. Large load capacity with almost high accuracy and precision.

2. Smooth movement.
3. Automatic lubricating provision to reduce to wear.
4. Division and distribution of hydraulic force are easily performed.
5. Limiting and balancing of hydraulic forces are easily performed.
Disadvantages of Hydraulic system

1. A hydraulic element needs to be machined to a high degree of precision.

2. Leakage of hydraulic oil poses a problem to hydraulic operators.
3. Special treatment is needed to protect them from rust, corrosion, dirt etc.,
4. Hydraulic oil may pose problems if it disintegrates due to aging and chemical
deterioration.
5. Hydraulic oils are messy and almost highly flammable.
8. List five advantages and five disadvantages of pneumatics

Advantages of Pneumatic system

1. Low inertia effect of pneumatic components due to light density of air.

2. System is light in weight.
3. Comparatively easy operations of valves.
4. Power losses and leakages are less in pneumatic systems.
5. Low cost.
6. Cylinder cushioning is not required
7. Leakage does not influence the systems and is not harmful

Disadvantages of Pneumatic systems

1. Suitable only for low pressure and hence low force applications
2. Availability of the assembly components is doubtful.
3. Generation of the compressed air is expensive compared to electricity
4. Exhaust air noise is unpleasant and silence has to be used.
5. Rigidity of the system is poor
6. Weight to pressure ratio is large
7. Less precise

9.List the main components of Fluid power system and their function

Pump To convert mechanical power to fluid power

Cylinder/motor To convert fluid power to linear or rotary mechanical power
Valves To control direction , pressure and flow
Filters and regulators To condition the fluid
Hose tube and couplings To conduct fluid
Seals To contain the fluid
Accumulators To store the fluid
Measuring instruments To monitor the performance of fluid power system and
such as Pressure switch, maintain it
Flow meter, Temperature
transducers
10. Compare different Power Systems used in industry

Property Mechanical Electrical Pneumatic Hydraulic

Input Energy I C Engines I C Engines I C Engines I C Engines
source Electric motor Water/Gas Pressure Tank Electric Motor
Turbines Air Turbine

Energy Levers, Gears, Electrical Pipes and Pipes and

Transfer Shafts Cables and hoses hoses
Element Magnetic field
Energy Carrier Rigid and Flow of Air Hydraulic
elastic Objects electrons liquids
Power to Poor Fair Best Best
weight ratio
Torque/Inertia Poor Fair Good Best
Stiffness Good Poor Fair Best
Response Fair Best Fair Good
speed
Dirt Sensitivity Best Best Fair Fair
Relative cost Best Best Good Fair
Control Fair Best Good Good
Motion Type Mainly Rotary Mainly Rotary Linear or Linear or
Rotary Rotary

11. What is the main difference between a open loop and closed loop fluid power system

i) Open loop system: there is no feedback in the open system and performance is based on
characteristics of individual components of system, Open loop system is not accurate and error
can be reduced by proper calibration and control.

ii) Closed loop system: This system uses feedback. The output of the system is fed back by a
measuring element to a comparator. The comparator compares the actual output to the desired
and gives a error signal to the control element. The error is used to change the actual output and
bring it closer to the desired value. Simple closed loop system uses servo valves and advanced
system uses digital electronics
12. List five major manufactures of fluid power equipments and systems in India.

1. Hycom Engineering (India) Pvt Ltd;

2. Hannover Milano Fairs India Pvt Ltd

3. Yuken India Limited.

3. Bosch Rexroth (India) Ltd;

4. Pall Corporation India limited

13. List five major manufactures of fluid power equipments and systems in world.

Rexroth, Vickers, Ingersoll-Rand, Eaton corporation, Brown and Sharp Manufacturing

Company, DeLaval IMP pump Division, Sheffer corporation.

14. Visit any Industry nearby and list the hydraulic/pneumatic parts or systems used and
its purpose.

Students should visit and make note of the following

1. Size of hydraulic power pack used

2. Oil used and its designation
3. Piping used – whether rigid, or flexible and their material and capacity
4. Valves used for control device
5. Type of controller used – like Siemens, Yamasaki etc
6. Valve mountings
7. Coolant recirculation system used
8. Lubricant unit and oil used and grade
9. Rating of pumps and motor
10. Safety devices used in machine
 LECTURE 2- PROPERTIES OF FLUIDS

FREQUENTLY ASKED QUESTIONS

1. What are the differences between a liquid and a gas

Liquids Gases
The molecules of a liquids are much less The molecules of a gas are much further
further apart than those of a gas apart than those of a liquid.
A liquid is relatively incompressible, and A gas is very compressible, and when all
if all the pressure, except that of its own external pressure is removed, it tends to
vapourpressure, is removed, the cohesion expand indefinitely
between molecules hold them together, so
that the liquid does not expand
indefinitely
The volume of a liquid isnot greatly The volume of a gas or vapouris greatly
affected by changes in pressure or affected by changes in pressure or
temperature or both. temperature or both.
They have definite mass and volume but They have definite mass, but no volume
no definite shape. and no definite shape

2. Define the terms specific density, specific weight and specific gravity

Density (ρ): It is defined as mass per unit volume.

Specific weight ( ): It is defined as weight per unit volume.

Specific weight
Specific gravity (SG): Specific gravity of a given fluid is defined as the specific weight of the
fluid divided by the specific weight of water.

Specific gravity of a liquid is the dimensionless ratio

3. Differentiate between absolute and gauge pressure

Atmospheric Pressure is the force per unit area exerted against a surface by the weight of air
above that surface in the Earth's atmosphere.

Gauge Pressure and Absolute Pressure: Gauge pressures are measured relative to the atmosphere,
whereas absolute pressures are measured relative to perfect vacuum such as that existing in outer
space.

4. What is meant by bulk modulus?. Give its typical value for liquid and gas.

Bulk modulus is a measure of the compressibility of a liquid and will be required when it is
desired to calculate oil volume changes for high pressure, large system volumes such as forging
pressures or natural frequencies generally caused by the interaction of fluid compressibility and
moving mass.For liquids it is 1.72 x106 kPa. The volume modulus of mild steel is about 170000
MPa. Taking a typical value for the volume modulus of cold water to be 2200 MPa we see that
water is about 80 times as compressible as steel. Thecompressibility of liquids covers a wide
range. Mercury, for example, is approximately8% as compressible as water, while the
compressibility of nitric acid isnearly six times greater than that of water.

5. Differentiate between viscosity and viscosity index

The viscosity of a fluid is a measure of its resistance to shear or angular deformation.Viscosity

index is a relative measure of an oils viscosity change with respect to temperature change. Oil
having a low VI is one that exhibits a large change in viscosity with temperature change. High
VI oil does not change appreciably with temperature change.
 LECTURE 3-FLUIDS FOR HYDRAULIC SYSTEMS

FREQUENTLY ASKED QUESTIONS

1.What is a fluid? What are the functions and characteristics of hydraulic fluids

Hydraulic fluid is the transmitting medium of a hydraulic system.

In fluid power systems, hydraulic fluid has to perform various functions such as

o Power transmission – to transmit power, which is the primary function

o Lubrication – to lubricate various parts , so as to avoid metal to metal contact and reduce
friction, wear, heat generation.
o Sealing – to seal the moving elements to avoid leakage.
o Cooling – to carry away the heat generated in the system and dissipates the heat through
reservoir or heat exchanger.
o Contaminant Removal – to carry along the contaminations to tank, where it can be
removed through filters.

2 List ten properties that hydraulic oil should possess

o Specific gravity
o Viscosity
o Stability in shear
o Foaming characteristics
o Cloud point and pour point
o Oil compressibility and bulk modulus
o Coefficient of thermal expansion
o Wettability
o Flammability
o Chemical stability
o Affinity to moisture
o Gumming tendency
o Oxidation tendency
o Corrosion resistance
o Wear resistance
o Compatibility with system material
o Heat dissipation property
o Nontoxic, easy to handle and availability
.

3. Discuss the role of additives used in fluid power systems

The performance of the hydraulic fluid can to some extent be improved by using additives.

The main additives are Pour point depressant, viscosity index improvers, de-foamers, oxidation
inhibitors, corrosion inhibitors, anti-wear agents

4. Differentiate between absolute and kinematic viscosity

Absolute viscosity (μ) : absolute viscosity of a fluid is defined as the force required to move a
flat plate of unit area at unit distance from a fixed plate with plates with unit relative velocity,
when the space between the plate is filled with the given fluid.

Kinematic viscosity (ν) : Kinematic viscosity equals absolute viscosity divided by density.

Unit of kinematic viscosity: m2/s

5. List some of fire resistant fluids used in hydraulic industry

Water – Glycol solution, Water in Oil Emulsions,Straight Synthetics, High-Water-Content

Fluids.

6. What is the commercial name of mineral oil being used by the industry?

Some of the commercial names of hydraulic oils are Servo system 32, servo system 68,
Servocirol68, Servo hydrex 32. India oils corporation was using their own names and standards
earlier but now they use ISO designation such asServo system 32,Servo hydrex 32.etc

7 Why water is not used as a medium in fluid power systems

Water is not used in fluid power system because it corrodes, encourages growth of bacteria,
easily evaporates and gets contaminated easily, has poor lubricity, viscosity and prone to more
leakage. So we chose petroleum based mineral oil as a medium in hydraulics.
8. What are the advantages of High water based fluids

Advantages of HWCF are

o Fire resistant due to high flash point of about

o Lower system operating temperature due to good heat dissipation
o Additives are biodegradable and environmental friendly
o HWCF have high viscosity index
o Cleaner operation of the system
o Low cost – involves only cost of concentrate, less storage cost

9. How are fire resistant fluids designated

The fire resistant fluids are designated as HF-A, HF-B, HF-C and HF-D

HF-A: High water content fluids ( 80% or more) For example : Water oil emulsions

HF-B This is water oil emulsion containing petroleum oil and water

HF-C This is a solution of water and glycols

HF-D This is synthetic fluid, For example Phosphates or phosphate petroleum blends.

10 What is Neutralization number?

The neutralization number is a measure of the acidity or alkalinity of hydraulic oil. This is
referred to as PH value of the oil. High acidity causes the oxidation rate in an oil to increase
rapidly
 LECTURE 4-GOVERNING PRINCIPLES AND LAWS

FREQUENTLY ASKED QUESTIONS

1. Define hydraulic power. Derive an expression for the hydraulic power if the flow is in
LPS and pressure in kPa.

Hydraulic power = fluid power = pressure x volume flow rate

Hydraulic power (watts) = P (N/m2) x Q (m3/s)

Q(LPS) = 1000 m3/sec

P(kPa) = 100 (N/m2)

Hydraulic power (watts) = P (N/m2) x Q (m3/s)=

2. How will you explain the Pascal’s law, with reference to working of a hydraulic cylinder?

Pascal’s law states that the pressure exerted on a confined fluid is transmitted undiminished in all
directions and acts with equal force on equal areas and at right angles to the containing surfaces
3 State Daniel Bernoulli’s theorem

Bernoulli’s theorem states that in a steady flow of fluid, the sum of the potential head, velocity
head and pressure head remains constant throughout.

4. What is continuity equation and what are its implications relative to fluid power

Continuity equation states that the weight flow rate is same for all cross sections of pipe. Larger
pipe gives smaller velocity and smaller pipes give larger velocity.

5. What is the significance of each term in the energy equation?

Velocity head signifies the kinetic energy of the fluid per unit weight .pressure head signifies
pressure energy of the fluid per unit weight and elevation head is potential energy per unit weight
of fluid.

6. Define: Pressure head, elevation head and kinetic head

Velocity head signifies the kinetic energy of the fluid per unit weight .pressure head signifies
pressure energy of the fluid per unit weight and elevation head is potential energy per unit weight
of fluid.

7. State Torricelli’s theorem and mention its significance

Torricelli's Theorem is Bernoulli's equation with certain assumption made. Torricelli’s theorem states that
the velocity of the water jet of liquid is directly proportional to the square root of the head of the liquid
producing it. This deals with the set up where you have a large tank with a narrow opening allowing for
the liquid to flow out. Both the Tank and the narrow opening (nozzle) are open to the atmosphere.

=jet velocity (m/s), g= acceleration due to gravity (m/s2);h= pressure head (m).
8. Explain how a siphon operates

The Siphon is a familiar hydraulic device. It is commonly used to cause a liquid to flow from one
container in an upward direction over an obstacle and then flow downwards into a second lower
container. As shown in Figure above, a siphon consists of a U-tube with one end submerged
below the level of the liquid surface , and the free end lies below it on the outside of the
container.

For the fluid to flow out of the free end, two conditions must be met:

1. The elevation of the free end must be lower than the elevation of the liquid surface inside
the container.
2. The fluid must initially be forced to flow up from the container into the center portion of
the U- tube. This is normally done by temporarily providing a suction pressure at the free
end of the siphon. For example, when the siphoning gasoline from automobile gas tank, a
person can develop this suction by momentarily sucking on the free end of the hose. This
allows atmospheric pressure in the tank to push the gasoline up the U- tube hose, as
required. For continuous flow operation, the free end of the U-tube hose must lie below
the gasoline level in the tank.

U tube

Zero elevation reference

 LECTURE 5- DISTRIBUTION OF FLUID POWER

FREQUENTLY ASKED QUESTIONS

1. What is the purpose of fluid distribution system?

The purpose of fluid distribution system is to take the oil from the oil tank to the various
components of the systems and bring oil back to the reservoir. -

2. Why should copper not be used in conductors or fitting

Oxidation of the copper with the steel is major problem so copper is not used

3. What metals cannot be used with glycol fluid?

Cadmium, zinc and magnesium must not be used with glycol fluid. water glycol fluid reacts with
cadmium, zinc and magnesium and corrode very rapidly leading leakage and unsafe working

4. Why should the conductor have greater strength than the system working pressure

Sometime pressure may raise very rapidly due to sudden closure etc. to handle high peak pressure and
prevent bursting conductor strength should be higher.

6. What are the major disadvantages of steel pipes?

Pipes are rigid they cannot be bent like hoses. Steel pipes are expensive and steel pipe joints is
cumbersome and may leak if properly not done with good sealant and thread.

7. What is the recommended factor of safety for fluid power system design ?

FOS = 8 for pressures from 0 – 70 bar

FOS = 6 for pressures from 70 – 180 bar
FOS = 4 for pressures above 180 bar

8. Why is malleable iron used for steel pipe fittings?

Malleable iron comparatively cheaper and can be used for low pressure applications
11. Why is steel tubing used more often than steel pipe?

Tubing can be bent easily to any shape and thus it reduces the number of fitting. It is reusable without any
sealing problem.

12 How can steel tube fittings be used with plastic tubing?

Pipes are rigid they cannot be bent like hoses. Steel pipes are expensive and steel pipe joints is
cumbersome and may leak if properly not done with good sealant and thread.

13 what major advantages does plastic tubing have over steel tubing

o Easily we can bend it to any shape

o Cheaper
o Storage is easy, we can roll and store it
o Transparent especially useful in pharmaceutical and chemical industry
o Light weight
o Less force is enough to connect parts, no expensive threaded tooling etc.

15 Describe how the quick connect coupling works.

Quick release couplings usually comprise a plug and socket arrangement which provides a leak

proof joint when two parts are connected together, and which can be released easily without the

use of tools. Each half of the coupling contains a spring loaded ball or poppet which

automatically closes on disconnection, so that two completely leak free end results. Leaking

during the process of disconnecting or connecting coupling is negligible. A typical quick release

coupling is shown in Figure 1 and in this example the two halves are released by sliding the

spring loaded outer sleeve in the direction of the arrow.

 LECTURE 6- ENERGY LOSSES IN HYDRAULIC SYSTEMS

FREQUENTLY ASKED QUESTIONS

1.Differentiate between Laminar flow and Turbulent flow

Laminar flow Turbulent flow

Laminar flow is characterized by the fluid Turbulent flow is characterized by the fluid
flowing in smooth layer or laminae. In this flowing in random way. Movement of particle
type of flow, a particle of in a given layer stays fluctuates up and down in a direction
in that layer. perpendicular as well as parallel to mean flow
For laminar flow , the friction is caused by the direction.
sliding of one layer or particle of fluid over This mixing action generates turbulence due to
another in a smooth continuous fashion the colliding fluid particles. This causes
considerable more resistance to flow and thus
greater energy losses than that produced by
laminar flow

2. List main causes of turbulence in fluid flow

(a) High fluid velocity

(b) Large Surface roughness of pipe

3Define Reynolds number and list its range for laminar and turbulent flow

2.8 REYNOLDS’S NUMBER

It is dimensionless number refereed to a compressible or incompressible fluid flow. It was
postulated by British engineer Osborne Reynolds. The Reynolds’s number set criteria by which
the fluid flow regime may be distinguished.
 , V= velocity of fluid (m/s), D= Diameter of the pipe (m) and is
absolute or dynamic viscosity Pa-s or ms/m2
Laminar flowIn laminar flow region, the flowis characterized by the smooth motion of the
laminae or layers. When there is no macroscopic mixing of adjacent fluid layer for the flow in
the laminar regimes, the Reynold number is less than 2000.
Turbulent flow In turbulent flow region, the flowis characterized by the random motion of the
fluid particles in three dimensions in addition to mean motion. There is considerable
macroscopic mixing of adjacent fluid layers and significant velocity fluctuations. For the
turbulent flow, the Reynolds number is greater than 4000
Transition flow In transition regime of flow, the flow is in transition between the laminar flow
and turbulent flow. The Reynolds number lies between 2000 and 4000.

4. Briefly explain the method to calculate the Equivalent length of a valve or fitting
Equivalent length technique
We can find a length of pipe that for the same flow rate would produce the same head loss as a
valve or fitting. This length of pipe, which is called the equivalent length of a valve or fitting can
be found by equating head losses across the valve or fitting and the pipe.

( ) ( ) ( )which gives ( ) is the equivalent length of a valve or fitting

6. Define: relative roughness and k factor of a valve or fitting

Relative roughness is defined as the pipe inside surface roughness divided y the pipe inside
diameter.

The K factor equals the head loss divided by the velocity head. ⁄
( )

7. Write an expression for pressure drop down a pipe in terms of friction factor.
( )( )

( )( )
 LECTURE 7 TO 9
HYDRAULIC PUMPS

FREQUENTLY ASKED QUESTIONS

1. What is the purpose of a hydraulic pump in a fluid power system ?

Purpose of hydraulic pump is to generate flow so that energy conversion from mechanical to
fluid energy is possible. Mechanical energy is provided to pump by electric motor.

2 Differentiate between positive displacement and non-positive displacement pump

Positive displacement pump is a pump in which Centrifugal pump is a non positive displacement
there is a physical displacement of boundary of pump. In this there is a relative motion between
fluid mass the fluid and motor
In positive displacement pump, outlet flow is In centrifugal pump, the outlet flow is dependent
(almost) independent of system pressure. on system pressure, so when pressure increases ,
the flow reduces
Flow

Flow

Pressure Pressure

3. What is the principle of operation of a pump?

Pumps operate on the principle whereby a partial vacuum is created at the pump inlet due to the
internal operation of a pump. This allows atmospheric pressure to push the fluid out of the oil
tank (reservoir) and into the pump intake. The pump then mechanically pushes fluid out of the
discharge line.

4. What are the three pumps classifications?

1. Classification based on displacement

 Non positive displacement pumps (hydrodynamic pumps)
 Positive displacement pumps (hydrostatic pumps)
2. Classification based on delivery
 Constant delivery pumps
 Variable delivery pumps

3. Classification based on motion

 Rotary pump
 Reciprocating pump.

5. Classify the positive displacement pumps

Based on the construction, Hydrostatic pumps are classified
1. Gear Pumps ( fixed displacement pumps)
(a) External gear pump
(b) Internal gear pump
a. Lobe pump
b. Gerotor pump
(c) Screw pump
2. Vane Pumps ( fixed or variable displacement pumps)
(a) Balanced Vane pump
(b) Unbalanced Vane pump

3. Piston Pumps ( fixed or variable displacement pumps)

(a) Axial piston pump b)Radial piston pump

6. Why must positive displacement pumps are protected by relief valves ?

Pumps are expensive items and if pressure shoots up do to some reason, then relief valve will
allow the fluid to go back to the tank, if not pressure will rise to due to blockage of fluid and
parts of pumps may fail. Relief valve thus limits the maximum pressure to which pump
components can be subjected with.

9. Why are centrifugal pumps used so little in fluid power system?

Flow output of a centrifugal pump is not constant. Therefore it cannot be used for fluid power
application. It is useful in fluid transport systems.

10. Why gear pumps cannot be used as a variable displacement pump

In the gear pump, once the design parameters are finalized all the dimensions of gear pair is fixed
and there is no way to vary the displacement.
11. What are the reasons for the popularity of external gear pumps?
o Simple to design
o Because gear pumps have only two moving parts, they are reliable, simple to operate, and
easy to maintain.
o Low cost compared to other pumps

12. What is the most important application for internal gear pumps?

o The speed of the internal gear pumps is considered relatively slow compared to
centrifugal types. Speeds up to 1,150 rpm are considered common. Because of their
ability to operate at low speeds, internal gear pumps are well suited for high – viscosity
applications and where suction conditions call for a pump with minimal inlet pressure
requirements
o They're also bi-rotational, meaning that the same pump can be used to load and unload
applications

13. How does the lobe pump differ from the other gear type pump

Lobe pumps are frequently used in food applications because they handle solids without
damaging the product. Particle size pumped can be much larger in lobe pumps than in other PD
types. Since the lobes do not make contact, and clearances are not as close as in other PD
pumps, this design handles low viscosity liquids 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. Reductions of 25% of rated speed
and lower are common with high-viscosity liquids

14. What is the most significant characteristic of the screw pump

o They are quiet pumps

o Screws are continuous , most reliable
o No pressure pulsation will occur
o High speed operation is possible
o No pump turbulence and oil churning

15. List four parameters that affect noise level of hydrostatic pump
o Pressure
o Size of the pump
o Speed of the pump
o Entrained air bubbles
16. How is the output of an unbalanced vane pump varied?

Output of the unbalance vane pump is varied by mechanically varying eccentricity between the
cam ring and rotor.

17. How can the displacement of an axial piston pump be varied

In axial piston pumps, by varying the stroke length the displacement can be varied . In bent axis
type, by varying the angle between the cylinder block and drive shaft centerline, the stroke
length is varied. In swash plate type by varying the swash plate angle the stroke length can be
varied.

18. What is cavitation?. Name four popular methods to reduce cavitation

During the working of positive displacement pump a vacuum is created at the inlet of the pump.
This allows atmospheric pressure to push the fluid in. In some situations the vacuum may
become excessive, and a phenomenon known as Cavitation occurs.

1) Keep the suction line velocities below 1.5 m/s

2) Keep the pump inlet as short as possible
3) Minimize the number of fittings in the inlet line
4) Mount the pump as close as possible to the reservoir.

19. What is pressure compensated vane pump and how does it work

In the unbalanced vane pump, the displacement can be varied by varying eccentricity. By a
compensator piston arrangement, the eccentricity is varied depending on the system pressure
there by pump delivery is varied.

20. Why is the operation of screw pump quiet

In the screw pump, the fluid moves linearly and do not rotate. Therefore even at high speed there
is no pulsations and operates quietly.

21. Define: Volumetric efficiency, Mechanical efficiency and overall efficiency

Volumetric efficiency ( )

Mechanical efficiency ( )
Overall efficiency (

22. Draw the characteristics curves of different types of pumps used in Industry

See Figure 7.19

23. List the important considerations in the selection of a pump for any given application

1) Flow rate requirement

2) Operating speed of pump
3) Pressure rating
4) Performance/application
5) Reliability
6) Maintenance
7) Cost
8) Noise level of the pump
9) Oil compatibility
10) Type of pump control
11) Pump contamination tolerance
12) Availability of pump and spars

24. Name the three ways by which noise of pump can be reduced
o By proper design of pump
o By proper clamping of hydraulic distribution like pipes , fittings etc.
o By using sound absorption material in the design of fluid power systems.

25 Why should the suction head of pump not exceed 35 kPa.

This is to avoid the cavitation. When the suction head pressure is too low and if the below the
vaporization pressure of the oil, then the bubbles will form and these bubbles produce very large
impact forces on the metallic components of pump and erodes them.
 LECTURE 10 AND 11

HYDRAULIC MOTORS

FREQUENTLY ASKED QUESTIONS

1. Differentiate between hydraulic pump and hydraulic motor

Pump converts mechanical energy provided by prime mover to fluid energy. Hydraulic motor
uses fluid energy and converts it to mechanical movement of the actuators, either rotary or linear.

2. List the advantages of hydraulic motor over electric motor

o Hydraulic motors are indeed smaller at identical power and especially torque. Their speed
and position can be regulated very well, though not as precisely as for electric motors.
Price also was a bit lower because of the inverter.
o When machine stalls due to some snag, direction of the hydraulic motor can be reverered
easily and safe using pressure relief valve. Electric motor would trip or burn out
o Where electric motors, which can deliver only rotational power and must be sized to suit
the load application, hydraulic motors are much smaller in size even when the application
involves heavy loads.
o In a heavy electromechanical system a big electric motor needs to be directly located on
the motion axis which may not be always feasible. It would also require a continuous
supply of electricity usually from an external source.

3. List four important application of hydraulic motor

o Electric motor coil winding

o Oil pipeline inspection equipment
o Undersea camera manipulation
o Jumbo jet maintenance jacks
o Milling and sawing applications
o Dynamite blast hole pump drive
o Automatic clamping
o Textile washing agitators
o Orange peeling machines
o Fan drives
o Diamond wheel dresser
o Drill and tap machine tool
o Chicken processing machinery
o Conveyor drives
o Due to the high torque at low speeds, loaders and other construction equipment use heavy
hydraulic motors to drive the wheels for moving the machines around
 o Cooling fans of equipment that already have hydraulic systems. For example a front end
loader or excavator.
o

4. Explain with neat sketch the working of Gear motor

5. Write the classification of Piston motor

Piston motors are classified into following types

According to the piston of the cylinder block and the drive shaft the piston motors are
classified as

o a) Axial piston motors

o b) Radial piston motors

According to the basis of displacement piston motors are classified as

o Fixed displacement piston motors

o Variable displacement piston motors
6. Define volumetric efficiency, mechanical efficiency and overall efficiency of hydraulic motor

7. Why is the actual flow rate required by the hydraulic motor is higher than the theoretical flow
rate

Actual flow rate required by the hydraulic motor is more than theoretical flow rate because of
the fluid frictional losses, losses in pipes, losses in fittings, leakage loss etc.

8. Why is the actual torque output delivered by the hydraulic motor is less than the calculated
theoretical torque

Actual output delivered by the hydraulic motor is less than theoretical torque because of the mechanical
frictional losses like bearing losses etc.

9. List the few applications of semi –rotary actuator

o Semi actuators are used for lifting, tilting in jigs and fixtures
o Partial Opening and closing of door in machine tools
o Indexing, swinging and bending in sheet metal applications

10. Where are external gear motor used

External gear motors are used for high speed (4000 RPM) and low torque application. Usually their
capacity is limited to 5-10 kW

o Used in Damper Actuators,

o hydraulic fan drive systems for mobile vehicles
o Material Handling
o Earthmoving machines
o Truck and Bus

11. List the advantages of external gear motor

o High drive speeds

o Compact dimensions and low weight in relation to the power rating
o Cost--effective
 LECTURE 12 TO 14

HYDRAULIC ACTUATORS

FREQUENTLY ASKED QUESTIONS

1. What is the function of a hydraulic cylinder in a hydraulic system

Function of hydraulic cylinder is to provide linear motion. It converts the fluid energy into
mechanical energy ( linear movement).

2. When is a telescoping cylinder used?

A telescoping cylinder is a cylinder employing several pistons which telescope into each other.
This cylinder is used when a relatively long working stroke is needed for a short cylinder
length.Telescopic configuration cylinders are used in a variety of applications that require the use
of a long cylinder in a space-constrained environment.

3. Explain the operation of Tandem type cylinder and mention its application

Tandem Cylinders

Figure 8.8: Tandem Cylinder

A tandem cylinder is used in applications where a large amount of force is required from a small-
diameter cylinder. Pressure is applied to both pistons, resulting in increased force because of the
larger area. The drawback is that these cylinders must be longer than a standard cylinder of
larger flow rate than a standard cylinder to achieve an equal speed because flow must go to both
pistons.

4. Explain the function of cushioning in cylinders

Due to inertial forces of the moving parts at the end of piston travel, the piston will hit the
cylinder head at full speed, To overcome this , the designers provide an arrangement by which
hydraulic cylinder can be slowly retarded or cushioned during the last portion of the cylinder
stroke.

5. Why are wiper rings used on cylinder rods ?

Wiper rings are used to prevent foreign abrasive or corrosive particles from entering a cylinder.
These particles cause scratches and thus the leakage. Their purpose is not seal against pressure.

6. Mention two applications of single acting cylinders.

o Single acting cylinder are extensively used in jigs and fixtures, for clamping a work piece
o Used in transfer lines to eject a heavy component like knuckle of automobile

7. How does a welded type of cylinder differ from tie rod type?. Mention the major parts of
tie rod cylinder

A tie-rod cylinder is a hydraulic cylinder that uses one or more tie-rods to provide additional
stability. Tie-rods are typically installed on the outside diameter of the cylinder housing. In
many applications, the cylinder tie-rod bears the majority of the applied load. A welded cylinder
is a smooth hydraulic cylinder that uses a heavy-duty welded cylinder housing to provide
stability.

8. What are the technical specification of a hydraulic cylinder ?,

Important operating specifications for hydraulic cylinders include the cylinder type, stroke,
maximum operating pressure, bore diameter, and rod diameter. Choices for cylinder type
include tie-rod, welded, and ram.Stroke is the distance that the piston travels through the
cylinder. Hydraulic cylinders can have a variety of stroke lengths, from fractions of an inch to
many feet. The maximum operating pressure is the maximum working pressure the cylinder can
sustain. The bore diameter refers to the diameter at the cylinder bore. The rod diameter refers to
the diameter of the rod or piston used in the cylinder.

9. Name the material that are commonly used to manufacture i) cylinder covers ii) Piston
rods iii) pistons iv) Tie rods

Cylinder High Precision Seamless Steel

tube,ST42,ST44,ST5216Mn 27SiMn
25Mn St52 SAE1026, plasma nitrited
Piston rod Forged steels, C45ground- hardened and hard
chrome plated.
Tie rods (inside) 4140HT steels, 1045 steel with heat treatment
subsequent to thread rolling to give sufficient
strength

10. What is hydraulic ram

A hydraulic ram is a device in which the cross-sectional area of the piston rod is more than one-
half the cross-sectional area of the moving component. Hydraulic rams are primarily used to
push rather than pull, and are most commonly used in high pressure applications.

11. Mention the different types of mountings used in fixing the hydraulic cylinders

Pivoted center line mounts Fixed centerline mounts Fixed non-centerline mounts
- Rod end trunnion - Tie rod - End lug mounts
- Blind end trunnion - Rod end flange - Side lug mounts
- Clevis mounted - Blind end flange - Integral key mounts
- Center truunion - Centre line lugs - Flush mounts
 LECTURE 15 TO 17

DIRECTIONAL CONTROL VALVES

FREQUENTLY ASKED QUESTIONS

1. Explain briefly the function of directional control valves

o To start, stop, accelerate , decelerate and change the direction of motion of hydraulic
actuator
o To permit the free flow from the pump to the reservoir at low pressure, when the pump’s
deliver is not needed into the system
o To vent the relief valve by either electrical or mechanical control
o To isolate certain branch of circuit

2. Draw a schematic of 4/3 DCV that is direct operated electrically and briefly explain its
Function
A B

A B

A
Spool
P T

P T

A B A B

P T
Spool

P T

Four way DCV are capable of controlling double acting cylinders and bi-directional motors.
Figure shows the operation of a typical 4/2 DCV. A four way has four ports labeled P,T A & B.
Pis the pressure inlet and T is the return to the tank. A & B are outlets to the system. In the
normal position, pump flow is sent to outlet B. Outlet A is connected to the tank. In the actuated
position, the pump flow is sent to port A and port B connected to the tank T. In four way DCV’s
two flows of the fluids are controlled at the same time, while 2 way and 3way DCV’s control
only one flow at a time. Figure (c) shows the complete graphic symbol for a four way two piston
DCV.
3. Draw a schematic of 3/2 DCV that is manually operated and briefly explain its function

3/2 way DCV (normally closed)

Three way valves either block or allow flow from an inlet to an outlet. They also allows the
outlet to flow back to the tank, when the pump is blocked, while a two way valve does not. A
three way valve has three ports namely a pressure inlet (P),an outlet to the system(A),and a
return to the tank(T). The above figure shows the operation of a 3/2 way 0valve normally closed.
In it’s normal position the valve is held in position by a spring as shown in figure(A). In the
normal position the pressure port P is blocked and the outlet A is connected with the tank. In the
actuated position shown in figure(B) the pressure port is connected with the tank and the tank
port is blocked.

P T
P T

Port A and T are connected when force is not

applied (Valve unactuated)

A
A

Spool P T

P T

Port A and P are connected when force is applied

(Valve actuated)

4. State the different ways of control of Directional control valves

i) Manually operated:
ii) Mechanically operated
iii) Solenoid operated:
iv) Pilot operated:
5. How are Directional control valves classified

Classification of Direction control valves based on fluid path

i) Check valves
ii) Shuttle valves
iii) 2 way valves
iv) 3 way valves
v) 4 way valves

Classification of Direction control valves based on design characteristics

i) Internal valve mechanism which directs flow of fluid of fluid. Such mechanism can
either be a poppet, a ball, a sliding spool, a rotary plug, a rotary disc.
ii) Number of switching positions (usually 2 or 3)
iii) Number of connecting ports or ways.
iv) Method of valve actuation; which causes the valve mechanism to move into alternate
position.

6. Explain the construction and operation of electric solenoids and compare the DC and AC
solenoids

1. When coil 2. Armature is pulled against

is energized push pin Coil
Pushpin

3. Push pin moves spool Spool Armature

Like mechanical or pilot actuators, solenoids work against a push pin, which in turn actuates a
spool. There are two types of solenoid design used to dissipate the heat developed in electric
current flowing in the coil. The first type dissipates the heat into surrounding air and is referred
to an “air gap solenoid”. In the second type “wet pin solenoid”, the push pin contains an internal
passage way that allows the tank port oil to communicate between the housing of the valve and
the housing of the solenoid. Wet pin solenoids do a better job in dissipating heat because the cool
oil represent a good heat sink to absorb heat from the solenoid. As the oil circulates, the heat is
carried in to the hydraulic system where it can be easily dealt with.
7. Cite the classification of check valves, and explain the function of pilot operated check
valve, giving the necessary drawing.

o Ball valve
o Poppet valve
o Pilot operated
o Shuttle valve

11.1.2 Pilot operated check valve

Pilot operated valve along with it's symbol is shown in figure 4 This type of check valve always
permits free flow in one direction but permits flow in the normally blocked opposite direction,
only if pilot pressure is applied at the pilot pressure point of the valve. The check valve poppet
has the pilot piston attached to the threaded poppet stem by a nut.
The light spring holds the poppet seated in a no flow condition by pushing against the pilot
piston. The purpose of the separate drain port is to prevent oil from creating a pressure build up
on the bottom of the piston The dashed line in the graphical symbol represents the pilot pressure
line connected to the pilot pressure port of the valve. Pilot check valves are used for locking
hydraulic cylinders in piston.

NO
PIL
OT
SIG
NA
L
Free flow

NO
PIL
OT
SIG
NA
L
No flow

PIL
OT
SIG
NA
L

Return
flow

Figure 4 : Pilot operated check valve

8. What is the difference between an open-center and closed-center type of directional
control valve?
The open center type connects all ports together when the valve is unacutated . The closed –
center design has all ports blocked when the valve is unactuated.

9. What is a shuttle valve? Name one application

A shuttle valve is another type of directional control valve. It permits a system to operate from
either of two fluid power sources. One application is for safety in the event that the main pump
can no longer provide hydraulic power to operate emergency devices.
 LECTURE 18 AND 19

PRESSURE CONTROL VALVES

FREQUENTLY ASKED QUESTIONS

1. Deal with the function of the pressure control valves in hydraulic power systems

o Restricting maximum pressure in a system thereby ensuring safety using relief valve etc
o Reducing /regulating pressure in certain section of the circuit like pressure reducing valve
o Unloading system pressure using unloader valve
o Providing pressure control for sequential operation of actuators in a circuit e.g sequence
valve
o Any other function accomplished by pressure control

2. Discuss in detail the static characteristics of a direct operated relief valve, and explain
how to reduce the override pressure.

Flow pump flow

pressure

Cracking
Pressur

pressure
e

Full Pump
flow
Flow through relief
valve
If the hydraulic system does not accept any flow, then all the pump flow must return to the tank
via the relief valve. The pressure relief valve provides protection against any overloads
experienced by the actuators in the hydraulic system. Of course, a relief valve is not needed if a
pressure compensated vane pump is used. Obviously one important function of a pressure relief
valve is to limit the force or torque produced by hydraulic cylinders or motors.
The main advantage of direct-acting relief valves over pilot operated relief valves is that they
respond very rapidly to pressure buildup. Any relief valve does not know there is a problem until
pressure is very near or at its setting. Then it must open to relieve excess flow as quickly as
possible to keep pressure overshoot low. Because there is only one moving part in a direct-acting
relief valve, it can open rapidly, thus minimizing pressure spikes.

3. Draw schematically a pilot operated relief valve and explain its function

The pilot operated pressure relief valve has a pressure port that is connected to the pump line and
the tank port is connected to tank. The pilot relief valve is a poppet type. The main relief valve
consists of a piston and stem. The main relief piston has a orifice drilled through it. The piston
has equal areas exposed to pressure on top and bottom and is in balanced condition due to equal
force acting on the both sides. It will remain stationary in the closed position. The piston has a
light bias spring to ensure that it will stay closed. When the pressure is less than that of relief
valve setting, the pump flow goes to the system. If the pressure in the system become high
enough , it will move the pilot poppet off its seat. A small amount of flow begins to go through
the pilot line back to tank. Once flow begins through the piston orifice and pilot line, a pressure
drop is induced across the piston due to restriction of the piston orifice. This pressure drop then
causes the piston and stem to lift off its seat and the flow goes directly from the pressure port to
tank.

4. Discuss the application of pilot operated relief valve

 o It is used in counter balance application
o It is used in locked cylinder circuits

5. Discuss the principle of pressure reduction in fluid power systems

A second type of pressure reducing valve is pressure reducing valve. This type of valve (which is
normally open) is used to maintain reduced pressures in specified locations of hydraulic systems.
It is actuated by downstream pressure and tends to close as this pressure reaches the valve
setting. See also question 6

6. Discuss briefly the operation of pilot operated pressure reducer

The pressure reducing valve uses a spring loaded spool to control the downstream pressure. If
downstream pressure is below the valve setting, fluid will flow freely from the inlet to the outlet.
Note that there is an internal passageway from the outlet, which transmits outlet pressure to the
spool end opposite the spring. When the outlet (downstream) pressure increases to the valve
setting, the spool moves to the right to partially block the outlet port. Just enough flow is passed
to the outlet to maintain its preset pressure level. If the valve closes completely, leakage past the
spool could cause downstream pressure to build up above the valve setting. This is prevented
from occurring because a continuous bleed to the tank is permitted via a separate drain line to the
tank.

Adjustable
screw

Drain
line
Sprin
g
Main
Press
ure
line
Redu
ced
press
ure
line

No pilot pilot
signal signal

Reverse free flow through the valve is only possible if the pressure exceeds the valve setting, the
valve will close, thus making reverse flow impossible. Therefore, pressure reducing valves are
often equipped with a check valve for reverse free flow.
External forces acting onto a linear actuator will increase the pressure between the pressure
reducing valve and the actuator. In some systems, it is therefore desirable to relieve excess fluid
from the secondary system to the tank in order to maintain a constant downstream pressure,
regardless of such external forces.

7. Explain the function of the direct operated sequence valve

A sequence valve is a pressure control valve that is used to force two actuators to be operated in
sequence. They are similar to pressure relief valves. The symbol for sequence valve is as shown
below.

Instead of sending flow back to tank, a sequence valve allows flow to a branch circuit, when a
preset pressure is reached. The check valve allows the sequence valve to be bypassed in the
reverse direction. The component enclosure line indicates that the check valve is an integral part
of the component. The sequence valve has an external drain line; therefore a line must be
connected from the sequence valve’s drain port to the tank.

Dr
ain
Secon
dary
I
port
Ou
n
t
Dire
ct
pilo
t
Remote pilot

8. What are the difference between the relief valve and the sequence valve

A sequence valve is a pressure control valve that is used to force two actuators to be operated in
sequence. They are similar to pressure relief valves. Instead of sending flow back to tank, a
sequence valve allows flow to a branch circuit, when a preset pressure is reached.

9. Discuss the application of sequence valve used in hydraulic systems

Application of Sequence Valve

The following hydraulic circuit is an example of an application of a sequence valve in which a

clamp cylinder extends first to hold a work piece, and then a second cylinder extends to bend the
work piece in the desired shape.

Sequence
Valve 1
Bending
Cylinder
(B)

Clamp
Cylinder (A) Sequence W
Valve 2

Figure 17 Application of sequence valve

In this circuit, two cylinders are connected in parallel. Without the sequence valve, these
cylinders would extend together as they are both unloaded. In order for this circuit to function
properly, the clamp cylinder must extend completely before the bending cylinder begins to
extend. But by the application of sequence valve which does not allow flow into the bending
cylinder branch of the circuit until the clamp cylinder extends completely. When the clamp
cylinder extends completely, the pressure will rise and open the sequence valve. Thus, allowing
the bending cylinder to extend. The sequence valve must be set enough so that it opens only after
the clamp cylinder has extended completely.

During the retraction of cylinders, check valve allows sequence valve to be bypassed. The
sequence valve has no effect on the circuit in this situation. Both cylinders will retract together
because both are unloaded and will split the pump flow.

10. Name two applications of counter balance valve

 o Used on counter balance application to prevent the load to run away like in
counterbalance of vertical broaching machine
o Used in hydraulic press to prevent the load from running away

11. What is the function of a sequence valve?

When the operation of two cylinders is required to be performed in sequence the sequence valve
is made use of.

12. What is the function of an unloading valve?

The unloading valve is useful to control the amount of flow at any given time in systems having
more than one fixed delivery pump

13. How the unloading valve different from a pressure relief valve

Unloading valves are pressure-control devices that are used to dump excess fluid to tank at little
or no pressure. Remote pilot signal is used to control. Where as in pressure relief valve pilot
from system pressure controls the valve.

14. What is the function of pressure relief valve in fluid power systems?

Function of the pressure relief valve is to unload the pump in the event of extreme pressure in the
circuit. When the set pressure is reached relief valve will send all the fluid back to the tank.

15. What is the advantage of using an unloading circuit, when feed and speed of a machine
need to be varied?

o When high speed is required during air cutting, high flow pump can be used to get the
rapid extension and cutting time is saved.
o When cutting is taking place ( torque requirement is high), low flow pump can be used
o This circuit eliminates the necessity of having a very expensive high pressure, high flow
pump.
 LECTURE 20

FLOW CONTROL VALVES

FREQUENTLY ASKED QUESTIONS

1. What is the function of a flow control valve

Flow control valves are used to regulate the speed of hydraulic cylinders and motors by
controlling the flow rate to these actuators.

2. What are the three ways of applying flow control valves

Meter in, meter out and bleed off are ways of applying flow control valves.

3. What is meant when a flow control valve is said to be pressure compensated

A pressure compensated flow control valve is one which provides the desired flow rate
regardless of changes in system pressure.

4. What is the meter in ciruit and where it is used

In meter in circuit flow control is placed in in the pressure line. Pump delivery in excess of
metered amount is divered to tank through pressure relief valve. This is used wehre load
characteristics are constant and positve

5. What is the meter out circuit and where it is used

In meter in circuit flow control is placed in in return lineThis is used in machine tools like
drilling in which tools is dragged suddenly at the end of drilling.

6. What are the advantage of meter in circuit

o Finer speed control is possible

o Suitable for high pressure applications
o Low level of friction – longer service life of components
7. What are the disadvantage of meter in circuit

o Cannot be used for hydromotor

o Pressure drops across due to throtlle and hence the pressure of the fluid fed into the
actuator will be less than required
o Inefficent because excess flow goes to tank
o Cannot prevent the load from running away as in the case of drilling machine
o Heat generated due to throttling is fed to the actuator.

8. What are the advantage of meter out circuit

o No loss of pressure of the oil at the head end of the cylinder

o The actuator movement is more stable
o Suitable for controlling the speed of both cylinder and motor
o Heat generated during throttling goes to the tank
o Provide positve speed control of cylinder
o Pump works against the maximum pressure
o Positive speed control and stable

9. What are the disadvantage of meter out circuit

o Even at no load the cylinder is subjected to maximum pressure

o Piston rod side is subjeted to counter pressure which increases as area ratio increases
o The friction is higher
o If the flow control is installed after the DCV, leakage in DCV will affect the accuracy

10. What are the advantage of By pass or bleed off circuit

o Efficiency is better
o Heat generated due to throttling is fed into the tank

11. What are the disadvantage of By pass or bleed off circuit

o Positive speed control is not possible

o Not suitable for accumulator circuit
o Fluctuation of flow rate in pump affects the speed of the actuator
 o Pump works against the load
o Can be used for fixed displacement pump and motor
o The motor continues to rotate even when the pump delivery is cut off from the fluid
motor
o Not efficient with variable displacement pump.

12. What is a modular valve and what are its benefits

Modular valve is a stack of control valve one on the other to perfomr a complete valve pack.This
arrangemetn forms a compact system, thereby reducing assembly cost and eliminates much of
the complex interconnection of pipe work. Modular valve saves space and easy to troubleshoot.

13. What is hydraulic fuse

A hydraulic fuse prevents hydraulic pressure from exceeding an allowable valve in order to
protect circuit components from damage. It is analogous to an electric fuse.

Drain to
tank
Hydraulic fuse

Electric Motor

Thin metal disk Inlet Pressure

Figure E8 : Hydraulic fuse

14. What is the need for temperature compenstaion in flow control valve
As the viscoisty of oil varies with temperature, the oil becomes less viscous when temperature
increases. As the less viscous fluid flow more rapidly through an orifice, the increase in
temperature causes increase in flow for a valve setting, so temperature compensation is needed to
offset the effect of such temperature variations.

15. What is the differnece between hydraulic fuse and Pressure relief valve

Hydraulic fuse Pressure relief valve

Hydraulic fuse is a safety device. When the line Pressure relief valve is also safety valve. which
pressure exceeds the design capacity of thin crack opens when the fluid line pressure
metal sheet, it ruptures and connects it to exceeds the set pressure. Once the pressure
drain drops below set pressure, Valve resets
It protects the hydraulic system. It is used to regulate the pressure and protects
the expensive parts of pump against the over
pressure which may be due to stopage, or
blocking.
It is analogous to electrical fuse. which need to It is analgous to cirucit breaker, which can be
be replaced once thin metal plate ruptures reset. like cirtuit breaker, relief valves are
available with different maximum set
capacities.
Rupture is due to plastic deformation of the Opening of the valve is due to set pressure
thin metal sheet. which can be adjusted by spring force.
 LECTURE 21

FLOW AND FORCE ANALYSIS OF VALVES

FREQUENTLY ASKED QUESTIONS

1. Discuss in detail the flow displacement relationship of the critical centre spool valves,
giving their possible applications in the hydraulic control valves.

Critical Centre Valve

In critical centre valves, the land of the spool are exactly the same width as the annual ports of
the valve body in the central or null position the lands exactly cover the ports. (Figure 16.1)

x x

Load

Figure 15.1 Four way valve

Flow rate prediction

Flow through sharp edged orifices is predicted by applying the ‘square root law’.

Treating the annular orifices formed within the valve in this way gives

The above equations can be simplified by making certain assumptions or approximations to the
actual situation with real valves.

Let = , =

Supply pressure is a constant and is negligible.

By introducing the term = , we have =2 and + =2

Then the equation can be written

(= = )

When

5/8 and ρ =870 Kg/

Using binomial approximation,

= (1- )

Equation becomes,

Then
The above analysis predicts that the flow gain can be treated as constant for a particular valve
and supply pressure but the pressure flow coefficient will vary with valve opening x. the
variation of are of minor significance for linear analysis.

In reality, spool lands will never exactly match the annular ports in valve body. Actual test
results with a constant pressure drop across the valve ports would show variations, particularly
near the central or null position of the spool as those illustrated in the Figure 15.3

The flow gain is the slope of the approximate line in Figure. Which can double its valve near
null with negative lap. The magnitude of is most important parameter of a valve and often
also of any system incorporating the valve.

Zero lap

Over lap

Under lap

Flow rates versus valve displacement for constant pressure drop

2. Discuss in detail the flow forces acting on :Pressure compensated flow control
valveForces

The steady state balance of forces for some equilibrium operating position with the poppet
stationary and open distance , for a supply pressure outlet pressure and consequent
chamber pressure is given by
( - ) = F- ( + - +) --------------(3)

Under dynamic conditions with the spool in motion for outlet pressure P L0+ PL, with the
instantaneous spool position distance x to the left of its initial position, noting that P C0+ PC is the
instantaneous chamber pressure, the balance of forces is given by

{( + )-( + } = F- x– { –( ++ )}(x+ )- f Dx – mD2x------------(4)

Assuming PC, PL, and x are small and terms PCx may be neglected, then (4)-(3) gives

- PC = x+ Dx + D2x - PL ------------------(

3. Derive an expression for the flow displacement relations of the under lapped four way
valve.

Open centre type (under lapped four way valve)

A valve in which the land of the spool never completely covers the ports of the valve body is
said to be under lapped. ( Figure 16.2)

a b c d

(u+x (u+x
(u-x)
(u-x) ) )
x

Load motion

Load

Figure 15.2 Open centre –four way valve

Referring to the figure 15.2 ,a displacement of x unbalances the symmetry of the ports. Two of
the annular orifices increase in width from u to u+x and two decrease from u to u-x.

The flow rates is estimated as follows

( ) ( )

( ) ( )

Assuming and remains constant and sothat and writing

, we obtain

( )

Which may be approximated as

( ) ( )

4. Derive an expression for the flow for a flapper nozzle valve.

We assume the valve has a balanced condition such that x=0 and =0 when q=0.

That is (steady state) = (steady state) =

( steady state) = (steady state) =

And

Which also implies that the orifice size and the curtain area in the null position are approximately
equal.

Implies =
Consider the valve is not in balance, that is x has some value as does , we have

q=

= - )/

Where =

q=

- )/

And using binomial approximations

q= (1- )- (1+ )+ )/ ( )

q= (1+ )+ (1- )+ )/ ( )

adding and dividing by 2

q= +

which is in the form of

5. What is the major limitation of a flapper nozzle amplifier and how you can overcome it?

The major limitation of a flapper nozzle amplifier is its limited air handling capacity. The
variation of air pressure obtained cannot be used for any useful application, unless the air
handling capacity is increased. An air relay serves the similar purpose as a power amplifier. It is
used after the flapper nozzle amplifier to enhance the volume of air. (The situation can be
compared with an operational amplifier in an electronic circuit. Though the operational amplifier
is useful in amplifying small voltage signals, the output current delivered by the operational
amplifier is limited and a power amplifier is used at the output stage in order to drive any device)
6. Why is feedback system used in a multi stage servo valve?

A small flapper motion creates an imbalanced pressure in one direction or the other on the ends
of the spool of the second stage. Hence the spool will tend to move in response to this imbalance
and allow flow to the actuator. Since continued imbalance in pressure would quickly move the
spool to its limits of travel, a form of feedback connects the motion of the spool to the effective
displacement of the flapper
 LECTURE 22 TO 23

PROPORTIAONAL HYDRAULIC VALVES

FREQUENTLY ASKED QUESTIONS

1. Compare electro hydraulic servo valve with proportional hydraulic valves

Servo Valve Proportional Valve

Close loop control Open loop control
Very expensive Less costly compared to servo valves
Low power input ( 1-3 w) Require more power (50 W)
High filtration Moderate filtration
Spool critically lapped Spools are overlapped
Linear Flow current relation Nonlinear flow current relations
Very low hysteris 0.1 % Hysteresis large 0.5 %
Used primarily in closed loop, high Can be used in closed loop control, with
performance circuits moderate performance circuits
Create flow and pressure control Can be used as flow, pressure , direction
control valves

2. Where are proportional valves are preferred

In general proportional valves find most of their applications in open loops situations where
pressure and flow are required to change continuously, where multiple fixed flow and pressure
valves can be replaced by a single valve and where acceleration and deceleration under control
are required.

3. Explain the principle of proportional pressure reducing valve

This operates in a similar manner to a conventional pressure regulating valve, the control spring
being replaced by a proportional solenoid. When this solenoid is not energized, the proportional
valve is closed unlike the conventional pressure reducing, which is normally open. The output
pressure of the valve shown diagrammatically (Figure 17.14), is proportional to the current
flowing through the solenoid.

Figure 17.14 Proportional pressure reducing valve

When the solenoid is energized it will move the spool to the right, the control orifice A will open
and allow fluid to flow to the output port X. As the aperture of orifice A increases the orifice B’s
aperture will reduce; the pressure at the control output X is dependent upon the openings of
control orifices A and B. This is shown in Figure 17.15

Figure 17.15 Principle of pressure reducing valve

Let the supply pressure be P1. The pressure drops the across the control orifices A and B are P A
and PB and the output pressure is Px .

And

If the control orifice B is fully closed, the Pxwill equal the supply pressure P1. The output
pressure is applied to the right hand end of the spool and if this is greater than the equivalent
pressure exerted by the proportional solenoid, the spool will move to the left. This increases the
opening of orifice B and reduces that of orifice A, so reducing the output PXa = F. The output
pressure is proportional to the current flowing in the proportional solenoid. There will always be
a flow to tank from this type of valve if the output pressure PX is less than the supply pressure P1.
It is essential that there is no back pressure in the tank line if the valve is to function properly.

4.With the help of neat sketch explain how speed of the cyliners can be controlled using
proportional valve

The conventional speed control of a cylinder is by meter in meter out or spill-off flow control
valves. This sets a cylinder speed which can be manually varied. Alternatively a cam drive can
progressively close or open an adjustable orifice in accordance with a preset speed profile which
is altered by changing the cam profile. Examples of these types of circuits are shown in Figure
17.18. The acceleration and retardation of a cylinder can be controlled by:

1. Relief valves limiting then maximum pressure available to accelerate the load.
2. Using a two stage directional control valve with a choke pack to control the speed of
movement of the main spool.
3. Using a variable displacement pump.
4. Internal cylinder cushions or external shock absorbers can be used to decelerate the
cylinder.
5. Brake valves, deceleration valves and counterbalance valves can be built into the circuit
to control the deceleration and sometimes the acceleration of the actuator.
All these manual methods are incapable of continuous variations whilst the system is operating.
A proportional control valve in the cylinder circuit enables continuous regulation of speed,
acceleration and retardation. If proportional control card is used to drive the valve any
adjustments to the maximum current ramp-up and ramp-down have to be carried out by adjusting
potentiometers on the card. However a microprocessor or minicomputer may be employed to
control the proportional valve by varying the solenoid current over different parts of the cycle.

a) Meter out speed control b) cam operated speed control

4. Discuss the various control of proportional valves

The simplest application of using a proportional solenoid is that of a throttle valve. Athrottle
valves creates a variable orifice in a line. If the upstream pressure is at the deadhead/R.V. setting,
then flow through the valve is proportional to the product of the orificearea and the pressure drop
across the valve. i.e. √ . For any , wecan change the flow (and hence the velocity
of the actuator) by changing the orifice area.Flow is in one direction only and is not controlled
(because can change even thoughAo (x) is controlled). A schematic is shown in Figure given
below
A logical extension to the proportional throttle valve is the directional control valve. A
schematic is shown below

The spool has symmetric metering orifices and two proportional solenoids (one for each
direction). The amplifiers know which solenoid to activate via the position transducers.
The amplifiers are designed to reduce the dead zone to about 5% of full stroke (compared
to 15.25% with no compensation). By changing the shape of the metering orifices, it is
possible to have different resistances in the various parts

In conventional pressure control valve a spring is used to control the pressure at which the valve
operates. The spring is replaced by a DC solenoid in the case of proportional valves; the force set
up by the solenoid is controlled by being dependent on the current flowing through it.

Direct acting proportional-relief valves are shown in Figure belowThe proportional solenoid
exerts a force on the poppet keeping the valve closed, until the hydraulic pressure at port P
overcomes this force and opens the valve. In the design of the relief valve the proportional
solenoid acts directly on the valve poppet.
 Solenoid
Coil

Armatur
e

P T Light
retur
n
sprin
Direct acting proportional relief valve
g

6. What is the difference between a standard solenoid and a proportional solenoid?

For an on/off solenoid the force generated increases as linear gap decreases. By superimposing
the return spring curve on this family of solenoid curves it is shown that there are a limited
number of intersection points where the spring force and solenoid force would be in equilibrium.
On/off solenoids are designed for single current supply systems, where the input current creates a
large enough force to exceed the spring force at all positions, moving the spool to its maximum
displacement.

With a proportional solenoid the gap is constant throughout the spool stroke. Thus, when the
return spring curve is superimposed on the proportional solenoid family of input current curves
many intersection (equilibrium) points are found. By utilizing a variable current supply to change
the input current many spool positions can be created; thus spool position is proportional to input
current.

7. Explain the concept of operation of a proportional solenoid

 Figure 1 : Proportional Solenoid
Solenoids are electro-mechanical interface devices that convert electrical input into an applied
force On/off type electro-hydraulic valves use a solenoid to move the valve spool from one
position (off or no flow) to another position (on or maximum flow). A mechanical spring
opposes spool movement and returns the spool to the opposite position once electrical power has
been removed from the solenoid. This operation can be classified as digital since the flow paths
can be in only one of two states. On the other hand, proportional type electro-hydraulic solenoid
valves can position the spool at an infinite number of locations between the start and end
positions. The mechanical spring employed in this application provides both the means for
proportionality and again returns the spool to the start position when no electrical power is
supplied. Consequently, proportional solenoid valves can be classified as analog devices which
provide more functionality and opportunities within the field of electro-hydraulics.

The key difference between on/off and proportional solenoids is the shape and orientation of the
core and armature to create a constant gap device. A proportional solenoid is constructed such
that the gap is perpendicular to the direction of armature movement and therefore independent of
armature position

Both on/off and proportional solenoids have the same basic construction; a wire coil surrounds a
ferromagnetic core with a paramagnetic guide tube (Figure 2)

Figure 2 : construction of solenoid

When an electric current is supplied to the coil a magnetic field that intersects the core and
armature is established. The coil creates two magnetic poles at the opposite ends of its length,
where the flux paths circulate. These magnetic flux paths generate a linear force attempting to
center the armature within the coil length (between the electromagnetic poles). An on/off
solenoid’s magnetic force increases as the gap between the core and armature decreases
(classified as a variable gap device) because the reluctance of the magnetic flux circuit is
decreased. The key difference between on/off and proportional solenoids is the shape and
orientation of the core and armature to create a constant gap device. A proportional solenoid is
constructed such that the gap is perpendicular to the direction of armature movement and
therefore independent of armature position (Figure 1). Thus, for a given current through the coil
a constant force over the working range of armature movement (spool stroke) is created.
Examining the equation for force generated by either an on/off or proportional solenoid can show
this principle:

8. What is the purpose of dither in a proportional circuit

The dither adjustment allows the system to be trimmed so that the valve spool moves with higher
dither frequency but at such a low amplitude that the load does not respond to it. This reduces the
valve dead band with no detrimental effect on the load.

9. Explain the difference between force control and position control in proportional control
valves.

In force control Proportional valves, force is controlled electrically and by applying the force to
a compression spring its deflection can be controlled. If the spool is acted on by a spring at one
end and a proportional solenoid on the other the orifice size can be varied along with the control
current.

In order to increase the accuracy and extend the range of applications of proportional control
valves, a linear transducer may be fitted to measure the spool position. The output from the
transducer is a voltage which is proportional to the spool displacement and is continuously
varying through the total spool movement.

When a conventional solenoid is energized, the plunger travels its full stroke. A given force is
developed at the moment actuation occurs. With a force controlled proportional valve , a
provision is made to increase the force output by the solenoid proportional to the input signal.
With a stroke controlled valve , the stroke distance is proportional to the input signal. Both types
of solenoid provide an opening of the valve proportional to the magnitude of milliamp current
applied to the valve. Spool movement is proportional to the input current.
 LECTURE 24 TO 26 - HYDRAULIC CIRCUIT DESIGN

FREQUENTLY ASKED QUESTIONS

1. List three important considerations to be taken into account while designing a hydraulic
circuit

There are 3 important considerations in designing a hydraulic circuit.

 Safety of machine and personal in the event of power failures

 Performance of given operation with minimum losses
 Cost of the component used in the circuit.

2. What are advantages of regenerative circuit?

The speed of the extension can be made greater than that of regular double acting cylinder. The
extending speed can be made greater than the retracting speed if the rod size is made small
enough.

3 Explain the Regenerative circuit for Drilling Machine:

C F LOAD

A B C – Double acting cylinder

D – 3 Position, 4 Way,
1 0 2 Regenerative center,
D P T solenoid actuated,
spring centered DCV
R – Relief Valve
E R F - Filter
P E – Electric Motor
F T T- Tank
T P - Pump
Figure shows an application of regenerative circuit in a drilling machine. Here a 3-position, 4-
way , regenerative center directional control valve is used. When the DCV is in the spring-
centered position, port P is connected to A and B and tank port T is blocked. In this position
pump flow goes to A and flow from rod end of the cylinder also joins the pump flow to gives
rapid spindle advance ( no work is done during this period )
Why does the spring-centered position give rapid extension of the cylinder (drill spindle)? The
reason is simple. Oil from the rod end regenerates with the pump flow going to the blank end.
This effectively increases pump flow to the blank end of the cylinder during the spring-centered
mode of operation. Once again we have a regenerative cylinder. It should be noted that the
cylinder used in a regenerative circuit is actually a regular double-acting cylinder. What makes it
a regenerative cylinder is the way it is hooked up in the circuit. The blank and rod ends are
connected in parallel during the extending stroke of a regenerative center.
When the DCV shifts to 1st position, P is connected to A and B to T gives slow feed
(extension) when the drill starts to cut into the work piece. Similarly when the DCV shifts to 2nd
position, P is connected to B and A is connected to T, since the ring area is less the cylinder will
have fast return motion.

4 With the help of neat sketch explain the pump unloading circuit

F LOAD
C

A B

1 0
2
D P T

CV

P
U
F T
T
. Pump unloading circuit.
C = Double acting cylinder
P = Pump
T = Tank
F = Filter
U = unloadingValve
D =3-position, 4 way ,closed center, Manually operated and Spring Centered DCV

Refer to the above figure, we see a circuit using an unloading valve to unload a pump. The
unloading valve opens when the cylinder reaches the end of its extension stroke because the
check valve keeps high-pressure oil in the pilot line of the unloading valve. When the DCV is
shifted to retract the cylinder, the motion of the piston reduces the pressure in the pilot line of the
unloading valve. This resets the unloading valve until the cylinder is fully retracted, at which
point the unloading valve unloads the pump. Thus, the unloading valve unloads the pump at the
ends of the extending and retraction strokes as well as in the spring-centered position of the
DCV.

5 With the help of circuit diagram explain Double Pump Hydraulic system ( Hi – Lo circuit

C F LOAD

A B

0
1 2
D P T

CV

R P1 P2 U
T T
F F

Double pump Hydraulic system

P1 -- Low discharge, High pressure pump CV – Check valve
P2 -- High discharge, Low pressure pump D – 3 Position, 4 Way, closed
R -- Relief valve center, manual actuated DCV
U – Unloading valve C- Double acting cylinder
T - Tank F - Filter

Figure shows a circuit that uses two pumps, one high-pressure, low-flow pump and the other
low-pressure, high-flow pump. One can find application in a punch press in which the hydraulic
ram must extend rapidly over a large distance with very low pressure but high flow requirements.
However, during the short motion portion when the punching operation occurs, the pressure
requirements are high due to the punching load. Since the cylinder travel is small during the
punching operation, the flow-rate requirements are also low.
The circuit shown eliminates the necessity of having a very expensive high-pressure,
high-flow pump. When the punching operation begins, the increased pressure opens the
unloading valve to unload the low-pressure pump. The purpose of the relief valve is to protect
the high-pressure pump from overpressure at the end of the cylinder stroke. The check valve
protects the low-pressure pump from high pressure, which occurs during the punching operation,
at the ends of the cylinder stroke, and when the DCV is in its spring-centered mode.

6 Explain the application of Counter Balance Valve

Figure illustrates the use of a counterbalance or back-pressure valve to keep a vertically mounted
cylinder in the upward position while the pump is idling i.e when the DCV is in its center
position. During the downward movement of the cylinder the counterbalance valve is set to open
at slightly above the pressure required to hold the piston up ( check valve does not permit flow in
this direction ). The control signal for the counterbalance valve can be obtained from the blank
end or rod end of the cylinder. If derived from the rod end, the pressure setting of the counter
balance valve equals FL/ (AP-Ar ). If derived from blank end the pressure setting equals FL / AP.
This pressure is less and hence usually it has to be derived from blank end. This permits the
cylinder to be forced downward when pressure is applied on the top. The check valve is used to
lift the cylinder up as the counterbalance valve is closed in this direction. The Tandem -center
directional control valve unloads the pump. The DCV is a manually -actuated, spring-centered
valve with tandem-center flow path configuration
 CB

F LOAD
CV
A B

1 0 2
D P T

P R
T
F
T

Counter balance application

C = Double acting cylinder mounted vertically
P = Pump
CB = Counter Balance Valve
CV = Check Valve
T = Tank
F = Filter
R = Relief Valve
D =3-position, 4 way , Tandem center, Manually operated and
Spring return DCV
7 Explain the application of pilot check valve for locking double acting cylinder

In many cylinder applications, it is necessary to lock the cylinder so that its piston cannot be
moved due to an external force acting on the piston rod. One method for locking a cylinder in
this fashion is by using pilot check valves, as shown in Fig 5.13. The cylinder can be extended
and retracted as normally done by the action of the directional control valve. If regular check
valves were used, the cylinder could not be extended or retracted by the action of the DCV. An
external force, acting on the piston rod, will not move the piston in either direction because
reverse flow through either pilot check valve is not permitted under these conditions

F LOAD
C

PCV1 PCV2

A B

1 0
2
D P T

P R
T
F
T

. Locked Cylinder using Pilot Check Valve.

 C= Double acting cylinder
P = Pump
PCV1 & PCV2 = Pilot Check Valve
R = Relief Valve
T = Tank ; F = Filter
D =3-position, 4 way , closed center, manually operated DCV

8 Explain the speed control circuit for hydraulic motor

Figure shows a circuit where speed control of a hydraulic motor ( Bi -directional motor) is
accomplished using a flow control valve to control the fluid flow to the motor.
In the spring-centered position of the tandem four-way valve, the motor is hydraulically locked.
When the four-way valve is actuated into the 1st position, the motor rotates in one direction. Its
speed can be varied by adjusting the setting of the throttle of the flow control valve. In this way
the speed can be infinitely varied as the excess oil goes to the tank through the pressure relief
valve. When the four-way valve is deactivated, the motor stops suddenly and becomes locked.
When the 2nd position of the four-way valve is in operation, the motor turns in the opposite
direction. The pressure relief valve provides overload protection if, for example, the motor
experiences an excessive torque load.
M

D 1 0
2

F R

Speed control of Hydraulic motor using Flow control valve.

 M = Bi-directional Hydraulic motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
D =3-position, 4 way ,Tandem center, Manually operated and Spring Centered DCV

9 Explain the speed control circuit for hydraulic motor using meter in and meter out
circuit. Write the equations for volumetric efficiency and comment
The speed of hydraulic motor can be controlled either by meter-in control or meter- out control.
Figure shows a unidirectional hydraulic motor speed is controlled by a meter- in circuit. Here
the flow control valve is placed between the pump and motor.
FCV Q1

P M
R QL
( Q1-QL)
F

Fig 5.20. Meter- in Speed control of Hydraulic motor

M = Uni-directional Hydraulic Motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve

Figure 5.21 shows a unidirectional hydraulic motor speed is controlled by a meter- out
circuit. Here the flow control valve is placed between the motor and tank.
Q1

P M
QL
FCV
F R
( Q1- QL)
. Meter- out Speed control of Hydraulic motor
M = Uni-directional Hydraulic Motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
We know that the volumetric efficiency of the motor is given by
Vol=Theoretical flow rate the motor should consume
Actual flow rate consumed by motor
Vol=QT /QA
Due to leakage, a hydraulic motor consumes more flow rate than it should theoretically
consume. The theoretical flow rate is the flow rate a hydraulic motor would consume if there
were no leakage. If Q1(=QA ) is the flow of fluid to the motor, and QL the leakage , Then QT is
equal to Q1 – QL

ThenVol= (Q1 – QL )/Q1

In meter- in control Q1 is maintained constant despite varying load , QL varies with load ,
therefore volumetric efficiency varies with load. Hence meter-in system will not give precise
control of speed. Whereas in meter – out control Q1 varies with load hence precise control of
speed regardless of flow.

10. Differentiate between open loop and closed loop Hydrostatic Transmission systems

Hydrostatic Transmission ( HST ): These are special cases of energy transmission system. It
consists of a drive with hydraulic energy as input. Hydraulic motor convert hydraulic energy to
mechanical energy. Hydrostatic transmission is a whole unit in which pumps and motors are
designed to match ( the speed torque characteristics ) to get optimum transmission. The HST
can be open or closed circuit.
P. E
M .E M.E
PUMP Hydrostatic transmission
MOTO
Open circuit HST : Figure shows open typeRcircuit. They are called open circuit drives because
the pump draws its fluid from a tank. Its output is then directed to a hydraulic motor and
discharged from the motor back to the tank. In the closed circuit drive, exhaust oil from the
motor is returned directly to the pump inlet.

Variable displacement pump

M

Open circuit (open loop ) HST

 Figure shows a closed circuit that allows either direction of motor rotation. The feed pump is
provided for replenishing the fluid in the circuit. The check valves prevent the oil flow from the
main pump to the feed pump. Here two relief valve R 1 and R2 are used to protect the main
pump in both the direction of rotation.
The motor speed is varied by changing the pump displacement. The torque capacity of
the motor can be adjusted by the pressure setting of the relief valve.
Closed circuit drives are available as completely integrated units with all the controls and
valving enclosed in a single, compact housing.

Variable displacement
Pump ( Main )

M
R1 R2

Feed Pump

Closed circuit (open loop ) HST

Performance:
1. Hydraulic power input ,Phyd = p QP ( Watts )
where p = pressure setting of relief valve in N / m2
QP = pump theoretical flow rate = pump displacement (m3/ rev) * Speed (rps)
2. Q1 = Qp* VP where VP = volumetric efficiency of the pump;
Q1 = Actual flow rate to motor
3. Motor theoretical flow rate ,QM = Q1*VM
Where VM = volumetric efficiency of the motor
1. Motor capacity , CM = QM/ speed of motor ( m3/ rev )

2. Power delivered to motor, Phyd = System pressure * Q1 ( Watts )

3. Mechanical power generated, PMech = Phyd* V M*MM

whereMM = mechanical efficiency of hydraulic motor
4. Actual Torque developed by motor, Ta = PMech / 2 N
Where N = speed of motor in rps
8. Ideal torque , Ti = CM * P / 2

9. Actual torque, Ta = Ti *MM

11. What are the conditions for the two cylinders to be synchronized?
For the two cylinders to be synchronized, the piston area of cylinder 2 must beequal to the
difference between areas of the piston and piston rod for cylinder 1.
i.e. Ap2 =Ap1 –AR1
Also, the pump should be capable of delivering a pressure force P1ApI in cylinder 1 to overcome
the loads F I and F 2 acting on both cylinders. .
i.e.P1Apl =FI +F2

12. What is the use of bleed-off circuit?

Bleed off circuit is used to .control the flow of fluid in both directions of flow (or) on a
specific line and limits speed in only one direction of the cylinder travel.
 LECTURE 27 – SERVO VALVES

FREQUENTLY ASKED QUESTIONS

1. Define a servo valve

Servo valve is a programmable orifice. Servo valve is an automatic device for controlling large
amount of power by means of very small amount of power and automatically and continuously
correcting the performance of a mechanism

2. How do servo valves differ from proportional control valves

A comparison of proportional valves and servo valves is given in the Table . Proportional valves
are less accurate, but they cost less. They are not used for closed loops control, there is no
feedback of the output to change the setting of the valve.

Parameter Proportional Hydraulic valve Electro hydraulic servo valve

Valve lap Overlap spool, causing a „dead Zero or underlap valve spool.
zone‟ On either side of the null No dead zone
position

Response time for valve 40-60 ms 5-10 ms

spool to move fully over

Maximum operating Approx. 10 Hz Approx. 100 Hz

frequency

Without armature feedback Approx. 0.1%

Hysteresis approx. 5%
With armature position feedback
approx. 1%

3. Explain the operation of torque motor

A torque motor is illustrated in Figure1given below. Torque motor is a simple electromagnetic
device consisting of one or two permanent magnets, two pole pieces, a ferromagnetic armature,
and two coils. The permanent magnet polarize the upper and lower pole pieces, so that they
present equal and opposite magnetic fields. Torque motors are very low power devices operated
on low-voltage DC power. The armature is mounted at its midpoint so that it is free to rotate
through a very limited arc either clockwise or counterclockwise. The ends of the armature are
extended into the gaps between the pole pieces. The magnetic field holds the armature in a
neutral position. The two coils surround the arms of the armature to form two small
electromagnets.

When a current is passed through the coils, a magnetic field is generated. The polarity of the
field depends on the direction of the current flow. In Figure 2 the current flow has caused the left
end to become the South Pole and right end to become the North Pole, resulting in counter
clockwise rotation of the armature.
4. Define underlap, overlap, and line to line in the context of servo valve spools.
The most common condition is the line-to-line (or zero overlap) spool. Here , the bandwidth
exactly matches the port width. Overlapped spool have lands that are 0.5 to 5% wider than the
ports. An underlaped spool has lands that are 0.5 to 1.5% narrower than the ports. This design is
often referred to as “open center” although there really are no open-center servo valves.

5. Define deadband
It is defined as the current required to move the spool from the exact centered position to the
position where the first flow output is seen. It is usually expressed in milliamps or percent rated
current. Deadband is the result of the spool inertia, overlap, static friction, and any other forces
that might impede the initial motion.
 +
Flo
w
-1 +1
Deadband

6. Define threshold -
Flo
Threshold is the current that must be applied before
w a response is detected. Good quality two
stage valves have a threshold less than 0.5% of the rated current.

7. Define hysteresis
In an ideal world, a unit of current input would produce a unit of valve output. This is not
possible to achieve practically. Hysteresis is expressed as the percent difference in the rated
current required to give the same output when approached from higher and lower inputs. For
servo valves it is typically 1 to 2%. To overcome the problem of hysteresis, some controllers are
designed so that the set point is always approached from the lower side. This requires a
deliberate undershoot when approaching from the high side

8. List and define the types of hydraulic amplifiers

Figure below shows a single stage servo valve. The mechanical connection between the torque
motor armature and the spool is a stiff wire. When there is no command input to the torque
motor, the armature is in the neutral (nulled) position, which, in turn, causes the spool to be in
the nulled position, and there is no flow through the valve. A clockwise deflection of the
armature pushes the spool to the left, opening up flow path from P to B and A to T. a
counterclockwise deflection opens P to A and B to T.
 Single stage spool type servo

For higher flow rates, two-or even three-stage valve must be used. In this valves second and third
stages are always sliding spools that are pilot operated from the previous stages. The first stage
may use the sliding spool, but there are other designs, also.

9. Servo valves are usually rated at what pressure drop

Servo valves are generally considered to be high pressure devices. They are pressure rated at
3000 PSI. , although most are capable of operating at 5000 PSI or even higher.
10. Define gain.
Gain is defined as = output/input. Two gains are defined for servo valves. Flow gain and pressure
gain.
11. Define Flow gain
It is defined as flow /input current. Flow gain is determined by measuring control flow versus
input current. Flow gain in the null region may range from 50 % to 200 % of the expected gain
based on the slope of the linear line.

12. Define pressure gain.

Pressure gain is defined as pressure/input current.
 LECTURE 28 to 29– ACCUMULATORS

FREQUENTLY ASKED QUESTIONS

1. Define an accumulator and explain its function

A hydraulic accumulator is a device that stores the potential energy of an incompressible fluid
held under pressure by an external source against some dynamic force. This dynamic force can
come from different sources. The stored potential energy in the accumulator is a quick secondary
source of fluid power capable of doing useful work.

It is a simple hydraulic device which stores energy in the form of fluid pressure. This stored
pressure may be suddenly or intermittently released as per the requirement. In the case of a
hydraulic lift or hydraulic crane, a large amount of energy is required when the lift or crane is
moving upward. This energy is supplied from the hydraulic accumulator. But when the lift is
moving in the downward direction, it does not require a huge amount of energy. During this
particular time, the oil or hydraulic fluid pumped from the pump is stored in the accumulator for
future use.

2. What are the different types of accumulators?

There are three basic types of accumulators
1. Weight loaded or gravity accumulators
2. Spring loaded accumulators
3. Gas loaded accumulators

3. Why are accumulators used?

To supplement pump flow: The most common use for accumulators is to supplement pump flow.
Some circuits require high-volume flow for a short time and then use little or no fluid for an
extended period. Generally speaking, when half or more of the machine cycle is not using pump
flow, the application is a likely candidate for an accumulator circuit.
 4. Explain the principle of operation and possible application of the hydraulic
accumulators

Like an electrical storage battery, a hydraulic accumulator stores potential power, in this case
liquid under pressure, for future conversion into useful work. This work can include operating
cylinders and fluid motors, maintaining the required system pressure in case of pump or power
failure, and compensating for pressure loss due to leakage. Accumulators can be employed as
fluid dispensers and fluid barriers and can provide a shock-absorbing (cushioning) action.

Accumulators are used mainly on the lift equipment to provide positive clamping action on the
heavy loads when a pump's flow is diverted to lifting or other operations. An accumulator acts as
a safety device to prevent a load from being dropped in case of an engine or pump failure or fluid
leak. On lifts and other equipment, accumulators absorb shock, which results from a load
starting, stopping, or reversal.

5. Define and derive an expression for the volumetric capacity of bladder type
accumulators
The volumetric capacity of the accumulator is defined as volume of the oil delievered to /from
the accumulator at pressure P in operating range P1= P=P2

Adiabatic
Isothermal
 {( ) ( ) }

{( ) ( )}

6. Explain the construction and operation of the piston type accumulator

Piston type accumulator: - It consists of a cylinder with a freely floating piston with proper
seals. Its operation begins by charging the gas chamber with a gas (nitrogen) under a
predetermined pressure. This causes the free sliding piston to move down. Once the accumulator
is precharged, hydraulic fluid can be pumped into the hydraulic fluid port. As the fluid enters the
accumulator, it causes the piston to slide up, thereby compressing the gas which increases its
pressure and this pressure is then applied to hydraulic fluid through the piston. Since the piston is
free sliding, the pressure on the gas and the hydraulic fluid is always equal.

Piston type accumulator

7. Explain the construction and operation of the bladder type accumulator
Bladder accumulator: - These accumulators function in the same way as the other two
accumulators. Here the gas and the hydraulic fluid are separated by a synthetic rubber bladder.
The bladder is filled with nitrogen until the designed pre-charge pressure is achieved. Hydraulic
fluid is then pumped into the accumulator, thereby compressing the gas and increasing the
pressure in the accumulator. The port cover is a small piece of metal that protects the bladder
from damage as it expands and contacts the fluid port.

Figure 6 Bladder type accumulator

In an accumulator, at any point of time, we are either compressing a pre-charged gas or allowing
it to expand. This compression or expansion brings about a status change in the gas, which is
governed by the perfect gas equation,

Where P is the absolute pressure in Bar, V is the gas volume in m3, m is the mass in kg, R is the
universal gas constant. (most common gas used in industry is Nitrogen) For the particular gas
and the accumulator, the value of WR is constant written as, PV/T = constant or

When the change takes place over a long period of time the temperature of the gas remains
constant and such a change is called isothermal, resulting in the equation
When the change occurs instantaneously, there is no time for heat transfer from the work to the
environment and such a change is called isentropic or reversible adiabatic and is given by,

All changes between isothermal and isentropic are called polytropic.

Pressure volume diagram shown in the figure 7will help us to understand how the volume
variation as a function of pressure is depending on the value of polytropic exponent n which for
nitrogen is contained within the limits . The value of n is taken to be equal to 1 if
the compression and expansion process takes place under isothermal process. For adiabatic
conditions, the value of n is taken equal to 1.4.
Isothermal conditions can be considered to exist if the accumulator is used as a volume
compensator, leakage compensator and pressure compensator or as a lubrication compensator. In
all other cases such as, energy accumulation, pulsation damping, emergency power source,
dynamic pressure compensator, shock absorber, hydraulic spring, etc., expansion and
compression process may be considered to take place under ‘adiabatic’ conditions. Generally,
adiabatic condition is considered to exist if the compression or expansion period is less than 3
minutes.

8. Explain the construction and operation of diaphragm type accumulator

In this type, the hydraulic fluid and nitrogen gas are separated by a synthetic rubber diaphragm.
The gas is filled through the gas port under predetermining pressure. The advantage of
diaphragm accumulator over piston accumulator is that they have no sliding surface that requires
lubrication and can therefore be used with fluids with poor lubricating qualities. They are less
sensitive to contamination due to the lack of any close fitting components
9. Discuss in detail the application of hydraulic accumulators as energy storage elements.
Draw a hydraulic circuit for this application.

1. Accumulator as an auxiliary power source

The purpose of accumulator in this application is to store the oil delivered by the pump during
a portion of the work cycle. The accumulator then releases the stored oil on demand to complete
the cycle, there by serving as a secondary power source.

Figure 8 Accumulator as an auxiliary power source

When the four way valve is manually activated oil flows from the accumulator to blank end of
cylinder. This extends the piston until it reaches the end of the stroke. When the cylinder is in its
fully extended position, the accumulator is being charged. The four way valve is then deactivated
for retraction of the cylinder oil flows from both pump and accumulator to retract the cylinder
rapidly.

10. Discuss in detail the application of hydraulic accumulator for protection against
shocks

Accumulator as a hydraulic shock absorber

 To system

Shut off
valve

Accumulator as a hydraulic shock absorber

One of the important applications of accumulator is the elimination of hydraulic shock.
Hydraulic shock is caused by the sudden stoppage or declaration of a hydraulic fluid flowing at
relatively high velocity in a pipe line. By rapidly closing a valve creates a compression wave.
This compression wave travels at the speed of sound upstream to the end of the pipe and back
again to the closed valve, which causes an increase in pressure.
The resulting rapid pressure pulsations or high pressure surges may cause damage to the
hydraulic system components. If an accumulation is installed near the rapidly closing valve, the
pressure pulsations or high pressure surges are suppressed.

11. Discuss in detail the application of hydraulic accumulator in protecting against

thermal expansion.
When closed loop hydraulic systems are subjected to heat conditions, both the pipe lines and the
hydraulic fluid expand volumetrically. Since the coefficient of cubical expansion of most fluid is
higher than that for pipe materials, this expanded liquid volume increases the entire system
pressure. This condition may cause pressures to exceed the limits of safety, and may damage the
system components. Under these conditions, an accumulator of proper capacity precharged to the
normal system working pressure is installed. It takes up any increase in the system fluid volume,
thus reducing the system pressure to its safe limits. The accumulator also feeds the required
volume into the system as thermal contraction takes place.
 Figure 12 Accumulator as a Thermal Expansion compensator
12. Discuss in detail the application of hydraulic accumulator for internal leakage
compensation and the application of constant pressure
Accumulator as a leakage compensator

Figure 9 Accumulator as a leakage compensator

Accumulator can be used as a compensator for internal and external leakage during an extended
period during which the system is pressurized but not in operation. The pump charges the
accumulator and the system until the maximum pressure setting on the pressure switch.
The contacts on the pressure switch then open to automatically stop the electric motor that
derives the pump. The accumulator then supplies leakage oil to the system during a long period.
Finally, when system pressure drops to the minimum pressure setting of the pressure switch, it
closes the electrical circuit of the motor until the system has been recharged. The check valve is
placed between the pump and accumulator so that the pump will not reverse when the motor is
stopped and will not permit all the accumulator charge to drain back into the power unit. With
this circuit the only time the power unit operates is when the pressure drops to a unsafe operating
level. This saves electric power and reduces the heat in the system.

13.What are the precautions you have to take in using Accumulator

 Always arrange some method to drain the accumulator at shut down.
 Never work on a circuit with an accumulator until it is depressurized.
 Make sure accumulator flow is restricted to a reasonable rate during operation and shut
down to avoid damage to the machine or piping. Accumulators will discharge fluid at any
rate the exit flow path will allow. Such high flow does not last long, but the damage it
causes is done quickly.
 Always isolate the pump from the accumulator with a check valve so fluid cannot back
flow into the pump. Without a check valve, accumulator back flow can drive the pump
backward -- and overspeed it to destruction in some instances.
 Check the accumulator’s pre-charge pressure at installation and at least once a day for the
first week of operation. If there is no noticeable loss of pressure during this time, do the
next check a week later. If all is well then, do a routine check every three to six months
thereafter. Whenever the accumulator pre-charge drops below nominal pressure, the
volume of available fluid is reduced and finally the cycle slows.

14. List the three method by which we can store enery using accumulator
Energy is stored in an accumulator by: Lifting a weight, compressing a spring, Compressing a
gas
 LECTURE 30 to 31– ACCESSORIES USED IN FLUID POWER SYSTEMS

FREQUENTLY ASKED QUESTIONS

1. Explain the two types of the leakages in hydraulic system. In what way do they affect the
performance of a fluid system?

Leakage in hydraulic system can be classified as

1. Internal Leakage
2. External leakage

Internal leakage increases the clearances between mating parts due to wear. If the entire system
leakage becomes large enough, the actuators will not operate properly.

External leakage represents a loss of fluid from the system. It is unsightly and represents a safety
hazard. Improper assembly of pipe fittings is the most common cause of external leakage.

2. What is a seal and what are their functions

Seals are used in hydraulic systems to prevent excessive internal and external leakage and to
keep out contamination. Functions are
 Prevent leakage – both internal and external
 Prevent the dust & other particles entering into the system
 Maintain pressure
 Enhance the service life & reliability of the hydraulic system.

3.How are hydraulic seals classified? What is meant by positive sealing and non
positivesealing?
Classification of hydraulic seals
1. Hydraulic seals can be classified according to the method of sealing as
a. Positive Sealing
b. Non-positive sealing
 2. Hydraulic seals can be classified according to the relative motion exist between the seals
and other pars as
a. Static seal
b. Dynamic seal
3. Hydraulic seals may be classified according to geometrical cross section as
a. O-Ring seal
b. V-Ring & U-ring seal
c. T-ring seal
d. Piston cup packings
e.Piston rings
f.Wiper rings

A positive seal prevents even a minute amount of oil from getting past. Positive seals do not
allow any leakage whatsoever (external or internal). A non-positive seal allows a small amount
of internal leakage, such as the clearance of the piston to provide a lubrication film.

4. Distinguish between static seal and dynamics seal

Static Seal: Static seals are used between mating parts that do not move relative to one another.
Typical examples are flange gaskets and seals, o-rings, etc. These are relatively simple. They are
essentially non-wearing and usually trouble free if assembled properly.
Dynamic Seals: There are assembled between mating parts that move relative to each other.
Hence dynamic seals are subject to wear because one of the mating parts rub against the seal.

5. How are seals classified based on geometrical cross section?

Hydraulic seals may be classified according to geometrical cross section as

a. O-Ring seal
b. V-Ring & U-ring seal
c. T-ring seal
d. Piston cup packings
e.Piston rings
 f.Wiper rings
6. Explain the different types of sealing materials commonly used
Natural rubber is rarely used as a seal material because it swells and deteriorates with time in the
presence of oil. In contrast, synthetic rubber materials are compatible with most oils. The most
common types of materials used for seals are leather, Buna-N, silicone, neoprene,
tetrafluoroethylene, viton and of course, metals.
 Leather. This material is rugged and inexpensive. However, it tends to squeal when dry
and cannot operate above 90 , which is inadequate for many hydraulic systems.
Leather does not operate well at cold temperatures to about -50 .
 Buna-N. This material is rugged and inexpensive and wears well. It has a rather wide
operating temperature range (-45 to 110 ) during which it maintains its good sealing
characteristics.
 Silicone. This elastomer has an extremely wide temperature range (-65 to
232 )Hence, it is widely used for rotating shaft seals and static seals where a wide
operating temperature is expected. Silicone is not used for reciprocating seal
applications because it has low tear resistance.
 Neoprene. This material has a temperature range of 50 to 120 F. It is unsuitable
above 120 because it has a tendency to vulcanize.
 Tetrafluoroethylene. This material is the most widely used plastic for seals of hydraulic
systems. It is a tough, chemically inert, waxy solid, which can be processed only by
compacting and sintering. It has excellent resistance to chemical breakdown up to
temperatures of 370 . It also has an extremely low coefficient of friction. One major
drawback is its tendency to flow under pressure, forming thin, feathery films. This
tendency to flow can be greatly reduced by the use of filler materials such as graphite,
metal wires, glass fibers and asbestos.
 Viton. This material contains about 65% fluorine. It has become almost a standard
material for elastomer-type seals for use at elevated temperatures up to 240 Its
minimum operating temperature is 28 .
7.What are the primary and secondary functions of a reservoirsystem
The function of a fluid reservoir in a power hydraulic system are the following
 To provide a chamber in which any change in volume of fluid in the hydraulic circuit can
be accommodated. When the cylinder extend there is an increased volume of fluid in the
circuit and consequently there is a decrease in the reservoir level.
 It provide a filling point for the system.
 The reservoir serves as a storage space for the hydraulic fluid used in the system.
 The reservoir also uses as the location where the fluid is conditioned.
 To provide a volume of fluid which is relatively stationery to allow entrained air to
separate out and heavy contaminants to settle. The reservoir is where sludge, water and
metal slips settle
 The reservoir is a place where the entrained air picked up by the oil is allowed to escape.
 The dissipation of heat is accomplished by a properly designed reservoir. It provides a
radiating and convective surface to allow the fluid to cool.

8. Explain the important elements of a reservoir system and explain the function of each
Elements of a reservoir are as follows
Filler Cap (Breather Cap)
It should be air tight when closed, but may contain the air vent which filters air entering the
reservoir to provide a gravity push for proper oil flow.
Oil Level Gauge
It shows the level of oil in the reservoir without having to open the reservoir
 Motor and
Filler Return pump
with flow
filter

Filling level
Indicator Intake
(Max) pipe

Servicing
aperture

Filling level
Indicator
(Min) OIL RETURN SUCTION
CHAMBER CHAMBER
Drain
screw

Baffle
plate

Hydraulic Reservoir

Baffle Plate
It is located lengthwise through the centre of the tank and is 2/3 the height of the oil leve. It is
used to separate the outlet to pump from the return line. This ensures a circuitous flow instead of
the same fluid being recirculated. The baffle prevents local turbulence in the tank, allows foreign
material to settle, get rid of entrapped air and increase heat dissipation.

Suction and Return Lines

They are designed to enter the reservoir at points where air turbulence are least. They can enter
the reservoir at the top or at the sides, but their ends should be near the bottom of the tank. If the
return line is above the oil level, the returning oil can foam and draw in air.

Intake Filter
It is usually a screen that is attached to the suction pipe to filter the hydraulic oil.

Drain Plug
It allows all oil to be drained from the reservoir. Some drain plugs are magnetic to help remove
metal chips from the oil.
Strainers and Filters
Strainers and filters are designed to remove foreign particles from the hydraulic fluid. Strainers
and filters are discussed later in detail.

9. What is a filter and How are filters classified?

Filter is a device whose primary function is the retention, by some fine porous medium, of
insoluble contaminants from the fluid. Fluid flow has to follow a winding path and through the
element.Filters are used to pick up smaller contaminant particles because they are able to
accumulate them better than a strainer.
Types of Filters
A). Filters may be classified according to the filtering methods as
i. Mechanical Filters
ii. Absorption Filters
iii. Adsorbent Filters

i) Mechanical filters: This type normally contains a metal or cloth screen or a series of metal
disks separated by thin spacers. Mechanical filters are capable of removing only relatively coarse
particles from the fluid.
ii) Absorption filters: These filters are porous & permeable materials such as paper, wood pulp,
diatomaceous earth, cloth, cellulose and asbestos. Paper filters are impregnated with a resin to
provide added strength. In this type of filter, the particles are actually absorbed as the fluid
permeates the material. Hence these filters are used for extremely small particle filtration.
iii) Adsorbent filters: Adsorption is a surface phenomenon and refers to the tendency of
particles to cling to the surface of the filters. Thus the capacity of such a filter depends on the
amount of surface area available. Adsorbent materials used include activated clay and chemically
treated paper.
B).Filters may be classified according to the size of pores in the material as
i. Surface filters
ii. In depth filters

i) Surface filters: These are nothing but simple screens used to clean oil passing through their
pores. The screen thickness is very thin and dirty unwanted particles are collected at the top
surface of the screen when the oil passes. e.g. Strainer
ii) Depth filters: These contain thick walled filter medium through which the oil is made to flow
& the undesirable foreign particles are retained. Much finer particles are arrested and the
capacity is much higher than surface filters.
C).Filters are classified according to the location of filters as
i. Intake or inline filter
ii. Pressure line filter
iii. Return line filter

10. What are surface and depth filters

i) Surface filters: These are nothing but simple screens used to clean oil passing through their
pores. The screen thickness is very thin and dirty unwanted particles are collected at the top
surface of the screen when the oil passes. e.g. Strainer
ii) Depth filters: These contain thick walled filter medium through which the oil is made to flow
& the undesirable foreign particles are retained. Much finer particles are arrested and the
capacity is much higher than surface filters.

11. What are the important locations of filters? Explain the advantages and disadvantages
of each locationC).Filters are classified according to the location of filters as
i. Intake or inline filter
ii. Pressure line filter
iii. Return line filter

i) Inline filter (suction strainer): These are provided first before the pump to protect the pump
against contaminations in the oil. These filters are designed to give a low pressure drop.
Otherwise the pump will not be able to draw the fluid from the tank. To achieve low pressure
drop across the filters, a coarse mesh is used. These filters cannot filter out small particles.

Figure 20.8 Suction filter

Advantages
1.A suction filter protects the pump from dirt in the reservoir. Since the suction filter is outside
the reservoir, an indicator telling when the filter element is dirty can be used.
2. The filter element can be serviced without dismantling the suction line or reservoir. (Easy to
maintain)

Disadvantages
A suction filter may starve the pump if not sized properly

ii) Pressure line filters (High pressure filter): These are placed immediately after the pump to
protect valves and actuators and can be finer & smaller mesh. They should be able to withstand
the full system pressure. Most filters are pressure line filters.

Figure 20.9 Pressure filter

Advantages
1.A pressure filter can filter very fine contaminant since the system pressure is available to push
the fluid through the element
2. A pressure filter can protect a specific component from the harm of deteriorating particles
generated from an upstream component

Disadvantages
1.The housing of a pressure filter must be designed for high pressure because it is operating at
full system pressure. This makes the filter expensive.
2. If pressure differential and fluid velocity are high enough, dirt can be pushed through the
element or the element may tear or collapse.

Return line filters (Low pressure filters): These filters filter the oil returning from the pressure
relief valve or form the system i.e. actuator to tank. It is generally placed just before the tank.
They may have a relatively high pressure drop & hence can be fine mesh. These filters have to
withstand low pressure only and also protect the tank & pump from contamination.

Figure 20.10 Return line filter

Advantages
1.A return line filter catches the dirt in the system before it enters the reservoir
2.The filter housing does not operate under full system pressure and is therefore less expensive
than a pressure filter

Disadvantages
1. There is no direct protection for circuit components.
2. In return line full flow filters, flow surges from discharging cylinders, actuators and
accumulators must be considered when sizing.

12. Why the temperature of the working fluid should be properly maintained
Heat is generated in hydraulic systems because no component can operate at 100% efficiency.
Significant sources of heat include the pump, pressure relief valves and flow control valves. Heat
can cause the hydraulic fluid temperature to exceed its normal operating range of 35 to 70 .
Excessive temperature hastens oxidation of the hydraulic oil and causes it to become too thin.
This promotes deterioration of seals and packing and accelerates wear between closely fitting
parts of hydraulic components of valves, pumps and actuators.
 LECTURE 32– MAINTENANCE OF FLUID POWER SYSTEMS

FREQUENTLY ASKED QUESTIONS

1. What is the difference between nominal and absolute ratings of filters

Nominal rating Absolute rating

The nominal rating is the micron valve The absolute rating represents the size of
specified for which 95% of entering the largest opening or pore in the filter
particles of size greater than the nominal and thus indicates the largest size particle
rating will be trapped that could pass through the filter.

2. Name five reasons for the overheating of the fluid in hydraulic system
1) Heat exchanger faulty or turned off
2) Underutilized component of piping
3) Incorrect fluid
4) Continuous operation of relief valve
5) Overloaded system
6) Reservoir size is small ( heat transfer area is less)

3. Name four causes of low or erratic pressure

1) Air in the hydraulic fluid
2) Pressure relief valve set too low
3) Pressure relief valve not properly seated
4) Leak in hydraulic line.

4. What three devices are commonly used in the troubleshooting of hydraulic circuits

o Flow meters
o Pressure gauges
o Temperature gauges

5. What is the significance of the neutralization number

The neutralization number is a measure of the relative acidity or alkalinity of hydraulic fluid and
is specified by PH factor.
6. Name four of the most common causes of hydraulic system breakdown
1) Clogged or dirty oil filters
2) Leaking seals
3) Loose inlet lines which cause the pump to take in air
4) Inadequate supply of oil in the reservoir

7. Explain how cavitaion causes damage to the hydraulic pumps

As the vapour bubbles are exposed to the high pressure at the outlet port of a pump, the bubbles
are collapsed therby creating extremely high local fluid velocities. Thus high velocity fluid
impacts on internal metal surfaces of the pump. The resulting high impact forces, cause flaking
or pitting of the surfaces of the internal components such as gear teeth, vanes , pistons. This
results in premature pump failure.

8. Name four locations where filters can be typically installed in hydraulic systems

o Proportional flow filer in separate drain line

o Full flow filter in suction line
o Full flow filter in pressure line
o Full flow filter in return line

9. List eight recommendations that should be followed for properly maintaining and
disposing of hydraulic fluid

1) Select the optimum fluid for the application involved

2) Utilize a well designed filtration system to reduce contamination and increase the useful
life of fluid
3) Follow proper storage procedure of the unused fluid supply
4) Transporting of fluids from the storage containers to hydraulics systems , should be done
carefully since the chances for contamination increase greatly with handling
5) Operating fluids should be checked regularly for viscosity, acidity, bulk modulus,
specific gravity, water content, color, additive levels, concentration of metals and particle
contamination.
6) The entire hydraulic system including pumps, piping, fittings, valves, solenoids, filters,
actuators and reservoir should be maintained according to manufacturer’s specifications.
7) Corrective action should be taken to reduce or eliminate leakage from operating hydraulic
system
8) Disposal of fluids must be done properly.

10. Name three disadvantages of fire resistant fluids.

1. Special paints must be used
2. Incompatibility with most natural or synthetic rubber seals
3. High costs
 LECTURE 33

INTRODUCTION TO PNEUMATICS

FREQUENTLY ASKED QUESTIONS

1. Define Pneumatics

Answer: Pneumatics may be defined as branch of engineering science which deals with the
study of the behavior and application of compressed air. Pneumatics can also be defined as the
branch of fluid power technology that deals with generation, transmission and control of power
using pressurized air

2. List four common ways of transmitting power in Industry

Answer: Four common ways of transmitting power are
1. Mechanical power transmission
2. Electrical power transmission
3. Hydraulic power transmission
4. Pneumatic power transmission

3. Name three reasons for considering the use of pneumatics instead of hydraulics
Answer
1. Liquid exhibit greater inertia than do gases. Therefore, in hydraulic systems the weight of oil
is a potential problem when accelerating and decelerating actuators and when suddenly opening
and closing valves
2. Liquid also exhibit greater viscosity than do gases. This results in larger frictional pressure and
power losses
3. Hydraulic systems use a fluid foreign to atmosphere, they require special reservoirs and no-
leak system designs. Pneumatics use air that is exhausted directly back to surrounding
environment. Generally speaking, pneumatic systems are less expensive than hydraulic systems.

4. What is the difference between free air and standard air?

Answer: Free air: Air at the atmospheric condition at the point where the compressor is located
is defined as free air. Standard air: It is defined as the air at sea level conditions that is at
pressure of 1.01324 bar, temperature of 20 and Relative humidity of 36%

5. Pneumatic systems cannot provide precise position control – Justify

Answer: Due to high compressibility of air, pneumatics cannot provide precise actuator control
and precise positioning control
 LECTURE 34

PRODUCTION OF COMPRESSED AIR

FREQUENTLY ASKED QUESTIONS

1. List four stages of compressed air preparation

Answer:
a) Air intake stage
b) Compressor stage
c) Conditioning stage
d) Compressed air distribution stage

2. Classify the compressor based on operating principle.

Answer
Depending on operating principle compressors can be classified as

Compressor types

Positive displacement Dynamic

Reciprocating Rotary Axial

Single acting Blower

Centrifugal

Double acting Screw

3. Name three types of reciprocating air compressors that are commonly used in industry
Answer:
a) Reciprocating Piston air compressor
b) Rotary Screw type
c) Rotary Sliding vane type
4. Define compressor ratio for a compressor
Answer

5. Name two types of dynamics air compressors that are commonly used in industry

Answer:
a) Axial dynamic compressor
b) Radial dynamic compressor

6. What does staging mean?

Answer
Staging means dividing the total pressure increase among two ore more cylinders by feeding the
exhaust from one cylinder into the inlet of the next cylinder. This improves the overall efficiency
of compression in compressor.

7. What is multistage compression?

Answer:
Compressors having more than one cylinder are called multistage compressors. Staging means
dividing the total pressure increase among two ore more cylinders by feeding the exhaust from
one cylinder into the inlet of the next cylinder. This improves the overall efficiency of
compression in compressor.

8. What are the advantages of multi stage compression

Answer:
Effective cooling can be implemented between stages
Reduces the power requirement
Increases the overall efficiency of the compressor
 LECTURE 35

COOLING AND DRYING OF COMPRESSED AIR

FREQUENTLY ASKED QUESTIONS

1. List four qualities required for a compressed air

Answer:
a) Compressed air must be clean
b) Compressor air must be dry
c) Conditioning air must be at low temperature
d) Compressed air must be free from dust and other contaminations

2. List three function of after cooler.

Answer
i) After coolers control the amount of water vapour in a compressed air system by condensing the water
vapour into liquid form. Pr
ii) protect downstream equipment from excessive heat
iii) Reduce the risk of fire.

3. Why after cooler is required in compressed air systems.

Answer
The compressed air discharged from an air compressor is hot . Compressed air at these
temperatures contains large quantities of water in vapor form. As the compressed air cools this
water vapor condenses into a liquid form. Moisture affect the performance of the pneumatic
systems. Therefore after coolers are required.

4. What is the difference between an after cooler and a chiller air dryer
Answer:
An after cooler is installed in the airline immediately downstream of the compressor.
Compressor do not remove the moisture. Thus, an after cooler is essential to reduce the air
temperature to convenient levels and to act as a first stage in removal of moisture prior to
entering an air dryer. After cooler remove only about 80% of the moisture from the air leaving
the compressor. An air dryer removes all moisture by lowering the temperature of the
pressurized air to a dew point of 10

5. What is meant by the term dew point?

Answer:
The dew point is the temperature at which air is saturated and thus the relative humidity is 100%
 LECTURE 36

CONDITIONING AND DISTRIBUTION OF COMPRESSED AIR

FREQUENTLY ASKED QUESTIONS

1. List three main elements of an FRL unit used in pneumatics

Answer:
a) Air filter
b) Air lubricator
c) Air regulator

2. List three function of air filter

Answer
a) To prevent entrance of solid contaminants to the system
b) To condensate and remove the water vapour that is present in the air passing through it
c) To arrest any submicron particles that may pose a problem in system components

3. Draw characteristic curves of pressure drop versus flow for air filter.
Answer

4. List three source of contamination

Answer:

a) The quality of air being drawn into the compressor

b) The type and operation of the air compressor:
c) Compressed air storage devices and distribution systems:

Additionally, piping and air receivers will also cool the moist compressed air forming condensate
which causes damage and corrosion.

5. Draw the simplified symbol of FRL unit.

Answer:
 LECTURE 37

PNEUMATIC ACTUATORS

FREQUENTLY ASKED QUESTIONS

1. What is the function of a pneumatic actuator?

Answer:
Function of pneumatic actuator is to convert the pressure energy of compressed air energy into
mechanical energy to perform useful work.

2. How do you classify pneumatic actuators?

Answer
We can classify the linear actuator as linear actuators, rotary actuators

3. What is the function of a pneumatic cylinder?

Answer
A cylinder converts air pressure into a straight line or linear motion.

4. Define Air cylinder

Answer
An air cylinder is an operative device in which the static input energy of compressed air that is
pneumatic power is converted into mechanical output power by reducing the pressure of air to
that of the atmosphere.

5. Why air cylinders cannot be used for precise speed control

Answer
Due to compressibility of air, the air cylinder tends to slow down if the load is increased and
accelerate when the load is decreased.

6. What are four uses for pneumatic cylinders?

Answer
Truck air brakes, parts positioning. Automobile lifts and robotic arm motions.

7. Put a check ( X) by each item which is part of a cylinder

X Piston X Bore
X Rod end port X Cylinder rod
X Seals Cylinder block
X Cylinder barrel Flow control valve
X Blind end port Regulator
 LECTURE 38

PNEUMATIC VALVE

FREQUENTLY ASKED QUESTIONS

1. What is the function of a pneumatic valve?

Answer:
Function of pneumatic valve is to control the pressure, flow rate and direction of air flow in
pneumatic circuits.

2. How do you classify pneumatic valves?

Answer
We can classify the pneumatic valves as
- Direction control valves
- Non – return valves
- Flow control valves
- Pressure control valves

3. What is the function of a Direction control valve?

Answer
Directional control valves start, stop or change the direction of flow in compressed air
applications.

4. Mention the application of a 2 way, 3 way and 4 way DCV

Answer
2 way valves are used for ON-OFF conditions. Three way DCV are used to control single acting
cylinders. Four way DCV are used to control double acting cylinders

5. What are functions of a check valve

Answer
The check valves are used to allow free flow of compressed air in only one direction and it
prevents the flow of compressed air in the opposite direction. Since check valves blocks the
reverse flow, they are also known as Non-return valves

6. How do you classify the DCV based on construction?

Answer
Based on construction we can classify DCV as
1) Poppet direction control valves
2) Sliding spool valves
3) Rotary spool valves
7. What are shuttle valves?
Answer
Shuttle valves, also known as double check valves, are used when control is required from more
than one power source. It can be used as OR gate fluid logic control valve.

8. What is a quick exhaust valve?. Mention its application.

Answer

A quick exhaust valve is a typical shuttle valve. The function of quick exhaust valve is to exhaust
the cylinder air to atmosphere quickly. It is used with spring return single acting cylinder to
increase the piston speed of the cylinders.

9. Mention two functions of pressure control valve

Answer:
Limit the maximum system pressure
Regulate the force or torque an actuator generates

10. Mention five control elements used in valves

Answer:
Five control elements used in valves are Poppet (ball or disc), Spool, Piston, Diaphragm and
sliding plates.
 LECTURE 39

SINGLE ACTUATOR CIRCUITS

FREQUENTLY ASKED QUESTIONS

1. List three functions of pneumatic circuits

Answer

 To control the entry and exit of compressed air in the cylinders.

 To use one valve to control another valve
 To control actuators or any other pneumatic devices

2. Where are three way valves used?

Answer:
The 3/2 way valves can be used to control single acting cylinders and other valves.

3. What are the advantages if internal pilot valve in pneumatic valve

Answer:
The major advantage of the pilot operated valve is that the actuating force is less compared to
direct operated.

4. Briefly describe working of disc poppet valve with internal pilot. Give also ISO symbol
Answer:

Actuated Unactuated Symbol

Figure 1

5. Draw as per ISO 1219 the pneumatic symbol for 3/2 roller operated normally closed direction
control valve.
Answer

Figure 2

6 Is there any functional difference between 4/2 and 5/2 way valve
Answer
There is no functional difference between 4/2 and 5/2 way valve.

7. Define the term “maintained signal “ as used in pneumatic control

Answer

8. Why pneumatic cylinders are not used in application where uniform speeds must be achieved
Answer
Due to compressibility of air when the load varies, air expands or compresses. Therefore it is
impossible to achieve a constant piston rod velocity within reasonable limits with an ordinary
flow control valve. Therefore pneumatic cylinders cannot give uniform speed.

9. List three factors that govern the speed of double acting cylinder
Answer
The maximum natural speed of a double acting cylinder is governed by three factors
 Cylinder -port size, load carrying capacity, mounting, cushioning
 Valves – Nominal flow rate and switching time
 Air supply- pressure, diameter and length of the tube , fittings

10. Exhaust air throttling is used for speed control of the double acting cylinder
Answer
This is also called meter out circuits. Throttle valves are installed such that exhaust air leaving is
throttled in both direction of the motion of the cylinder. There are double cushioning effects
with exhaust throttling. First cushion effect is due to supply air entering the cylinder and second
cushioning effect is due to air leaving the cylinder. Therefore, exhaust air throttling used
practically.
 LECTURE 40

MULTI ACTUATOR CIRCUITS

FREQUENTLY ASKED QUESTIONS

1. What is signal lap?

Answer

Signal Overlap can occur when simultaneously two active signals appear on both set and reset
pilot ports of Final Control Valve. This is due to the required sequencing of cylinder. At the start,
both signals ao and bo appear at the same time. This will not result in any change

4 2
14 12

5 3
1

2 2
B0 AO

1 3 1 3

2. List four ways to overcome signal overlap or signal conflict

Answer:
To overcome this problem signal elimination techniques are used as listed below:

• Use of Idle return lever limit switches

• Use of N.O Timers
• Use of Cascading with the help of reversing valves
• Use of Stepper Sequencer modules

3. What are reversing valves?

Answer:
Reversing Valves [Double piloted 5/2 way or 4/2 way] .These are signal processing valves which
are used to change over from one signal to next signal. Depending on the presence of set or reset
signal at the reversing valves, output change over takes place from port 4 to port 2 of the valve.
There is no need to examine exact step where signal over lap occur in the circuit
4. List the conditions for cascading
Answer:

Conditions for Cascading are

• Number of signal inputs [from limit switches] must be equal to number of output signals
[pilot signals to final control valves]
• Each input signal is assigned to a particular output signal
• It should be possible to store an output signal even when the corresponding input signal is
no longer present
• Only one output signal may exist at any one point or it must be possible to eliminate any
specific output signal
• The input signal should be effective in the same required sequence
• No. of reversing valves required are (n-1), where n is total number signals from limit
switches or signal groups

5. Draw the figure to show the group changing valves for 5 groups showing clearly input, output
and reset signal.
Answer

Ist Out of Cascade to I Signal Line S1 II Out put of Cascade to Signal line S2

4 2
14 12
Reset Signal from Signal line S5 II Input from Limit Swtich e2
5 3
1

4 2 Out put from II Cascade to Signal line S3

14 12
Reset signal from Signal line S3 III rd Input from limit swtich e3
5 3
1

4 2 IV Out put of Cascade to Signal line S4

14 12
Resest Signal from Signal line S2 IV Input from Limit Switch e4
5 3
1

4 2 V Out put from cascade to Signal line S5

14 12
I Input from Last signal + Start Switch Last Input Signal from Limit Switch e5
5 3
1

Figure 2
 LECTURE 41

ELECTRO PNEUMATIC CIRCUITS

FREQUENTLY ASKED QUESTIONS

1. List seven basic elements used in Electro pneumatic circuits

Answer

Seven basic electrical devices commonly used in the control of fluid power systems are

1. Manually actuated push button switches

2. Limit switches
3. Pressure switches
4. Solenoids
5. Relays
6. Timers
7. Temperature switches

2. Draw the symbols for NO, NC and Change over push buttons
Answer:

3 2 4

4
1

Normally ope Normally closed Change over type

3. List the advantages of electrical actuation of pneumatic valves over pure pneumatic
control

Answer:
1. Signal transmission over long distance is very fast
2. Signalling components are inexpensive
3. Air consumption is less compared to pure pneumatics ( compressed air is expensive)
4. Flexible and easy to modify and change the circuit
 5. Laying of electrical wires is much easier than tube and tube bending affects the
performance.
6. Interfacing of electrical device with PLC and other sensors is much easier
7. It is cost effective and easy to maintain and trouble shoot.

4. List the possible voltages used for electrical components in electro pneumatics

Answer
The possible voltages used for electrical components used in electro pneumatics circuits are
12 VDC, 24VDC, 24 V with 50 or 60 Hertz, 48 V, with 50 or 60 Hertz, 110V/120 V with 50 or
60 Hertz, 220V/230V with 50 or 60 Hertz

5. What is a relay?
Answer

A relay can be considered as an electro magnetically operated switch that operates under the
control of an additional electrical circuit. It is a simple electrical device used for signal
processing. This switch is designed to withstand heavy power surges and harsh environment
conditions.

6. What is a reed switch. Explain briefly its function

Answer

A reed switch is magnetically operated proximity switch. Reed switch consist of two metallic
contacts hermetically sealed in glass tube and encapsulated in epoxy resin to prevent moisture
and mechanical damage. These types of switches are used on pneumatic cylinders. When piston
( which also contains magnet) moves near to the reed contact, contact closes. When piston moves
away from the reed contacts, contact opens.

15. Compare Inductive, capacitive and optical diffuse sensor

Answer
Parameter Inductive Capacitive Optical
Operating voltage 30 V DC 30 VDC or 250 VAC 30 VDC or 250 VAC
Objects which can be Metal Any object can be Any opaque body
sensed sensed
Maximum Switching 10mm 20 mm 2m
distance
Service life Very long Very long long
Operating temperature -25 to 70 -25 to 70 -25 to 70

Symbol
 LECTURE 42

DESIGN OF PNEUMATIC CIRCUITS USING PLC

FREQUENTLY ASKED QUESTIONS

1. Define PLC as per IEC

Answer

As per IEC , PLC is defined as a digitally operating electronic system, designed for use in an
industrial environment, which uses a programmable memory for the internal storage of user-
oriented instructions for implementing specific functions such as logic , sequencing , timing ,
counting and arithmetic, to control through digital or analog inputs and outputs, various types of
machines or processes. Both the PC and its associated peripherals are designed so that they can
easily integrated into an industrial control system and easily used in all their intended function

2. List two disadvantages of hard wired control system

Answer:

1. The wiring of control element such as sensors, solenoids etc through relay defines
hard wired control system. They are cumbersome and difficult to modify when the
production requirement changes frequently.
2. They are complex and difficult to maintain and trouble shoot. Any small bug in the
design could be a major problem to correct and time consuming

3. List the essential elements which defines Structure of PLC

Answer:
PLC is basically a micro computer consisting of both hardware and software. The hardware part
consists of PCBs, ICs, Memory locations, Wires and power supply etc. The software is used to
operate the PLC. There are two types of software programs used in PLC. One is firmware and
other is user program. Firmware is supplied by the vendor and it is permanently installed. User
program is the program written by the end user.

4. List PLC system components.

Answer:
PLC system components consist of
1. Power supply module,
 2. Central processing unit(CPU),
3. Memory,
4. Input module,
5. Output module,
6. Software. – Firmware and user program

5. Draw the block diagram showing PLC system components

Answer

INTERFACE (PC OR PG )

OUTPUT DEVICE S -VALVES, LAMPS, CONTACTOR

INPUT DEVICE S PUSH BUTTON, LIMIT SWITCH

POWER
SUPPLY

MODULE
PROGRAM MEMORY
MODULE

OUTPUT
INPUT

CENTRAL PROCESSING UNIT

6. List the possible voltages used for power supply of a PLC

Answer
The power source is used for control systems and external signaling devices. The power supply
is required to convert line voltage of 120 or 240 VAC to standard 24 VDC. 24 VDC is used for
input – output modules. 5VDC is required for logic processor. Power supply can be integral or it
is available as separate module.

7. What is the function of analog input module?

Answer

The analog input module converts analog signal from analog device such as sensors, temperature
probes, pressure indicators etc to equivalent digital values using ATD converter.
8 What is the function of digital input module?
Answer

The digital input section converts signal of 240 VAC, 120 VAC, 24 VDC from digital input
devices to 5V digital signals and send it to central processing unit for further processing.

9. Differentiate among load memory, work memory and system memory

Answer

Load memory Work memory System memory

This is used to store the user This memory consists of some These are 16 bit registers.
program. This can be relevant portion of user They consists of process
incorporated as Volatile RAM programs required for running image input, process image
or Flash EPROM, Programs in a program. Work memory is output, bit memory (M),timer
EPROM enable PLC to start part of CPU. (T) , counter (C) etc. Bit
up when power is On. Using memory stores the
this program PLC can intermediate results, which
interpret the instructions can be accessed throughout
received by the user through the program for control.
key board or user section of
memory.

10. What is program scan cycle

Answer

CPC scans and executes the main program cyclically. A program scan cycle consist of a
sequential operations that include input scan , program scan and output scan. In the input scan,
the CPU updates the process image input table and in output scan , CPU updates the process
image output table. During the program scan, the CPU executes the program. After the
completion of each scan cycle, the CPU returns to the beginning of the next cycle and again
repeats the cycle. The time taken to scan one program cycle is called scan cycle time.
 LECTURE 2-PROPERTIES OF FLUID

SELF EVALUATION QUESTIONS AND ANSWERS

1.A tank trunk contains 125000 liters of hydraulic fluid having a specific gravity of 0.9.
Determine the fluid’s specific weight, density and weight.

2. At a depth of 8 km in the ocean the pressure is 81.8 MPa. Assuming that the specific
weight of seawater at the surface is 10.05 and that the average volume modulus is
2.34 109 for that pressure range.(a) What will be the change in specific volume
between that the surface and at that depth? (b) What will be the specific volume at that
depth? (c) What will be the specific weight at that depth?

3 A vessel contains 85L of water at 10 and atmospheric pressure. If water is heated to

70 , what will be the percentage change in its volume? What weight of water must be
removed to maintain the volume at its original value?

Take
QUESTION 1 - Solution

=1103.6 kN

QUESTION 2- Solution

Sea water

2
Q2
QUESTION3- Solution

10 70

Q3

Volume,

9.804(0.085) 9.589

0.08691 m3

Must remove (at 70):

( ) =
 LECTURE 4 – GOVERNING LAWS AND PRINCIPLES

SELF EVALUATION QUESTIONS AND ANSWERS

1 : In the hydraulic press shown in figure 1, a force of 100N is exerted on the small piston.
Determine the upward force on the large piston. The area of the small piston is 50 x 102
mm2. Also find the distance moved by the large piston if the small piston moves by 100 mm.

Figure 1 for the Problem No 1

2: Fluid is flowing horizontally at 0.006309 from a 50.8mm diameter pipe to a 25.4mm

diameter pipe, as shown below (Figure 2). If the pressure at a point 1 is 68950 Pa, find the
pressure at the point 2. The specific gravity of the oil is 0.9
 V1

V2

Fluid in
D1 D2
Fluid out

1 2

Figure 2

3 Determine the Torque delivered by a hydraulic motor if the speed is 1450 rpm and the
mechanical output power is 10 kW.

4 A turbine in a hydroelectric plant has flow of 22.65 m3/s at a pressure at inlet of 413.7 KPa.
If the turbine discharges the water to the atmosphere, determine the work output of the
turbine. Assume that the inlet and the outlet pipes have the same diameter and that losses in
turbine equal 1.524 m.

1
P2 =413.7 kPa

D1

P2 =0

2
Z1 ~Z2

Hydraulic
D2 Turbine
 Figure 3 for the Problem No4

5 A pump is required to pump water from a large reservoir to a point located 20m above the
reservoir. (Figure 4) If 0.05 m3/s of water having a density of 1000 kg/ m3 is pumped through
a 50-m pipe, how much power is required to be delivered to the water by the pump? Neglect
all the flow losses in the pipe.

2
P2 =Pa Z2

20 m

Z1 =0

Pump

P1 =Pa
1

Figure 4 for the Problem No5

6 Water at is flowing at the rate of 115 LPM through the fluid motor shown in Fig 5. The
pressure at A is 700 kPa and the pressure at B is 125 kPa. It is estimated that due to friction in
the piping there is an energy loss of 4.0N.m/N of water flowing (a) calculate the power
delivered to the fluid motor by the water.(b) if the mechanical efficiency of the fluid motor is
85%, calculate the power output.
 A (P1 =1000 kPa)

Flow Direction

Pipe 25mm
diameter
1.8 m

Fluid Motor
Pipe 75 mm
B diameter

Figure 5 for the Problem No 6

7. Water flows through the double nozzle as shown in Fig. 6. determine the magnitude and
direction of the resultant force the water exerts on the nozzle. The velocity of both the nozzle
jets is 12 m/s. the axes of the pipe and both nozzles lie in a horizontal plane.

. Neglect friction.
 100 mm dia jet
150 mm dia jet

75 mm dia jet

Figure 6 for the Problem No 7

8 Fluid flows from a large reservoir at the rate of 0.366 m3/s through a pipe system as shown
in Figure 7 below. Calculate the total amount of energy lost from the system because of the
valve, the elbows, the pipe entrance, and fluid section.

3.66
m

3.96 m
7.62 cm
Flow Direction
2

Figure 7 for the Problem No 8

9 For the fluid system shown in Figure 8 below ,point (1) is at a height of 10m above point (2).
If the diameter of the outlet at ( 2) is 50 mm, determine :

The jet velocity (m/s) and flow rate (in LPM ) for an ideal fluid.

The jet velocity (m/s) and flow rate (in LPM ) for a head loss of 2m.

10m
2

Figure 8 for the Problem No 9

Example 10 For the pump test arrangement shown in Figure 9. below, determine the
mechanical efficiency of the pump if the input power is measured to be 2.2371kW when
pumping 1.892 m3/min of oil (
 Flow
150 mm dia pipe 100 mm dia pipe
Oil

PUMP

52 cm

Mercury ( SG =13.54)

Figure 9 for the Problem No 10

11 The inlet pipe to a pump is 20 mm in diameter and 2.5 m long. If the tank, at atmospheric
pressure, is positioned 1 m above the pump inlet and the pump flow rate is 90 L/min when
losses are taken into account, calculate the pump inlet pressure. Assume a high-water-
content fluid having , . At what temperature would the
pump cavitate?

Pa

20 mm dia pipe
2.5 m long
H=1 m

PUMP – 90 LPM

Figure 10 for the Problem No 11

Q1-Solution:

Figure E4.2 for the Problem No 2

F1= 100N
A1= 50 102 mm2
A2= 500 102 mm2
d1= 100 mm
d2= ?
F2=?

Force on the large piston, F2.

By Pascal’s law, we have

Distance moved by the large piston, d2

We also know that by conversation of energy,
Q2-Solution:

Applying Bernoulli’s theorem

(
Q3-Solution:

Where,

P= Power (kW)

N= Speed (rpm)

T= Torque (Nm)

Q4-Solution:

Given : , , , ,

Find:

Assumptions: Steady incompressible flow, no losses

Basic Equations: Continuity:

Energy :

Solution:

Write the energy equation

As before , but , therefore

Substituting and solving we get

Notice that the losses subtract from the ideally possible output of the turbine.

Q5-Solution:

Given: Pump, , , , , , ,
,

⁄ , .

Find: Required pump horsepower

Assumptions: Steady incompressible flow, no losses

Basic Equations: Continuity:

Energy :

Power (P)

Solution:

Let us first write the energy equation between sections 1 and 2

since there are no losses in the pipe.

As , = , is given by

Since , we have

( ⁄

Using this value of V gives us

We can now obtain the horsepower required as follows:

Q6-Solution:
Writing the energy equation.

Choosing points A and B as our reference points, we get

Compare this equation with your results:

 (

The correct results are:

( (

Solving for

( )

( )

(( ( ( (

(given)

Substituting the known values we get

Where
This is the power delivered to the fluid motor by the water. How much useful power can be
expected to be put out by the motor?Because the efficiency of the motor is 85%, we get 0.92
kW of power out.

We get

( (

Q7-Solution:

( (

(
( (

Jets 2 and 3 are free, i.e., in the atmosphere, so .

 =0

Fx

+y

Fy
+x

Writing the energy equation along a streamline:

(
( (

Eq. (6.7 a):∑ (

(
 ( ( ( ( ( (

Eq.(6.7b):

∑ ( )

So ( ( ( ( ( (

The minus sign indicates that the direction we assumed for was wrong. Therefore it acts in
negative y direction. is equal and opposite to .

( ) (

( ) (

( )
Q8-Solution:
Using an approach similar to that used with Bernoulli’s equation, select two sections of interest
and write the general equation before looking at the next panel.

The sections at which we know the most information about the system are selected.
The complete general equation is:

The value of some of these terms is zero. Determine which are zero and simplify the energy
equation accordingly.

The value of the following terms is zero

Surface of reservoir exposed to atmosphere

Free stream of fluid exposed to the atmosphere

(Approximately) surface area of reservoir is large

No mechanical device in the system (i.e., head addition or removal is zero)

Then, the general energy equation becomes

Since we are looking for the total energy lost from the system, solve this equation for , which
gives

Now evaluate the terms on the right side of the equation to determine in the units of m.

The answer is . Here is how it is done:

Since Q was given as 0.034 m3/s and the area of a 0.0762m diameter jet is 0.00456m2, we have
 (
( (

Then the total amount of energy lost from the system is

Q9-Solution:
h1=10 m
D2= 50mm =50×10-3
v2 and Q2? At HL=0
v2 and Q2? At HL=2m
Let us apply the energy equation to the system, i.e.,

Where Z1= h
P1=P2= atmospheric pressure =0, Pa (g)
v1=0, as the tank is quite large, hence negligible velocity.
Hp= 0(no pump)
Hm=0 (no motor)
Z2= base reference=0
By substituting these values in equation (1), we get,

or
(

Or
( ((
a. When HL=0 (ideal fluid)
√ (

The flow rate is given by,

( ( )
 b. When HL= 2m
Velocity,
( (

Flow rate,
(

Q10-Solution:
Using the points identified as 1 and 2 in above figure, we have

Because we must find the power delivered by the pump to the fluid, we should now solve for

This equation is used:

( (

It is convenient to solve for each term individually and then combine the results. The
manometer enables us to calculate ( because it measures the pressure difference.
Write the manometer equation between points 1 and 2.

Starting at point1, we have

( (
Where y is the unknown distance from point 1 to the top of the mercury column in the left leg
of the manometer. The terms involving y cancel out. Also in this equation containing is the
specific weight of the oil and is the specific weight of the mercury gage fluid.

( ( ( ( ) (

( (

( (

(
( )(

(
( )( ( (
(

( ( ( ) (

The next term in the Equation is . What is its value?

It is zero because both the points are on the same elevation. These terms could have been
cancelled from the original equation. Now find (

Now you should have

(
(

( )
Using ( and from appendix F, we get

( )
(

Now place these results into energy equation and solve for

Solving for , we get

We can now calculate the power delivered to the oil,

The result

( )( )

(
(
( ( )
(

The final step is to calculate , the mechanical efficiency of the pump.

Expressed as a percentage, the pump is 77 percent efficient at the stated conditions.

Q11-Solution:
The solution to this problem is to consider both the energy equation and the pressure-drop
equation. First, the number is calculated:

Pump inlet conditions

Hence the flow is turbulent. From the earlier work, it is deduced that

Turbulent flow ⁄ ⁄

( )( ) ( )( )

The absolute inlet pressure at the pump is, therefore:

It can be seen that the temperature can increase to a value of around - that is, almost to
the boiling point of water before cavitation occurs. The pressure drop that is due to pipe
friction exceeds the pressure-head advantage of the raised tank.
 LECTURE 5-DISTRIBUTION OF FLUID POWER

SELF EVALUATION QUESTIONS AND ANSWERS

1. A pump produces a flow rate of 100 LPM. It has been established that fluid velocity in
the discharge line should be between 5 and 7 m/s. determine the minimum and maximum
pipe inside diameter that should be used.

2 What minimum size of commercial pipe tubing with a wall thickness of 2mm would be
required at the inlet and out let of a 100 LPM pump? The inlet and outlet velocities are
limited to 1.6 m/s and 6 m/s respectively.

3.A steel tubing has a 35mm outside diameter and a 29mm inside diameter. It is made up of
commercial steel of tensile strength of 600 MPa. What is the safe working pressure?
Assume tubing is subjected to high pressure shock. Determine the tensile stress for an
operating pressure of 12 MPa.

4.A steel tube of 31 mm inner diameter has burst pressure of 70 MPa. If the tensile strength
is 400 MPa. Find the minimum acceptable OD.

5.Select the proper steel tube for a flow rate of 0.00190 m3/s and a operating pressure of 70
bars. The maximum recommended velocity is 6.1 m/s and the tube the material is dead soft
cold drawn (DSCD) steel having a tensile strength of 379 MPa.
Q1 Solution:

100 LPM = 0.1/60=1.667 10-3 m3/s

We know that Discharge Q= Area velocity

( )
( )

Solving we get (for maximum velocity)

( )
( )

Solving we get (for minimum velocity)

Q2 Solution:

100 LPM = 0.1/60=1.667 10-3 m3/s

We know that Discharge Q= Area x velocity

( )
( )

Solving we get ( for maximum velocity)

Refer to that Table we select 20(OD) 16(ID) for pump inlet

( )
( )

Solving we get (for minimum velocity)

Refer to that Table we select 42(OD) 36(ID) for pump outlet

Q3 Solution:

Since the tubing is subjected to high pressure shock, we can take factor of safety as 10

Tensile stress =

Q4 Solution:

Also

Q5 Solution:

( )

Solving we get

Let us select OD=22mm , ID =20mm wall thickness =1mm

Since the bursting pressure is less than the working pressure, 1mm wall thickness is not enough.
Let us select next size 28 24 2mm

Since the bursting pressure is more than the working pressure, 28 24 2mm pipe is acceptable.
 LECTURE 6- ENERGY LOSSES IN HYDRAULIC SYSTEMS

SELF EVALUATION QUESTIONS AND ANSWERS

1. What is the head loss ( in units of bars) across a 30mm wide open gate valve when oil
( SG=0.9) flow through at a rate of 0.004 m3/s

2.A directional control valve with an effective area of 0.00032258 m2 provides a pressure
drop of 275.8 kPa at 0.00379 . if the fluid has a specific gravity of 0.9, find flow
coefficient K factor for the valve. Find also the capacity coefficient of this valve.

3. Oil ( SG=0.9 and kinematic viscosity = 0.0001 m2/s) flows at a rate of 0.002 m3/s through
a 20 mm diameter commercial steel pipe . What is the equivalent length of a 20mm wide
open gate valve placed in the line.

4.Oil with a kinematic viscosity of 0.32 × /s is flowing through a 25 mm pipe at the

rate of 375 l/min. Is the flow laminar or turbulent?

5. Oil with a specific gravity of 0.85 and an absolute viscosity of 0.44Ns/ is flowing in a
25mm diameter pipe 120m long at the rate of 55.1 l/min. Determine the type of flow and
calculate the pressure drop.

6. Oil with a specific gravity of 0.85 and a kinematic viscosity of 1.932× /s is flowing
through a 50 mm diameter commercial steel pipe at the rate of 3500 l/min. What is the
pressure drop in 150m.

7. A hydraulic pump delivers oil at 60 bar, 120 l/min into a circuit laid on a horizontal
plane. There are four elbows (K = 0.75), one globe valve fully open (K=10) and a direction
control valve (pressure drop = 3 bar) with the inside diameter of the pipe as 30 mm. The
total length of the straight run pipe is 20m and the specific gravity of the oil is 0.9. The
kinematic viscosity of the oil is 0.0001 /s. Determine the pressure at the exit point of the
pipe.
8. The system as shown in Figure 1 contains a pump delivering high pressure oil of specific
gravity 0.9 and kinematic viscosity 1.25 × /s, to a hydraulic motor. A pipe connects
the pump and motor has an inner diameter of 25 mm and length 15 m. The pipe has two
elbow fittings (K=0.75) and one check in valve (K=4.0). The motor is placed 6m above the
pump. The inlet pressure to the motor is 34 bar. Determine the pump discharge pressure, if
the discharge from the pump is 150 l/min.

2
Moto
r
Elbow K=0.75

Load

Pipe length = 15m

1
25 mm (ID)
Pump
Elbow
C K=0.75
Check Valve
K=0.75

Figure 1 for the Problem No 8

Q1 Solution

K = 0.19 for the wide open gate valve ( from the table)

( )

( ) ( )

The pressure loss is

Q2 Solution
We know that

( )------ 1

---------2
Using 2 in 1, we get

( )

Also

( )

( ) ( )

For a give opening position, a valve behaves as an orifice Flow through the orifice is given by
( for details see chapter on flow through valves).
 √

Where Q= volume flow rate in LPM= 0.00379 =227.13 LPM

= capacity coefficient = 0.80 for sharp edges orifice, c= 0.6 for square edged orifice.
A = area of orifice opening in mm2=0.00032258 m2=322.58 mm2
= pressure drop across the orifice ( kPa)= 2.758 bar =275.8 kPa.
SG= specific gravity of flowing fluid = 0.9

√ √

Substituting all the values we get =0.473

Note that and K are dimensionless. Values are independent of system of units.

Q3 Solution
We know that

( )

( )

( ) =( )
Q4 Solution
Velocity of flow, V =
( )
=
( )

= 12.73 m/s
Reynolds number, Re=

= 9945.3
The Reynolds number is greater than 2000. So the flow is turbulent.

Q5 Solution

( )
Velocity of flow V = = = 1.87 m/s
( )

( )
Reynolds number, Re =

The Reynolds number is less than 2000. So the flow is laminar.

For laminar flow,Friction factor f = = = 0.0709

Head loss, = f( ) ( )= 0.0709( )( )= 60.66m

Pressure drop = = (0.85 × 1000 × 9.81) × 60.66

= 5.06 × Ns/
= 5.06 bar
Q6 Solution
( )
Velocity of flow V = = = 29.71 m/s
( )

Reynolds number Re = =

The Reynolds number is greater than 2000. So the flow is turbulent.

The pipe used is a commercial steel pipe. So absolute roughness ( ) = 0.046 mm

Relative roughness =

Now locate and values in Moody diagram. Draw the projections and find the meeting point.

Draw the projections and find the meeting. Draw a projection from the meeting point to ‘f’ axis.
The ‘f’ value obtained is 0.02

Head loss =f( ) ( )= 0.02×( )( )= 2699

Pressure loss=
= (0.85 × 1000 × 9.81) × 2699
= 225 × N/
= 225 bar

Q7 Solution
( )
Velocity of flow V = = = 2.83m/s

Reynolds number Re = = = 849

The Reynolds number is less than 2000, so the flow is laminar.

Since the flow is laminar,Friction factor f = = = 0.075

K factors for the valves and fittings

4 elbows (K=0.75) = 3
 1 Globe valve(K=10) = 10/13
( )

Total equivalent length, Le = Pipe length + Equivalent length for fittings

= 20 + 5.2 = 25.2 m

Head Loss =f( ) ( )= 0.075 × ( ) ( ) = 25.72 m

Pressure drop in pipe and fittings = = (0.9 × 1000 × 9.81) × 25.72
= 2.27 × N/ = 2.27 bar
Pressure drop in direction control valve = 3 bar
Pressure at the exit of the pipe = 60 – (2.27 + 3) = 54.73 bar

Q8 Solution
( )
Velocity of flow in the pipe V =( )={ } = 5.09 m/s
( )

2
Moto
r
Elbow K=0.75

Load

Pipe length = 15m

1
25 mm (ID)
Pump
Elbow
C K=0.75
Check Valve
K=0.75

Figure 1 for the Problem No 8

( )
Reynolds number = = = 1018
( )

The Reynolds number is less than 2000. So the flow is laminar.

Since the flow is laminar f = = = 0.0629
 K value for the fittings and valves = (2 × 0.75) + 4
Total equivalent length = length of pipe + equivalent length of fittings
( )
= 15 + ( ) = 15 + { } = 17.19 m

Head Loss = f( ) ( ) = 0.0629 × ( )( )= 57.11 m

Applying Bernoulli’s equation between station 1 and 2

Here, ;
( )
( )

= 6 + 57.11, [where, change in datum head ]

= 63.11 m
= (0.9 × 1000 × 9.81) × 63.11
= 5.6× N/m2
= 5.6 bar
Pump discharge pressure = 5.6 + 34= 39.6 bar.
 LECTURE 7 TO 9 – HYDRAULIC PUMPS

SELF EVALUATION QUESTIONS AND ANSWERS

1. A gear pump has a 75mm outside diameter, a 50mm inside diameter, and a 25mm width.
If the actual pump flow at 1800rpm and rated pressure is 0.106 , what is the
volumetric efficiency?

2.A gear pump has a 75mm outside diameter, a 50mm inside diameter, and a 25mm width.
If the volumetric efficiency is 90% at rated pressure, what is the corresponding actual flow-
rate? The pump speed is 1000rpm.

3. A vane pump is to have a volumetric displacement of 5 cm3. It has a rotor diameter of 2

cm, a cam ring diameter of 3 cm. What must be the eccentricity?

4. A vane pump has a rotor diameter of 50 mm, a cam ring diameter of 75mm, and a vane
width of 50 mm. If the eccentricity is 8mm, determine the volumetric displacement.

5.A vane pump is to have a volumetric displacement of 82 cm3. It has a rotor diameter of 5
cm , a cam ring diameter of 7.5 cm , and a vane width of 4 cm. what must be the
eccentricity?. What is the maximum volumetric displacement possible?

6 An axial piston pump has nine pistons arranged on a piston of circle 125 mm diameter.
The diameter of the piston is 15mm. The cylinder block is set to an off set angle of 10 . If
pump runs at 1000 RPM with an volumetric efficiency of 94 %. Find the flow rate in LPS.
7. A fixed displacement vane pump delivers 68.94 bar oil to an extending hydraulic

cylinder at 0.00126 When the cylinder is full extended, oil leaks past its piston at rate of

4.42x The pressure relief valve setting is 82.75 bar. If a pressure-compensated vane

pump were used it would reduce the pump flow 0.0012 6 to 4.42x when the

cylinder is fully extended to provide the leakage flow at the pressure relief valve setting of
82.75 bar. How much hydraulic horse power would be saved by using the pressure
compensated pump?

8.Find the offset angle for an axial piston pump that delivers 0.001 at 1000rpm .The

pump has 9 pistons and each piston has 24.2 mm diameter and arranged on a 127mm
diameter pitch circle. The volumetric efficiency is 90 %

9.A pump has displacement volume of 100 cm3. It delivers 0.0015m3/sec at 1000rpm and
70bar.If the prime mover input torque is 120 N.m, calculate a) the overall efficiency of the
pump b) theoretical torque required to operate the pump.

10. A hydraulic circuit consists of a fixed displacement gear pump supplying hydraulic
fluid to cylinder which has a bore of 100 mm diameter, a rod of 56mm diameter and a
stroke of 400mm. Pumps are available with displacement increasing in steps of 1 ml/rev
from 5 ml. the volumetric efficiency is 88% and its overall efficiency is 80%. The pump is
driven directly by an electric motor with an on load speed of 1430 RPM. Select a suitable
pump so that the cylinder can be reciprocated through a complete once a every 12 seconds.
 Q1 Solution:
Volume

Theoretical flow rate

The volumetric efficiency,

Q2 Solution:
Volume

Actual flow-rate

Q3Solution Eccentricity,
Q4 Solution
Volumetric displacement,

Q5 Solution

a) Eccentricity
Volumetric displacement,

b) Maximum possible displacement

Volumetric displacement,

Q6Solution
Theoretical discharge of axial piston pump

Actual discharge,

1L =1000cc = 1000 x
5.493 =0.5493 L

Thus actual discharge = 0.5493

Q7 Solution
The fixed displacement vane pump produces 0.00126 at 82.75 bar when the cylinder is fully
extended (4.42x leakage flow through the cylinder and 0.001216 through the relief
valve).Thus, we have
Hydraulic HP lost =
A pressure-compensated pump would produce only 4.42 at when the cylinder is fully

extended. For this case have

Hydraulic HP lost =
Hence, the hydraulic power saved = 10427 – 367 = 10060 Watts=10.060 kW. This power saving
occurs only while the cylinder is fully extended.

Q8 Solution
:

Volumetric efficiency

Theoretical discharge of axial piston pump

Solving

Q9 Solution

Volumetric efficiency,

i.e.
Mechanical efficiency

Overall Efficiency

Theoretical torque required to operate the pump

Note that the product gives power in units of N.m/s (W), where torque ( has units of
N.m and shaft speed has units of rad/s .
Theoretical torque = Actual torque x Mechanical efficiency = 120 x 0.9284 = 111.4 Nm
Thus, due to mechanical losses within the pump, 120 Nm of torque are required to drive the
pump instead of 111.4 Nm

Q10 Solution

Cycle time = extend time + retract time

Actual flow pump ( Q) is obtained by solving above equation

Q = 0.0265 m3/min

Pump displacement
A pump with 21 ml /rev displacement is to be selected.
 LECTURE 10-HYDRAULIC MOTORS

SELF EVALUATION QUESTIONS AND ANSWERS

1.A rotary vane motor has a displacement volume of 80cm3/rev and operate at 1750rpm.The system
pressure is 7 bar. Calculate the flow rate and the kW power output of the motor.

2.A hydraulic motor has a volumetric displacement of 125 and a pressure rating of 150 bars. It
receives a theoretical flow of oil of 0.0015 from a pump. Find the motor: a) Speed b)
theoretical torque c) theoretical power.

3.A hydraulic motor has a displacement of 150 cm3 and operates with a pressure of 120 bars and a
speed of 2500 rpm. The actual flow rate consumed by the motor is 0.0078 m 3/s and the actual
torque delivered by the motor is 250 Nm. Find

a. Volumetric efficiency

b. Mechanical efficiency

c. Overall efficiency

d. Power delivered by the motor

4.A motor has a displacement 300 cm3 and a speed of 200 rpm with a pressure drop of 200 bar. The
volumetric efficiency is 90% and the mechanical efficiency is 95%. Determine theoretical and
actual a. Discharge b. Torque c.Power

5.A hydraulic motor with a displacement of 475 is used to directly drive a conveyor drum having a
diameter of 0.7m. The pressure drop over the motor is 140 bar and the actual flow into the motor is
48 l/min. The overall and mechanical efficiency of the motor are 0.9 and 0.94 respectively.
Determine

a. the torque at the conveyor drum

b. the power in kW supplied to the conveyor drum

c. the linear speed of the conveyor belt

Q1Solution

Flow rate

Power output in kW

Q2Solution

Theoretical flow rate = 0.0015 /s

Displacement of motor = 125

= 125 ×

Pressure rating = 150 bars

= 150 ×

a. The motor speed N =

= 12 rev/s

= 12 × 60 = 720 rev/min

b. Theoretical torque =

= 298.4 Nm

c. Theoretical power =

= 22500 W

= 22.5 kW
Q3Solution

Displacement of motor

= 150 ×

Pressure = 120 bar

= 120 ×

a. Volumetric efficiency × 100

= ×100

= ×100

= 80%

b. Mechanical efficiency ×100

= ×100

= 87%

c. Overall efficiency

= 0.8 × 0.87 × 100

= 69.6%

d. Power delivered by the motor = NT/60

= 65450 W

Q4Solution

Displacement of motor Dm = 300 cm3

= 300 m3

Speed of the motor N = 200 rpm

Pressure drop = 200 bar

 = 200 x 105 N/m2

Volumetric efficiency = 90%

= 0.9

Mechanical efficiency = 95%

= 0.95

a. Theoretical discharge QT= Dm .N

= 300 x x 200

= 0.06 m3/min

Actual discharge =

= 0.0667

b. Theoretical torque TT =

= 955 Nm

Actual torque TA = TT x

= 955 0.95

= 907.3 Nm

c. Theoretical power the motor should deliver =

= 20000 W

= 20 kW

Actual power delivered by the motor = 20 0.95

= 19 Kw
Q5Solution

The pressure drop over the motor = 140 bar

= 140 105 N/m2

Displacement of motor Dm = 475 cm3/rev

= 475 x 10-6 m3/rev

Actual flow into the motor QA = 48 lit/min

= 48 10-3 m3/min

Mechanical efficiency = 0.94

Overall efficiency = 0.9

a. Mechanical efficiency =

The torque at the conveyor drum T = x

= 995 Nm

b. Overall efficiency =

Power supplied by the motor to the conveyor drum =

= 10.1 kW

c. Power =

Speed of the hydraulic motor,

N=

= 97 rpm

Linear speed of the conveyor =

 LECTURE 12 TO 14 – HYDRAULIC ACTUATORS

SELF EVALUATION QUESTIONS AND ANSWERS

1A pump supplies oil at 0.002 m3/s to a 50mm diameter double acting cylinder and a rod
diameter is 20mm. If the load is 6000N both in extending and retracting, find

a. Piston velocity during the extension stroke and retraction stroke

b. Pressure during the extension stroke and retraction stroke
c. Power during the extension stroke and retraction stroke

2A hydraulic cylinder has to move a table of weight 13kN. Speed of the cylinder is to be
accelerated up to a velocity of 0.13m/s in 0.5 seconds and brought to stop within a distance
of 0.02m. Assume coefficient of sliding friction as 0.15 and cylinder bore diameter as
50mm. Calculate the surge pressure.

3.A cylinder has a bore of 80mm diameter and a rod of 45mm diameter. It drives a load of
7000N, travelling at a velocity of 15m/min. The load slides on a flat horizontal surface
having a coefficient of friction of 0.12. The load is to be decelerated to rest within a cushion
length of 20mm. If the relief valve is set at 50 bar, compute the fluid pressure developed in
the cushion.

Load

Pressure force

Declaration Force

Figure 1 for the Problem No 3

4.A cylinder has a bore of 125mm diameter and a rod of 70mm diameter. It drives a load of
2000 kg vertically up and down at a maximum velocity of 3 m/s. The load is slowed down to
rest in the cushion length of 50mm. If the relief valve is set at 140 bar, determine the
average pressure in the cushions while extending and retracting.

2000 N

Figure 2 for the Problem No 4

5 For a second class lever system given in figure 3 determine the hydraulic cylinder force
required to overcome the load.
 Cylinder
Rod pin
Fixed
Hinge pin
Lever

Cylinder

Figure 3 for the Problem No 5

6 For the crane system given in figure below, find the cylinder the force required to lift a
load of 9000 N.

1.5 m D

mm

C
0.75 m 9000 N

A B

Figure 4 for the Problem No 6

7.For a bent lever system shown in figure 5, the cylinder force is 1400N. How much load
can the system drive.

Figure 5 for the Problem No 7

8: A two stage telescopic cylinder is used to tilt the body of a lorry. When the lorry is fully
laden, the cylinder has to exert a force equivalent to 40kN at all points in its stroke. The
outside diameters of the tubes forming two stages are 75mm and 100mm. If the pump
powering the cylinder delivers 12 l/min, calculate the extend speed and pressure required
for each stage of the cylinder when tilting fully laden lorry.

9: A mass of 2000kg is to be accelerated upto a velocity of 1m/s from rest over a distance of
50mm. The coefficient of friction between the load and the guides is 0.15. Select the bore
of the cylinder required to accelerate this load if the maximum allowable pressure at the
full bore end is 100 bar. Take seal friction to be equivalent to a pressure drop of 5 bar

10.A Press cylinder has to exert a force to lift the crosshead and tooling. The cylinder is
rigidly fixed by a front flange and the load is pivoted and fully guided. Maximum thrust
from the press is 20kN with a stroke of 1.7m. Determine the suitable cylinder. The system
working pressure should not exceed 250 bar.
11. A hydraulic cylinder has to move a load horizontally through a distance of 3m. The
cylinder is front flange mounted and load is rigidly connected to the piston rod and fully
guided. The extend force to be exerted by the cylinder is 1.6 tonnes and the retract force is
0.7 tonnes. Assume the effective dynamic thrust is 0.9 tonnes the static thrust,

If the system pressure is limited to 150 bar

Determine a suitable standard metric size of cylinder

Calculate the actual operating pressure

12. A machine tool cylinder is connected regenerateively to give a rapid approach speed of
10 m/min for a stroke of 1 m with a theoretical thrust of 2.5 Tonnes. It is then switched to
conventional connection to provide a pressing speed of 0.25 m/min for 0.5 m with a
theoretical thrust of 10 Tonnes. The maximum pressure at the cylinder is to be 200 bar.

Select a suitable standard metric cylinder

Calculate the pump delivery required for both parts of extend stroke.

13 A hydraulic cylinder is to accelerate a load of 50 Tonnes horizontally form rest with a

velocity of 10 m/min to 50mm . Take coefficient of friction between the load and the guide
as 0.1. Assume zero back pressure. Determine

a) a suitable size of standard metric cylinder if the maximum allowable pressure at the
cylinder is 180 bar

b) the fluid flow rate required to drive the piston forward at 3m/min

Load

μ=0.1
P1=180 bar P2=0
Q1Solution

Oil flow rate from pump, Q = 0.002 m3/s

Diameter of the cylinder, D = 50mm

= 0.05 m

Diameter of the rod, d = 20mm

= 0.02m

Load during the extension and retraction F = 6000N

a. Piston velocity during extension stroke VE =

= 1 m/s

Piston velocity during retraction stroke VR =

Cylinder pressure during extension stroke PE = =30.6 bar

Cylinder pressure during retraction stroke PR =

Cylinder power during extension stroke =

Cylinder power during extension stroke =

Q2 Solution

Initial velocity u = 0m/s

Final velocity v= 0.13m/s

Acceleration a = =

Force required to move the piston = Dynamic force + frictional force

=* + =* +

= 2294.5N

To overcome this force, the pressure required in the hydraulic cylinder is

From the equation for velocity, acceleration and distance v2 – u2 = 2as

a=

(The –ve sign indicates that it is deceleration)

The total force required to stop the motion of a cylinder

Then pressure created by this opposing force is

= =12.78 bar

Thus surge pressure Ps= P1 + P2 = 11.69 + 12.78= 24.47 bar

Q3 Solution

Cushion length s = 20mm = 0.02m

Velocity u = 15 m/min = 0.25 m/s

From the equation of motion,

v2 = u2 + 2as (final velocity is zero)

a=

Decelerating force to retard load = a = =

= 1067N

Pressure force on blank end = P A = 50

= 25133N

Friction force = μ.w

= 0.12 6700

= 804 N

Cushion force = (Pressure force + Decelerating force ) – Friction force

= 25133 + 1067 – 804

= 25396N

Fluid pressure developed at the cushion =

= 74 bar
Q4 Solution

2000 N

From the equation of motion,

v2 = u2 + 2as (final velocity is zero)

a=

Decelerating force to retend = m.a

= 180 kN

Weight of the load = mg

= 2000 9.81 = 19.6 Kn

 a. During extension

Load

Pressure force Declaration Force

Figure E8.15 for the Problem No E4

Pressure force = P Ap

= 140

= 171.8 kN

Cushion force = (Pressure force +Decelerating force – weight )

= 171.8 + 180 – 19.6

= 332.2 kN

Cushion pressure =

= 39438 kN/m

= 394.38 bar
 b. During retraction

Load

Pressure force Declaration Force

Figure E8.16 for the Problem No E4

Pressure force = P (

= 140 )

= 117.9kN

Cushion force = (Pressure force +Decelerating force + weight )

= 171.8 + 180 + 19.6

= 317.5kN

Cushion pressure =

= 25872 kN/m2

= 258.72 bar
Q5 Solution

Taking moments about C, Fc

Cylinder Force Fc = W

= 5000

= 2500 N

Q6 Solution

Fc is the cylinder force

Taking moments about A,

= 34710 N

Q7 Solution

Taking moments about O, Fc

Load W=

= 1000N

Q8 Solution

First stage

First stage speed = = = 1.52 m/min

First stage pressure = = = 50.9bar

Second stage

Second stage speed = = = 2.72 m/min

Second stage pressure = = = 90.5 bar

Q9 Solution

In this case

u=0

v=1m/s

s = 0.05m

Using the equation,

v2 =u2 + 2as

a=

= 10m/s

Force to accelerate this load F =m.a

= 2000 x 10

=20000N

Force to overcome load friction P =

= 0.15 x 2000 x 9.81

= 2943N

Total force = F + P

= 20000+2943

= 22943N

Pressure available = (pressure at full bore end) - (pressure drop due to seal friction)

= 100-5

= 95 bar

=95 x 105 N/m2

Cylinder area required for given thrust

A=

= 0.002415 m2

Daimeter of cylinder bore

D= ( ) =( ) = 0.0554m

= 55.4mm

The nearest standard cylinder has a 63mm diameter bore.

Q10 Solution

Piston rod diameter

Load F =200kN

Modulus of Elasticity E = 2.1 x 1011 N/m2

Equivalent buckling length L =

= 1.2m

Consider the factor of safety (S) as 3.5

Buckling load K = F x S

=200 x 103 x 3.5

= 700 x 103 N

Buckling load K = where I =

= x

d4 = K ( )( )

= 700 x 103 x ( )x( )

= 992 x 10-8 m4

Piston rod diameter d = (992 x 10-8) 1/4

= 0.056m
= 56mm

This is of standard size ( from table)

Check for bore diameter :-

Maximum allowable pressure = 250 bar

=250 x 10 5 N/m2

Assume dynamic thrust = 0.9 x pressure x area

Piston area A =

= 0.0088 m2

Bore diameter D =* +

=* +

= 0.105 m

=105mm

But from the table of preferred sizes suitable bore diameter is 125 mm and corresponding piston
rod diameter is 70mm. This diameter is more than the previously calculated value. So it can
withstand the buckling load.

Thus, Bore diameter = 105mm

Diameter of piston rod =70mm

Preferred Sizes

BS : 5785 1980 gives a table of the preferred sizes for the cylinder bore and rod diameter. Most
manufacturers are offering two rod sizes for each cylinder bore size. It is shown in following
table

Piston 40 50 63 80 100 125 140

diameter(mm)
Piston rod Small 20 28 36 45 56 70 90
Diameter(mm) Large 28 36 45 56 70 90 100

Piston 160 180 200 220 250 280 320

diameter(mm)
Piston rod Small 100 110 125 140 160 180 200
Diameter(mm) Large 110 125 140 160 180 200 220

The large piston rod to piston diameter ratio is in the range of 0.7, which gives an annulus
area which is approximately one half the full bore area. This ratio is used in regenerative circuits
to give similar values of speed and thrust on both the extending and retracting strokes.

Q11 Solution

a. Piston rod diameter

The first step in the solution is to determine the minimum piston rod diameter for the buckling
strength.

The thrust force exerted by the cylinder = 1.6 Tonnes = 1.6 x1000x 9.81 = 15696 N

Assuming a factor of safety of 3.5

Bucking load K = 3.5 x 15696 = 54936 N

The cylinder is front flange mounted and load rigidly connected to the piston rod and fully
guided. For these conditions
Free buckling length

Buckling load K = where I =

= x

d4 = K ( )( )

= 54936 x ( )x( )

Piston rod diameter d= 0.033m = 33mm

Select the standard size of 36mm from the above table.

Check for bore diameter :-

Maximum allowable pressure = 250 bar

=250 x 10 5 N/m2

Assume dynamic thrust = 0.9 x pressure x area

Piston area A =

= 0.001162 m2

Bore diameter D =* +

=* +
= 0.038 m

=38 mm

But from the table of preferred sizes suitable bore diameter is 50 mm and corresponding piston
rod diameter is 36 mm.

So the 50mm bore diameter x 36 mm rod diameter cylinder is selected.

b) the extend pressure required to give a dynamic thrust of 15696 N

( ) ( )
⁄

The retract pressure required to give a dynamic thrust of 6867 N

( ) ( )
⁄ ⁄

Q12 Solution

During regeneration, the forward thrust is the difference between the forces on the full bore and
annulus sides of piston.

Forward thrust =

Solution

Qin=0.016m3/s

Fext=Fret=5000N

dc=40 mm=0.04m

dr=20 mm=0.02m

(a) Hydraulic pressure during the extending stroke: -

( ) ( )
Select the standard rod diameter 45mm

During conventional connection

( ) ( )

Select the standard piston diameter =80mm

So the bore diameter 80 x 45mm rod diameter cylinder is selected.

B. Rapid approach flow during

Regeneration =

Flow during conventional connection

Q13 Solution

In this case u=0, v = 10m/min = 10/60 m /sec

s=0.05m and a is unknown.

Using the equation

Force to accelerate load is given by

( )

( )
Force P to overcome load friction is given by

Total force to accelerate load and overcome friction is (F+P) =13900+49050=62950 N

Cylinder area required for a given thrust is calculated from

Thrust = Force x area

The Pressure available if pressure at full bore end of the cylinder less the equivalent seal break
out pressure.

Pressure available = 189-0 = 180 bar= 180 x105N/mm2

Where D is the diameter

Substituting we get D= 67 mm.

The nearest standard cylinder above has a 80 mm diameter bore.

b) Flow rate required to drive the piston forward at 3 m/min

 LECTURE 15 TO 17– DIRECTION CONTROL VAVLES

SELF EVALUATION QUESTIONS AND ANSWERS

1. A spool valve is controlling an ideal motor. The system characteristics are given in the following
table. Calculate the following (a) Load pressure (b) Load flow (c) Power delivered by the motor (d)
Motor displacement

Parameters Value
Orifice discharge constant ( 0.62
Valve area gradient (w) 0.01 m
Valve opening ( ) 0.25mm
Supply side pressure ( 20 MPa
Drain side pressure ( 0
Upstream pressure to motor( 12 MPa
Fluid density 855
Motor speed (n) 1000 RPM
2. A cylinder with bore diameter of 8 cm and a rod diameter of 4 cm is to be used in a system with a
30 LPM pump. Use the graph in the figure to determine the pressure drops across the DCV when the
cylinder is retracting (P->B,A->T).

P-T
A–T ,B-T

7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

3. A cylinder with bore diameter of 10 cm and a rod diameter of 6 cm is to be used in a system with a
200 LPM pump. Use the graph in the figure to determine the pressure drops across the DCV when the
cylinder is retracting (P->B,A->T).
Q1 Solution

First calculate certain properties associated with the initial conditions. Calculate the load pressure. The
valve was indicated to be ideal with no leakage and the motor is also ideal. Thus:

So the load pressure can be determined:

Calculate the initial load flow:

(
= √

(
= 0.62 x 0.01 x 0.25 √

Now we shall evaluate at initial operating point. The flow gain coefficent,

(
√
 (
√

The flow pressure coefficeint ,

The pressure sensitivity coefficeint ,

Pa/m

Calculate the power delivered by the motor

Calcute the motor shaft speed ,

Calculate the power coefficeint

Calculate th motor displacement

= =

Now we shall develop a relationship that will allow the calculation of load pressure , when the load
follows = ( )

Which leads to an expression for

( )

Noting that may also be expressed as

(
√

Thus can be eliminated leaving

(
( ) √
This expression can be rearranged as a quadratic equation to calucalte

( ) ( )

Let

( )

For the new operating condition where

( (
) =

Now solve the quadratic in :

Only the positive root has meaning in this context, so substituting C= 1

√(
=4

Calcute the load flow, under the new conditions:

 ( (
√ √ =

Now caluclate and verify that the predicted is correct by calculating the power under the new
conditons in two separate ways:

= =

calculate the power from

and from:

= ( ) =924.8 watts

Both the power expressions yield the same result. Calculate the increment in valve opening

Now calculate the approximate value of the load flow, from the linearisation appraoch:

( /s
and the approximate value of the load pressure

Q2 Solution:

The flow from P to B is the pump flow into the rod end, so this can be read from the graph

p =1.5 bar (approx.)

The flow from A->T is the return flow out of the blind end. This flow rate is greater than the pump flow
and must be determined by the following method

a. Calculate the piston area

( ) (

b. Calculate the rod area

( ) (

c. Calculate the return flow

The flow from A to T can now be read from the graph

p =5.8 (approx.)
 13.5
P-T
12
A–T ,B-T
10.5

7.5 P – A , P–B
6

4.5

1.5

7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Q3 Solution:

The flow from P to B is the pump flow into the rod end, so this can be read from the graph

p =1.5 bar (approx.)

The flow from A->T is the return flow out of the blind end. This flow rate is greater than the pump flow
and must be determined by the following method

a. Calculate the piston area

( ) (

b. Calculate the rod area

( ) (

c. Calculate the return flow

The flow from A to T can now be read from the graph p =1.9 bar (approx.)
 LECTURE 18 AND 19 – PRESSURE CONTROL VAVLES

SELF EVALUATION QUESTIONS AND ANSWERS

1. A piston of 50 mm diameter is to support a load of 20 kN. Find the pressure setting

required if the counter balance valve is used

2. A hydraulic press has a capacity of 200 kN and has tools weighing 10 kN. Piston
diameter is 80 mm and rod diameter is 60mm. Determine the i) pressure setting of Counter
balance valve ii) Oil supply pressure to provide rated capacity iii) if over centre valve is
used with pilot input ration of 2:1 set at 46.43 bar to balance the tool weight instead of
counter balance valve , what is the supply pressure of oil required to give the rated
capacity.

From Pump 80 cm From Pump 80 cm

To tank 60 cm To tank 60 cm

200000 N
With counter With Over center
balance valve valve

3. If in the problem 2, pump is unloaded using the unloaded valve. If the discharge pressure
from pump during unloading is 2 bar, calculate the power loss.

4. A pressure relief valve has a pressure setting of 125 bar. Compute the power loss across
this valve if it returns all the flow back to tank from 15 LPM pump
5. Repeat the problem 3 with pressure setting of 140 bar and 1.62 LPS and comment

6. Repeat the problem 3 with 80 bar and 50 LPM and comment

7. A primary port of certain hydraulic cylinder is operating at 210 bar. A secondary circuit
supplied from a primary circuit through a pressure reducing valve requires a constant flow
of 40 LPM at 150 bar. Calculate the loss of power over the pressure reducing valve. ( Ans 4
kW)
8. What is the cracking pressure of the relief valve of Figure shown below? If the area of
the poppet piston is 1 cm2 and the spring is adjusted to a force of 50 kg
Q1 Solution

Load pressure p is given by

PRV setting is given by 1.3 x 101.9 = 132.47 bar

Q2 Solution

Full bore area = 0.082×π/4=0.005 m2

Annulus area = (0.0082-0.0062)×π/4 = 0.0028m2

Case 1: Using counter balance valve

Pressure at annulus side to balance tools = 10-5 = 35.71 bar

Suggested counterbalance valve setting 35.71×1.3 = 46.5 bar

Pressure at full bore side of cylinder to overcome counterbalance = 46.43×0.0028/0.005

=26 bar

Pressure to achieve 100kN pressing force= +26= 426 bar

Case 2: Using over -center valve (brake valve)

Let us use an over-center valve with a 2:1 pilot input ratio, set at 46.43 bar to balance the tools ,
instead of the counterbalance valve

Pressure on the pilot required to open the valve=46.43/2=23.23 bar; pressure at full bore side to
drive down the tooling=11.5 bar

Pressure required to achieve 100kNpressing force is =

( )
=380 bar
This is greater than 46 bar pressure needed to pilot the over-center valve open. Therefore there
will be no back-pressure set up on the annulus side of the piston during the pressing operation

Q3 Solution

( ) ( )

Q4 Solution

Therefore there is a reduction of loss of power due to unloaded valve

( ) ( )

Q5 Solution

( ) ( )

Q6 Solution

( ) ( )

Q7 Solution

The power loss over the pressure-reducing valve will be:

( )
=4 kW

This may well be more than can be dissipated by natural cooling. In practice , the cost of fitting a
heat exchanger and operating costs should be weighed against alternative circuitry such as two-
pump system.
Q8 Solution
 LECTURE 20 – FLOW CONTROL VAVLES

SELF EVALUATION QUESTIONS AND ANSWERS

1: A cylinder has to exert a forward thrust of 150 kN and a reverse thrust of 15 kN. The
effects of using various methods of regulating the extend speed will be considered. In all the
cases, the retract speed should be approximately 5m/min utilizing full pump flow. Assume
that the maximum pump pressure is 160 bar and the pressure drops over the following
components and their associated pipe work (where they are used):
Filter = 3 bar
Directional control valve (DCV) = 2 bar
Flow control valve (controlled flow) = 10 bar
Flow control valve (check valve) = 3 bar
Determine:
(a) The cylinder size (assume 2:1 ratio piston area to rod area)
(b) Pump size, and
(c) Circuit efficiency when using:
Case 1: No flow controls (calculate extend speed)
Case 2: Meter-in flow control for extend speed 0.5 m/min
Case 3: Meter-out flow control for extend speed 0.05 m/min

2: A flow control valve is used to control the speed of the actuator as shown in the figure 1
and the characteristics of the system are given in the following table. Determine the
cylinder force Fp, and the cylinder piston velocity, that is developed in the system when
cylinder flow, Q2, is equal to 80% of the pump flow Q.
 Figure 1

Parameters Value
Orifice discharge constant ( 0.6
Length of flow area ), h 6 mm
Width of the flow area( ), b 1.5 mm
Fixed orifice flow area ( 5 mm2
Valve face area 130 mm2
Piston diameter , d 38 mm
Spring preload, F 255 N
Spring constant 65.7 kN/m
Drain side pressure ( 0
System pressure ( 13.97 MPa
Fluid density 830
Pump flow 0.32 LPS

3: Determine the flow – rate through a flow control valve that has a capacity coefficient of
√ and a pressure drop of 897 kPa. The fluid is hydraulic oil with a specific
gravity of 0.95.

4: A 60 mm diameter sharp edged orifice is placed in a pipe line to measure flow rate. If the
measured pressure drop is 500 kPa and the fluid specific gravity is 0.92, find the flow rate
in units of
5: The speed control circuit shown in figure 2 has the following data:
Component A: Capacity 120 ml/rev. Shaft speed 1000 rev/min. Volumetric efficiency = 95
% . Component B: set at 70 bar. No pressure over ride. Component C: Flow equation Q c =
80 × a × √ , where Qc = ml/min area(a)=200mm2.Component D: Capacity 160 ml/rev.
Volumetric efficiency = 95 %. Mechanical efficiency =80 %. Load = constant torque (60
Nm).Determine the flow through the valve C under the conditions and maximum speed of
motor.

B
A

Figure 2 : Speed control of hydraulic motor

6: The system shown below (Figure 3) has a hydraulic cylinder with a suspended load W.
The cylinder piston and rod diameter are 60 mm and 30 mm respectively. The pressure
relief valve setting is 5000 kPa. Determine the pressure for a constant cylinder speed,

(a) W = 10000 N
(b) W= 0 ( load is removed)
(c) Determine the cylinder speeds for parts (a) and (b) if the flow control valve has a
capacity coefficient of √ . The fluid is hydraulic oil with a specific
gravity of 0.90
 W

Figure 3 : Hydraulic cylinder with suspended weight

Q1 Solution:

Case 1: No flow controls

Figure 1 : Hydraulic cylinder with no control

Maximum available pressure at full bore end of cylinder is =160-3-2=155bar

Back pressure at annulus side of cylinder = 2 bar. This is equivalent to 1 bar at the full bore end
because of 2:1 area ratio. Therefore, maximum pressure available to overcome load at full bore
end is 155-1 = 154 bar

Full bore area = Load/Pressure= =0.00974 m2

Piston Diameter = ( )

Select a standard cylinder; say with 125 mm bore and 90 mm rod diameter.

Full bore area = 12.27 × 10-3 m2

Annulus Area = 6.36 × 10-3 m2

This is approximately a 2:1 ratio

Flow rate for a return speed of 5 m/min =Annular Area x velocity

= (12.27-6.36 )× 10-3 ×5 m3/min=29.55 LPM

Extend speed = = 2.41 m/min

Pressure to overcome load on e×tend is= = 12.223 MPa = 122.3 bar

Pressure to overcome load on retract is = 2.538 MPa = 25.38 bar

i) Pressure at pump on extend (working back from DCV tank port)

Pressure drop over DCV B to T 2×½ 1

Load induced pressure 122.23
Pressure drop over DCV P to A 2
Pressure drop over filter 3

Therefore, pressure drop required at pump during e×tend stroke = 128.33 bar

Relief valve setting = 128.23 + 10%= 141.05 bar

ii) Pressure required at the pump on retract (working from DCV port as before)
= (2 × 2) + 25.38 + 2 + 3 = 34.38 bar
Note: The relief valve will not be working other than at the extremities of the cylinder stroke.
Also, when movement is not required, pump flow can be discharged to tank at low pressure
through the centre condition of the DCV.
iii) System efficiency

Efficiency on extend stroke = × 100 = 86.66 %

Efficiency on retract stroke = × 100 = 73.822 %

Case 2: Meter-in flow control for extend speed of 0.5 m/min

From Case 1,
Cylinder 125 mm bore diameter × 90 mm rod diameter
Full bore area = 12.27 × 10-3 m2
Annulus area = 7.525 × 10-3 m2
Load induced pressure on extend = 122.23 bar
Load induced pressure on retract = 25.38 bar
Pump flow rate = 29.55 l/min
Flow rate required for extend speed of 0.5 m/min is = 12.27 × 10-3 × 0.5
= 6.136 × 10-3 m3/min
= 6.136 l/min
Working back from DCV tank port:
Pressure required at pump on retract is 2 × 2) + (2 × 3) + 25.38 + 2 + 3 = 40.38 bar
Pressure required on pump at extend is (2 × ½) + 122.23 + 10 + 2 + 3 = 138.23 bar
Relief valve setting = 138.23 + 10 % = 152 bar
This is close to the maximum working pressure of the pump (160 bar). In practice, it would be
advisable to select either a pump with a higher working pressure (210 bar) or use the next
standard size of the cylinder. In the latter case, the working pressure would be lower but a higher
flow rate pump would be necessary to meet the speed requirements.

Now that a flow control valve has been introduced when the cylinder is on the extend stroke, the
excess fluid will be discharged over the relief valve.

System efficiency on extend is = × 100 = 18.877 %

System efficiency on retract is= = 62.853 %

 Figure E4 : Hydraulic cylinder with meter in control

Case 3 : Meter-out flow control for extend speed of 0.5 m/min

Cylinder, load, flow rate and pump details are as before. Working back from DCV tank port:
Pressure required at pump on retract is= (2 × 2) + 25.38 + 3 + 2 + 3 = 37.38 bar
Pressure required at pump on extend is =(2 × ½) + (10 × ½) + 122.23 + 2 +3 =133.23 bar
Relief valve setting is 133.33 + 10 % = 146.55 bar
 Figure E5 : Hydraulic cylinder with meter out control

System efficiency on extend is= × 100 =19.05 %

System efficiency on retract is= × 100 = 67.897 %

As can be seen, meter-out is marginally more efficient then meter-in owing to the ratio of piston
area to piston rod area. Both systems are equally efficient when used with through rod cylinders
or hydraulic motors. It must be remembered that meter-out should prevent any tendency of the
load to run away.
Q2 Solution
Flow from pump divides as and . The pressure drop occurs acoss office Ao This make valve
to move to right against the spring force F. the area of orifice A v then adjusts to control the flow to the
motor.

√ √

Q3 Solution
For a sharp edged orifice we can write,

√ √

Q4 Solution

For a sharp edged orifice we can write,

√
Where Q= volume flow rate in LPM
= capacity coefficient = 0.80 for sharp edges orifice, c= 0.6 for square edged orifice.
A = area of orifice opening in mm2
= pressure drop across the orifice ( kPa.
SG= specific gravity of flowing fluid = 0.92

( )

√ = 4487.35 LPM

Q5 Solution
HP = 2;
mMt = 9 × p × m
Mt =

Torque exerted by the motor = = 75 Nm

Mt = = 160 × p/2

p = 75 × 2 × π × 10/5160
= 30 bar
ΔP = 40 bar
Qc = 80 × 200 × 401/2 = 102000 ml/min = 102 l/min
Actual flow to the motor = 96.9 l/min
Motor speed = 96.9 × 10 / 160 = 605 rpm
Q6 Solution
For constant cylinder speed, the summation of the forces on the hydraulic cylinder must be
equal to zero. Thus we have.

( )

( )

For a sharp edged orifice we can write,

√ √
Where since the flow control valve discharges directly to the oil tank. This is the flow
rate through the flow control valve and thus the flow rate of the fluid leaving the hydraulic
cylinder. Thus we have

√ √

⁄
 LECTURE 21 – FLOW AND FORCE ANALYSIS OF VALVES

SELF EVALUATION QUESTIONS AND ANSWERS

1 A flow control valve is used to control the speed of the actuator as shown in the figure
and the characteristics of the system are given in the following table. Determine the
variable flow area Av, , the pressure downstream of the valve fixed orifice p 2, the valve
displacement x, and the spring preload F for the given motor operating conditions.

Parameters Value
Valve flow constant ( 0.6
Length h 7.8 mm
Valve area gradient for flow area 1.25 mm2/mm
( ), b
Fixed orifice flow area ( 4.9 mm2
Valve face area 125 mm2
Spring constant 57 kN/m
Motor displacement ( 40 cm3/rev
Motor torque 60 Nm
Motor speed 350 RPM
Motor Volumetric efficiency ( 96 %
Motor mechanical efficiency ( 97 5
System pressure ( 14.5 MPa
Return pressure ( 1 MPa
Fluid density 840
2 Leakage input flow , passes through the spool valve as shown in the figure.
The oil flows past the two spool lands in annular passages as and . Write a set of
equation, based on conventional fluid flow theory that can be solved for pressure and
the flow and .

To drain From pump

Leakage
flow to tank
To actuators Leakage flow
to tank

Characteristics of flow division in a spool valve is given below

Spool diameter 20 mm
Land length 93 mm
Land length 73 mm
Spool radial clearance (centered) 0.025mm

3. Use the equations determined in the problem 2 to solve for numerical values of pressure
Leakage flow , when the leakage input flow , equal to 0.01 L/s
Q1 solution

Flow from pump divides as and . The pressure drop occurs acoss office Ao This make
valve to move to right against the spring force F. the area of orifice Av then adjusts to control the flow to
the motor.

√ √

√ √ ( √ √
Q2 solution

[ ( ) ]

( )

Solving we get

[ ]

[ ]

Q3 solution

[ ]

[ ]

Use trial values of

Find { }
 LECTURE 22 TO 23 – PROPORTIAONAL VALVES

SELF EVALUATION QUESTIONS AND ANSWERS

1 Consider the hydraulic system shown in the Figure below. The cylinder ratio is 2:1,

Pressure , .

i) Find the load which will cause negative pressure at the cap end of the cylinder &

corresponding pressure at the rod end & pressure drop across port P to A and port B to T

ii) If the load is 5000 N, find the pressure drop across port P to port A & corresponding

pressure at the rod end. Is it possible to obtain this pressure drop valve area ratio 1:1

iv) If the valve area ratio is 2:1 what is the overrunning load. Comment on result
2: Consider the hydraulic circuit with resistive load shown in the Figure below. The

cylinder ratio is 2:1, Pressure ,

. . If the valve has 2:1 area ratio,

Determine, and total pressure drop
Q1 Solution

Since the cylinder area is 2:1

[ ]

To find the load which causes the negative pressure on cap end set =0

[ ] [ ]

[ ] [ ]

[ ] [ ]

[ ] [ ]

[ ] [ ]

Any load greater than 3500 N will cause a negative pressure at the cap end of the cylinder. If the
overrunning load is 3500 N, the pressure at the rod end is given by

The pressure drop across the port P to port A orifice is

For any overrunning load greater than 3500N , the valve will not create enough pressure drop
across the port B to port A orifice to maintain control of load. Suppose the load
then we can calculate
 [ ] [ ]
[ ] [ ]

[ ] [ ] [ ] [ ]

To create =-33.33bar , the pressure drop across the port P to port A orifice must be

, which is not possible.

The required pressure at the rod end is

Let the use the valve with the area ratio of 2:1

√ √

Solving we get

Using in the equation

 { }

Solving for the pressure at the end of the cylinder we can get

{ }

[ ] [ ]

[ ] [ ]
Setting

[ ] [ ]

For 2:1 area ratio [ ]

[ ] [ ]

Therefore 2:1 area ratio valve can control the overrunning load more than 2.5 times the size load
controlled with a 1:1 area ratio valve.

Now the cap end pressure can be calculated using the equation

[ ] [ ]

[ ] [ ]

[ ]
[ ]
[ ] [ ]
 [ ]

The pressure drop across the valve is

Total pressure drop across the valve is

Q2- solution

We can write the force balance on the cylinder as

Where

solving for

If the area ratio is unity ( i.e. ) and the orifice equation becomes

√
Solving we get

Also

Solving we get

{ }

[ ]
[ ] [ ]

If and other parameters as same as previous example

[ ]
[ ] [ ]
[ ]

[ ] [ ]

Using

The pressure drop across the valve is

Also

If the valve has a 2:1 area ratio.

[ ]
[ ] [ ]
[ ]

[ ] [ ]

The pressure drop across the valve

Also
 LECTURE 24 TO 26 – HYDRAULIC CIRCUIT DESIGN

SELF EVALUATION QUESTIONS AND ANSWERS

1 A hydraulic cylinder is to compress a car body in 10 seconds. The operation requires a

stroke of 3 m and a force of 40,000 N. If a 7.5 N/mm2 pump has been selected, find the
following:
i) Required piston area and piston diameter.

ii) The necessary pump flow.

iii) The hydraulic power capacity in kW

2: A pump supplies oil at 20 gallons/min to a 50 mm diameter double acting hydraulic

cylinder. If the load acting during the extending and retracting stroke is 5000 N and
diameter of rod is 25 mm, find:
(a) Hydraulic pressure during extension stroke
(b) The piston velocity during extension stroke
(c) The cylinder kW capacity during extension stroke
(d) Hydraulic pressure during return stroke
(e) The piston velocity during return stroke
(f) The cylinder kW capacity during return stroke

3 Operator of a hydraulic jack makes one complete cycle per second using hand pump.
Each complete cycle consists of two punch strokes (intake and power strokes). The pump
has a 25 mm diameter cylinder and load cylinder is of 90 mm diameter. If the average hand
force is 150 N during power stroke, determine:
i. The load that can be lifted
ii. The number of cycles required to lift the load through 250 mm, assuming pump
piston has 50 mm stroke and there is no oil leakage.
iii. The power exerted by the operator assuming 100 % efficiency
The details of the pump are given in below diagram
 Hand force

150 mm 50 mm Load

C
A B

Handle

Pump piston Check valve 2

Check valve 1

Atmospheric Load Cylinder

Pressure

Bleed valve

Oil Tank

4 Determine the force that can be applied by a hydraulic booster with the following details:
Air Piston area = 12500 mm2
Oil piston area = 625 mm2
Load piston area = 15600 mm2 .
Air Pressure = 0.75 N/mm2

Area = 625mm2 Area = 15600

mm2

Oi Oi
l l

AIR
Area = 12500
mm2

P =0.75 MPa
5 Design a hydraulic circuit for a punching press with five stations operated by 5 parallel
cylinders connected to an intensifier. The cylinders are spring return type and the
punching stroke required is 10 mm travel and used for punching 10 mm diameter holes on
sheet metal of 1.5mm thickness of mild steel. The ultimate shear stress of the material of
the sheets is 300 N/mm2. determine the oil pressure of hydraulic system. The details of the
intensifier used and cylinder details are as below:
Number of load cylinders = 5
Inlet Piston area of intensifier = 12500 mm2
Outlet piston area of Intensifier = 625 mm2
Load piston area = 15600 mm2

6 Hydraulic ram type accumulator is shown in the figure below. Write an expression for
the capacity of accumulator. If A=2m2, lift of the ram = 10 m. a) Calculate the capacity of
accumulator. b) If the displacement volume of the accumulator is 4 litres of fluid and
diameter of its plunger is 375mm. find the stroke.

Weight

Ram

Oil

Inlet Outlet
7.An accumulator is loaded with 500 kN weight. The ram has a diameter of 30cm and a
stroke of 6m. Its friction may be taken as 3%. It takes 120 sec to fall through its full stroke.
Find the total work supplied and power delivered to the hydraulic appliance by the
accumulator, when 7.5 LPM delivered by a pump, while the accumulator descends with
the stated velocity. Take specific weight and density of oil as 1000 units.

8.An accumulator has a ram of 37.5 cm diameter and 7.5 m lift. It .is loaded with 120
tonnes of total weight. If the packing friction accounts for 2.5 % of the total force on the
ram, determine power being delivered at the mains, if the ram falls steadily through its full
range in 2.5 min and if pumps are delivering 900 LPM at the same time.
Q1 Solution

Load required = 4000 N.

Stroke length = 3 m.

Time taken to compress = 10 s.

Pump discharge pressure = 7.5 N/ mm2.

We know,

i) Force acting on the piston rod = Area of piston × Pressure from the pump

40,000 = A × 7.5

Required piston area, A = 5333.33 mm2

Piston area ( ) = 5333.33 mm2

Piston diameter, D = 82.4 mm

ii) Pump flow = Area × Velocity = 5333.33 × 0.3 = 1.6 × 10-3 m3/s

(Velocity = stroke length / time taken = 3000/10 = 300 mm/s = 0.3 m/s)

iii) Power capacity in kW = Force × Velocity

= 40000 × 0.3 = 12 kW

Q2 Solution

Pump discharge = 20 gallons/min

Piston diameter = 50 mm
Rod diameter = 25 mm
Load = 5000 N
Let us first consider extension stroke
i) To calculate hydraulic pressure during extension stroke

Force = Pressure × Area

Pressure during extension P = (4 × 5000)/(π × 502)

= 2.55 N/ mm2.
 ii) To calculate piston velocity during extension

Pump discharge = Area × Velocity

Pump discharge = 20 gallons/min

= 20 × 3.785 litres/min ( 1 gallon = 30785 litres )

= (20 × 3.785 × 10-3) / 60 m3/s

Substituting the values,

(20 × 3.785 × 10-3) / 60 = (π/4) × (50 × 10-3)2 × Velocity

Velocity V = 0.643 m/s

iii) To calculate Kilowatt capacity:

Kilowatt capacity = Force × Velocity

= (5000 × 0.643) / 1000 = 3.21 kW

Let us now consider Return Stroke

iv) To calculate hydraulic pressure during retraction stroke

Pressure = Force / Area

= (4 × 5000) / (π × (502 - 252)) = 3.40 N/mm2.

v) To calculate piston velocity during return

Velocity = Q / A = [(20 × 3.785 × 10-3) × 4)/(π × [(50 × 10-3)2 – [(25 × 10-3)2])]

= 0.857 m/s

vi) To calculate Kilowatt capacity

Kilowatt capacity = Force × Velocity

= (5000 × 0.857) / 1000 = 4.28 kW

Q3 Solution
 Length of the lever = 200 mm

Hand force = 150 N

Pump piston diameter = 25 mm

Load cylinder diameter = 90 mm

Lift required = 250 mm

Pump piston stroke = 50mm

As per Pascal’s Law,

Pressure in the System = Force applied (Fp) / Area of pump cylinder piston

Taking moment at the hinge of the hand lever, Force Fp can be calculated as below:

Fp ×50 = 150 ×200

Fp = (150 ×200) / 50 = 600 N

Pressure P = (600 × 4)/ (× 252) = 1.22N/mm2

(i) Load that can be lifted = Pressure ×Area of the load cylinder

= (l.22x x902)/4=7761N

(ii) Number of Cycles:

Let N be number of cycles

The amount of volume required to lift through 250mm

= (N ×Volume displaced per cycle of the piston pump.)

Rearranging,

(N × ×252 ×50) / 4= (250 x ×902) /4

 N= 65 cycles

Since 1 cycle takes 1 second,

Total time taken = 65 seconds

(iii) Kilowatt capacity = Force ×Velocity

Velocity = Lift/ Time taken = 250 ×10-3 / 65

Therefore,

Kilowatt capacity = (7761 ×250 ×10-3) / (65 ×1000) = 29.85 W = 0.029 kW.

Q4 Solution

Air Piston area = A1 = 12500 mm2 (given)

Oil piston area = A2 = 625 mm2 (given)

Air pressure = P1 = 0.75 N/mm2 ( given)

Lord position area = 156000mm2

Oil Pressure = P2

For intensifier / boosters, we can write

A1xP1 =A2 ×P2

Therefore,

Pressure at oil cylinder P2 (A1 ×P1) / A2 (12500 ×0.75) /625 = 15 N/mrn2

This pressure acts on the load piston area.

Thus, the force applied = Pressure ×Area = 15 ×15600 = 234 kN

Q5 Solution

Diameter of hole to be punched (D) = 10 mm

Stroke length required (L) = 10 mm

Thickness of the sheet material (t) = 1.5 mm

Shear stress of the sheet material = 300 N/mm2

The shear area on the sheet metal =  ×D ×t =  ×10 ×1.5 = 47.12 mm2

The cutting force required to shear the above area = Shear stress ×Shear area

= 300 ×47.12 = 14137.16 N

Therefore, the pressure required at the load cylinder

= (Cutting Force / Cross section of load cylinder piston)

= 14137.16 / 15600 N/mm2 = 0.91 N/mm2

This pressure is to be delivered at the outlet of the intensifier

Therefore, the pressure required at the inlet of the intensifier from the pump is

P ×12500= 0.91 ×625

Pump pressure required P = 0.0455 N/mm2

Area = 625mm2
Area = 15600 mm2

Oil
10mm

AI
R Area = 12500 mm2

Supply from pump

To determine the stroke of the Intensifier to have a punching stroke of 10 mm at all five load cylinders:

Let, Length of Intensifier stroke required to supply oil to 5 load cylinders= L1

Volume of fluid required at the punching end, Qp= 5 ×Area of load piston ×Stroke

= 5 ×15600x10=780000mm3

Volume at the Intensifier, Qp = Area of Outlet piston ×L1 = 625 ×L1

Therefore, The stroke of Intensifying cylinder required, L1 780000/625 = 1248 mm = 1.248 mm

Q6 Solution

Part (a)

The Sliding rum is loaded with weights. When the fluid under pressure enters the accumulator cylinder

through the inlet valve, it lifts the loaded ram until the cylinder is full of fluid. At this stage, the

accumulator has stored its maximum amount of energy, which is known as capacity of the accumulator,

Let, A = Area of the cylinder

H = Lift of the cylinder

P =Intensity of fluid pressure supplied by the accumulator

Then,

The capacity of the accumulator = PAH

If A=2m2, lift of the ram = 10 m

and fluid pressure = 1.5 kg/cm2 = 150000 N/m2)

Capacity of accumulator = 150000 ×2 ×10 = 3000000 N/m

The above diagram shows the ram type of accumulator

Part (b)

Displacement volume = 4 litres = 4000 cm3

Diameter of plunger (D) = 375 mm = 37.5 cm

Area of the plunger = ( /4)D2 = (/4) 37.52 = 1104.47 cm

Length of the stroke = Displacement Volume / Area of the plunger

= 4000 / 1104.47 = 36.2mm

Q7Solution

Load on the accumulator = 500 kN = 500000 N

Diameter of the ram, D = 30 cm = 0,3 m

Length of the stroke = 6 m

Friction in the accumulator =3 %

Time taken to fall one stroke =120 sec

Discharge of the pump, Q =7.5 lit/mm = 0.0075 m3/min

Area of the ram = (/4) D2 = (/4) 0.32 = 0.070685 m2

Net load on accumulator = Actual load ×(l – percentage of friction)

= 500000 ×0.97 = 4,85,000 N

To calculate work supplied to the hydraulic machine:

Work supplied by the accumulator per mm = Load ×velocity

Velocity to descend, V =6 m in 120 sec = 6 m in 2min
Work supplied by the accumulator per min = 4,85,000 ×(6/2)
14,55,00 Nm/min
Intensity of pressure in the accumulator, P= Net load / Area
 = 4,85,000 / 0.070685
6861427.46 N/m2

P = H ×density ×g

Rearranging, H = p/ (density ×g)

= 6861427.46 / (1000 ×9.81)

= 699.43 m

Work supplied by the pump per min = (Sp.wt ×Q) ×H

= 1000 ×.81 ×0.0075 ×699.43

= 51460.56 Nm/min

Total work supplied to the hydraulic machine = 14,55,000 + 51460.56

= 1506460.56 Nm/min

Total Power delivered to the hydraulic machine:

Power delivered in watts = Work supplied per second

= 150646056 / 60

= 25107.676 Nm/sec = 25107.676W

Power delivered = 25.107 kW

Q8 Solution
Total weight of the ran = 120 tonnes = 120 ×103× 9.81N

Frictional force = 2.5 %

Net force = Total weight ×(1-2.5%)

= 0.975 ×Total weight

= 0.975 ×120 ×103 ×9.81 N = 1147770 N

Diameter of the rain, D = 37.5 cm = 0.375 m2

Pump discharge = 900 LPM

Lift = 7.5m
Time to fall = 2.5min

Pressure of fluid leaving the accumulator = Net force/Area

p = (1147770)/(/4)D2

p = 1147770 / ( /4) 0.3752

p = 10392079.3 N/rn2

p = 10.39 N/mm2 = 10.39 MPa

Rate of discharge from the accumulator, Q1 = (Area ×lift)/ Time to emptying

= ( /4) 0.3752 ×7.5) / (2.5 ×61)

= 0.00552 m3/sec

Rate of discharge from pump, Q2 = 900 LPM

= 900 × 10-3/60 = 0.015 m3/sec

Total rate of supply to the mains Q = Q1 + Q2

= 0.00552 + 0.015 m3/sec = 0.02052 m3/sec

Power delivered to the mains = Q × p= 0.02052 × 10392079.3

= 213245.467 W=213.2kW
 LECTURE 27 – SERVO VALVES

SELF EVALUATION QUESTIONS AND ANSWERS

1 A torque motor is connected in a push-pull circuit. Each coil has a resistance of 30 ohms
and is rated at 100 mA.

Find:

a. The voltage of each coil when the armature is centered.

b. The maximum value of ΔI
c. The maximum control power for the torque motor.

2 A torque motor is connected in a parallel circuit. Each coil has a resistance of 30 ohms
and is rated at 100 mA.

3 A torque motor is connected in a series circuit. Each coil has a resistance of 30 ohms and
is rated at 100 mA.

4: A servo valve is flow rated at 80 LPM at 90 bar differential. It is to be operated in a 150

bar system. What will its adjusted flow rate be at the optimum power transfer ?

5 : For the servo valve of previous problem, determine the power loss, heat generation rate,
and the temperature rise across the valve. The specific heat of the oil is 1.8 kJ/kg c and
specific gravity of oil is .895

6:In the given servo system, suppose the forward loop contains a hydraulic motor. The
forward loop gain is 200rpm/V and that the feedback loop consists of a tacho generator
that has a gain of 0.1V/rpm. What will be the speed of the hydraulic motor for an input of
4V?
Q1Solution:

a. The maximum voltage for the coil is E = IR

E = 100 mA х 30Ω = 3V

The armature is centered when

E = Emax/2 = 1.5 V

b. The differential current is I = IAD – IBC

The maximum value will occur when the maximum voltage is applied to one coil, so that
zero voltage is applied to the other. In this case
ΔI = IAD – IBC = Emax/R -0 = 3V / 30Ω = 100 mA
c. The maximum control power is then to each
P =( ΔI2)R = (100 mA)2(30 Ω) = 0.3 W

Q2 Solution: the voltage to each coil will remain the same (3 V); however, the current through
the circuit will increase because of the lower resistance. For a parallel circuit made up of two
equal resistors, the equivalence resistance is R/2; in this case, 15 ohms.

The value of I is the total current, which we find from

IP = E/R = 3V/15Ω = 0.2 A = 200 mA

Control power, P = (IP)2(R/2) = (200 mA)2(30Ω/2) = 0.6 W

Q3 Solution: here, the total resistance is 2R, or 60 ohms. The maximum current will be 100 mA
because of the series connection. The maximum voltage, then, is

E = IR = (100 mA)(60 Ω) = 6 V

The control power , P = (Is)2 (2R) = (100 mA)2(2)(30 Ω) = 0.6 W

Q4 Solution: For optimum power transfer, the pressure drop across the valve should be = 50

bar

From equation we have

Q = QR √ = 80√ = 59.63 LPM

Q5 Solution

The power loss is

HP = Δp × Q = 50×105×(59.63/1000)×(1/60)

= 4.97 kW

The resultant heat generation rate is found fro equation to be

The increase in the fluid temperature is

The weight flow rate is

Therefore,

This is the temperature rise experienced by every drop of oil that flows through the valve. The
rise occurs in the time required for the fluid to flow through the portion of the valve where the
pressure drop occurs.
Although the weight flow rate appears in the equation, the temperature rise is actually
independent of flow rate. So the temperature rise for any fluid is a function of pressure drop
only.

R C
Q6 Solution:

R E
+ G C

Figure for problem 6

Reference input, R = 3.5V.

Forward loop gain, G = 200 rpm/V
Feedback loop gain, H = 0.1V/rpm
The equation of closed loop transfer is given by,

+
=> [ + ]
=> [2 +2 ]
=>
 LECTURE 24 TO 26 – ACCUMULATORS

SELF EVALUATION QUESTIONS AND ANSWERS

1. An accumulator has a ram diameter of 25 cm and lift 5 m. it is loaded with 50 Tonnes of

total weight. The packing friction is 5% of the load on the ram. Find the power delivered
to the main if the ram descends steadily through its full stroke in 200 seconds while the
pump delivers 800 LPM though the accumulator

2 Calculate the accumulator volume of a bladder type accumulator having a gas ration of
3:1 at full charged condition. The index of polytropic expansion is 1.25. The system
demand volume is 6 liter. The permissible drop is 5% (x = 0.05).

3. What size of accumulator is necessary to supply 10000 cm3 of fluid is a hydraulic system
of maximum pressure of 200 bar to 100 bar minimum. Assuming N2 gas per-charged
pressure of 80 bar. Find adiabatic and isothermal solution.

4. A gas charged accumulator supplies energy to a system with 10litres of oil within the
pressure range of 200bar to 150 bar. The accumulator has the per-charge pressure of
90bar. What should be the size of the accumulator, if the oil is to be supplied i) in about 8
seconds and (ii) in about 8 minutes time?

5 The circuit has been designed to crush a car body into bale using a 150 mm diameter
hydraulic cylinder. The hydraulic is to extend 2.50 m during a period of 10s. the time
between crushing strokes is 8 min. the following accumulator gas absolute pressures are
given:
P1 = Gas precharge pressure 90bar(abs), P2 = Gas charge pressure when pump is turned
on 200 bar(abs) = pressure relief value setting,P3 = Minimum pressure required to actuate
load 125 bar (abs).Calculate: (i) the required size of the accumulator
(ii) What are the pump hydraulic kW power and the flow requirements with and without
accumulator?
Q1 Solution:

Pressure of water during descent =

P = Pa

= 9492.76 kPa
Pressure head =

= 967.66 m
work done by the accumulator due to pump work
= m × g × head N-m
=

= 12650 watts
work done by the accumulator during its discharge

= 11637.5 watts
Total work added to the pipe line = Work supplied by the accumulator
+ Work supplied by the pump
= 138207.67 W
Therefore, power delivered to the pipe line = 138.208 kW

Q2 Solution:

( ) =

 = 0.96(VHP+6) = 144 litres

 VAcc = 144+ litres

Q3 Solution:
V1 = Volume of accumulator cm3
V2 = Volume of gas at high pressure, mc3
 P2 = Maximum pressure, bar
P = Minimum pressure, bar
P1 = Per-charged pressure, bar
V1=? V2 ? = P1 = 80 bar, p2 = 200 bar, P= 100 bar

Let V1be the volume of gas occupied in the accumulator at per-charged 80 pressures.
Let V2 be the volume of gas occupied in the accumulator at 200 bar and that time
10,000 cm3 of oil has also occupied in the accumulator.
V1 = V2+10000 cm3
V2 = V1-10000
(a) Adiabatic process: =
= 1.25
=

= ( )

0.4 = ( )

V1-10000 = 0.4804 V1
V1-0.4804 V1 = 10000
0.5195 V1 = 10000
V1 = 19249.27 cm3
Size of accumulator = 19249.27 cm3
(b) Isothermal precess:
P1 V1 = P 2 V2
80 × V1 = 200 × (V1 – 10000)
=

0.4 =
 V1- 10000 = 0.4V1
V1-0.4V1 = 10000
0.6 V1 = 10000
V1 = 16666.66 cm3
Size of accumulator = 16666.66 cm3

Q4 Solution:
Stages of precharging, charging and delivery is shown below

= 200bar
=90 bar

10 L

Let precharging pressure be P1 (90 bar) and V1 . Gas is compressed by incoming oil
from pressure 90 to 200 bar and when the bladder is compressed to 200 bar the volume
of oil inside the accumulator is 10 Liters. Therefore we can write.
V3-V1=10
Considering adiabatic condition with = 1.3
(i) In about 8 seconds:
=

= ( )

=( )

( ) =( )

V1=2.723 LPS
Capacity of accumulator =2.723 8 =21.78 Liters
(ii) In about 8 minutes:
Capacity of accumulator =2.723 8 =1307.34 Liters

Q5Solution: Stages of precharging, charging and delivery is shown below

= 125bar
=90bar bar

Let precharging pressure be P1 (90 bar) and V1 . Gas is compressed by incoming oil
from pressure 90 to 200 bar and accumulator is discharged till pressure reaches
125bar.
Solution
Case a – Without the use of accumulator
Let compression and expansion of gas follows isothermal law
P1 V1 = P2V2 = P3 V3
Vc=volume of hydraulic cylinder. It can accommodate (V3 - V2) amount of oil
Vc = (V3 - V2)
P3 V3 = P2 V2
V3 = ---- (a)

Vc = ---(b)

Using (a) in (b) and solving we get

V2 = 0.07362 m3
V3 = 0.11780 m3
V1 =

Case b – With the use of accumulator

Pump charges accumulator in every 2.5 minutes. In other words, 2 times in 5 minutes.

Flow supplied by the pump Qp =

 Qp =

Neglecting all losses, Power supplied to pump

Ppump =
( )( )
=

Without accumulator: Pump extends cylinder in 10 sec.

Flow supplied by the pump Qp=

Neglecting all losses, Power supplied to pump

( )( )
Ppump =

It can be see that Flow and power requirement by pump is more without accumulator.
 LECTURE 30 to 31 – ACCESSORIES USED IN FLUID POWER SYSTEMS

SELF EVALUATION QUESTIONS AND ANSWERS

1. Determine the Beta ratio of a filter when , during test operation, 20000 particles greater
than 10 enter the filter and 2000 of these particles pass through the filter. What is the
beta efficiency.

2. The pressure drop across a sticking control valve is observed to be 80 bar if the fluid
has a specific gravity of 0.9 and a flow rate of 0.2 LPS, estimate the rise in temperature of
fluid that can be attributed to the control valve.

3 Oil at 50 and 70 bar is flowing through a pressure relief valve at 40 LPM. What is the
downstream oil temperature?

4. Hydraulic machine has the following duty cycle. Idle at 15 bar for 30 seconds. Clamp

work piece at 100 bar for 5 seconds. Approach at 15 bar for 2 seconds, perform work at

300 bar for 3 seconds, declamp , return at 15 bar for 2 seconds. The pump flow is 100 LPM.

Total surface area of the oil reservoir is 2.5 m2. Hydraulic pipe line is 25 mm in diameter

and 2500 mm long. Calculate the netw wasted energy that needs to be dissicpated and

recommend a suitable heat exchanger if necessary. Room temperature is 20 . Volumetric

efficiency of pump =0.85. density of the oil used = 806 kg/m3.

5. A hydraulic pump operates at 70 bars and delivers oil at 0.00126 m3/s to a hydraulic

actuator. Oil discharges through pressure relief valve (PRV) during 50 % of the cycle time.

The pump has an overall efficiency of 85 % and 10 % of power is lost due to frictional

pressure losses in the hydraulic lines. What heat exchanger rating is required to dissipate

all the generated heat.

6. What would be size an adequate size of reservoir for a hydraulic system using 0.001 m3/s

pump?

7. A pump delievers oil to a hydraulic motor at 10 LPM at a pressure of 15 MPa. If the

motor delivers 2kW and 70% of the power loss is due to internal leakage , which heats the

oil, calculate the heat generation rate in kJ/min.

Q1 Solution

Beta Efficiency =

Beta Efficiency = 1 -

Q2 Solution: The heat generated by the pressure drop across the control valve is
Heat loss generated = 80 x 105x0.2 x10-3 = 1600 Watts/s
The mass flow rate of fluid through the valve is computed from
Mass flow rate , = 900 x 0.20 x10-3 = 0.18
Solving for the temperature rise in of the fluid
( )
T ( )
( ⁄ ) ( ⁄ )

Q3 Solution
First calculate the power lost/wasted
Power Lost = P (bar) × Q (LPM) = (70 x105 N/m2) (40x10-3 m3/min) x1/60(seconds) = 4370
watts = 4.67 kW
Next calculate the oil flow-rate in units of kg/second and the temperature increase:
Oil flow-rate (kg/s) = 895 × oil flow-rate (m3/s) = 895x40x10-3/60 = 0.596 kg/s
( )
Temperature ( ) =
( ) ( )

Downstream oil temperature = 50+4.35 =54.35

Q4 Solution

Power dissipated in kW
Energy consumed during 30 seconds.

Power dissipated during clamping

Since clamping takes place in 5 seconds, energy consumed is

Power dissipated during approach

Since approach takes place in 2 seconds, energy consumed is

Power dissipated during Forward (work)

Since work takes place in3 seconds, energy consumed is

Power dissipated during retrun

Since return takes place in 2 seconds, energy consumed is

Total power dissipated in 42 seconds = 0.058 kWh =

Mass flow rate = 860 0.001=0.86 kg/second

( )
Temperature ( ) =
( ) ( )

Temperature rise is small, therfore there is no need for a heat exchanger.

Q5 Solution

{ }

{ } ( )

* + ( )

* + ( )

Total loss = 1.56+4.41+0.44=6.41 kW

Select heat exchanger rating of 6.41 kW

Q6 Solution

Size of the reservoir = 3 to 4 times the capacity of pump = 4 ( )

( )
Q7 Solution

Motor delivers 2 kw ,therfore loss is 0.5 kW

 LECTURE 33 – INTRODUCTION TO PNEUMATICS

SELF EVALUATION QUESTIONS AND ANSWERS

1. If an empty 0.076 water system tank on which pressure gauge initially reads 1.38 bar
is half filled with water, such as that shown in Figure , what will be the pressure reading on
a gauge attached to the tank.

0.076 Half filled with

water tank liquid

2. If an accumulator using dead weight ballast against an initial volume of 0.025 of a

gas is heated from 300 K to 366 K. what volume will the heated gas occupy?
3. The constant volume vessel shown in Figure on which pressure gauge reads 138 bar is
heated from 300 K to 395 K , what will the gauge read ?

= 138 bar = ?

Control Control
valve (1) valve (2)

300 K 395 K

Heat
Pressure vessel

4. Gas in a 0.025 cylinder at 138 bar is reduced in volume to 0.016 . While heated
from 297 K to 395 K. what is the final gauge pressure in the cylinder?

138 bar 297 K

395 K

0.025
0.016

5. A fixed quantity of gas, at constant pressure, occupies a volume of 8.50 L and has a
temperature of . (a) What volume will the gas occupy if the temperature is increased
to ? (b) At what temperature will the volume be 5.00 L?
Q1 Solution:

Since the temperature is constant, we can use Boyle’s Law

Q2 Solution:

Since the pressure is constant, From Charles law, we have

Solving we get,

Q3 Solution

Since the volume is constant, by applying Gay –Lussac’s law, we get,

Solving we get,
Q4 Solution

Using General gas law

Solving we get,

Q5 Solution

Part a

Since the pressure is constant, From Charles law, we have

Solving we get,

Part b

Again rearranging the gas law for constant pressure term, we get

Solving we get,
 LECTURE 34 – PRODUCTION OF COMPRESSED AIR

SELF EVALUATION QUESTIONS AND ANSWERS

1: The bore and stroke of a single acting air compressor are both 10 cm.
Clearance volume 80 cc, index of compression and expansion 1.23. Suction
pressure 1 bar, delivery pressure 7 bar , speed 4000 RPM. If the temperature
at the beginning of the compression is 22 Find the amount of free air dealt
with by the compressor per minute at a pressure of 1.05 bar and temperature
of 16

2: A single acting stage air compressor is required to deal with 17 m3/min of

air measured at 1bar and 15 The pressure and temperature at the end of
suction is 0.98 bar and 30 . the delivery pressure is 6.3 bar. The RPM of
the compressor is 500. Assuming a clearance volume of 5% of the stroke
volume, laws of compression and expansion as ) ,
calculate the necessary stroke volume, temperature of the air delivered and
power of the compressor.

3: A single stage , single cylinder air compressor has a cylinder diameter 15

cm, and a stroke of 22.5 cm. Air is drawn into the cylinder at a pressure of
1.05 bar and a temperature of 15 . It is then compressed adiabatically to 6.3
bar. Find the theoretical power required to drive the compressor if its speed
is 100 RPM. Find also the weight of the air compressed per minute.

4: A two stage air compressor compresses 1 kg/min of air from 1 bar to

42.18 bar. Initial temperature is 15 . At the intermediate pressure the
intercooling is perfect. The compression takes place according to law
Neglecting the effect of clearance determine the
minimum power required to run the compressor. Also find the mass of
cooling water required in the intercooler, if the temperature rise of water is
limited to 5
Q1 Solution

( )

( )
[ ( ) ]

[ ( ) ]

Thus,
Q2 Solution

6.3 bar

p
0.98 bar

( )
[ ( ) ]

[ ( ) ]
 ( ) ( )

( )

( )

Q3Solution

Solution

( )

[( ) ]

[( ) ]

( )
 ( )

( ) ( )

( )

Q4 Solution

Solution

For perfect intercooling

√ √

( ) ( )

Minimum power required

( )

( )

Heat rejected in the intercooler

( )

( )

Solving we get
 LECTURE 35 – COOLING AND DRYING OF COMPRESSED AIR

SELF EVALUATION QUESTIONS AND ANSWERS

1: A compressor delivers 500 m3 of free air per hour at a pressure of 8 bar gauge and a
temperature of 60 . Atmospheric air at compressor intake has a relative humidity of 70
% and a temperature of 20 . Determine the amount of water that can be extracted from
the compressor plant per hour.

2 : Find the amount of condensate in one hour if 22 kW compressor operates under the
following condition a) Air at 60% relative humidity and 30 ambient temperature is
pressurised to 7 kg/cm2(7 bar). It is then cooled to 25 . Compressor output is 3 Nm3/min
at 7 kg/cm2(7 bar)

3 : Air is used at a rate of 2 from a receiver at 40 and 1000 kPa (gauge). If the
atmosphere pressure is 101 kPa (abs) and the atmospheric temperature is 20 . How many
of free air (standard ) must the compressor provide?

4: a. Calculate the required size of the receiver that must supply air to pneumatic system
consuming for 10 minutes between 828 kPa and 690 kPa before the
compressor resumes operation b. what size is required if the compressor is running and
delivering at
Q1 Solution: Refer to Table 3.3

At 20 and zero bar gauge pressure, 100 m3 of free saturated air contains 1.73 kg of water.
From the definition of RH

Amount of water actually present in air = 1.211 kg

Since 400 m3is delivered, water content of air entering the compressor = 1.211 =6.055 kg

From the Table 3.3, corresponding to 60 , and 8 bar compressor output pressure, amount of
water per 100 m3 of free saturated air is given by 1.44

Since 400 m3is delivered, water content of air leaving the compressor = 1.44

=7.2 kg

Therefore the amount of water extracted from the compressor plant per hour is

7.2-6.055=1.145 kg

Q2 Solution:
Refer the nomogram given in the Figure 3.6, locate point 1 which corresponds to inlet
temperature of the compressor and erect a perpendicular line to meet 60%RH line. And then
draw the horizontal line to cut 6bar pressure line. We get pressure dew point temperature as
60 . Since the air is cooled to 25 erect a vertical line to cut 6 bar pressure line. From the
nomogram water liquid collected is 20.7-3.6 = 17.1 g/Nm3

Q3 Solution:

( ) ( )

( )
Using General gas law

Solving we get

Q4 Solution: The air receiver size can be determined by using the following equation
[ ]
[ ]
Part a
( )
( )

( )

( )

( )
( )

[ ]
[ ]
Solving we get

Part b
The required size of the compressor when the compressor is running and delivering air at
[ ]
[ ]
Solving we get
 LECTURE 36 – CONDITIONING AND DISTRIBUTION OF COMPRESSED AIR

SELF EVALUATION QUESTIONS AND ANSWERS

Problem 1:

Refer to the relevant air consumption chart and compressor specification chart, select a suitable
compressor for a machine tool workshop having the following air tools

Item Air tools Quantity Working Utilization

no pressure factor
(
bar)(absolute)
1 Cylinder (70 mm) 5 6 0.3
2 Spray gun(1.3mm) 4 5 0.3
3 Air screw driver(5mmPT) 2 6 0.2

Problem 2:

In machine shop, there are four numbers of compressors installed for compressed air
requirement. All the four will be in operation at any point of time. The rated capacities of
compressors are 2.84 m3/minute, whereas the actual output of each are given below

Compressor 1 2.17
Compressor 2 2.23
Compressor 3 2.75
Compressor 4 2.50

The power consumption of these compressors is 29kW, 27Kw, 22 and 25 kW The

compressor is continuously operated at 7 bar pressure. During the measurement it was
observed that the leakage losses constitute around 45% of the actual output of the
compressor. Estimate the following

a) Power loss due to leakage

b) The power saving if 50% of leakages are arrested
Note that the compressors have on and off control
Q1 Solution

Let us first calculate the total demand

Item Air tools Quantity Working Utilization Air Air Total air demand
no pressure factor demand demand
( bar)(absolute) LPM at STD
@9bar
A C B A B C
1 Cylinder (70 5 6 0.3 4.6 3.5 5 3.5 0.3=5.2
mm)
2 Spray 4 5 0.3 50.9 31.8 4 31.8 0.3=38.2
gun(1.3mm)
3 Air screw 2 6 0.2 250 187.5 2 0.2=75
driver(5mmPT
)
Total demand =
118.4 LPM @9
bar

Step 1: Standard pressure (STD) = 6+2 = 8 bar

Step2: Find the air demand at STD pressure

To find Q3 at FAD ( at FAD, P2 = 1bar)

Therefore
From the compressor specification chart, the selected compressor is as follows

Model Number M6
Power 11 kW
Working pressure 12 bar
Compressor speed 710 RPM
Tank capacity 283 Liter

Q2 Solution

Part a

Output of all four compressors

2.17+2.23+2.75+2.50= 9.65

Power consumed by the compressor

29+27+22+25 = 103 kW

Specific power consumption =

Leakage quantity = 45 % of the actual output = 0.45 9.65 = 4.3425

Equivalent power loss = 10.68 4.3425= 46.4 kW

Part b

If 50% leakages are arrested that is = , power loss is 46.4

23.2 kW

Hence power saving is 23.2 kW

 LECTURE 37 – PNEUMATIC ACTUATORS

SELF EVALUATION QUESTIONS AND ANSWERS

1. A pneumatic cylinder has a bore of 200 mm and a piston rod diameter of 140 mm. For
an extend speed of 5m/min. Calculate

a) The supply flow rate

b) The flow rate from the annulus side on extend
c) The retract speed using QE
d) The flow rate from the full bore end on retract

2. A compressor supplies air at 0.002 m3/s to a 50mm diameter double acting cylinder and
a rod diameter is 20mm. If the load is 1000N both in extending and retracting, find

a. Piston velocity during the extension stroke and retraction stroke

b. Pressure during the extension stroke and retraction stroke
c. Power during the extension stroke and retraction stroke

3. A pneumatic cylinder has to move a table of weight 2000N. Speed of the cylinder is to be
accelerated up to a velocity of 0.13m/s in 0.5 seconds and brought to stop within a distance
of 0.02m. Assume coefficient of sliding friction as 0.15 and cylinder bore diameter as
50mm. Calculate the surge pressure.
Q1Solution

a) Flow rate of oil to extend cylinder at 5m/min

QE = area of piston × velocity

= × (200/1000)2× =0.00262m3/min

=0.00262 ×60 ×1000 = 157 LPM

b). Flow of oil leaving cylinder qEis given by

= annulus area × velocity

= ×((200/1000)2- (140/1000)2)× = 80 LPM

c). The same fluid flow rate used to extend the cylinder(157LPM) is used to retract the cylinder.
Retract cylinder velocity V is given by

v= QE/ (A-a)

QE= 157 LPM = 0.00262m3

(A-a)= annulus area= 0.01602m2

v= =0.614m/s = 9.8 m/min

d) Flow from full bore end of cylinder QR is given by

Q= A× v

= 0.03142×0.164 =0.00515m3/s = 309 LPM

Q2 Solution

Oil flow rate from pump, Q = 0.002 m3/s

Diameter of the cylinder, = 50mm = 0.05 m

Diameter of the rod, = 20mm= 0.02m

Load during the extension and retraction F = 1000N

Part a

Piston velocity during extension stroke VE =

Piston velocity during retraction stroke VR =

Part b

Cylinder pressure during extension stroke PE = = 5.1 bar

Cylinder pressure during retraction stroke PR =

Part c

Cylinder power during extension stroke =

Cylinder power during extension stroke =

Q3 Solution

Initial velocity u = 0m/s

Final velocity v= 0.13m/s

Acceleration a = =

Force required to move the piston = Dynamic force + frictional force

=[ ] =[ ]

= 353 N

To overcome this force, the pressure required in the hydraulic cylinder is

From the equation for velocity, acceleration and distance v2 – u2 = 2as

a=

(The –ve sign indicates that it is deceleration)

The total force required to stop the motion of a cylinder

Then pressure created by this opposing force is

Thus surge pressure Ps= P1 + P2 = 1.79 + 1.92= 3.75 bar

 LECTURE 38 – PNEUMATIC VALVES

SELF EVALUATION QUESTIONS AND ANSWERS

Problem 1:

A process engineer needs to calculate the flow rate of Fluorine at 605 K, flowing through
flow control valve, with inlet and outlet pressure of 99 bar (guage) 96.5 bar (gauge)
respectively. Take

Problem 2:

A semiconductor process engineer in wafer fabrication units is replacing a diaphragm shut

off valve in the existing computer chip manufacturing facility. The process uses phosphine
(PH3) gas at 550 K. The gas runs in 7 mm tube line, supplying an inlet pressure of 30 bar to
the shut-off valve. He selects a diaphragm valve of 55 LPM. Verify whether his selection is
correct. Take flow coefficient as 0.01
Q1 Solution: Remember to use the absolute pressure for calculation of critical pressure ratio.

Since the condition for low pressure drop is satisfied, we can use nomogram for the low pressure
drop

From the nomogram we get flow as q = 6200 LPM.

Since , actual flow is 6200 x 1.1 = 6820 LPM

Q2 Solution:

Since the outlet pressure is unknown, we can assume the high pressure drop condition

From the nomogram we get flow as 60 LPM, Therefore his selection is correct.
 LECTURE 39 – SINGLE ACTUATOR CIRCUITS

SELF EVALUATION QUESTIONS AND ANSWERS

1: Study the following given circuit. Label all the components. Explain what happens if 1S1
or 1S2 is pressed. How cylinder is retracted.

1A 1S3

1V2 4 2
14 12

1V1 2 5 3
14 12 1

1S1 2 2 2
1S2 1S3

1 3 1 3 1 3

2: A double acting cylinder is to be advanced using three hand operated valves which are
positioned at different locations from the cylinder. If any of three push buttons are pressed,
cylinder must extend. Cylinder must be in retracted condition if all push buttons are not
pressed.

3: A double acting cylinder is to extend and clamp a work piece when two push button
valves are pressed simultaneously. For safety reasons, these push buttons valves are
installed such a way that both valves cannot be operated with one hand, that is, the both
the hands must be used to operate these two valves. The cylinder is to retract when a one
or two push button is released. Develop a pneumatic circuit to implement the given control
task using AND logic
4: A currency coin is embossed using a die driven by a double acting cylinder. The die is to
advance and emboss the coin when a push button is operated. The return of the die is to be
effected when a preset pressure is reached. The embossing pressure is to be adjustable so
that different coins can be embossed in the same machine.
Q1 Solution: IS1 and IS2 are 3/2 direction control valves- push button operated
IS3 is 3/2 DCV with limit switch
IV1 is OR valve
IV2 is 5/2 DCV – pilot operated
1A is double acting cylinder

Working: If one of the push button (1S1 or IS2) is pressed, then there is an output at OR valve.
OR valve will actuate 5/2 DCV and cylinder moves forward. The cylinder will fully extend,
since the effect of the signal at input 14 of the 5/2 way double pilot valve 1V2 is maintained until
a signal is applied at input 12. As soon as the piston rod has reached the forward end position,
the limit switch 1S3 generates a signal at input 12, and the valve 1V2 is reversed. The retracted
end position of piston rod can also be sensed. This requires an additional limit switch.

Q2 Solution
Shuttle valves can be used to create this OR logic circuit.

1A

1V3 4 2
14 12

1 3 5
1V2
2
14 12

1V1
14 12

2
1S1 2 2 1S3 3
1S2

1 3 1 3 1
When any one of 3/2 valve (IS1, IS2, and IS3) is operated, the pilot air is available at 14 of the
valve IV3 and cylinder extends. If all three valves (ISI, IS2 and IS3) are not pressed, then
cylinder will be in retracted position.

Q3 Solution

4 2 4 2
14
14

5 5 3
3
1 1

2 2
12 14 12 14

Quick return AND valve

3 2
2 valveAND

1 3 valve 1 3 1 3 1 3

a) Signal from one push button b) Signal from two push buttons

The above circuit is well known two hand safety circuit. This means that an operator can operate
the machine for clamping the work piece only by pressing the two push buttons simultaneously
and he has to use both his hands to do this. The two positions of the pneumatic circuit for the
control task, with signal input from only one push button and signal input from two push button
valve are shown in Figure ,,, The double acting cylinder does not extend when only one push
button valve is pressed Figure(a). This cylinder extends when both push button valves are
pressed simultaneously as shown in Figure (b).
Q4 Solution

4 2 4 2
14 12 14 12

5 3 5 3
1 1
1.5 1.5
Pressure Sequence valve
1 4 bar
2 4 bar 2

1 3 1 3
12
12

1.21 2 .2 2

1 3 1 3

a) Cylinder extending a) Cylinder fully extended

 LECTURE 40 – MULTI ACTUATOR CIRCUITS

SELF EVALUATION QUESTIONS AND ANSWERS

1. Square shaped work has to be drilled using a drilling machine which is pneumatically
operated. Work pieces are fed from a gravity magazine to a drilling machine. These work
pieces are pushed and clamped by means of clamping cylinder 1.0 (A). hole is drilled by the
drilling cylinder 2.0 (B). and work piece is ejected by ejecting cylinder 3.0 (C). The
displacement step diagram is shown in Figure1 . The sequence of operation has to be carried
out either for one cycle or for continuous cycle with start and stop controls. Develop a
pneumatic circuit to implement the given control task.

1
A+ A-
A
0

1
B B+ B-

C+ C-
C
Step 0 Step1 Step2 Step 3 Step 4 Step 5 Step 6 Step7 Step 8

Position step
2 Two clips are to be riveted together on a semi automatic press. Components and rivets
are positioned by hand and then removed by hand on completion of the components
operation. The automated part of the working cycle consists of the holding and clamping of
the components (cylinder A) and also the riveting (cylinder B), and the cycle be performed
ending at the starting position after operating a start button.

Design circuit using cascade method.

 1.0 2.0 3.0

2.1 4 3.1 2 4
12 2 4
C+ C-
B+ B-
1.1 5
2 4 5 3
A- 3
A+

5 3 4
1

III
I
0.1I
III
0.2I

Start
Single
cycle
a0
a1
b0

b1 c0

c1

b0 1 3 b1 1 3 c0 1 3 c1 1 3 1 3
a0
a1
Start for continuous cycle Stop for continuous cycle
1 3
Q2 Solution

1
A+ A-
A a0
0
a1 b1 b0
1
B+
B B-
0
Step 1 Step 2 Step 3 Step 4 Step 5=1

Position step

A(1.0) B(2.0)

a0 a1 b0 b1
0

1.1 2.1 4
2 4 2
4 B+
A+ B-
A-
Start
5 3 5
3
1
1

II I

G a1
a0
2 (line1)
b1 (line 3)
(line2)
b0 (line 4)
a1 a0 b1 b0

2 2 2
2
a1 & b1 Connected to
group ̅ a0 & b0 Connected to group

Pneumatic circuit for 2A+ B+ B- A-

 LECTURE 41 – ELECTRO PNEUMATICS

SELF EVALUATION QUESTIONS AND ANSWERS

1.A double acting cylinder is used for embossing slide rules as shown in Figure 1. The cylinder
extends only when two push buttons are pressed simultaneously within two seconds to ensure the
complete safety of operators. The cylinder should retract immediately if any of the push button is
released. Develop a pneumatic circuit to implement the control task.

Figure 1

Figure 2 shows the arrangement for cleaning washers for injection pumps in a cleaning bath. A
double acting cylinder is used to move the container filled with washers up and down in the bath
several times. The operator provides a start signal manually. The washing operation is turned off
automatically. The washing operation is turned off automatically after a preset time. Develop a
pneumatic control circuit to implement this control task.

Figure 2
3.The schematic diagram of Assembly fixture for greasing of roller bearings is shown in Figure
3(a). After assembling individual roller bearing parts, roller bearings are to be pressed by a
pneumatic cylinder A(1.0). Cylinder B(2.0) is required to operate a grease press twice for
injecting grease into the roller bearing. The required sequence diagram is shown in Figure 2(b).
Develop a pneumatic control circuit using Cascade method for implementing this control task.

Figure 3(a) Assembly fixture for greasing of Figure 3(b) Displacement step diagram
roller bearings
 Solution to Question No 1

4 2

Y
5 3
1

+24V 1 2 3 4 5

PB1
PB1 PB2
K

PB2

T
K

K T 2 Y

0V

2 1
5

Figure S1
 Solution to Question No 2

S1 S2

A(1.0)

4 2

Y1
5 3
1

+24V 1 2 3 4 5

T
PB K1 K1 S2

S1

K2

T 10 K1 Y1 K2

0V

2 3 2
4
 Solution to Question No 3

S1 S2 S3 S4

A(1.0) B(2.0)

4 2 4 2

Y1 Y2 Y3 Y4
5 3 5 3
1 1

+24V 1 2 3 4 5 6 7 8 11 14 16 17

K1 K2 K3 K4

PB K1 S4 K2 S3 K3 S4 K4
9 10 12 20
G1
S1 18
K1 K2 K3
G2

G3

G4

S2
S3
K2 K3 K4 K1

K1 K2 K3 K4 Y1 Y3 Y2 Y4

0V

7 2 1 4 3 6 5 8
3 5 7 17
11 14 16
 LECTURE 42 – DESIGN OF PNEUMATIC CIRCUIT USIGN PLC

SELF EVALUATION QUESTIONS AND ANSWERS

Q1.A multi position cylinder consisting of cylinder A and Cylinder B is used to operate a
pneumatically actuated switching station. ( Figure 1) for distributing work pieces to four
different conveyors. Assume the maximum stroke of cylinder A as 50 mm and that of cylinder B
is 100mm. Switching to any of the distribution conveyor is to be initiated by means of push
button(PBs) and any desired sequence should be possible. Complete the control scheme and
develop a control circuit to accomplish the desired control task.

Figure 1
Solution question no 1

Position Distance PB Notation

1 0mm PB1 A- A+
2 50 mm PB2 A+ B-
3 100mm PB3 A- B+
4 150 PB$ A+ B+

Press one pushbutton at a time. Or you can imagine that it is a selector switch to select any one of the
four positions.
Q2 A pneumatically controlled double sliding door is used in the metrology lab(figure 2).
Double sliding door is to be controlled either from OUTSIDE by pressing pushbutton. Or an
INSIDE push button. The opening and closing operations are initiated by the same pushbutton in
each case. The speeds of the double sliding door movements are to be adjustable. Develop a
pneumatic control circuit to implement this given task.

PB2
OUTSIDE
Door

Cylinders
PB1

Figure 2

Solution question no2

Q3. In a automobile manufacturing unit, components are to be supplied to a processing machine
from the discharge rail of a vibrator conveyor as shown in Figure 3. Cylinder 1.0 to extends and
picks up the component from the discharge rail and then retracts. Cylinder 2.0 extends and shifts
the component to the machine. Cylinder 1.0 extends once again, lowering and dropping the
component to the machine. At the end, cylinders 1.0 and 2.0 retract one after another. Develop a
pneumatic control circuit to implement the control task. Avoid signal conflicts in the circuit

Figure 3

1 A+
A+ A- A-

B+ B-
B
Step1 Step 2 Step 3 Step 4 Step 5

Figure 4 Displacement step diagram

Solution question no 3