Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

Unit V

Accessories of Hydraulic and Pneumatic Systems

8 Marks
5.1 Filters:

Functions of Filter and strainers:

1) To remove the impurities and other foreign matters from the oil.
2) Filter removes small particles (<40 micron) and strainer removes large particles (>40
micron)
3) To maintain system and components clean.
4) To increase the system reliability.
5) Filter is used to avoid blockage of small ports, flow area of pipes because of solid
impurities present in the oil.

Classification of filters:

A. Oil filters
1) Full flow filter
2) Proportion flow filter
B. According to material used
1) Surface or screen filter
2) Depth type filter
C. According to location of filter
1) Suction line filter
2) Pressure line filter
3) Return line filter
D. Pneumatic type or air type filter

A. Hydraulic or Oil filters:

1. Full flow type filter

2. Proportional flow filter

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

1. Full flow type filter:

Fig. 5.1 Full flow type filter

a. As shown in figure, in full flow filter oil comes in through port A, passes through filter
element and goes out through port B.

b. In this filter all flow passes through filter, hence it is called as a full flow filter.

c. This is very efficient filter but only drawback of this filter is that there is large pressure
drop. It increases due to clogging of filtering element.

2. Proportional flow filter:

Fig. 5.2 Proportional flow filter

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

Working principle:

a. By reducing cross sectional area of flow passage, a pressure difference is created, due to
which proportionate quantity of oil passes through filter element.

Construction and Working:

a. Main parts of Proportional flow filter are: Venturi passage, Filtering element.

b. In this filter main oil flow passes through venturi, which create localize low pressure area
inside the filter element.

c. Outside of the filter element there is high pressure oil, due to the pressure difference
crated across filter element.

d. The propionate quantity passes through filter element.

e. In this filter the pressure drop is very low hence is having wide application.

Difference between Filters and Strainers:

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

b. Pneumatic or Air filter:

Mechanical type pneumatic filter:

Fig. 5.3 Mechanical type pneumatic filter

a. The compressed air which is unfiltered enters through the port A and comes into bowl. It
has no alternative than to enter into the filtering element.

b. The special zigzag passages created in filtering element, arrest the micron and sub micron
particles and clean air go out through port B.

FRL Unit:-

Function of FRL Unit:-

1. Filter:

i) To prevent entrance of solid contaminants to the system.

ii) To condensate and remove the water vapour that is present in the air.

iii) To arrest submicron particles that may pose a problem in the system components.

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

2. Regulator:

To regulate the incoming pressure to the system so that the desired air pressure is capable of
flowing at a steady condition.

3. Lubricator:

To provide lubrication for mating components of valves, cylinders etc.by forming a mist of oil
and air.

Symbol of FRL Unit:

Fig. 5.4 Symbol of FRL Unit

5.2 Hoses and Connctors for Hydraulic and Pneumatic Systems:

Functions of Flexible hoses:

1) To transfer energy generating liquid.

2) It can allow torque, flexibility and elasticity in tool arm movement.

3) They should flow machine geometry as much as possible.

4) To reduce a rigidity.

5) It can place anywhere in complicated region very easily where rigid tubes, pipes are
not possible to fit.

6) To sustain internal high pressure of hydraulic oil.

Features of hoses used in hydraulic and pneumatic circuits:

Hydraulic hose replaced the ridged pipes and tubes used in early hydraulic and pneumatic
circuits because of following features:-

1) It is less costly and Weighs less.

2) It is better able to absorb shock and vibration.

3) It Is easier to route and install.

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

4) Needs no brazing or specialized bending.

5) Allows for movement between components of equipment.

6) Absorbs sound better.

7) Dampens pressure surges

Types of hoses:

Rubber reinforced with fiber or steel wire braiding flexible hoses are classified as-
a. Medium pressure (SAE- 100 R1,R3, R4)
b. Medium high pressure (SAE- 100 R2,R5, R6)
c. Super high and heavy duty type including Teflon and metallic hoses(SAE- 100
R9,R12)
Construction of hydraulic hose:

Fig. 5.5 Hydraulic hose

a. Hydraulic Hoses are manufactured in layers of elastomers & braided cloth or wire.
b. Hoses are in 3 layers.
1. Layer A
This is inner tube through which oil or fluid flow. This layer comes in contact with
pressurized hydraulic fluid directly. This layer is called Hose Material layer.
2. Layer B
This layer is called Hose reinforcement. This increases strength of inner layer. It provides
structural strength to entire hose to withstand against hydraulic pressure of oil which is
very high in hydraulic system.
3. Layer C

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

This is outer layer called as protective layer. It protect middle layer from corrosion,
abrasion & other damages which can occur accidents.

Materials for hoses:

Layer A :- Plastic, Nylon, braided nylon, PVC, Teflon, synthetic elastomers, natural rubber.

Layer B:- cotton, nylon, wires, synthetic yarn, Rayon.

Layer C:- Neoprene, synthetic GRS rubber, cotton /synthetic yarn.

Applications of Hydraulic hoses:

1) Earthmoving equipments

2) Machine tools

3) Robotics

4) Material handling equipments

5) CNC/VMC machines

6) Hydraulic automobile brakes SAE 100 R series hoses should be used with petroleum-
and water-based hydraulic fluids, within a temperature range from -40° to 100° C.

Types of connectors or End fittings or couplings:

1. Male fixed coupling

2. Compression fittings
3. Quick coupling

End fitting or coupling end is that part attached to hose and other end is connected to the
component of hydraulic circuit. Following are some end fittings:

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

Fig. 5.6 End fittings

Types of Hoses and connectors in pneumatic system:

Hoses: -

a. Poly Urethane –PU tubing

b. PVC tubing
c. Nylon braided tubing
d. Metal wire braided rubber hose
e. Metal tubing
f. Straight Reinforced Polyurethane Hose
g. Coiled Reinforced Polyurethane Hose
h. Coiled Polyurethane Hose
i. Coiled Nylon Hose

Connectors:

1) Threaded elbow, tee, y-connectors

2) Push-in connectors
3) Reducer
4) Expanders
5) Plug.

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

6) Couplings

Applications of Pneumatic hoses:

1) Construction equipments like breaker, drill, air compressor

2) Mining

3) Printing presses

4) Air motor

5) Pneumatic automobile brakes 6) Pneumatic crane

5.3 Seals and Gaskets for Hydraulic and Pneumatic Systems:

1. Seals:
 The seal is an agent or element which prevents leakage of oil from hydraulic elements
and protects the system from dust and dirt.
Functions of seals:
1. To stop leakage of oil.
2. To maintain pressure of oil.
3. To prevent loss of fluid from system.
4. To keep out contamination in the system.
5. To enhance the working life of the system.
6. To enhance the functional reliability of components over a longer period.
Types of seals:
 Seals are classified as follows:
1. Based on Sealing –
Positive and Non-Positive Seals
2. Based on Applications –
Static seals and Dynamic Seals
3. Based on shape of seal-
a. ‘O’ Ring,
b. Quad ring seals,
c. V- Packing,
d. U-Packing,

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

e. Cup Packing,
f. Composite seals
Function of each type of seal:

1) Positive seals do not allow any leakage whereas non positive seal permits a small
amount of internal leakage.

2) ‘O’ ring is a static seal gives very effective sealing at high pressure.

3) Quad ring seal is quite versatile and can be used as static seal as well as for rotary and
reciprocating motion.

4) V- Packing seal is capable of holding almost all pressure .

5) U-Packing seal is used in various dynamic sealing.

6) Cup Packing seal is exclusively used to seal pistons in both low-and high pressure
hydraulic and pneumatic applications.

7) Composite seals is a combination of various types and are available in the form of sets
used for special application.

Materials of Seal:

 Two materials of seals used in hydraulic systems.

a. Metallic seal like Aluminum alloy.

b. Non metallic seal like Synthetic rubber, leather, asbestos.

Applications of Seals:

 Piston ring, oil ring in gear pump, motors, Hydraulic and Pneumatic actuators, Gear box
casings, Centrifugal pump, Automotive braking system, food processing machine, CFC
based automotive refrigeration system, car engine etc.

Seals Location-

1) Seal between piston and cylinder.

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur

Department of Automobile Engineering Hydraulic and Pneumatic Controls (22650)

2) Seal between spool and direction control valve.

3) Seals for pump.

2. Gaskets:
 A gasket is a mechanical seal which fills the space between two or more mating surfaces,
generally to prevent leakage from or into the joined objects while under compression.
Functions of Gaskets:
1. To create and retain static seal between two relatively stationary parts
2. To protect the working condition or environment from contamination
3. It fills irregularities in the matching surface.
4. To resist extrusion and creep under operating condition.
5. To avoid the leakage.
Types of gaskets:
1. Rubber gasket,
2. non-asbestos gasket,
3. cork gasket;
4. Flanged gasket,
5. Spiral wound gasket;
6. Man-way gasket,
7. Transformer gasket
Materials of Gasket:

 Gaskets are normally made from a flat material, a sheet such as paper, rubber, silicone,
metal, cork, felt, Aluminum alloy, Graphite, neoprene, nitrile rubber, fiber
glass,polytetrafluoroethylene or a plastic polymer (such as polychlorotrifluoro- ethylene

Applications of Gaskets:
• Cylinder head gasket, gasket in pumps, air compressor, oil pan gasket, gear boxes etc.
Gasket Location-
1) Hydraulic oil tank cover and tank
2) Various connections of flanges and pipe
3) End covers and cylinders

Mr. Gaikwad S N Karmayogi Institute of Technology, Pandharpur