UBMCC05

PNEUMATICS, HYDRUALICS AND

ELECTRICAL CONTROL SYSTEM LTPC3003
Common for BE (MECH, EEEM & ME)
UNIT 1: FLUID POWER SYSTEMS AND FUNDAMENTALS 9

Introduction to fluid power, Advantages of fluid power,

Application of fluid power system. Types of fluid power
systems, Properties of hydraulic fluids – General types of
fluids – Fluid power symbols. Basics of Hydraulics-
Applications of Pascal's Law- Laminar and Turbulent flow –
Reynolds's number – Darcy‘s equation – Losses in pipe,
valves and fittings.
 Introduction to fluid power
Fluid:
• A fluid is a substance that flows under the action of
shearing forces. All liquid and gaseous substances
are considered to be fluids.
• Example: water, gas

Friction force
of wall on fluid
 Difference between solid, liquid & gas
Solid Liquid Gas
Have fixed volume and shape Assumes the shape of the part of Assumes the shape and
container which it occupies volume of its container
Not easily compressible Not easily compressible compressible

Little free space between Little free space between Lot of free space between
particles particles particles
Does not flow easily Flows easily Flows very easily

Rigid particles, cannot move, Particles can move, slide past Particles can move, past
slide past one another one another one another
Gas

Solid

Liquid
 Fluid Systems
• There are two different types of fluid systems
Fluid transport system & Fluid power system
• Fluid transport system – sole objective is the delivery
of a fluid from one location to another to accomplish
some useful purpose. Examples: water pumping
stations, gas lines, chemical processing pipe lines.
• Fluid power system – designed to perform work. It is
accomplished by pressurizing fluid and operating
mechanical elements.
 Fluid power
• Fluid power is the use of fluids under pressure to generate,
control, and transmit power.
• Fluid power is subdivided into hydraulics and pneumatics.
• When the fluid is a liquid - Hydraulics.
Example: petroleum based oil, synthetic oils & water
•When the fluid is a gas - Pneumatics. Example: air.
•Air is compressible, while oil is relatively incompressible.

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Applications for fluid power systems

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 Advantages of Fluid Power System
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.
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 Advantages of Fluid Power System

1. Fluid power systems are simple, easy to operate and

can be controlled accurately
2. Multiplication and variation of forces
3. Multifunction control
4. Low-speed, high torque
5. Constant force or torque- regardless of speed
6. Economical
7. Low weight to power ratio
8. Fluid power systems can be used where safety is of vital
importance
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Types of Fluid Power Systems
1. Based on the control system
2. Based on the type of control
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.

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• 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.

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2. Based on the type of control:
Fluid logic control: controlled by hydraulic oil or air. Uses fluid
logic devices such as AND, NAND, OR, NOR, etc. Two types of
fluid logic systems are available:

(a) Moving part logic (MPL): miniature fluid elements using

moving parts such as diaphragms, disks and poppets to implement
various logic gates.

(b) Fluidics: contain no moving parts and depend solely on

interacting fluid jets to implement various logic gates.

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Electrical control: 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.

Electronic control: 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.
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 Properties of Hydraulic fluids
1. Viscosity - measure of internal resistance offered to flow. Expressed in SSU-
Saybolt second universal
2. Viscosity index –rate of change of viscosity with temperature. Viscosity index
3. Oxidation Stability – Resistance to oxidation
4. Demulsibility – ability of a hydraulic fluid to separate rapidly from moisture &
resist emulsification
5. Lubricity – ability to lubricate parts effectively
6. Rust prevention – Preventing the entry of moisture (inhibitors are added to
keep the moisture away,
7. Pour point – lowest temperature at which oil is able to flow easily
8. Flash point – Temperature at and above which a liquid gives off enough
flammable vapor to form a mixture with air that can be ignited
9. Fire point - Temperature at a liquid catch fire and continue to burn
10. Neutralization number – measure of acidity or alkalinity of a fluid (PH value -
ranges from 0 to 14. Seven is neutral. Below 7 becomes increasingly acidic, 17
 General types of fluids
 Petroleum-based fluids (Hydraulics) - Crude oil
that is quality refined can be used for light services.
 Lubricating oils (Hydraulics) - Improved lubricity
also provides wear resistance.
 Air (Pneumatics)- The system eliminates the return
lines as air can be simply exhausted back to the
atmosphere.
 Hydraulics versus Pneumatics
Hydraulic Pneumatics
Operate at high pressure 200 bar or Operating pressure 5 to 10 bar
more (1 bar = 0.1 N/mm2, = 105 pa
1 Pascal (pa) = 1 N/m2)

High power/high load applications Low power/light to moderate load

applications

Accurate & Precise positioning Low to medium precision because of

spongy characteristics due to
compressibility of air

Smooth movement Quick response

High cost Low cost
Example: Lifting m/c, earth moving Robotics & industrial automation
equipment, CNC machines applications 19
Fluid power symbols- Hydraulic Symbols
Hydraulic & Pneumatic Valves
Fluid power symbols- Pneumatic Symbols
 Basics of Hydraulics
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 Basic Principle of Hydraulics
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. The force is
multiplied in the process. The picture below shows the simplest
possible hydraulic system:
A simple hydraulic
system consists of
hydraulic fluid,
pistons, cylinders, oil
reservoir,
a complete working
mechanism, and
safety devices.

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 Basic Principle of Hydraulics

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 aircraft’s maneuvering devices.
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Transmission and Multiplication of Force

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 Transmission and Multiplication of Force

Two pistons are fitted into two cylinders filled with oil (shown
in light blue) and connected to one another with an oil-filled
pipe. A force F1 is applied to a small piston of area A 1. The
pressure is transmitted through a liquid to a larger piston of
area A2. According to Pascal’s law, the pressure is the same
on both sides, P1 = P 2
F1/A1 = F2/A2 --------------- (1)29
Transmission and Multiplication of Force

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Transmission and Multiplication of Force

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Transmission and Multiplication of Force

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 Transmission and Multiplication of Force

Problem (1): A hydraulic system as shown in Figure having a

cylinder-1 with a piston diameter of 10 mm and another
cylinder-2 with piston diameter of 50 mm. Force @ small
piston F1 = 25 N. Calculate the force @ larger piston (F 2).
*Area= ŋ/4 D2
F1= 25 N F2= ? N

Cylinder-1 Cylinder-2

Problems in Anthony Esposito – page 85 – Ex 3.4, page 118 problem No. 3.15, 3.16 (Home work),
R. Srinivasan – page 8 - problem No. 1 (Home work),
page 9- problem No. 2 (class work) 33
 Liquid flow
The fluid in a hydraulic systems flow to various
operating components through fluid conductors and
fittings and returns to the reservoir.
There are two basic types of flow in pipes.
1. Laminar flow
2. Turbulent flow

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 1. Laminar flow:
• Re < 2000, ‘low’ velocity & fluid particles move in straight
lines
• Layers of water flow over one another at different speeds
with virtually no mixing between layers.
• The flow velocity profile for laminar flow in circular pipes is
parabolic in shape, with a maximum flow in the center of
the pipe and a minimum flow at the pipe walls.

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 2. Turbulent flow.
• Re > 4000, ‘high’ velocity & flow is characterized by
the irregular movement of particles of the fluid.
• Average motion is in the direction of the flow
• The flow velocity profile for turbulent flow is fairly flat across
the center section of a pipe and drops rapidly extremely close
to the walls.
 Turbulent flow occurs when tubes pipes , fitting, and other
components are too small or not properly selected for job.

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Reynolds’ Number (R).

 Reynold’s experiments involved injecting a dye streak into fluid

moving at constant velocity through a transparent tube.
 Fluid type, tube diameter and the velocity of the flow through the
tube were varied.
Reynolds’ Results

Dye followed a straight path.

Dye followed a wavy path

with streak intact.

Dye rapidly mixed through

the fluid in the tube
The Reynolds number is the ratio of inertial forces to viscous
forces and is a convenient parameter for predicting if a flow condition
will be laminar or turbulent.
It is a dimensionless number comprised of the physical
characteristics of the flow. An increasing Reynolds number
indicates an increasing turbulence of flow.

where:
U/V is the flow velocity,
D is a characteristic linear dimension, (travelled length of the
fluid; hydraulic diameter etc.)
ρ fluid density (kg/m3),
μ dynamic viscosity (Pa.s),
ν kinematic viscosity (m2/s); ν = μ / ρ.
The value of R determined the type of flow in the experimental tubes:
UD
R

< 2000

2000- 4000

>4000
 Darcy-Weisbach Equation
•

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MOODY DIAGRAM

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Relative roughness = Є/D.
The values of roughness for various types of pipes is
given below.
Type Є (mm)
Drawn tube (brass, lead, glass) 0.0015
Commercial steel 0.046
Galvanized Iron 0.15
Cast iron 0.25
Riveted steel 0.9 to 9
Concerete 0.3 to 3

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Losses in Valves & Fittings

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 Losses in Valves & Fittings
Procedure for calculating pressure drop in hydraulic circuits
1. Determine flow velocity (v)
2. Compute Reynolds number (Re)
3. Determine friction factor (f)
4. Calculate equivalent length for each valves & fittings
5. Find total equivalent length (Le)
6. Calculate head loss using Darcy –Weisbach equation
7. Determine pressure drop (∆p)

Problems: R.Srinivasan, page 28 to 31; problem nos. 2, 3, 4 & 5

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