UNIT-1.

INTRODUCTION TO HYDRAULIC AND PNEUMATIC

SYSTEMS
- Jayant J. Pharne
SUB-TOPICS

General layout of oil hydraulic system, applications merits, limitations and oil
hydraulic systems and pneumatic systems. Properties of fluids, ISO and SAE grades of
oil, ISO symbols used in hydraulic and pneumatic systems. Hazards and safety in
industrial hydraulics and pneumatic.

 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.

Pascal’s Law states:

“Pressure applied to a confined liquid is transmitted undiminished in all directions, and
acts with equal force on all equal areas, and at right angles to those areas.”

PURPOSE OF THE FLUID

Many types of fluids are used in hydraulic systems for many reasons, depending on the
task and the working environment, but all perform basic functions:
1. First, the fluid is used to transmit forces and power through conduits (or lines) to
an actuator where work can be done.
2. Second, the fluid is a lubricating medium for the hydraulic components used in the
circuit.
3. Third, the fluid is a cooling medium, carrying heat away from the “hot spots” in
the hydraulic circuit or components and discharging it elsewhere.
4. And fourth, the fluid seals clearances between the moving parts of components to
increase efficiencies and reduce the heat created by excess leakage.
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Water would be unsuitable because:
1. It freezes at cold temperatures and boils at 100ºC.
2. It causes corrosion and rusting and furnishes little lubrication

 DESIRABLE PROPERTIES OF OIL IN HYDRAULICS

A hydraulic fluid must have following desirable properties
1. Optimum viscosity-It is a measure of a fluid’s resistance to flow.
2. Good lubricity to prevent friction and wear between the closely fitted working
parts such as vanes of pumps, valve spools, piston rings and bearings.
3. Good demulsibility: The ability of a hydraulic fluid to separate rapidly from
moisture and successfully resist emulsification is known as “demulsibility.”
Highly refined oils are basically water resistant by nature.
4. Good Chemical and Environmental Stability (Oxidation and Corrosion
Resistance). It is because; most fluids are vulnerable to oxidation, as they come in
contact with oxygen in air.
5. High incompressibility- 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.
6. Low flammability-There are many hazardous applications where human safety
requires the use of a fire-resistant fluid. 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.
7. 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.
8. 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.
9. The oil should have high flash point and high fire point.
10. The oil must have Non-toxic, easy to handle, available.

 VISCOSITY INDEX AND ITS SIGNIFICANCE

Viscosity index: It is defined as rate of change of viscosity with respect to temperature.
Significance: It is the most important property which determines the performance of
lubricating oils under operating conditions.
Viscosity index used to characterize the viscosity-temperature behavior of lubricating
oils. The lower the Viscosity index, the more the viscosity is affected by changes in
temperature. On machine part moving at slow speeds under high pressures, a heavy oil
should be used as it better resists being squeezed out from between the rubbing parts light
oils can be used for lower pressures and high speeds. It is not possible to maintain a
liquid oil film between two moving or sliding surfaces if the viscosity is too low.
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  Hydraulic system with general layout

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 shows a simple circuit of a hydraulic system with
basic components. 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. 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.
Valves are used to control the direction, pressure and flow rate of a fluid flowing through
the circuit. External power supply (motor) is required to drive the pump. Reservoir is
used to hold the hydraulic liquid, usually hydraulic oil. Piping system carries the
hydraulic oil from one place to another. 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. Pressure regulator regulates (i.e., maintains) the required level of pressure in
the hydraulic fluid.
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
pressure 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.

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 HYDRAULIC SYSTEM ADVANTAGES

1. Hydraulic power is easy to produce, transmit, store, regulate and control, maintain
and transform.
2. Weight to power ratio of a hydraulic system is comparatively less than that for an
electro-mechanical system. (8.5kg/kw for electrical motors and 0.85kg/kw for
hydraulic system).
3. It is possible to generate high gain in force and lower power amplification.
4. Hydraulic systems are uniform and smooth, generate stepless motion and variable
speed and force to a greater accuracy.
5. Division and distribution of hydraulic power is simpler and easier than other form
of energy.
6. Limiting and balancing of hydraulic forces are easily performed.
7. Frictional resistance is less.
8. Hydraulic elements can be located at any place and controlled reversely.
9. Noise and vibrations produced by hydraulic pumps is minimum.
10. Hydraulic systems are cheaper.
11. Easy maintenance.
12. It is mechanically safe and compact.
13. Hydraulic output can be linear, rotational or angular.
14. Hydraulics is a better over load safe power system.
15. Accurate feedback of load, position, etc can be achieved.

 HYDRAULIC SYSTEM DIS-ADVANTAGES

1. Hydraulic elements have to be machined to a high degree of precision which

increases the manufacturing cost of the system.
2. Leakage of hydraulic oil poses a problem to hydraulic users.
3. Hydraulic elements have to be specially treated to protect them against rust,
corrosion, dirt, etc.
4. Hydraulic oil may have problems if it disintegrates due to aging and chemical
deterioration.
5. Petroleum based hydraulic oil may pose fire hazards thus limiting the upper level
of working temperature.

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 APPLICATIONS OF FLUID POWER

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HYDRAULICS APPLICATIONS
Industrial: Electro-hydraulics is the mechanism used for controlling the industrial
applications of hydraulics. Precise and fast response is an advantage of this. Plastic
processing machinery, steel making and primary metal extraction applications, automated
production lines, machine tool industry, paper industries, loaders, crushers, presses,
textile industry machinery, etc. are some of the examples of industrial hydraulics.
Mobile Hydraulics: In mobile hydraulics, the hydraulic system is controlled manually.
Building and construction equipment like cranes, excavators, backhoe, earth moving
equipment, etc., tractors, irrigation system, material handling equipment, tunnel boring
equipment, rail equipment, etc. are some examples of mobile hydraulics.
Automobiles: Hydraulics have many interesting applications in the automobile
industry. Most of the important work using the principle of hydraulics. Power steering,
shock absorbers, windshields, and brake are the common applications of hydraulics in
vehicles. Two-post lifts and four-post lifts are used in the automobile industry to lift
vehicles for servicing and inspecting.
Marine Applications: Hydraulics plays an important role in maintaining the stability
and control of ships. Steering gears, bow and stern thrusters, engine room maintenance
systems including pumps and jacks, deck machineries like cranes, winches, hatch covers,
mooring drums and others are examples of hydraulics in the marine industry.
Aerospace Applications: Airplanes, rockets, spaceships, etc.. use hydraulic systems for
various applications. Aerospace industry uses hydraulics for adjusting wings, retraction
and extension of landing gears, opening/closing of doors, brakes, steering, etc.
Mining: Hydraulic fracturing is one of the advanced mining technology used for
extracting unused gases/oils beneath the earth surface. In this approach, a high-pressure
mixture of water, sand and other chemical additives are passed into the cracks.

PNEUMATICS
A fluid system that uses gas as a working fluid is known as pneumatic system. Energy is
stored in gas in the form of pressure energy.

 FEATURES OF AIR
Major characteristics available in the air are termed as features of the air, because of
those features air is widely used in industrial applications.
1. Wide availability of air
2. Compressibility of air
3. Easy transportability
4. Explosion proof characteristics of the medium
5. Simple construction of pneumatic elements and easy handling
6. High degree of controllability of pressure, speed and force
7. Possibility of easy but reasonably reliable remote controlling
8. Easier maintenance
9. Comparatively cheaper in cost than other systems
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  GENERAL LAYOUT OF PNEUMATIC SYSTEM

1. Compressor: This unit compresses the air which is at atmospheric pressure. The
pressure of air increases.
2. Air reservoir/ Air Tank: This tank stores compressed air which is output of air
compressors.
3. Moisture separator: moisture (water vapour) is separated. Type-chemical or
mechanical.
4. Air filter-Air pressure regulator-Air lubricator: Filtered, pressure regulated fine
particles helps in proper lubrication of sliding or rotary parts of actuator or valves.
5. DCV/FCV: These valves direct flow of air, control flow of air, speed of actuators.
6. Air actuators: These items are the heart of pneumatic system. These are taking part
in obtaining mechanical advantage. These are either linear or rotary actuators.
7. Air conducting elements: The compressed air flow through pipes, valves are
conducting elements.

ADVANTAGES OF PNEUMATIC SYSTEM

1. Pneumatic system provides cheaper and light weight equipment’s as they work on
air which is freely available and no robust construction is required.
2. No return lines are required.
3. Pneumatic system is fire proof, explosion proof and non-reactive thus a safer
system. Hence can be used in fire prone area.
4. Pneumatic system is clean as air is dry. Hence it is widely used in food processing,
electronic and automation industry

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DIS-ADVANTAGES OF PNEUMATIC SYSTEM

1. High cost of compression.

2. Reduced accuracy.
3. Noisy working.
4. High operating cost.
5. Low pressure application.
6. Additional lubrication required.

PNEUMATICS APPLICATIONS
Automobile: Automobile industry use pneumatic systems for dismantling vehicle tire,
filling compressed air in the tire, vehicle painting, opening and closing of doors, air
brakes on heavy vehicles, etc.
Transporting Goods: Pneumatics is used to transport goods from shelf to other
location inside the company. The cylinder will push the item on the shelf into the moving
belt if the button is pushed.
Industrial Applications: Material handling, drilling, sawing, filling, packaging,
clamping, shifting, etc. are some of the general applications of the pneumatic system.

 COMPARE OIL AND AIR AS A MEDIUM IN FLUID SYSTEM

1. When the system requirement is high speed, medium pressure (usually 6 to 8 bars)
and less accuracy of position, then pneumatic system is preferred.
2. If the system requirement is high pressure and high precision, a fluid system with
oil is good.
3. 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.
4. Air is used where quick response of actuator is required.
5. If temperate variation range in the system is large, then use of air system may run
into condensation problems and oil is preferred.
6. 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
7. 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. If the application requires only a medium pressure.

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  COMPARISON BETWEEN HYDRAULIC AND PNEUMATIC SYSTEM

Hydraulic system Pneumatic system

1.It employs pressurized liquid as a fluid 1. It employs a compressed gas usually air as
fluid
2. Power source is hydraulic pump 2. Power source is air compressor
3. An oil hydraulic system operates at pressure 3. A pneumatic system usually operates at 5-10
up to 700bar bar
4. Heavier in weight 4. Lighter in weight
5. Valve operations are difficult 5. Valve operations are easy
6. The system is unsafe to fire hazards 6. The system is free from fire hazards
7. Automatic lubrication is provided 7. Special arrangement for lubrication is
needed
8. Generally designed as closed system 8. Usually designed as open system
9. The system slows down when leakage 9. Leakage does not affects much
occurs
10. Oil change required as per schedule 10. No change of fluid

ISO AND SAE GRADES OF OIL

 SAE Designation of gear oils by viscosity
The Society of Automotive Engineers (SAE) established a viscosity grading system for
gear and Engine oils.
According to the SAE viscosity grading system all oils are divided into two classes:
Monograde and Multigrade:

MONOGRADE GEAR OILS

 Monograde gear oils are designated by one number (70, 90, 140, 250, etc.). The
number indicates a level of the oil viscosity at a particular temperature. The higher
the grade number, the higher the oil viscosity. Viscosity of gear oils designated
with a number only without the letter “W” (SAE 80, SAE 90, SAE 140 etc.) was
specified at the temperature 212°F (100°C). These gear oils are suitable for use at
high ambient temperatures. Viscosity of gear oils designated with a number
followed by the letter “W” (SAE 70W, SAE 75W, SAE 80W etc.) was specified at
the temperature 0°F (-18°C). The letter “W” means winter.
 These grades are used at low ambient temperatures.

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MULTIGRADE GEAR OILS

 Viscosity of gear oils may be stabilized by polymeric additives (viscosity index

improvers). Viscosity of such gear oils is specified at both high and low
temperature. These oils are called multigrades and they are designated by two
numbers and the letter “W” (SAE 75W-90, SAE 80W-90, SAE 85W-140 etc.).
The first number of the designation specify the oil viscosity at cold temperature,
the second number specifies the oil viscosity at high temperature. For example:
SAE 85W-140 oil has a low temperature viscosity similar to that of SAE 85W, but
it has a high temperature viscosity similar to that of SAE 140. Multigrade gear oils
are used in a wide temperature range.

ISO DESIGNATION OF INDUSTRIAL GEAR OILS

 International Standardization Organization (ISO) established a viscosity grading

(VG) system for industrial gear oils. According to the system industrial gear oils
are designated by the letters ISO followed by a number equal to the oil viscosity
measured in centistokes at 40°C (104°F): ISO VG 32, ISO VG 46, ISO VG 68,
ISO VG 100, ISO VG 150, ISO VG 220 etc.

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HAZARDS AND SAFETY IN INDUSTRIAL HYDRAULICS AND PNEUMATICS

1. Examine the machine, inspect the parts, starting and stopping switches, protective
devices, etc.
2. Ensure safe pressure of the hydraulic and pneumatic system.
3. Ensure safe clamping and declamping procedures for automatic systems.
4. Adjust the control levers and switches against malfunctioning.
5. Use protective guards in case of hydraulic and pneumatic presses.
6. Use proper oil and have regular inspection of oil
7. Use face shields for self protection against pressure actuated system and machine
tools.
8. Never work the machine with higher than designated pressure.
9. Equipment for protection against fire should be kept always in readiness for any
eventuality.
10. For proper working and safe handling, hydraulic and pneumatic elements should
not be hit hard by external means.
11. Both hydraulic and pneumatic elements should be kept in clean atmosphere in
order to avoid their premature failure due to contaminants.
12. Use the correct tool for dismantling parts.
13. While checking for mechanical faults, disconnect the power source fully and then
do the work
14. Hydraulic and pneumatic hoses and pipes should not be kinked

FACTORS AFFECTING SELECTION OF FLUID

1. Operating pressure of hydraulic system
2. Operating temperature of hydraulic system
3. Operating environment
4. Expected service life
5. Cost considerations
6. Compatibility with seals and other metals

FUNCTION OF:
(i) Oil Reservoir – To store the Hydraulic oil for the circuit
(ii) Pressure Relief Valve- To release the extra pressure whenever not required by
system
(iii) Direction Control Valve- To give the direction to the actuator
(iv) Filters- To filter the foreign particle from the oil and to separates sub-micron level
contamination

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