“ Design a small model for hydraulic system”

INTRODUCTION

Hydraulic circuits are the life blood of many engineering applications including engine fuel
systems, drivetrains, power transmission, and component actuation. Often these systems exhibit
complex internal interactions while the pressure dynamics within the hydraulic circuit strongly
influence on the overall system’s performance and stability/ controllability. Czero’s proficiency
in hydraulic component and system level design and analysis, coupled with our client’s insights
and application specific expertise, aid in determining the best modeling practices and physics
which are needed to capture the desired phenomena efficiently and effectively.

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DIAGRAM
v

Fig. Block Diagram of Hydraulic System

Working Principle of a Hydraulic System:

1. Fluid Reservoir:
o The hydraulic fluid (often oil) is stored in the reservoir. The reservoir ensures that
the system has enough fluid for operation and allows fluid to cool and be filtered.
2. Pump:
o The pump draws the fluid from the reservoir and generates flow, creating pressure
in the system. This is typically achieved by mechanical energy (from an engine or
motor). The pump moves fluid through the pipes or hoses into the hydraulic
system components, creating the required pressure to perform work.
3. Control Valve:
o The control valve is used to control the direction of the fluid flow. Depending on
whether the fluid is directed to extend or retract the hydraulic cylinder, the valve
controls the path of the fluid. It determines how much fluid is sent to the cylinder,
which dictates the speed of the motion of the actuator.
4. Hydraulic Cylinder (Actuator):

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oThe hydraulic cylinder uses the pressurized fluid to perform mechanical work. As
the fluid enters one side of the cylinder, it pushes the piston, causing it to move
(either extend or retract). The movement of the piston is converted into linear
motion that can be used to lift, push, or perform other tasks.
5. Pressure Relief Valve:
o To avoid damage to the hydraulic system, a pressure relief valve is used. It
maintains system pressure within safe limits. If the pressure exceeds a certain
value, the valve opens, allowing fluid to flow back to the reservoir, preventing
excess pressure buildup.

. The hydraulic actuator

 It is a device used to convert 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.
 The pressurized hydraulic fluid delivered by the hydraulic pump is supplied to the actuators,
which converts the energy of the fluid into mechanical energy. This mechanical energy is
used to get the work done.
 TYPES OF ACTUATORS:
1. Linear Actuators (Hydraulic cylinders)
2. Rotary Actuators (Hydraulic motors)
a. Continuous rotary actuators
b. Semi rotary actuators
 Functions Of Actuators :
1) To produce motion in one line
2) To produce continuous rotary motion
3) To produce rotary or oscillatory motion less than 3600
4) To apply a force and clamp the job.
2. The hydraulic Pump

 It is used to force the fluid from the reservoir to the rest of the hydraulic circuit by converting
mechanical energy into hydraulic energy.
 A pump which is the heart of a hydraulic system converts mechanical energy into hydraulic
energy. The mechanical energy is delivered to the pump via prime mover such as the electric
motor. Due to the mechanical action the pump creates a partial vacuum at its inlet. This
permits atmospheric pressure to force the fluid through the inlet line and into the pump. The
pump then pushes the fluid into the hydraulic system.
Importance of Pump :

1. They convert mechanical energy into hydraulic energy.

2. The Volumetric efficiency of the pump is relatively high

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3.They have high-performance characteristics under varying speed and pressure requirements
4.Pumps used to generate high pressure in the hydraulic system

3. Valves

 Valves are used to control the direction, pressure, and flow rate of a fluid flowing through the
circuit.
Motor 1 – Off 2 – Forward 3– Return 3 2 1 Load Direction control valve Pump Oil tank Filter
Actuator Pressure regulator.
 A fluid power system can be broken down into three segments. The power input segment
consisting of the prime mover and the pump. The control segment consisting of valves that
control the direction, pressure, and flow rate. The power output segment, consisting of the
actuators and the load. This unit is devoted to each of the following categories of control
valves.
1. Directional control valves
2. Pressure control valves
3. Flow control valves
 DCVs control the direction of flow in a circuit, which among other things; can control the
direction of the actuator. PCVs control the pressure level, which controls the output force of a
cylinder or the output torque of a motor. FCVs control the flow rate of the fluid which
controls the speed of the actuators.

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Components:

1. Reservoir:
o Stores the hydraulic fluid (typically oil or water-based fluid). The reservoir
ensures that there is always a supply of fluid for the system.
2. Pump:
o The pump is responsible for converting mechanical energy (from an engine,
motor, or manual source) into hydraulic energy by moving the fluid and creating
pressure.
3. Control Valve:
o The control valve directs the flow of hydraulic fluid into the hydraulic cylinder. It
regulates the direction and flow rate of the fluid, which controls the speed and
motion of the actuator (hydraulic cylinder).
4. Hydraulic Cylinder (Actuator):
o The hydraulic cylinder is the actuator that converts the hydraulic energy (fluid
pressure) into mechanical motion, typically in the form of linear motion. The
movement of the piston in the cylinder allows lifting, pushing, pulling, or other
mechanical work.
5. Pressure Relief Valve:
o The pressure relief valve protects the system from excess pressure. If the pressure
exceeds a safe threshold, the valve opens, allowing excess fluid to return to the
reservoir, preventing damage to the system.

6. Fluid Reservoir:
o The hydraulic fluid (often oil) is stored in the reservoir. The reservoir ensures that
the system has enough fluid for operation and allows fluid to cool and be filtered.
7. Pump:
o The pump draws the fluid from the reservoir and generates flow, creating pressure
in the system. This is typically achieved by mechanical energy (from an engine or
motor). The pump moves fluid through the pipes or hoses into the hydraulic
system components, creating the required pressure to perform work.
8. Control Valve:
o The control valve is used to control the direction of the fluid flow. Depending on
whether the fluid is directed to extend or retract the hydraulic cylinder, the valve
controls the path of the fluid. It determines how much fluid is sent to the cylinder,
which dictates the speed of the motion of the actuator.
9. Hydraulic Cylinder (Actuator):
o The hydraulic cylinder uses the pressurized fluid to perform mechanical work. As
the fluid enters one side of the cylinder, it pushes the piston, causing it to move
(either extend or retract). The movement of the piston is converted into linear
motion that can be used to lift, push, or perform other tasks.
10. Pressure Relief Valve:
o To avoid damage to the hydraulic system, a pressure relief valve is used. It
maintains system pressure within safe limits. If the pressure exceeds a certain
value, the valve opens, allowing fluid to flow back to the reservoir, preventing
excess pressure buildup.

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Step-by-Step Process:

1. Fluid Pumping:
o The pump pulls hydraulic fluid from the reservoir and sends it to the control valve
under pressure. The pump uses mechanical energy to move the fluid.
2. Fluid Direction Control:
o The control valve directs the flow of fluid to either side of the hydraulic cylinder,
depending on the desired motion (extension or retraction of the piston).
3. Hydraulic Cylinder Movement:
o The fluid entering the hydraulic cylinder causes the piston to move. Depending on
the valve’s position, the piston extends or retracts, creating mechanical force that
performs work.
4. Pressure Regulation:
o The pressure relief valve monitors system pressure. If it exceeds a set limit, the
valve opens and allows fluid to return to the reservoir, protecting the system from
damage due to overpressure.
5. Fluid Return:
o After the fluid has done its work (either pushing or lifting), it flows back from the
hydraulic cylinder to the reservoir, where it is cooled, filtered, and reused in the
system.

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APPLICATIONS

1. Ticket Booking and Reservation:

 Online Access:
Passengers can access the reservation system through a user-friendly web interface or mobile
app to view train schedules, select seats, and book tickets from anywhere with internet
connectivity.
 Real-time Availability Check:
The system instantly updates seat availability across different trains and classes, preventing
overbooking and ensuring accurate information to passengers.
 Payment Gateway Integration:
Secure payment processing through online payment gateways allows for immediate ticket
purchase and confirmation.
2. Passenger Information Management:
 Centralized Database:
A centralized database stores comprehensive passenger details including name, address,
contact information, travel history, and loyalty program data, accessible across the network.
 Passenger Profile Creation:
Users can create personalized profiles for easy booking and access to previous reservation
details.
 Data Security:
Robust security measures like encryption protect sensitive passenger data from unauthorized
access.
3. Train Schedule and Status Updates:
 Live Train Tracking:
Real-time train location information can be accessed by passengers through the network,
allowing them to monitor delays or schedule changes.
 Departure and Arrival Information:
Accurate information regarding train departure and arrival times is readily available on the
system.
4. Cancellation and Refund Management:
 Online Cancellation:
Passengers can easily cancel their tickets online and request refunds through the system.
 Automatic Refund Calculation:
The system calculates refund amounts based on cancellation policies and generates refund
requests automatically.
5. Ticketing and Fare Calculation:

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Benefits

1. High Power Density

 Hydraulic systems can generate a significant amount of power relative to their size and
weight. This makes them ideal for applications that require high force in compact,
lightweight designs. For example, excavators, lifts, and other heavy machinery benefit
from hydraulic systems' ability to deliver high power efficiently.

2. Precision and Control

 Hydraulics allow for precise control of speed, force, and motion. Components like valves
and actuators can be adjusted to provide fine control over movements, making hydraulic
systems ideal for tasks that require accuracy, such as in robotics, industrial presses, and
automotive applications (e.g., braking and steering systems).

3. Easy Force Multiplication

 One of the greatest advantages of hydraulic systems is their ability to easily multiply
force. By varying the size of pistons in cylinders, hydraulic systems can generate large
amounts of force in relation to the input force, making them effective for heavy lifting
and moving large loads.

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Advantages

1. High Power-to-Weight Ratio

 Hydraulic systems can generate significant force relative to their size and weight. This
makes them ideal for applications requiring high power in compact spaces, such as in
heavy machinery, construction equipment, and aircraft.

2. Precise Control

 Hydraulic systems provide precise control of movement, allowing for accurate

positioning, speed control, and force regulation. This is especially important in
applications like robotic arms, CNC machines, and industrial presses.

3. Easy Force Multiplication

 One of the key advantages of hydraulics is the ability to easily multiply force. By using
cylinders with different diameters (such as a small piston for force input and a larger
piston for force output), hydraulic systems can amplify force in a manageable and
efficient way.

4. Smooth and Continuous Operation

 Hydraulics offer smooth and continuous motion. There are no starts and stops or jerky
movements typically associated with mechanical systems (such as gears or cams). This is
crucial for tasks requiring consistent motion, like lifting, clamping, or molding.

5. Compact and Flexible

 Hydraulic systems are relatively compact for the power they provide, making them useful
for applications where space is limited. They can also be flexible in design and can be
adapted to work in different orientations and configurations.

6. Easy to Overload Protection

 Hydraulic systems can be easily designed to incorporate overload protection, such as

pressure relief valves. These valves prevent the system from damaging itself or the load
in case of excessive pressure, providing enhanced safety.

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Disadvantages

1. Complexity and Cost of Maintenance

 Hydraulic systems can be complex to design and maintain, especially when dealing with
high-pressure components, seals, and pumps. Regular maintenance is required to prevent
leaks, contamination, and wear on parts. If not maintained properly, they can be costly to
repair.

2. Leakage and Contamination

 One of the most significant disadvantages of hydraulic systems is the risk of fluid
leakage. Leaks can occur at connections, seals, or hoses, leading to loss of fluid, reduced
efficiency, or damage to the environment. Additionally, contaminants like dirt or
moisture can enter the hydraulic fluid, leading to wear and damage to components such
as pumps and valves.

3. Fluid Storage and Disposal Issues

 Hydraulic fluids can be toxic, environmentally harmful, or difficult to dispose of

properly. Handling, storing, and disposing of hydraulic fluid poses environmental and
safety concerns. Spills can cause contamination of soil and water, and certain hydraulic
fluids are flammable.

4. Efficiency Losses (Heat Generation)

 Hydraulic systems often experience energy losses due to fluid friction and the
compression of fluids. These inefficiencies can lead to heat generation, which may
require cooling systems to prevent overheating and further efficiency losses.

5. Noise

 Hydraulic systems can be noisy, especially at high pressures. The operation of pumps,
valves, and actuators can generate significant noise levels, which may be a concern in
environments where noise reduction is important (e.g., in indoor factories or residential
areas).

6. Risk of Overheating

 The fluid in hydraulic systems can heat up during continuous operation or if the system is
overworked. Overheating can lead to the degradation of the fluid, which in turn can cause
damage to system components. Cooling systems or heat exchangers are often required to
maintain optimal operating temperature

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Conclusion
Hydraulic systems play a crucial role in modern engineering, offering significant advantages such as high
power-to-weight ratios, precise control, and the ability to generate large forces in compact spaces. They
are widely used in industries ranging from construction and manufacturing to aerospace and
automotive. The ability to easily multiply force and transmit power over long distances makes hydraulics
indispensable in heavy-duty applications like lifting, clamping, and moving large loads.

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Reference

 https://sarum-hydraulics.co.uk/white-paper/design-miniature-hydraulic-system/
 https://www.youtube.com/watch?v=hnSfRQONL5M&pp=ygUJI2hheWRvbGlr
 https://www.youtube.com/watch?v=zyWsSs_OMaI&pp=ygUUI2h5ZHJhdWxpY
2V4Y2VsbGVuY2U%3D
 https://www.vectorsolutions.com/resources/blogs/what-is-a-hydraulic-system-
definition-design-and-components/

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