What are the Basic Principles Of Hydraulics?

Pascal's Law states that the "Pressure applied to any part of a confined fluid transmits to every other part with no loss. The pressure acts with equal force on all
equal areas of the confining walls and perpendicular to the walls. This is the basic principle for any hydraulic system."

Introduction:

Earlier, weights werelifted using pulleys,levers, block and tackles, etc. Movements for a ships rudder or steering a vehicle where achieved by mechanical linkages
like cams, levers, couplings, and gears which made the system complicated. These manual or mechanical methods of operation had several limitations. They also
involved huge man power and long working hours for a particular job. As the population and technology increased exponentially, the demand for quicker and
easier to operate equipment increased. To cater to this need, hydraulic machines were introduced.

Basic Hydraulic Principles

A simple hydraulic system consists of hydraulic fluid, pistons or rams, cylinders, accumulator or oil reservoir, a complete
working mechanism, and safety devices. These systems are capable of remotely controlling a wide variety of equipment
by transmitting force, carried by the hydraulic fluid, in a confined medium. Modern developments in hydraulics have
involved many fields in engineering and transportation. These systems transfer high forces rapidly and accurately even in
small pipes of light weight, small size, any shape, and over a long distance. These systems play a vital role from small
car's steering to super sonic aircrafts maneuvering devices. More powerful and accurate systems are also used in
maneuvering huge ships.
Pascals Law:

Pascal's Law, framed by Blaise Pascal, states that Pressure applied to any part of aconfined fluid transmits to every other
part with no loss. The pressure acts with equal force on all equal areas of the confining walls and perpendicular to the
walls." This is the basic principle for any hydraulic system.

Hydraulic Pressure & Force:

Pressure can be defined as the force acting on unit area, applied in a direction perpendicular to the surface of the object".
Pressure = Force/ Area.
So, hydraulic pressure can be stated as the force exerted by a fluid on unit area, anywhere on the surface within the
container.

A Simple Hydraulic System:

A closed toothpaste tube can be considered as an example for a simple hydraulic system. The toothpaste can be
considered as a hydraulic fluid working inside the system which is confined. Four or five holes are made on the
tube. By keeping the cap of the toothpaste tube closed, apply pressure at a particular point on the tube. This
makes the toothpaste to come out from all the holes evenly. This is a simple example to understand Pascals law.
Thus force applied at a particular point on a fluid in closed system, transfers equal force on all other parts of the
system. Further, the force acts perpendicular to the walls of the confined area.
Other example is the hydraulic brakes used in automobiles. The driver applies force at the break pedal (one
particular point on fluid in closed system), thus transmitting this force onto the hydraulic fluid under the piston
(break pedal), transfers equal force to all other brake shoes, thus stopping the vehicle.

There are several other areas where hydraulics are applied. They are:
1. Automobile garage

Hydraulic Braking System (Automobile)

Hydraulic Braking System
A hydraulic braking system transmits brake-pedal force to the wheel brakes through pressurized fluid, converting the fluid
pressure into useful work of braking at the wheels. A simple, single-line hydraulic layout used to operate a drum and disc
brake system is illustrated in Fig. 28.36. The brake pedal relays the drivers foot effort to the master-cylinder piston, which
compresses the brake fluid. This fluid pressure is equally transmitted throughout the fluid to the front disc-caliper pistons
and to the rear wheel-cylinder pistons. As per the regulations a separate mechanical parking brake must be incorporated
with at least two wheels. This provision also allows the driver to stop the vehicle in the event of failure of the hydraulic
brake system.

Fig. 28.36. Hydraulic single-line braking system.

In a hydraulic braking system the braking force is directly proportional to the ratio of the master-cylinder cross-sectional
area to the disc or drum-brake wheel-cylinder cross-sectional areas. Therefore these cylinder diameters are appropriately
chosen to produce the desired braking effect. The wheel-cylinder cross-sectional areas of the front and rear disc-and
drum-brakes respectively may be chosen to produce the best front-to-rear braking ratio. Hydraulic fluid is incompressible
provided there is no trapped air in the system. If air is present in the braking circuit, the foot-brake movement becomes
spongy. In a hydraulic system the internal
friction exists only between the cylinder pistons and seals. The friction is caused by the fluid pressure squeezing the seal
lips against the cylinder walls as the piston moves along its stroke. A hydraulic braking system is suitable only for
intermittent braking applications, and a separate mechanical linkage must be incorporated for parking brakes.
The hydraulic system offers the following advantages over the mechanical layout, (a) This provides equal braking effort on
all wheels. (6) This requires relatively less braking effort to deliver the same output.
(c) This is a fully compensated system so that each brake receives its full share of the pedal effort.
(d) The efficiency of the hydraulic system is greater than that of the mechanical layout.
(e) This system is suitable for vehicles having independent suspension.
(/) It is easy to alter thrust on shoe because the force exerted on a piston depends on the piston area. The larger the area,
the greater the thrust on the trailing shoe, so a larger piston can be used.

Various Components
Various components and their functions in a hydraulic braking system are as follows.

Brake Pipes.
These are steel pipes which form part of the fluid circuit between the master-cylinder and the wheel-cylinders. These
pipes transfer the fluid along the body structure and rigid axle members. Flexible hoses connect the sprung body pipes to
the unsprung axle wheel-brake units, to allow for movement (Fig. 28.36).

Master-cylinder.
This converts foot-pedal force to hydraulic pressure within the fluid system by means of the cylinder and piston (Fig.
28.36).

Disc-brake.
This comprises of a disc bolted to the wheel hub. This is sandwiched between two pistons and friction pads. The friction
pads are supported in a caliper fixed to the stub-axle (Fig. 28.36). When the brakes are applied, the pistons clamp the
friction pads against the two side faces to the disc.

Drum-brake.
This uses two brake-shoes and linings supported on a back-plate. The back-plate is bolted to the axle-casing. These
shoes pivot at one end on anchor pins or abutments attached to the back-plate (Fig. 28.36). The other free ends of the
both shoes are forced apart when the brakes are applied. The shoes expand radially against a brake-drum positioned
concentrically on the wheel hub.

Wheel-cylinders.
As the hydraulic line pressure acts on the cross-sectional area of the disc and drum cylinder pistons (Fig. 28.36) in wheel
cylinders, the hydraulic pressure is converted into braking effort. This braking effort either presses the friction pads against

the side faces of the disc or forces the shoe friction linings against the inside of the drum.
28.8.2.

The Mechanics of a Hydraulic Braking System

To appreciate the machines of the hydraulic braking system, a simple analysis is presented to show how a suitable force
ratio is obtained between the foot-pedal and the wheel-cylinder pistons. A braking system shown in Fig. 28.36 is
considered.

Brake Master cylinders

The brake master-cylinder contains a cylinder and a piston whose function is to produce hydraulic pressure in the
pipeline. This pressure is subsequently converted to force to actuate the wheel-cylinder disc-pads or shoe-expanders. The
master cylinders are either (i) residual-pressure type or () non-residual-pressure type.

The Basic Principle Of Hydraulics

The principle of hydraulics is based on Pascal's famous theory. It states the pressure of the liquid produced in an enclosed structure has the
capacity of releasing a force up to ten times the pressure that was produced earlier.
Through hydraulics, the basic result to be achieved is that with little pressure, a great force should be produced.

The Evolution Has Begun

With the invention of hydraulics lift kits, you can actually make your car dance. These cars are popularly called as the "lowriders".
They are named for a specific reason. These cars are custom- made to ride very low to the ground. The hydraulic systems installed in these cars
make them hop around by raising and lowering these cars. To make these cars look like they're hopping, the hydraulic systems also demand the
installation of 12 to 48 volts Hydraulic Pumps. These hydraulic inventions can be seen in movies like The Fast and the Furious and in some
lowriding competitions.

How The Basic System Works

The working of a hydraulic system

is very simple. The basic fluid used in this system is oil. A hydraulic
machine has two or more cylinders
that are connected to a single pipe containing the oil and the
pistons that helps in pushing the fluids in the cylinders. Even the car brakes are based on the hydraulic system.
When you apply your car brakes, your brake pedal makes the piston to act and apply force on the master Cylinder.
The main pipe is connected to four slave pistons that activate the brake pads of your car to the brake rotor, which in turn makes the car come to a
stop. The basic hydraulic components are as follows:
Hydraulic Cylinders: These components of the hydraulic system are those in which, pressure is applied on the fluids (oil), to get the desired
force. The force acquired is used to power the hydraulic machine of car brakes, cranes, turbines and a large number of excavators. These
cylinders also include the pistons of different sizes. The hydraulic pistons are used to push down the fluids in the other cylinder, which in turn
exerts the pressure and pushes it back again.
Hydraulic Pumps: The hydraulic pump is a component that is responsible for supplying the fluids to the other essential parts of the hydraulic
system. The power generated by a hydraulic pump is about ten times more than the capacity of an electrical motor. There are different types of
hydraulic pumps such as the vane pumps, gear pumps, piston pumps, etc. Among them, the piston pumps are relatively more costly. But they
have a guaranteed long life and are even able to pump thick, difficult fluids.
Hydraulic Wrench: A hydraulic wrench is used to tighten the nuts and bolts.
Hydraulic Lifts: Hydraulic lifts are the similar components used for powering the hydraulic system in cars such as the lowriders. These lift kits are
available in any custom- made car shops.

 Hydraulic Press: This is a process in which, the pressure is compressed to a full extent. The structure again involves two cylinders of different
diameters and two different sizes of pistons. In order to generate a powerful pressure, the basics of Pascal's Law are followed. The pressure is
created by applying force and pushing the smaller piston through the cylinder and the fluids are pushed through the connecting pipe to the larger
cylinder till a great pressure is exerted. The use of a hydraulic press is seen in the process of crushing cars. For crushing cars, a motor powers the
hydraulic press. A car crushing hydraulic system has the capacity to generate about 2500 pounds per square inch (psi) and apply a force of about
200 tons that is more than enough to crush any car. A hydraulic press has the potential to crush an aluminum metal into a thin scrap of paper. The
hydraulic press too is comprised of many components such as the pumps, the various valves, the pipes and the engine.
Hydraulic Motors: This is the one most widely used. The power in hydraulic motors is achieved with the help of exerting pressure on the
hydraulic fluids, which is normally oil. The benefit of using hydraulic motors is that when the power source is mechanical, the motor develops a
tendency to rotate in the opposite direction, thus acting like a hydraulic pump.
Pascal's Law strictly states "pressure exerted on a fluid is distributed equally throughout the fluid".

Where Are Hydraulics Used

Hydraulics is used in many machines that we see in our daily lives. Some of its uses are:
Hydraulics is used in heavy equipments like log splitters. You can find the simplest hydraulics system in log splitters as it consists of most of the
components of a basic hydraulics system such as the hydraulic pump, an engine, the hydraulic cylinders, the various valves and the hydraulic
pistons.
The heavy- duty machines make use of the hydraulics system that is often seen at construction sites and other excavations. A large machine
such as the excavator may weigh anything around thirty tons but it has the capacity to move around easily and carry mud weighing about two
tones without any difficulty. An excavator has a motor for each of its tracks and a motor for swinging its huge arm that all runs on the system of
hydraulics. Other construction vehicles making use of hydraulics system include the loading machines, also known as the skid. This machine
makes use of 3 pairs of hydraulics pistons and also hydraulics motors on each of its four wheels. Another vehicle that we often see in our daily
routine are the garbage dump trucks. They make use of all the hydraulic components. The only exception in its case is the use of telescopic
cylinders that helps them to attain the feat of positioning the dump bucket to an almost vertical stance to allow the garbage fall over.
Hydraulics is also used in mechanical wheel chairs to push the wheel chair forward. It is also used for aircraft landing gears to push the wheels
out when landing the plane.

Precautions For Handling Hydraulics System

The components of a hydraulics system should be handled very carefully. It is not advisable to touch the hydraulic machine even if the system may
not be running since the fluids may still be flowing under pressure. Even if the hydraulic fluid is found leaking, no one should attempt to touch it
because the fluid pressure can tear through your skin.

Use Of The Hydraulic Wrench For Industrial Applications Leads To Better Productivity
A hydraulic wrench is an indispensable tool for industrial applications and large projects in view of the
demands of controlled torque bolting operations required in modern technological methods.

Controlled Torque Requirements Make The Hydrauc Wrench A Tool Of Choice In Industries and
Large Projects

Development Of The Hydraulic Wrench

A hydraulic wrench is used to fasten and unfasten nuts and bolts. There can be no doubts about the
importance of nuts and bolts in the manufacture and maintenance of machinery and equipment.
It is also a proven and recognized fact that the incorrect use of these vital fasteners can lead to severe
maintenance problems; even disasters at times.
A close study fastening methods and devices led to the evolvement of torque wrenches. For many years the
only tools available were manual torque wrenches to apply correct force for bolting applications. Then the
first half of the 1970s experienced an increased trend towards improving worker productivity engaged in
bigger projects posing new technological challenges. The resulting necessities led to the development of the
hydraulic wrench for correct and controlled torque application to bolted connections.
Constraints of working in confined and cramped spaces, undersea operations, novel metallurgy and speed of
work all catered to the fast increase of the use of hydraulic wrenches. With the use of these versatile tools,
assembly and maintenance crews can apply thousands of ft.lbs pressure to tighten or loosen very large size
nuts and bolts even in precarious locations. During disassembly, fasteners
virtually jammed solid due to corrosion can also be loosened/broken with
extreme ease using this tool.
Hydraulic Wrench Design
The design of the hydraulic wrench transforms lenier hydraulic motion
into an arcing motion in order to facilitate opening and tightening of
fasteners. The inline hydraulic wrench is designed to carry a drive pawl,

drive gear/ratcheting wheel, the body which houses the hydraulic cylinder and the reaction device which
bears against an adjacent object to prevent the wrench from pulling off the bolt during operation. The
hydraulic wrench is supplied with pressurized hydraulic fluid from a hydraulic pump driven either by an
electric motor or through pneumatic pressure.
The pump is usually a compact portable unit and is connected to the wrench through high-pressure hoses;
connectors at the wrench end are designed to swivel 360 degrees to let the wrench be positioned for operation
at different angles.
The pressurized fluid supplied to the cylinder of the wrench mechanically operates the drive pawl through a
lever arm attached to the piston in the cylinder.
The drive pawl delivers torque to the ratcheting wheel. The wheel has a square or other suitably shaped drive
head to which a socket/box spanner etc. can be attached for opening/tightening a fastener.
Factors Governing Torque Delivery Of A Hydraulic Wrench
There are three factors that mainly govern the power characteristics of a hydraulic wrench: the fluid pressure
in the cylinder, the arm length of the wrench and cylinder position. How far reaching are the effects can
understood by treating a comparison of two different model of hydraulic wrenches manufactured by Enerpac
as a typical example.
Enerpac model W15000 of the LP series can deliver a maximum torque of 15000 Ft.lbs at a pressure of 10000
psi whereas at the same pressure Model S25000 of series S is capable of delivering 25400 Ft.lbs. The
operating pressure is adjustable in all the models within a specified range to suit needs of specific
applications. The pressure is delivered to the wrench through the hydraulic fluid supplied by the pump

connected to the wrench.

The pumps are usually powered by an electric motor of suitable size. However, in working conditions where
an electric spark can be hazardous, pneumatically powered hydraulic pumps are employed. Keeping in view
the need for working in hard to reach places constant technological efforts are leading to the development of
easily portable light weight pumps.
The formidable fluid pressure these pumps can build during their working cycles and the pressure variations
demanded by different operating conditions compels a pressure regulation device to be incorporated in the
pressure circuit. This finds shape in the form a relief valve mounted on the pump unit as a damage control
measure.
This is set to open at a predetermined pressure and allows fluid to flow back to the reservoir to maintain
specified pressure in the circuit. There are also controls on the wrench that let the user regulate torque
delivery within preset limits for bolting operations.
Accuracy In Torque Delivery Is A Basic Characteristic Of A Hydraulic Wrench
Hydraulic wrenches are geared to cater to the high degree of precision required in bolting equipment and
machinery incorporating complex technological design and material composition. These wrenches provide
accuracy tolerances of + 1/2 to - 3% which is far above the pneumatic or electric power wrenches.
Productivity is also increased tremendously and is dependent upon the flow of the pressurized fluid from the
pump unit. It is directly related to the volume required for extension and retraction of the hydraulic cylinder,
which in turn governs the amount of rotation delivered to the nut/bolt with each stroke of the cylinder.
An increase in the hydraulic flow to the cylinder would increase the rotational speed saving overall time in

the operation. Therefore a pump with a higher flow rate would cut down many crucial worked hours.
However, the pump would need to be optimally sized vis a vis the bolting operations.
To understand why correct torque application (which is a characteristic feature of hydraulic wrenches) is so
important one needs to look into the technical aspects of bolting operations which in fact are far from simple.
101 Of Bolting
A bolt/fastener is designed to fulfill the purpose of bringing together two mating pieces of equipment. The
force exerted on the joint by clamping is due to the preload that is generated by torquing the bolt to rotate it to
effect tightening or loosening.
The threads of the bolt offer resistance against the threaded grooves in its hole/nut, literally stretching the bolt
to a certain extent. With an inherent tendency to return to its original position, the bolt exerts pressure through
its head or the nut to clamp the two pieced together.
Critical and complex fastening applications rely upon tightening of bolts within specifications related to the
material of the bolt, the material being fastened together and functional performance of the equipment.
Vibration can make a 'too little tightened' bolt to shake loose and cause a structural support member to break
apart or cause leakage(s) in flange gaskets in pipelines. Tightening a bolt too much can cause immense stress
that can eventually lead to bolt breakage.
From the discussions above, the importance of precision required in bolting operations becomes very clear.
Hydraulic torque wrenches provide the means of near perfect control of tightening torque making them tools
of choice as compared to other uncontrolled methods of bolt tightening such as sledge hammers and striking
wrenches or pneumatic wrenches that are devices with limited control.

The Working And Usage Of Hydraulic Press

A hydraulic press is a machine that has a bed or a plate in which the metallic material is placed so that it can be crushed, straightened
or moulded.

All Of It Made Possible With The Hydraulic Press

The concept of the hydraulic press is based on Pascal's theory, which states that when pressure is applied on fluids in an enclosed
system, the pressure throughout the system always remains constant. In simple words, a hydraulic press is a machine that makes
use of the pressure exerted on the fluids to crush something.
Joseph Bramah invented the hydraulic press, hence it is also known as the Bramah Press.

How the Hydraulic Press works

Since the hydraulic press works on the basis of Pascal's Law, its working is similar to the one of the hydraulic system. A hydraulic
press consists of basic components used in a hydraulic system that includes the cylinder, pistons, the hydraulic pipes, etc.The
working of this press is very simple. The system comprises of two cylinders, the fluid (usually oil) is poured in the cylinder having a
small diameter. This cylinder is known as the slave cylinder.
The piston in this cylinder is pushed so that it compresses the fluid in it that flows through a pipe into the larger cylinder. The larger
cylinder is known as the master cylinder. The pressure is exerted on the larger cylinder and the piston in the master cylinder pushes
the fluid back to the original cylinder.

The force applied on the fluids by the smaller cylinder results in a larger force when pushed
in the master cylinder. The hydraulic press is mostly used for industrial purposes where a
large pressure is required for compressing metals into thin sheets. An industrial hydraulic
press uses the material to be worked upon along with the help of the press plates to crush
or punch the material into a thin sheet.

Uses Of A Hydraulic Press

A hydraulic press is used for almost all industrial purposes. But basically it is used for transforming metallic objects into sheets of
metal. In other industries, it is used for the thinning of glass, making powders in case of the cosmetic industry and for forming the
tablets for medical use. The other common uses of the hydraulic presses are as follows:

 For crushing cars. A hydraulic press is the heart of any car crushing system. In this process, a hydraulic motor
applies a large pressure on the fluids into the cylinders. The fluid pressure makes the plates rise and with a large force, the
plate is driven on the car thereby crushing it.

Fat-free cocoa powder. While processing the cocoa beans, a liquid known as chocolate liquor is derived. For
making fat-free cocoa powder, this liquid is squeezed out in a hydraulic press. After this stage, this liquid is processed further
to make a powder. The powder thus derived is cocoa powder, which is fat-free.

For sword making. In the process of making swords, a hydraulic press is used to give a flat shape to the raw steel.
Types Of Hydraulic Press
There are many different types of hydraulic presses catering to the various requirements of industries. Some of them are as follows:

Arbor presses: These presses are usually used when the work involved is not of a heavy- duty nature. These presses come
in a variety of sizes and specifications. But compared to other hydraulic presses, they do not compress large amounts of pressure
required to generate more output. Arbor presses are used in processes like piercing holes into metals, stamping, to flatten metals,
tearing, marking inscriptions, etc.

Laminating presses: Unlike other hydraulic presses that are operated automatically, these presses make use of manual
labor. Laminating presses have two openings that are known as plates. One is used for heating whereas the other is used for cooling.
This makes the lamination process comparatively faster. Through these presses, materials like polymer can be laminated onto paper
and metal. In case of laminating presses, the plates are usually heated with oil or through electricity. A laminating press is also used
for common uses such as laminating the identity cards, certificates and even book covers. In this way, laminating presses facilitates
fast and easy lamination for industrial and domestic needs.

C- frame presses: These presses have a 'C' like shape, which is specifically designed to maximize the floor space for the
workers in order to move around easily at the workplace. Unlike other presses that have multi-processes, the C- frame presses only
include a single press application. Its application includes straightening, drawing and mostly includes assembling work. C- frame
presses come in a variety of weights. The C- frame presses are also available with extra features such as wheel stands and pressure
gauges.

Pneumatic presses: These presses are the most basic hydraulic presses used in industries because they compress the

air to create a pressure in order to gain movement. The advantage of pneumatic presses is that the operations are performed fast
whereas the disadvantage of this press is that it cannot create extremely high pressures, as other hydraulic presses are able to
create. The pneumatic presses are often used in car and aircraft brakes system. The industrial uses of pneumatic presses would
include assembling, drawing, punching, etc. A pneumatic press usually requires a full time operator and for the sake of his safety,
additional safety accessories such as electrical safety devices are also included.

Power presses: These presses are used in large industries that demand the use of heavy machinery and equipments.
There are 2 kinds of power presses on the basis of the type of clutch used. They are full revolution and part revolution clutch. In case
of a full revolution clutch, the clutch cannot be disrupted until and unless the crankshaft makes a full revolution. In case of part
revolution, the clutch can be disrupted at any time, before or after the full revolution. Power presses involve a lot of danger because of
the heavy operations associated with it. A lot of safety measures are taken while using power presses.

Assembly presses: These presses use the extreme pressure generated by the pistons and the hydraulic fluids to
assemble and maintain the parts.

H- frame presses: These presses have a peculiar 'H' shape and are capable of handling more that one press application.
Safety Measures
As of today, hydraulic presses are available in both the categories, i.e., automatic and manually operated. In case of manually
operated hydraulic presses, many safety measures have to be taken such as using interlocking and barrier guards.

Benefits Of the Hydraulic Press

Unlike their mechanical counterparts, hydraulic presses can compress any material to a full extent. Also, hydraulic presses take only
half of the space that the mechanical ones take because they have the ability to compress a large pressure in a cylinder having a less
diameter.

Hydraulic Pump
The mechanical device that is used to convert mechanical power into hydraulic energy is known as a hydraulic pump.

Definition for Hydraulic Pumps

The mechanical device that is used to convert mechanical power into hydraulic energy is known as a hydraulic pump. The load that is
responsible for the pressure is overcome with this device by creating sufficient power and generating a flow.
The hydraulic pump has two functions to perform during operation, allowing atmospheric pressure to push liquid into the inlet line
from the reservoir to the pump by the mechanical action created vacuum at the pump. The other function it performs is that the
pumps mechanical action supplies the liquid to the pump outlet and then forced into the hydraulic system.

Categories of a Hydraulic Pump

Positive-displacement and non-positive-displacement is what hydraulic pumps can be classified into, though a majority of the
hydraulic systems utilize positive-displacement. The slippage in the positive-displacement pump is minor compared to volumetric
output flow of the pump.
Now if the output port were blocked the pressure in the pump would increase immediately
causing the pumping element or its case to stop working or the pump's prime mover could
stall or even explode incase the drive shaft does not break.
But in the non-positive-displacement pump a continuous flow is produced since a positive
internal seal is not provided to avoid slippage and this causes the pressure top to vary,
which indirectly or directly causes a variable output. Examples of non-positivedisplacement pumps are propeller and centrifugal pumps.

Working, Functioning and Specifications of Hydraulic Pumps

The pump outlets receive a high-pressure fluid flow from hydraulic pumps that pressurize fluid and are powered by mechanical
energy resources. The hydraulic pumps can work as a motor since it rotates in forward and reverse direction when powered by
pressurized fluid. When looking for hydraulic pumps there are a few specifications that are required to be considered like housing
materials, operational specification etc.
When considering operational specifications, there are two that are most important, the pump type, and the pump stage. The types of
hydraulic pumps range from radial piston, axial piston, gears- internal and external, and vane. The axially mounted piston that is used
in an axial piston pump pressurizes the fluid and the piston is moved through the chamber pressurizing the fluid by the mechanical
motion from the pump's power source.

The fluid flow is directed from the inlet pipe to the outlet or discharge using port plates or check valves. Another point to remember is
that a majority of the axial piston pumps are multi-piston. In the radial piston pump, as the name suggests, the pistons are mounted
radially with reference to a central axis. It is a variation of the axially mounted piston using a number of pistons that are
interconnected, typically in a star pattern.
The stroke length of the pistons, their size and number, determines liquid displacement by the pump. Moving the reaction ring to
increase or decrease piston travel, varying eccentricity, can vary displacement. There are a variety of controls available to monitor
this. The pistons are forced in the chambers and pressurize the fluid because of the piston movement that is sourced from the
hydraulic pumps' power.
The gear pump is another type of hydraulic pump in which the flow is produced by carrying the fluid in between the two meshing
gears teeth. The pump housing and wear or pressure plates (side plates) enclose the chambers formed between the adjoining gear
teeth.
Below optimum conditions the volumetric efficiencies of gear pumps reach a maximum of 93%. There is a always a certain loss when
fluid is pumped at a fixed pressure and variable volume because of the clearances run in between gear tooth crests, gear faces and
housing. So in order that the gear pumps operate at their maximum rated speeds, the volumetric efficiency is kept low and leads to a
poor flow.
A gear pump is differentiated into internal and external, the fluid is pressurized using internal gears in the internal gear pump. The
fluids are forced through the pump outlet by turning the internal gears using the pump's power source. The internal gear pumps are
compact units and so they are used as portable units. With respect to the external gear pumps the fluid is pressurized through the
pump outlet using external gears and the external gears are also turned using the power source from the pump.
The vane pump pressurizes the fluid using a vane and the vane rotates using the pumps power source. A vacuum is created during
the vane rotation as the rotor, which is enclosed in the chamber increases. As this takes place in the inlet side of the pump, the
atmospheric pressure forces oil in the chamber and as the space reduces, liquid is forced out from the outlets. Considering the stages
of the pumps, they are set at single, double, triple, four and many more stages.

Other Hydraulic Pump Specifications

The additional specifications that are included in the operation of a hydraulic pump are:

1.

Weight of the pump.

2.

Operating speed - The pump's moving parts rotation speed and denoted in revolutions per minute, or similar terms.

3.

Operating temperature - The pumps accommodation capabilities with relation to the fluid temperature range.

4.

Operating horsepower - This is dependent on the liquid flowing through the pump and its pressure and the measure of power
the pump is competent of delivering.

5.

Maximum operating pressure - The pump outlets available maximum peak pressure available on an irregular basis.

6.

Continuous operating pressure - The outlet pumps maximum pressure available.

7.

Fluid Temperature- This is a specification that varies from every manufacturer and depends on the internal component
materials

8.

Maximum fluid viscosity- The fluid's resistance to shear

9.

Maximum fluid flow

10.

Displacement per revolution

Units of Measurement in Hydraulic Pumps

Gallons/unit is unit of measurement for the volumetric flow, and the fluid viscosity unit is centipoises for the hydraulic pump. The
centipoise is equal to one mill Pascal second or 0.01 poise and is a universal metric unit of dynamic viscosity.
CC or cubic centimeters is the unit of measurement for the fluid volume displaced per revolution. And a pound is the measurement
unit for the weight of the hydraulic pump.

Uses of Hydraulic Pumps

The hydraulic pump is one of the main components used in manufacturing, construction, and machining equipment. The hydraulic
pump affects the machineries precision, productivity, efficiency and basically the overall system performance. In order that the
hydraulic pumps last longer and wear less there are a number of materials that are used in it's manufacturing and in different

composition depending on the purpose it has to serve.

For high-pressure systems, high strength alloys and polymers are utilized, while for low-pressure systems less expensive and
minimal pressure pumps are available. It is always practical to consider the machineries operating conditions and requirements prior
to purchasing a hydraulic pump. There are a variety of manufacturers to choose from.

Hydraulic Motors
The General Construction of Hydraulic Motors Is Quite Simple And Uncomplicated
Hydraulic motors are part of hydrostatic power transmission systems. Their purpose is to convert hydraulic energy into mechanical
energy. Depending upon specific applications, these motors prove more efficient, suitable and economical over their electrical or
pneumatic counterparts.
Hydraulic motors make use of fluid pressure for driving mechanical loads. A hydraulic motor cannot function as an isolated unit like an
electric motor does.
It has to be part of a hydraulic circuit that incorporates a hydraulic pump along with other hydraulic gadgetry such as valves, filters,
high-pressure hoses, metal tubing, hydraulic fluid reservoir etc.
The pump draws hydraulic fluid from the reservoir and supplies it under pressure to the hydraulic motor linked mechanically to the
workload. The pump receives mechanical power for its operation through a prime mover that is either an internal combustion engine
or an electric motor.
After going through the hydraulic motor, the hydraulic fluid is returned to the reservoir, filtered, and reused as required. Hydraulic
motors are fluid power actuators capable of delivering linear or rotary motion depending on their design.
They are fast becoming popular for a variety of technical applications. Due to their inherent advantages they are being preferred to
replace electrical motors or systems incorporating complex mechanical linkages as also for fresh applications.
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. 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.

For the same application, a relatively small hydraulic motor can be placed with ease and connected to a pump located remotely within
the system through an arrangement of high-pressure flexible hoses that can be conveniently routed even through disadvantageous
twists and bends.

Types Of Hydraulic Motors

Hydraulic motors delivering rotary power are mainly of two types and are classified on torque and rotational speed. One is referred to
as HSLT or High Speed Low Torque and the other as LSHT or Low Speed High Torque
motor.
The LSHT motor can have a speed range from 0.1 to 1000 revolutions per minute whereas
HSLT motor speeds can range from 1000 to 5000 revolutions per minute.
The size advantage can be gauged from the fact that the size of a 5hp hydraulic motor will
be roughly that of a 350ml beer can. In addition, there would be very low level noise and
vibration generation and much higher efficiency. HSLT and LSHT hydraulic motors are
available in different types.

Three types that find popular use are piston, gear and vane type hydraulic motors. Piston motors, which use reciprocating pistons to
transmit energy to the workload, are basically of two types.

a. Axial piston motors

b. Radial piston motors
The axial piston motor is of the 'swashplate type' and has a bank of cylinders arranged in a circle (360 degrees) parallel to each other.
Each cylinder has a piston, which reciprocates with one end of the piston pushing against an eccentric swash-plate located at one
end of the bank of cylinders. There is a mechanical arrangement through which the eccentric plate is connected to an output shaft
that is axially aligned with the cylinders. During motor operation, the cylinders are filled with high-pressure hydraulic fluid in a
particular sequence making the pistons move outwards to push sequentially against the swash-plate causing it to rotate. On the
return stroke of the piston the fluid is swept back at low pressure to return to a reservoir. The operation imparts rotational movement

to the output shaft, of which one end is connected to the swash-plate and other to the workload. This is a design that caters to a very
compact cylindrical hydraulic motor. Most axial hydraulic motors are HSLT.
A radial piston hydraulic motor has a bank of cylinders arranged like a car engine with a series of pistons riding on cams along a
camshaft, which is attached to the output shaft. The reciprocating movement of the pistons gives rotary movement to the
camshaft/output shaft that is tapped for power. In another variation cylinders are arranged radially like that of an aircraft engine with
the pistons moving inwards to push against a cam located in center causing it to rotate. The cam is mechanically linked to the output
shaft/workload. Yet another type of radial piston hydraulic motor with cylinders placed radially like an aircraft engine has the pistons
moving outwards to push against cams in a housing that surrounds the motor. This makes the housing rotate. The rotating housing is
tapped for power. These motors are generally used as wheel motors and for other suitable applications like forklifts etc.
Gear type hydraulic motors can be classified as internal gear or 'gerator' type and external gear motors. Gerator motors are very quiet
in operation and designed to transmit rotary power through an output shaft connected to a rotor moving inside an outer stator. Supply
of hydraulic fluid under pressure makes the rotor move eccentrically along the inner periphery of the stator. An external gear hydraulic
motor has a set of meshing gears enclosed in a sealed housing have passages supply and return of hydraulic fluid. Pressurized
hydraulic fluid flowing into the housing has an action on the gear teeth and makes the gears rotate. The rotational movement of the
gears is transmitted to the workload through an output shaft connected to the rotating gears and passing through the motor housing.
Vane type hydraulic motors have movable vanes connected to a centrally located output shaft. The whole arrangement is enclosed in
a housing/ case that receives hydraulic fluid under pressure from the pump. This fluid exerts force of the vanes to make them move
like fan blades. This action results in rotating the output shaft, which is tapped for power.

Hydraulic Motor Applications

Hydraulic motors are mainly used in construction and agricultural equipment. They can be commonly seen in heavy earth moving
equipment like excavators, skids, forklifts, heavy dumper trucks, bulldozers etc. where hydraulic cylinders extend and retract as vital
operational parts while the machine performs various work. These cylinders are hydraulic motors transmitting linear power.
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. There is one motor for each wheel and the diesel engine is used to drive the pump, which deliver
hydraulic fluid to the motors. A hydraulic motor with the right specifications needs to be fitted to enable the machine to function
properly.
Due to the very heavy loads imposed on car crushers, hydraulic motors are the preferred power delivery system. When the machine
stalls' due to something 'uncrushable' creating a snag, the building pressure inside the supply circuit of the hydraulic operates a
pressure relief valve preset to a specific pressure to return the supply of the fluid back to the reservoir. It also triggers a mechanism to

reverse the direction of rotation to release the snagging materiel and free the machine after which normal rotational direction is
resumed. An electric motor would either trip or burn out.
Compact and extremely efficient, small hydraulic motors can be used for various machining operations like boring, reaming, drilling
etc. Due to their small size they are tools of choice for applications like:

Electric motor coil winding

Oil pipeline inspection equipment

Undersea camera manipulation

Jumbo jet maintenance jacks

Milling and sawing applications

Dynamite blast hole pump drive

Automatic clamping

Textile washing agitators

Orange peeling machines

Fan drives

Diamond wheel dresser

Drill and tap machine tool

Chicken processing machinery

Conveyor drives

Cost-wise, piston type hydraulic motors are the costliest whereas gear type motors are the least expensive. However, each has its
own advantages depending on the use it is put to.

Hydraulic Cylinders
An actuation device that makes use of a pressurized hydraulic fluid is known as a hydraulic pump. This mechanism is used for

producing in linear motion and force in applications that transfer power.

In Insight Into Hydraulic Cylinders

What Are Hydraulic Cylinders?
An actuation device that makes use of a pressurized hydraulic fluid is known as a hydraulic pump.
This mechanism is used for producing linear motion and force in applications that transfer power. In other words, a hydraulic cylinder
converts the energy stored in the hydraulic fluid into a force used to move the cylinder in a linear direction.

Operation Of A Hydraulic Cylinder:

The hydraulic pressure in these cylinders is in the form of hydraulic fuels that are stored under pressure in these cylinders. The
energy stored in these oils is converted into motion. In a complete hydraulic system, a hydraulic motor consists of one or more
hydraulic cylinders. A pump regulates the oil-flow in the hydraulic system. The pump is a part of the generator of a hydraulic system.
The hydraulic cylinders initiate the pressure of the oil, which cannot be more than that required by the load.
A hydraulic cylinder consists of a cylindrical barrel, piston, and a piston rod. The piston that is placed within the barrel is connected to
the piston rod. The cylinder bottom, and the cylinder head, closes the bottom and the head of the barrel respectively. The cylinder
head is the side from where the piston rod exits the cylinder.
The cylinder bottom and the piston rod are mounted with mounting brackets or clevises. The piston in the hydraulic cylinder consists
of sliding rings and seals. The piston rod chamber and the bottom chamber are the two
chambers within the cylinder.
The piston rod starts moving outwards, as the hydraulic fluid is pumped into the bottom
side of the hydraulic cylinder. In the reverse process, the hydraulic fluid is pushed back into
the reservoir by the piston. The pressure in the cylinder is the ratio of unit force per unit
piston area.
The pressure generated in the piston rod chamber is the ratio of the unit load per the
difference in the unit piston area and unit piston rod area. This calculation is used when the
hydraulic fluid is let into the piston rod chamber as well as the fluid flows smoothly (without
pressure) from the piston area to the reservoir. In this way, the expansion and retraction

(push and pull) action of the hydraulic cylinder is generated.

Classification Of Hydraulic Cylinders According To Function:

Single Acting Cylinders:

In single acting cylinders the fluid is pressurized from only one side of the cylinder during both the expansion as well as the retraction
process. A spring or an external load is used to return the cylinder top to its original position i.e. when pressure of the fluid is cut off.

Double Acting Cylinders

In the double acting cylinders, the pressure from the fluid is applied in both the directions. Single cylinders that consist of springs are
not used in large stroke applications because there are inherent mechanical problems associated with the spring. The double acting
rods could be of two types:
Single rod ended
Double rod ended

Classification Of Cylinders According To Specifications:

Plunger Cylinders:
These cylinders are also known as Ram cylinders. These types of hydraulic cylinders are placed in an upright position. This is done
so that once the supply of the fluid is stopped, the weight on the cylinder will make it return to its original position. The cylinders used
in automobile service centers are a good example of the plunger cylinders.

Telescoping Cylinders
Telescopic cylinders are also known as multistage hydraulic cylinders. These cylinders have at the most six stages. These are
specially used in applications where there is less area. Telescopic cylinders can either be single action or double action. The stroke of

these cylinders is long and is used in applications such as cranes and forklifts, etc.

Cable Cylinders
The cable cylinders can either be hydraulic or pneumatic powered cylinders that are of the double acting type. These cylinders have
long strokes and produce moderate force. The cable cylinders can be operated in limited space.

Diaphragm Cylinders
Diaphragm cylinders are of two types i.e. flat diaphragm and rolling diaphragm. These cylinders have zero leak around the piston.

Components of A Hydraulic Cylinder:

There are various components that form a part of the hydraulic cylinders.
The various parts are the cylinder bottom, cylinder bottom connection cylinder barrel, and cylinder head. It also consists of the piston,
piston rod, and the piston rod connection. And some of the hydraulic cylinders may comprise of the feet. These are used to mount the
barrels.
The cylinder barrel is a thick tube that has to be machined from the inside. The interior of the barrel is honed or ground and in some
cases both. The cylinder barrel and the bottom of the cylinder are welded together in most of the hydraulic cylinders.
This welding of the bottom of the cylinder to the barrel can damage the interior of the barrel. Hence, it is preferred to have the two
screwed together. This type of connection will be helpful during repairs or maintenance of the cylinder barrel. On the other hand, the
barrel is connected to the cylinder head with a lock.
There is a simple lock system used for a simple cylinder. In most of the hydraulic cylinders the flanged or screwed connections are
used. The best type of connections and most expensive connections are the flanged connections. It is considered to be the best type
of connection because before machining a flange is welded onto the tube.
The other positive aspects are that the flange is always bolted and can be removed easily when required. The disconnection process
as well as the alignment process while mounting is much tougher for the bigger hydraulic cylinders. This problem in particular arises

where the screw size is between 300 mm to 600 mm.

There should be no bending moments implied on the hydraulic cylinder as they are applied in expansion and retraction actions. The
single clevis connection with a ball bearing is considered to be the most appropriate connection, as all the above-mentioned problems
do not arise.

Specifications To Be Considered While Purchasing A Hydraulic Cylinder:

The specifications that need to be considered while purchasing a hydraulic cylinder are:

Bore Diameter: It is the diameter of the cylinder bore.

Maximum operating pressure: The maximum working pressure a cylinder can carry is known as maximum operating
pressure.

Rod Diameter: It is the diameter of the piston or the rod that are used in hydraulic cylinders.
Stroke: The distance traveled by a piston in a hydraulic cylinder is known as stroke. The length of a stroke could be several
feet, or a fraction of an inch.

Type Of Cylinder: The different types of cylinders are tie-rod cylinder, ram cylinder and welded cylinder.
Tie-rod cylinder: These types of hydraulic cylinders make use of a single or multiple tie-rods to provide extra stability to the cylinder.
The tie-rods are mostly installed on the exterior diameter of the cylinder. The tie-rods carry most of the load in this type of hydraulic
cylinder.
Welded cylinder: There are heavy-duty welded cylinders used to balance the cylinder. The welded cylinders are smooth hydraulic
cylinders.
Ram cylinders: As the name suggests, this cylinders act as a ram. The cross-section of the moving components is half of the crosssection area of the piston rod. These hydraulic ram cylinders are not used to push and are mostly used to pull. The ram cylinder is a
hydraulic cylinder that is used in applications of high pressure .

The Working of a Hydraulic Lift

One of the most important equipment used in transporting goods and people is the hydraulic lift. By the way of hydraulics, such lifts
are able to carry heavy loads with great ease, and lift it vertically. Hydraulic lifts come in the form of passenger lift, service lifts (to
carry goods to higher floors etc.)

Lift Heavy With A Hydraulic Lift

For more than 150 years since the birth of the modern elevator, lifts have formed an important part of our life. While lifts are widely
used for transporting men to higher floors, and in multistoried buildings all over the world, there is also a completely different use for
lifts, as far as work and industries are concerned.
At such places, lifts are increasingly required to raise heavy loads in the form of machinery, and equipment at different levels. Due to
the heavy weight to be lifted, the standard roped elevator design is not very efficient for the purpose.
A hydraulic lift typically uses hydraulic cylinders to either raise or lower platforms for work, or other lifting devices. Hydraulic lifts are
ideally used for support, as well as lift and move heavy to very heavy, and large objects; at the same time providing a safe
environment that is ergonomically useful. While hydraulic lifts are mainly used for loading, and positioning work objects, at times this
can also used for transporting personnel, if required. The kind of hydraulic lift to be used in a particular situation will depend upon the
style of the platform, and its mounting style, as well as the material that it uses. Commonly used types of hydraulic lifts are table lifts,
dock lifts, fork lifts, pallet lifts etc.

Various Uses for Hydraulic Lifts

Table lifts, and positioners are used for positioning the work material such that the material
to be worked on is placed at an ergonomically comfortable access points. Truck or vehicle
lifts are used to lift materials for the purpose of lading them onto the trucks, which is done
by lifting such materials to the height of the truck bed. Vehicle lifts come with attachments
by which they can be mounted at the rear of a vehicle.
Transport companies, that transports heavy goods and machinery by roads commonly
uses such lifts. A dock lift is similar to a vehicle lift; however, these are mounted at the
docks and are used to position material and/or personnel for loading purpose.
Personnel lifts, as the name implies, are used to move workers to materials or the work
area. This is done when it is more feasible to move personnel to the work area, rather than moving the work area to the workers.
Such situations can arise when the work has to be done at great heights, or the work area is very large, and highly impossible to
move.
Fork lifts and pallet lifts are used to lift the load from the base or pallets. Forklift trucks are a common sight at docks, as well as
warehouses, and storage places. These trucks are mobile forklifts that are used to lift and transport goods at short distances. Fork

lifts, and pallet lifts are used for loading, unloading, as well as storage and working purposes. Tilt table are hollow bins with four sides,
and (usually) open at the top. These cannot only raise or lower the work piece, but can also tilt it an angle to place it in an
ergonomically optimal position to be worked upon.
The main reason for the widespread use of the hydraulic lifts is the benefits it provides by creating ergonomically safe working
conditions. This helps to greatly reduce, or even eliminate the large amount of injuries caused to workers due to repetitive stress.
Such injuries frequently occur when the job is much more physically demanding as compared to the physical limitations of the
workers. Hydraulic lifts help to place the work material at positions that is not awkward to the workers, in an easy, and safe manner.
The worker may not only benefit from the better posture for work, but the lifts can also help in placing the objects in such a manner
that the worker would require the minimum force, and labor to get the job done. Due to creation of such work friendly environment, it
not only results in reduced injuries, but also better productivity on the part of the workers.
By using hydraulic lifts, this can be successfully achieved in a variety of conditions that are otherwise very demanding or dangerous.
Hydraulic lifts can also be used to move materials horizontally, as well as vertically. Many hydraulic lifts come with wheel, and are thus
mobile in nature, and thus can be used in various situations (the best example being the forklift truck). For sustained use in a
repetitive work environment, hydraulic lifts can be permanently fixed, and be made a part of the process line. In a manufacturing
workshop, smaller hydraulic lifts are commonly used for holding and moving various products.
For employees that are engaged in repetitive motion activities, the tilting, as well as the height adjustment capacity of the hydraulic
lifts, are very important capabilities for maintaining ergonomically safe environment. A hydraulic lift can either be controlled by the way
of a remote control, or can be done manually, depending on the purpose and the size of the lift. Hydraulic lifts are commonly used in
production facilities, auto-repair shops, docks, warehouses, construction sites etc. The strength and sturdiness of hydraulic lifts, along
with the dimension requirements of the purpose are important criteria to consider for selecting a hydraulic lift.
Hydraulic lifts require special care and regular maintenance to make sure it works in the desired manner. Improperly maintained lifts
can cause serious injury. As with any hydraulic system, care should always be taken when operating hydraulic lifts. Even when the
whole system is shut down, the oil can still be under pressure, which can be very dangerous if not handles properly. Leaks of
hydraulic fluid are especially dangerous, as it is at very high pressure, and has the capability of puncturing human skin.
Care should be taken to allow only those people that are properly trained in the use of hydraulic lifts, and positioning vehicles are
operating the equipment. The required hydraulic pressure should always be maintained, and should never be allowed to cross the
recommended levels. The lift area should be kept clean of dirt, oil, tools, grit, etc. Also, it is never a good idea to overload a hydraulic
lift.

High-Pressure Hybrids: Fuel-Efficient Hydraulic Vehicles Come of Age

Once relegated to the sidelines due to bulky components and complicated

controls, these systems are benefiting from lightweight materials and ecofriendly
fluid formulas

Image courtesy of the U.S. Environmental Protection Agency

Thanks to hybrid hydraulics, there is something especially awesome in the power of the next generation of
garbage and delivery trucks that will soon be rolling through your neighborhood. Although they may still
look like big, bulky trucks, inside they boast hydraulic power-train systems that are significantly more energy
and fuel efficient than similar conventional or gasoline-electric hybrid vehicles. If hybrid hydraulics prove
their mettle for more industrial uses, cars may not be far behind.
A hydraulic system replaces all of the electronic components of an gas-electric hybrid (starter motor,
generators, controllers, batteries, etcetera) with three parts: a small diesel motorpowered pump, a
hydraulic motor and an accumulator. (Hydraulic-powered vehicles also contain an electric battery to power

secondary equipment such as lights or a radio.)

The diesel pump pushes hydraulic fluid into the accumulator to reach pressures of up to 385 kilograms per
square centimeter. By pressing down on the accelerator, the driver releases that pressurized fluid from the
accumulator to then drive the hydraulic motor.
The best analogy might be a person operating a handheld air pump to pressurize a balloon, says Joe Kovach,
group vice president of technology and innovation for Cleveland-based Parker Hannifin Corp.'s Hydraulics
Group. In this comparison the person equals the pump, which drives air (technically a fluid) into the balloon,
and the balloon represents the accumulator. The energy that can be harnessed comes from the force of the
air released from the balloon.
"We think it's quite possibly the most cost-effective technology to achieve high fuel efficiency with low
carbon emissions," says John Kargul, director of technology transfer with the U.S. Environmental Protection
Agency's(EPA) Office of Transportation and Air Quality in Ann Arbor, Mich. Since the early 1990s Kargul
and his research team have been testing hybrid hydraulic systems as a core drive-train technology for
roughly 20 different sizes of vehiclesfrom 1,500-kilogram passenger cars to 18,000-kilogram commercial
trucks. They also partner with automotive manufacturers including Ford Motor Co., Parker Hannifin and
Eaton Corp. as well as delivery companies UPS and FedEx to design, build and field-test prototype vehicles.
They have found several compelling reasons to employ hybrid hydraulic systems for a range of larger,
heavier vehiclestrucks and buses as well as military, construction and dock-loading equipment. For
starters, these systems can store and discharge energy much faster than electric batteries. They provide 10
times the power in the same size and space as a hybrid electrical system.
Perhaps most vital of all, these vehicles have demonstrated up to 50 percent fuel reduction compared with
the latest, most fuel-efficient conventional garbage trucks, Kovach says, adding that recent field trials of
trucks equipped with Parker Hannifin's new RunWise hydraulic system in Detroit, Las Vegas and Miami
even "freaked out" the garbage truck drivers. "They kept saying, 'There's something wrong with the gas
pump,'" says Kovach, whose company will roll out a dozen new hybrid hydraulic refuse trucks in Miami in

September. "They were used to putting 44 gallons of gas or diesel fuel in every day, and now they were
putting in an average of 22 gallons of fuel."
Hydraulic systems also have the ability to recover up to 75 percent of the energy the vehicle expends in
braking and pump it back into the accumulator, whereas gas-electric hybrids only recoup about 15 to 20
percent. (This is significant, given that the energy lost from the brakes on a garbage truck traveling a
standard route over three days equals the amount of energy needed to power a typical U.S. household for one
month, according to Kovach.)
Additionally, because they draw power from the pressure stored in the accumulator when fully charged,
hybrid hydraulic vehicles can shut off their engines and drive for up to 0.2 kilometer before turning them
back on. This is especially handy for start-and-stop delivery truck routes. Moreover, rather than have a fleet
of trucks fire up their engines simultaneously in the morning, the trucks can drive off for 0.2 kilometer first,
eliminating that concentration of noise and exhaust, much to the relief of their neighbors and the EPA.
Hybrid hydraulic systems in trucks actually date back to the 1960s, long before hybrid gas-electric systems
were available. Several key deficiencies, however, relegated the technology to the sidelines in favor of gaselectrics for a couple of decades. Primarily, hydraulic accumulators were made of steel, making them
extremely heavy. Early hydraulic systems were also more complicated and harder to control, especially
because the viscosity, or resistance, of the hydraulic fluid changes depending on its temperature.
During the past decade, though, improvements in several areas have eliminated those challenges.
Accumulators are now made of the same lightweight, carbon-composite materials used to fabricate jet
fighter planes, and advanced computerized systems have simplified the control issues. More efficient pump
systems, leak-proof components, and ecofriendly hydraulic fluid formulas have reduced leakage concerns as
well, Kovach says.
Now that these vehicles are beginning to appear on the marketEaton Corp. has several models of trucks,
and Parker plans to roll out their delivery trucks and dock-handling equipment in 2011smaller applications
for hybrid hydraulics are likewise being developed for wind and wave energy equipment as well as bicycles

and rickshaws. Carmaker BMW already has several hybrid models that incorporate hydraulic components in
development and close to the preproduction stage.
Peter Achten, owner and CEO of Innovation Associates, an engineering company in the Netherlands, sees
the trend continuing in the U.S. and Europe, with growth in several emerging markets like South America,
China and India where the average customer cannot afford to pay for a vehicle that requires a battery that
costs $5,000 or more.
"The hybrid hydraulic will come to the automobile," Achten says. "It is the only way to have a strong
reduction in fuel consumption and CO2 emissions without the cost and weight increase of electric batteries,
power converters, motors and generators."