By:-Prof(Dr) SS Chauhan 2019

INTRODUCTION TO HYDRAULICS AND PNEUMATICS

Learning Objectives

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

 Explain the meaning of fluid power.

 List the various applications of fluid power.
 Differentiate between fluid power and transport systems.
 List the advantages and disadvantages of fluid power.
 Explain the industrial applications of fluid power.
 List the basic components of the fluid power.
 List the basic components of the pneumatic systems.
 Differentiate between electrical, pneumatic and fluid power systems.
 Appreciate the future of fluid power in India.

1.1 Introduction

In the industry we use three methods for transmitting power from one point to
another. Mechanical transmission is through shafts, gears, chains, belts, etc.
Electrical transmission is through wires, transformers, etc. Fluid power is through
liquids or gas in a confined space. In this chapter, we shall discuss a structure of
hydraulic systems and pneumatic systems. We will also discuss the advantages
and disadvantages and compare hydraulic, pneumatic, electrical and mechanical
systems.

1.2 Fluid Power and Its Scope

Fluid power is the technology that deals with the generation, control and
transmission of forces and movement of mechanical element or system with the
use of pressurized fluids in a confined system. Both liquids and gases are
considered fluids. Fluid power system includes a hydraulic system (hydra
meaning water in Greek) and a pneumatic system (pneuma meaning air in
 By:-Prof(Dr) SS Chauhan 2019

Greek). Oil hydraulic employs pressurized liquid petroleum oils and synthetic
oils, and pneumatic employs compressed air that is released to the atmosphere
after performing the work.

Perhaps it would be in order that we clarify our thinking on one point. By the
term “fluid” we refer to air or oil, for it has been shown that water has certain
drawbacks in the transmission of hydraulic power in machine operation and
control. Commercially, pure water contains various chemicals (some deliberately
included) and also foreign matter, and unless special precautions are taken when
it is used, it is nearly impossible to maintain valves and working surfaces in
satisfactory condition. In the cases where the hydraulic system is closed (i.e., the
one with a self-contained unit that serves one machine or one small group of
machines), oil is commonly used, thus providing, in addition to power
transmission, benefits of lubrication not afforded by water as well as increased
life and efficiency of packings and valves. It should be mentioned that in some
special cases, soluble oil diluted with water is used for safety reasons. The
application of fluid power is limited only by the ingenuity of the designer,
production engineer or plant engineer. If the application pertains to lifting,
pushing, pulling, clamping, tilting, forcing, pressing or any other straight line
(and many rotary) motions, it is possible that fluid power will meet the
requirement.
Hydraulics and pneumatics have almost unlimited application in the production
of goods and services in nearly all sectors of the country. Several industries are
dependent on the capabilities that fluid power affords. Table 1.1 summarizes
few applications of fluid power.

Table 1.1 More applications of fluid power

Agriculture Tractors; farm equipment such as mowers,

ploughs, chemical and water sprayers, fertilizer
spreaders, harvesters
 By:-Prof(Dr) SS Chauhan 2019

Automation Automated transfer lines, robotics

Automobiles Power steering, power brakes, suspension

systems, hydrostatic transmission
Aviation Fluid power equipment such as landing wheels in
aircraft. Helicopters, aircraft trolleys, aircraft test
beds, luggage loading and unloading systems,
ailerons, aircraft servicing, flight simulators
Construction For metering and mixing of concrete rudders,
industry/equipment excavators, lifts, bucket loaders, crawlers, post-
hole diggers, road
graders, road cleaners, road maintenance vehicles,
tippers
Defense Missile-launching systems, navigation controls
Entertainment Amusement park entertainment rides such as roller
coasters
Fabrication industry Hand tools such as pneumatic drills, grinders,
borers,
riveting machines, nut runners
Food and beverage All types of food processing equipment, wrapping,
bottling,
Foundry Full and semi-automatic molding machines, tilting
of
furnaces, die-casting machines
Glass industry Vacuum suction cups for handling

Hazardous gaseous areas Hydraulic fracturing technologies: It involves

pumping large volumes of water and sand into a
well at high pressure to fracture shale and other
tight formations, allowing hazardous oil and gas to
flow into the well. However, hydraulic fracturing
has serious environmental and water pollution
related issues.
Instrumentation Used to create/operate complex instruments in space
rockets, gas turbines, nuclear power plants,
industrial labs
 By:-Prof(Dr) SS Chauhan 2019

Jigs and fixtures Work holding devices, clamps, stoppers, indexers

Machine tools Automated machine tools, numerically

controlled(NC)
machine tools
Materials handling Jacks, hoists, cranes, forklifts, conveyor systems

Medical Medical equipment such as breathing assistors,

heart assist devices, cardiac compression
machines, dental drives and
human patient simulator
Movies Special-effect equipment use fluid power; movies
such as
Jurassic park, Jaws, Anaconda, Titanic
Mining Rock drills, excavating equipment, ore conveyors,
loaders
Newspapers and periodicals Edge trimming, stapling, pressing, bundle wrapping

Oil industry Off-shore oil rigs

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

Robots Fluid power operated robots, pneumatic systems

Ships Stabilizing systems, unloading and loading unit,

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

Transportation Hydraulic elevators, winches, overhead trams

 By:-Prof(Dr) SS Chauhan 2019

Under sea Submarines, under sea research vehicles, marine

drives and
control of ships
Wood working Tree shearers, handling huge logs, feeding clamping
and
saw operations

The following are the two types of hydraulic systems:

1. Fluid transport systems: Their sole objective is the delivery of a fluid

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

1.3 Classification of Fluid Power Systems

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

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

performance is based on the characteristics of the individual
components of the system. The open-loop system is not accurate and
error can be reduced by proper calibration and control.
Closed-loop system: This system uses feedback. The output of the system is fed
back
to a comparator by a measuring element. The comparator compares the
actual output to the desired output and gives an error signal to the
control element. The error is used to change the actual output and bring
it closer to the desired value. A simple closed- loop system uses servo
valves and an advanced system uses digital electronics.
 By:-Prof(Dr) SS Chauhan 2019

2. Based on the type of control

Fluid logic control: This type of system is controlled by hydraulic oil or

air. The system employs fluid logic devices such as AND, NAND, OR,
NOR, etc. Two types
of fluid logic systems are available:
(a) Moving part logic (MPL): These devices are miniature fluid elements
using moving parts such as diaphragms, disks and poppets to
implement various logic gates.
(b) Fluidics: Fluid devices contain no moving parts and depend solely on
interacting fluid jets to implement various logic gates.
Electrical control: This type of system is controlled by electrical
devices. Four basic electrical devices are used for controlling the fluid
power systems: switches, relays, timers and solenoids. These devices
help to control the starting, stopping, sequencing, speed, positioning,
timing and reversing of actuating cylinders and fluid motors. Electrical
control and fluid power work well together where remote control is
essential.
Electronic control: This type of system is controlled by microelectronic
devices. The electronic brain is used to control the fluid power muscles
for doing work. This system uses the most advanced type of
electronic hardware including programmable
logic control (PLC) or microprocessor ( P). In the electrical control, a
change in system operation results in a cumbersome process of redoing
hardware connections. The difficulty is overcome by programmable
electronic control. The program can be
modified or a new program can be fed to meet the change of operations.
A number of such programs can be stored in these devices, which makes
the systems more flexible.
 By:-Prof(Dr) SS Chauhan 2019

1.4 Hydrostatic and Hydrodynamic Systems

A hydrostatic system uses fluid pressure to transmit power. Hydrostatics deals

with the mechanics of still fluids and uses the theory of equilibrium conditions in
fluid. The system creates high pressure, and through a transmission line and a
control element, this pressure drives an actuator (linear or rotational). The
pump used in hydrostatic systems is a positive displacement pump. The relative
spatial position of this pump is arbitrary but should not be very large due to
losses (must be less than 50 m). An example of pure hydrostatics is the transfer
of force in hydraulics.

Hydrodynamic systems use fluid motion to transmit power. Power is

transmitted by the kinetic energy of the fluid. Hydrodynamics deals with the
mechanics of moving fluid and uses flow theory. The pump used in
hydrodynamic systems is a non-positive displacement pump. The relative
spatial position of the prime mover (e.g., turbine) is fixed. An example of pure
hydrodynamics is the conversion of flow energy in turbines in hydroelectric
power plants.

In oil hydraulics, we deal mostly with the fluid working in a confined system,
that is, a hydrostatic system.

1.5 Advantages of a Fluid Power System

Oil hydraulics stands out as the prime moving force in machinery and
equipment designed to handle medium to heavy loads. In the early stages of
industrial development, mechanical linkages were used along with prime movers
such as electrical motors and engines for handling loads. But the mechanical
efficiency of linkages was very low and the linkages often failed under critical
loading conditions. With the advent of fluid power technology and associated
electronics and control, it is used in every industry now.
 By:-Prof(Dr) SS Chauhan 2019

The advantages of a fluid power system are as follows:

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

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

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

6. Economical: Not only reduction in required manpower but also the

production or elimination of operator fatigue, as a production factor, is an
important element in the use of fluid power.
7. Low weight to power ratio: The hydraulic system has a low weight to
power ratio compared to electromechanical systems. Fluid power systems are
compact.
 By:-Prof(Dr) SS Chauhan 2019

8. Fluid power systems can be used where safety is of vital importance:

Safety is of vital importance in air and space travel, in the production and
operation of motor vehicles, in mining and manufacture of delicate products.
For example, hydraulic systems are responsible for the safety of takeoff,
landing and flight of aeroplanes and space craft. Rapid advances in mining
and tunneling are the results of the application of modern hydraulic and
pneumatic systems.

1.6 Basic Components of a Hydraulic System

Hydraulic systems are power-transmitting assemblies employing pressurized

liquid as a fluid for transmitting energy from an energy-generating source to an
energy-using point to accomplish useful work. Figure 1.1 shows a simple
circuit of a hydraulic system with basic components.

Load
1 – Off 2 – Forward 3–
Motor
Return

3 1
2
Pressure
Filter regulator

Pump

Direction control valve

Actuator

Oil tank
 By:-Prof(Dr) SS Chauhan 2019

Figure 1.1 Components of a hydraulic system

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

1. The hydraulic actuator is a device used to convert the fluid power into
mechanical power to do useful work. The actuator may be of the linear
type (e.g., hydraulic cylinder) or rotary type(e.g., hydraulic motor) to
provide linear or rotary motion, respectively.
2. The hydraulic pump is used to force the fluid from the reservoir to rest
of the hydraulic circuit by converting mechanical energy into hydraulic
energy.
3. Valves are used to control the direction, pressure and flow rate of a fluid
flowing through the circuit.

4. External power supply (motor) is required to drive the pump.

5. Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.
6. Piping system carries the hydraulic oil from one place to another.
7. Filters are used to remove any foreign particles so as keep the fluid
system clean and efficient, as well as avoid damage to the actuator and
valves.
8. Pressure regulator regulates (i.e., maintains) the required level of pressure
in the hydraulic fluid.

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

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

 By:-Prof(Dr) SS Chauhan 2019

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

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

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

In industry, a machine designer conveys the design of hydraulic systems using

a circuit diagram. Figure 1.2 shows the components of the hydraulic system
using symbols. The working fluid, which is the hydraulic oil, is stored in a
reservoir. When the electric motor is switched ON, it runs a positive
displacement pump that draws hydraulic oil through a filter and delivers at
high pressure.
Cylinder
Extended

Retract

Motor Directional control valve

Pump
Filter
Pressure regulator

Breather
Reservoir

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

 By:-Prof(Dr) SS Chauhan 2019

The pressurized oil passes through the regulating valve and does work on
actuator. Oil from the other end of the actuator goes back to the tank via
return line. To and fro motion of the cylinder is controlled using directional
control valve.
The hydraulic system discussed above can be broken down into four main
divisions that are analogous to the four main divisions in an electrical system.

1. The power device parallels the electrical generating station.

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

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

4. The fluid power motor (whether it is a rotating or a non rotating cylinder or a

fluid power motor) parallels the solenoids and electrical motors.

1.7 Basic Components of a Pneumatic System

A pneumatic system carries power by employing compressed gas, generally

air, as a fluid for transmitting energy from an energy-generating source to an
energy-using point to accomplish useful work. Figure 1.3 shows a simple
circuit of a pneumatic system with basic components.
 By:-Prof(Dr) SS Chauhan 2019

Figure 1.3 Components of a pneumatic system.

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

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

Air is drawn from the atmosphere through an air filter and raised to required
pressure by an air compressor. As the pressure rises, the temperature also rises;
hence, an air cooler is provided to cool the air with some preliminary
treatment to remove the moisture. The treated pressurized air then needs to get
stored to maintain the pressure. With the storage reservoir, a pressure switch is
fitted to start and stop the electric motor when pressure falls and reaches the
required level, respectively. The three-position change over the valve delivering
air to the cylinder operates in a way similar to its hydraulic circuit.
 By:-Prof(Dr) SS Chauhan 2019

1.8 Comparison between Hydraulic and Pneumatic Systems

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

Table 1.2 Comparison between a hydraulic and a pneumatic system

S. No. Hydraulic System Pneumatic System

It employs a pressurized liquid It employs a compressed gas,

1.
as a fluid usually air, as a fluid

2. An oil hydraulic system operates at A pneumatic system usually

operates
pressures up to 700 bar
at 5–10 bar
3. Generally designed as closed Usually designed as open system
system
The system slows down when Leakage does not affect the
4.
leakage occurs system much
5. Valve operations are difficult Valve operations are easy

6. Heavier in weight Lighter in weight

Pumps are used to provide Compressors are used to provide

7.
pressurized liquids compressed gases

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

hazards hazards
Automatic lubrication is provided Special arrangements for
9.
lubrication are needed
 By:-Prof(Dr) SS Chauhan 2019

Objective Type Questions

Fill in the Blanks

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

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

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

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

speed changes.

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

of an electromechanical system.

State True or False

1. Hydraulic lines can burst and pose serious problems.

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

3. Pneumatic system is not free from fire hazards.

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

5. Water is a good functional hydraulic fluid.

 By:-Prof(Dr) SS Chauhan 2019

Review Questions

1. Define the term fluid power.

2. Differentiate between fluid transport and fluid power systems.
3. Differentiate between hydraulics and pneumatics.
4. List the six basic components used in a hydraulic system.
5. List the six basic components used in a pneumatic system.
6. List 10 applications of fluid power in the automotive industry.
7. Name 10 hydraulic applications and 10 pneumatic applications.
8. List five advantages and five disadvantages of hydraulics.
9. List five advantages and five disadvantages of pneumatics.
10. List the main components of a fluid power system and their functions.
11. Discuss in detail the future of fluid power industry in India.
12. Compare different power systems used in industries.
13. What is the main difference between an open-loop and a closed-loop
fluid power system?
14. List five major manufactures of fluid power equipment and systems in India.
15. List five major manufactures of fluid power equipment and systems in the
world.

16. Visit any industry nearby and list the hydraulic/pneumatic parts or
systems used and their purposes.
17. Why is the hydraulic power especially useful when performing heavy work?
18. Differentiate between oil hydraulics and pneumatics.
19. List any five applications of fluid power systems.

20 List the main components of a fluid power system and their functions.
 By:-Prof(Dr) SS Chauhan 2019

Answers

Fill in the Blanks

1. Control

2. Work

3. Fluid power

4. Fluid power systems

5. Less

State True or False

1. True

2. True

3. False

4. True

5. False