Hydraulic Systems: Operation, Maintenance, Troubleshooting

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TM

Hydraulic Systems
Operation, maintenance,
troubleshooting

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HYDRAULICS
Hydraulics is the
system of fluid power
which transmits and
controls the force using
an incompressible
fluid.

Fluid power: the


transmission of force
by the movement of a
fluid.
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Why Automation Is Required?


 In order to increase the productivity,
industries are spending more and more on
automation. This can be accomplished by-
– Speed up of production process.
– Material handling.
– Manufacturing processes.
 The fluid power is a backbone of
automation. It offers the following
advantages
– With the application of smaller force at
one point within the system, a force of
several hundred tonnes can be produced
at some other location efficiently.

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Why Automation Is Required?


– With the use of simple levers, knobs the
fluid power system can be started,
stopped, speed up, slow down the
operations easily and accurately.
– The fluid power system provides a
constant torque or force irrespective of
the change in the speed.
– It has few moving parts, therefore it is
simple to operate and maintain.
– It is simple and compact.
– It provides maximum safety and high
degree of reliability and low
maintenance cost.
– It provides instantly reversible motion,
automatic protection against overloads
and infinitely variable speed control.

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Fluid Power Application


Some of the fluid power devices used in
various fields are :
Automobile: power seat adjustment,
power steering, power brakes.
Metal working and machine tools:
table movements of shapers, milling
machine, feeding of tools on lathe,
grinding machines, clamping of work
piece etc..
Construction: road rollers, rock drills,
paving hammers, bulldozers, shovels,
etc..
Material handling: Lifts, hoist, cranes,
dumpers, fork-lifters, conveyors,
tilting ramp etc..
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Fluid Power Application


Agriculture: hullers, harvesters,
harrows, pickers, diggers, to lift
plough.
Packaging: wrapping machinery,
sealers, harrows, labels, cartoon-
fillers, jar or tube loaders, etc.
Food processing: filling, capping,
sealing of the containers,
agitators, pulverisers etc..
Mining: excavation, classifying,
handling, refining operations,
cranes, crushers, shovels, drills,
chippers, hammers, etc.

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PASCAL’S LAW

 Pascal’s law states


that pressure in an
enclosed container
is transmitted
equally and
undiminished to
all parts of the
container and acts
at right angle to
walls of that
encloses it.

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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.

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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.

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THE BASIC IDEA


The basic idea behind any hydraulic system is
very simple:
Force that is applied at one point is
transmitted to another point using an
incompressible fluid.
The fluid is almost always an oil of some sort.
The force is almost always multiplied in the
process.

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Basic elements of fluid


power system
Fluid power system is divided into
four main divisions.
Power device : hydraulic pump set,
air compressor.
Control valves : pressure, flow &
direction control valves.
Fluid power lines : pipe lines,
connectors and fittings,
Actuators : cylinders (rotating/non
rotating), air/hydraulic motors.

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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.

They can produce almost any


force needed.
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BASIC HYDRAULIC
SYSTEM 1

All the hydraulic systems must have several


basic components, a fluid to transmit the
force, a reservoir to hold the fluid, a pump
to move the fluid, an actuator to change the
flow of fluid in to mechanical work, lines to
carry the fluid, and valves to control the
flow and the pressure of the fluid. Other
components increase the efficiency of the
systems.

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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.

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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.

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Manual Pump Control Valve System

In this basic system an electrically driven pump receives its


fluid from the reservoir and pressurises it continually. When
no units are actuated the fluid flows through the pump
control valve back to the reservoir through the filter and the
fluid circulates continually. To actuate any unit one has to
close the pump control valve (select OFF). This shuts off
the return of fluid to the reservoir and the pump forces the
fluid into the actuating cylinder to operate the service. On
completion of the service the pump starts building the
pressure, but it cannot damage the system because the
pressure is relieved by the pressure relief valve until the
pump control valve is opened (selected ON) and the pump
is unloaded. Some pump control valves are power
controlled and open when the pressure builds up after the
actuation is completed.

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Automatic Unloading valve System

The final stage in evolution of basic hydraulic system includes an


automatic pump control valve called an ‘unloading valve’ or ‘system
pressure regulator’ and an accumulator to maintain the system
pressure when the pump is unloaded. When the system pressure rises
to a specified value called the kick-out/cut-out pressure the pressure
regulator shifts and directs the pump outlet to the return line. A
check valve inside the pressure regulator traps the fluid in the
pressure line where it is kept pressurised by the accumulator. The
pump circulates the fluid through the pressure regulator and the
system return filter to the reservoir all the time the system pressure
is above cut-out pressure. When some unit in the system is actuated,
the system pressure drops below a specified value called the kick-
in/cut-in value the regulator valve shifts to shut-off the flow to the
reservoir and directs the pump out put into the system pressure line.
The pump supplies all the fluid needed for the actuation.

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Closed-Centre Hydraulic System

 A hydraulic system in which the


selector valves are installed in parallel
with each other. When no unit is
actuated, fluid circulates from the
pump, back to the reservoir without
flowing through any of the selector
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Open-Centre Hydraulic System

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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Types of hydraulic fluids


 Vegetable base.
 Mineral base.
 Synthetic base.
 Phosphate ester hydraulic oil.

These fluids are not compatible with


each other, and you must be able to
identify each of them and understand
their advantages and limitations. If a
system is inadvertently serviced with
the wrong type of fluid, all the fluid
must be drained, the system flushed
with the proper solvent, and all of the
seals in the system changed.
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Vegetable-base hydraulic fluid

 Vegetable oil is being used to produce


bio-degradable hydraulic fluid.
 Vegetable–base hydraulic fluid is
essentially caster oil and alcohol, and it
is dyed blue for identification. Natural
rubber seals can be used vegetable-base
fluid, and a system using this fluid can
be flushed with alcohol.
 Castor oil is non-toxic and quickly
biodegrades; whereas, petroleum-based
oils are potential health hazards, and
take a very long time to biodegrade.
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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.

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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.

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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.

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Phosphate ester Hydraulic


Fluid
 MIL-H-5606 hydraulic fluid can
create a fire hazard if a line breaks
and sprays the fluid out. In 1948 a
fire resistant phosphate ester
hydraulic fluid named Skydrol 7000
was developed. and later in 1978
Skydrol LD-4 and Skydrol 500B-4
hydraulic fluids were created. These
fluids are light-purple and are only
slightly heaver than water. The main
advantage of this type of fluid is its
wide range of operating temperature.
(-65 °F to 225 °F)

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Characteristics Hydraulic Fluids


 Chemically stable: prevent formation of
sludge, gums carbon, etc.
 Freedom from acidity: non corrosive. It
must be compatible with the metal in the
components and with the materials of the
seals used.
 Lubricating Properties: It must not foam in
operation. must have strong film strength.
 Satisfactory viscosity: It must have a low
viscosity so it will flow through the
pipelines with minimum of friction, within
the normal temperature ranges of the
machinery.
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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.

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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

 The reservoir is the


component that stores
the fluid and serves
as an expansion
chamber to provide a
space for the fluid
when its volume
increases because of
temperature. The
reservoir also serves
as a point at which
the fluid can purge
itself of any air it
accumulates in its
operational cycle.

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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).

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Construction of Reservoir

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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

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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.

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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

Absorbent filters contains


porous materials such as
cotton waste, paper, wood
pulp, cloth, asbestos etc.
They will filter out by
mechanical absorption
coarser particles as well as
fine insoluble particles. But
they do not remove oil
soluble oxidation products.

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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

Magnetic filters uses a stack


magnetised soft steel grids to
remove the ferrous particles
flowing through grids by
magnetism.

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Tubing and Hoses (Fluid Power


Plumbing)
The connecting pipes or tubes are
used to contain and to conduct the
hydraulic fluid or gases from one
part of hydraulic system to
another are termed as fluid power
plumbing. The connection
between reservoir and a pump and
from pump through a valves to
linear or rotary actuator with lines
to return the fluid to the reservoir
can constitutes a fluid power
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Tubing and Hoses (Fluid Power


Plumbing)

The function of piping in the fluid


power system is to act as a leak
proof carrier of the fluid.

It is important that the piping in


any fluid power system should be
properly arranged to provide
maximum efficiency and trouble
free service.

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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.)

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Hand Pumps

Single acting hand pump.


Double acting hand pump.
On the stroke of the handle that pulls the
piston outward, fluid is drawn into the
pump through the inlet check valve.
The outlet check valve inside the piston
is seated, and the fluid on the back side
of the piston is forced out of the pump
outlet.
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Hand Pumps

On the return stroke of the pump handle, the


piston is forced into the cylinder. The pump
inlet check valve seats, and the outlet check
valve opens, allowing fluid to flow into the
chamber that has the piston rod. Approximately
1/3 of the fluid is forced out of the pump as the
volume of this side of the pump is less then the
volume of the fluid taken in.
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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

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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

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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

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Positive displacement pumps

Rotary
Vane-type pumps
Gear pumps
Piston pumps

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Positive displacement pumps

Rotary
Vane-type pumps
Fixed displacement
Unbalanced vane pump
Balanced vane pump
Variable

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Positive displacement pumps

Rotary
Gear pumps
External gear
Internal gear
Gerotor

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Positive displacement pumps


Rotary
Piston pumps
Axial Piston Pump
Inline
• Fixed Displacement
• Inclinable swash plate (Variable
Displacement)
• Cam/crankshaft driven
Bent axis
Radial piston pumps
 Stationary
 Rotating Cylinder Block

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Non positive
Displacement Pumps

Centrifugal pumps
Axial flow pumps
Radial flow pumps

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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.

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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.

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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.

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Un-Balanced Vane Pump


• As system pressure reaches the
compensator setting, outlet
pressure pushes against the inside
surface of the cam ring, causing it
to pivot left. The maximum
displacement stop is diametrically
opposed to the compensator
spring. It provides manual
adjustment of maximum
eccentricity of the ring. If the
eccentricity is zero, the pump
delivers just enough flow to
maintain compensator pressure
setting. In converse, if the
eccentricity is maximum, the pump
delivers maximum fluid.

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Balanced Vane Pump


 The operation of this type of pumps
is identical to the unbalanced
pumps, except that the shape of
cam ring is elliptical rather than
circular. This configuration forms
two sets of input ports and two sets
of output ports. Because the alike
ports are placed 180 apart, forces
caused by pressure buildup on one
side are cancelled out by equal but
opposite forces on the other. This
prevents side loading of the drive
shaft. This is why the design is
called balanced.

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Balanced Vane Pump


 The displacement of cam ring in
the pump cannot be adjusted.
Changing the position of the cam
ring to 90 from its original position
can reverse the direction of the
drive shaft. This way, the major
diameter of the inner cam is
rotated 90 that allow the pumping
chamber to increase in size at inlet
and decrease in size at outlet. Flow
in the pump remains same but the
direction of the drive shaft changes

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External Gear Pump

 Gear type pumps move a


medium volume under a
pressure of 300-1500 psi.
these gears have two
meshing external tooth
gears that fit closely into
a figure-8-shaped-
housing. One of the gear
is driven by power and
this gear drives the other
one.

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External Gear Pump


As the gear rotates the
space between teeth on
the inlet side of the pump
becomes larger. Fluid is
pulled into this space,
trapped between the teeth
and the housing and
carried around to the
discharge side of the
pump. Here the teeth of
the two gears come into
mesh and decrease the
volume. As the volume is
decreased, fluid is forced
from the pump outlet.
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Internal Gear Pump


• This pump consists of an
external gear that meshes
with the teeth that are on the
inside of a larger gear. The
pumping chambers are
formed between the gear
teeth. A crescent seal is
machined into valve body
between the inlet and outlet
where the clearance between
the teeth is maximum.
Internal gear drives are fixed
displacement.
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Gerotor

It combines an internal gear


inside an external gear. The
internal gear is keyed to the
shaft. It has one less tooth than
the outer gear. As the gears
revolve, each tooth of the inner
gear is in constant contact with
the outer gear, but with one
more tooth, the outer gear
revolves slower. Spaces
between the rotating teeth
increase during the first half of
each turn, taking fluid in. They
decrease in the last half, forcing
the fluid into the outlet port
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In-Line Fixed Displacement Pumps

 In hydraulic systems with a working


pressure above aprox. 250 bar the most
used pump-type is the piston pump.
The pistons move parallel to the axis of
the drive shaft. The swash plate is
driven by the shaft and the angle of the
swash plate determines the stroke of
the piston. The valves are necessary to
direct the flow in the right direction
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In-Line Variable-Displacement Pump

 The axial piston pump with variable displacement.


The animation shows how the displacement of an axial
piston pump can be adjusted. In this example we use an
Axial Piston Pump with a rotating cylinder barrel and a
static swash-plate. The cylinder barrel is driven by the
drive shaft which is guided through a hole in the
swash-plate. The position (angle) of the swash-plate
determines the stroke of the pistons and therefore the
amount of displacement of the pump.

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In-Line Variable-Displacement
Pump

 By adjusting the position of the swash-plate


the amount of displacement can be changed.
The more the swash-plate turns to the vertical
position, the more the amount of displacement
decreases. In the vertical position the
displacement is zero. In that case the pump
may be driven but will not deliver any oil.
Normally the swash-plate is adjusted by a
hydraulic cylinder built inside the pump
housing.

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Bent Axis Axial Displacement Pumps

 Hydraulic systems that require a relatively small


volume of fluid under a pressure of 2500 psi. or
more often use fixed-angle, multi-piston pumps.
There are usually 7 or 9 axially-drilled holes in the
rotating cylinder block and each hole contains a
close fitting piston attached to a drive plate by a
ball joint rod. The cylinder block and the pistons
are attached as a unit by a shaft that is driven by a
motor. The housing is angled so that the pistons on
one side of the cylinder block are at the bottom of
their stroke while the pistons on the other side of
the block are at top of their stroke.

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Bent Axis Axial Displacement Pumps


As pump rotates one half of a turn, half
of the pistons move from the top of
their stroke to the bottom, and the
pistons on the other side of the block
move from the bottom of their stroke
to the top.
A valve plate that has two crescent-
shaped openings covers the end of
the cylinders. The pump out let port
is above the pistons that are moving
up, and the inlet port is above the
pistons that are moving down.
As the pistons move down in the
cylinder block they pull fluid into
the pump, and as they move up, they
force this fluid out of the pump into
the system.

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Radial Piston Pump


It has pistons arranged radially in
a cylinder block. The cylinder
block rotates on a stationery
spindle inside a circular reaction
ring or rotor. As the block
rotates, centrifugal force or
changing pressure causes the
pistons to follow the inner
surface of the ring, which is
offset from the cylinder block
centerline. Porting in the spindle
permits the pistons take in the
fluid as they move outward and
discharge it as they move in.
The size and number of
pistons, and length of their
stroke determine pump
displacement. Prolific Systems & Techno
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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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