Hydraulic Systems: Operation, Maintenance, Troubleshooting
Hydraulic Systems: Operation, Maintenance, Troubleshooting
Hydraulic Systems: Operation, Maintenance, Troubleshooting
Hydraulic Systems
Operation, maintenance,
troubleshooting
HYDRAULICS
Hydraulics is the
system of fluid power
which transmits and
controls the force using
an incompressible
fluid.
PASCAL’S LAW
MECHANICAL
ADVANTAGE
The mechanical
cylinders produce a
mechanical advantage.
The work done by the
small piston is exactly
the same as that done
by the large piston. A
small force on the
small piston will
produce large force on
the large piston but
the small piston must
travel farther than the
large one.
Bernoulli’s Principle
In a streamline flow of an ideal fluid the sum
of the energy of position & energy of motion
will remain constant. The total energy in
fluid is made up of potential energy and
kinetic energy. The potential energy relates
to the pressure of the fluid and the kinetic
energy relates to its velocity.
ADVANTAGES OF FLUID
POWER SYSTEM
Hydraulic systems are highly
efficient, and experience very
little loss due to fluid friction.
They are light weight compared
to mechanical system.
They are very easy to maintain.
BASIC HYDRAULIC
SYSTEM 1
BASIC HYDRAULIC
SYSTEM 2
The pump is driven by
electric motor or IC
engine or air motor
etc. Sucks oil from
the reservoir through
a pipe. A filter is
used to remove dirt
and foreign material.
The pressurised fluid
from the pump flows
to the direction
control valve where
the direction of the
flow can be changed.
BASIC HYDRAULIC
SYSTEM 2
A pressure relief valve is used to
protect the system which can be
set to a desired maximum
pressure. The fluid from DC
valve enters into the actuating
cylinder and acts on the area of
the piston which develops a
force on the piston rod. The
force on the piston rod can be
used to move an object of load.
The oil form the other side of
cylinder returns to the reservoir.
A fluid power
system in which the
selector valves are
arranged in series
with each other.
Fluid flows from
the pump through
the centre of the
selector valves,
back into the
reservoir when no
unit is being
actuated.
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Caster oil
Castor oil is a vegetable-oil obtained from the
castor bean (technically castor seed as the castor
plant, Ricinus communis, is not a member of the
bean family).
Castor oil (CAS number 8001-79-4) is a colorless
to very pale yellow liquid with mild or no odor or
taste. Its boiling point is 313°C and its density is
0.961 kg/m3.
Castor oil maintains its fluidity at both extremely
high and low temperatures. Castor oil and its
derivatives have applications in the manufacturing
of soaps, lubricants, hydraulic and brake fluids,
paints, dyes, coatings, links, cold resistant plastics,
waxes and polishes, nylon, pharmaceuticals,
perfumes and in internal combustion engines.
The lubricants company Castrol takes its name
from castor oil. However, castor oil tends to form
gums in a short time, and its use is therefore
restricted to engines that are regularly rebuilt, such
as motorcycle race engines.
Mineral-Based Hydraulic
Fluid
MIL-H-5606 mineral-base is still widely used
for aircraft hydraulic systems. A kerosine-type
petroleum product that has good lubricating
characteristic and contains additives that
inhibit foaming and keep it from reacting with
metal to form corrosion. This fluid is
chemically stable and it has very small change
in its viscosity as its temperature changes. Its
main disadvantage is that it is flammable.
Mineral based hydraulic fluid is dyed red for
identification and the system that use this fluid
may be flushed with naphtha, varsol, or
stoddard solvent. Neoprene seals and hoses
may be used with mineral-based hydraulic
fluid.
Refined mineral oil is used as transformer oil.
Synthetic Hydrocarbon-based
Hydraulic Fluid
• The familiar “red oil”, (mineral-base) as
MIL-H-5606 is commonly known is
replaced with MIL-H-83282 fluid. This is
also dyed red, but it has a synthetic
hydrocarbon base. It is compatible with all
of the minerals used with 5606 fluid. The
main advantage of 83282 fluid is that it is
fire resistant. Another fluid that is
compatible with 5606 fluid is MIL-H-
81019 fluid. Which is used in extremely
low temperatures (-90 °F). This fluid is
also dyed red to prevent it being
inadvertently used with systems that have
fluid other than mineral-base.
Characteristics Hydraulic
Fluids
Low pour or freezing point:
High flash point:
Minimum toxic: less harmful.
Fluids that is used in the
hydraulic system must be as
incompressible as practical.
Contamination of hydraulic
fluids
Hydraulic system operate with very high
pressure, and the components used in this
system have such close fitting parts that any
contamination in the fluid will cause the
components to fail.
Use the patch test to determine whether or
not fluid is contaminated. Pass a measured
volume of fluid through a special patch-type
filter in a test kit. After all of the fluid is
passed through, analyse the filter and
observe the type and amount of
contaminants. The instructions that
accompany test kit explains the procedures
used to evaluate the test patch.
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Reservoir
Construction of Reservoir
The reservoir is constructed of welded steel plates, with legs
to raise the reservoir above the ground level to ensure
cooling around all the walls and bottom of the reservoir.
The reservoir should be compact. A square or rectangular
shaped tanks are compact one. The reservoir should be
sealed properly by the top cover. The top cover should be
strong enough to carry the weight of the pump and the
electric motor.
A baffle plate or fin is fitted lengthwise across the centre of
the reservoir. Its height is about 70% of the height of the oil
level. Its purpose is to separate temporarily the incoming
and the out going fluid. Baffle plate allows foreign matters
to settle to the bottom and entrained air to escape from the
fluid. Baffle prevents localised turbulence in the reservoir
and promotes heat dissipation of the fluid through the
reservoir walls.
To prevent rusting, reservoir should have protective coating
from inside and outside.
The capacity of the reservoir should never be less than three
times the pump flow rate(9 lpm).
Construction of Reservoir
Construction of Reservoir
The pump suction strainer should be well below the
normal oil level in the reservoir and at least 1½ pipe
diameter above the bottom of the tank.
The return line should be on one side of the baffle
plate the suction line on the other. The suction line
should be below the fluid level to prevent undue
aeration of the fluid.
The hot oil returning from the system should not
cause the oil temperature to exceed 50°C, and if
necessary must be cooled. The fluid temperature
gauge must be provided.
A suitable air breather device should be provided so
that the tank is always vented to the atmosphere.
A drain plug should be provided at the lowest
section of the reservoir for removing the sludge and
other foreign materials. The bottom of reservoir
should slope towards the drain plug and clean out
holes of ample size should be provided in the side
walls of the reservoir to clean the reservoir easily
Hydraulic Filters
The industrial fluid power operates best
when the fluid is free of all impurities
and other foreign matters. However, the
fluid can tolerate some amount of
foreign matter depending up on the type
of fluid power system and the
components used in it. The fluid filters
are used to remove the smallest possible
particle of foreign matter from the fluid.
There are four types of filters used in the
industrial hydraulic systems.:
Mechanical.
Absorbent.
Adsorbent.
Magnetic.
Mechanical Filters
These filters contain fine
wire mesh, closed stocked
metal disks or cloth in the
form of bag.
They remove the large
coarse contaminants such as
dirt, dust, grit and metallic
particles. But they cannot
remove the oil-soluble
contaminants.
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Absorbent Filters
Adsorbent Filters
Adsorbent filters contain
materials such as fuller’s earth,
charcoal, activated clay,
chemically treated paper.
It removes both coarse and fine
particles, also it removes
insoluble sludge and oil-soluble
contaminants.
These filters may remove
chemical additives, therefore they
should not be used for hydraulic
systems containing additive type
hydraulic oils.
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Magnetic Filters
Hydraulic Pumps
Fluid power is produced when fluid
is moved under pressure. The pumps
used in hydraulic system are simply
fluid movers rather than pressure
generators. Pressure is produced
only when the flow of fluid is
restricted. There are two basic types
of pumps:
– Operated by hand
– Operated by power (electric motor or
IC engine/ aircraft engine.)
Hand Pumps
Hand Pumps
H y d r a u lic P u m p s
P ow er P um ps
P o s it iv e d is p la c e m e n t p u m p s N o n p o s it iv e d is p la c e m e n t p u m p s
Pow er Pum ps
P o s i t iv e d is p la c e m e n t p u m p s
R o ta ry R e c ip ro c a ti n g
F ix e d & V a ri a b l e
G ear V ane S c re w A x ia l p is to n R a d ia l P is to n
E x te rn a l In lin e B e n t A x is S ta ti o n a ry R o ta tin g
F ix e d V a ria b l e C y lin d e r B lo c k C y lin d e r B lo c k
D is p la c e m e n t D i s p la c e m e n t
In te rn a l
V a ria b l e
U n b a la n c e d P la te
Vane pum p
G e ro to r
In c l i n a b l e
B a la n c e d S w a s h p la te
Vane Pump
C a m /c ra n k s h a ft
D riv e n
Pow er Pum ps
N o n p o s it iv e d is p la c e m e n t p u m p s
C e n t r if u g a l A x ia l F lo w R a d ia l F lo w
Rotary
Vane-type pumps
Gear pumps
Piston pumps
Rotary
Vane-type pumps
Fixed displacement
Unbalanced vane pump
Balanced vane pump
Variable
Rotary
Gear pumps
External gear
Internal gear
Gerotor
Non positive
Displacement Pumps
Centrifugal pumps
Axial flow pumps
Radial flow pumps
Vane pumps
Vane pump is one of the
simple types of constant
displace pump used to move
large volumes of fluid with a
pressure of up to about
300psi. the steel vanes are
free-floating in slots cut in the
rotor. They are held against
the walls to the steel sleeve
by a steel pin spacer. As the
rotor turns clockwise, the
volume between the vanes on
the inlet side of the pump
increases and the volume
between the vanes on the
discharge side of the pump
decreases. This change of
volume pulls fluid into the
pump through the inlet port
and forces it out through the
discharge port. These types of
pumps are used ain hydraulic
as well as pneumatic systems.
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Vane-Pump Variable
Displacement
On many
industrial
installations with
a maximum
pressure of about
200 bar, vane
pumps are
applied. This type
of pump is also
available with a
variable
displacement. The
shaft of the rotor
with the radial
mounted vanes is
driven by an
engine or motor.
Vane-Pump Variable
Displacement
The stator ring is circular in form
and is held in an eccentric position.
The amount of eccentricity
determines the displacement of the
pump. By steering the stator ring
towards the rotor (by hydraulic
pressure, working on a piston) the
amount of eccentricity and thus the
displacement of the pump is
decreased. At an eccentricity of
zero, the displacement of the pump
becomes 0 cm3: from that moment
on the pump doesn't deliver any
oil.
Un-Balanced Vane
Pump
• In unbalanced vane pumps, the
pressure capability is limited because
of its unbalanced hydraulic loading.
Displacement of unbalanced vane
pump can be altered or reduced to
zero through some external controls
such as hand wheel or pressure
compensation. The control moves the
circular cam ring relative to motor
centerline. This reduces or increases
the size of the pumping chamber. This
is called changing throw. The cam ring
is held in the eccentric position by a
compensator spring.
Gerotor
In-Line Variable-Displacement
Pump
Stationary Cylinder
The connecting rods of
the five radial mounted
pistons are 'pushing' on
the eccentric part of the
central shaft. A rotating
sleeve valve, which is
driven by the central
shaft, is taking care for
the proper oil supply
to/from the cylinders.
By changing the
direction of oil supply to
the motor the direction
of rotation can be
changed.
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