Hydraulic

Principles

@Autogurukul
 What is Hydraulics?

“It is the engineering science

pertaining to liquid pressure and flow.”

@Autogurukul
 Pascal’s Law

In 1650 Blaise
Pascal made a
discovery that
provided a way to
transmit power
using liquids.

PRESSURE = FORCE ÷ AREA

@Autogurukul
Pascal’s Law

FORCE (lbs/kgs)
PRESSURE (PSI) =
AREA (in.2 /cm2)

Mr. Pascal weighs 200lbs (90.7kgs)

2 2
Piston surface area is 20 in. (129cm )

1. What is the pressure?

2. Is the pressure indicated on

all three gauges the same?
3. Why are they the same?

@Autogurukul
@Autogurukul
 And the rest is history . . .
Using Blaise Pascal’s discovery, Joseph Brahma (1748-1814)
patented the first hydraulic jack in 1795.

@Autogurukul
Advantages of Hydraulics
• Ease of accuracy and control

• Variable speed

• Multiplication of forces

• Constant force or torque

• Reversible

• Absence of vibration

• Compact

• Quiet operation

• Can be stalled

@Autogurukul
 Disadvantages of Hydraulics

• One drop of oil per second from a 20 gallon (76

litre) reservoir equals a total makeup of
2,098% or seven and a half 55-gallon (208 litre)
drums of oil per year.

• It has been estimated that over 100 million gallons

(378 million litres) of fluid could be saved every year
in North America if external leakage, which includes
leakage incidental to maintenance and repair, from
hydraulic machinery and other lubricated
equipment is eliminated.

• In Canada alone, over 12 million gallons (45 million

litres) of oil are wasted due to leakage annually
(that’s equal to one Exxon Valdez spill every year!)

@Autogurukul
 Disadvantages of Hydraulics

• Mobil Oil Corporation completed a study in the

U.S. that compared hydraulic oil reservoir
capacity to actual oil consumption. This resulted
in Mobil’s Hydraulic Fluid Index (HFI)
which concluded that in the United States the
national HFI is 4.

This means that every year in the U.S., the

average industrial plant uses four
times more oil than its machines actually hold!

• Let’s assume, conservatively, that

one half of the 100 million gallons
(378 million litres) of lost lubricants are
hydraulic fluids.
Assuming an average cost of US$7 per gallon,
(US$1.85 per litre), the resulting direct cost to
the industry to replace these hydraulic fluids is
$350 million.
@Autogurukul
HORSEPOWER (HP)

@Autogurukul
 How To Calculate Fluid Horsepower

We have many occasions to calculate the rate of power transfer through

the hydraulic fluid. It can be calculated by measuring flow, GPM, and
pressure, PSIG, then using one of these formulae:

HP = GPM x PSIG x 0.0005833 or HP = GPM x PSIG ÷ 1714

The method we will use to equate HP in the flowing liquid to 1 mechanical

HP of 33,000 ft.lbs per minute is to imagine a frictionless cylinder having a
piston area of 1 square inch, and to supply a flow of 1 GPM (231
cu.in./min.) at a pressure of 1 PSIG (1 lb/sq.in.), then calculate the HP
which would be produced on the piston rod of this cylinder.

@Autogurukul
 How To Calculate Fluid Horsepower

Piston Area = 1 square inch

FRICTIONLESS CYLINDER
FORCE = 1lb

231 inch
distance

Inlet: 1 GPM @ 1 PSI Work = 231 inch-lbs

Power Rate In Cylinder:

231” (distance of travel) x 1lb (force), per minute = 231 inch-lbs. per
minute. Convert to ft.-lbs., then divide by 33,000 to get HP:
231 ÷ 12 ÷ 33,000 = 0.0005833 HP

To find the HP transfer in the liquid of any system, multiply:

GPM x PSIG x 0.0005833
A more familiar formula is to take the reciprocal of 0.0005833 and use
it as a divider: 1÷ 0.0005833 = 1714
These factors
appeared in the
above formulae.

@Autogurukul
 • Electrical motor
Mechanical • Air motor
Power Input • Engine

• Gear
• Vane
• Piston

• Relief valve
• Reducing valve
• By-pass valve
Fluid Power
• Compensated
• Non-compensated
• Needle valve

• 2-way
• 3-way
• 4-way
• 5-way

Mechanical Power • Cylinder

Output • Hydraulic motor
• Rotary oscillator
@Autogurukul
Hydraulic Reservoir - Parts Identification

ANSI Symbol ANSI Symbol

(open to atmosphere) (pressurized)

Mounting plate Suction line

Baffle plate
Filler/Breather cap

Dished bottom
Oil level gauge

Clean-out cover

Return line

Drain plug
Drain line

@Autogurukul
 Transmission Line Symbols actuator
(motor)
actuator
Working or Main line includes: (cylinder)

Suction and
Drain directional
control valve
Pilot line (for control)
Exhaust and drain lines
Component outline

pump pressure
relief valve

reservoir

@Autogurukul
 actuator
(motor)

actuator directional
(cylinder) control valve
Transmission Line
Symbols

pressure
pump relief valve

reservoir

@Autogurukul
Purpose of actuator
Hydraulic (motor)
Components

There are 6 primary

components actuator directional
in a hydraulic system (cylinder) control valve

pump pressure
relief valve

prime
reservoir
mover

@Autogurukul
ORGANIZATION

@Autogurukul
A hydraulic system can be compared to an organization

@Autogurukul
Hydraulic System Departments
Department 1
SAFETY
DEPARTMENT

@Autogurukul
Preventing Hydraulic System Failure

Positive Incompressible System

Displacement Liquid Overpressure
Pump

Failure at the weakest link

SOLUTION: Design-in a weak link!

@Autogurukul
 actuator
(motor)

actuator
(cylinder) directional
control valve
What Component(s) Protects
The System From Overload?

pressure
pump relief valve

reservoir

@Autogurukul
Department 1

@Autogurukul
Pressure Relief Valve - SYMBOL

DEFINING CHARACTERISTICS:
- Arrow
inside square, offset from line in and out -
Normally non-passing.

- Has internal pilot.

- Always located in parallel with pump/circuit.

- Exhaust port always terminates directly to tank.

@Autogurukul
Pressure Relief Valve - SYMBOL

The dashed lines

(long/short)
represent . . .

. . . the valve body.

@Autogurukul
Pressure Relief Valve - SYMBOL

The envelope
represents . . .

. . . the spool.

@Autogurukul
Pressure Relief Valve - SYMBOL

The arrow inside

the envelope
represents . . .

. . . that the valve is

normally closed.

@Autogurukul
Pressure Relief Valve - SYMBOL

The dashed line

(long dashes)
represents . . .

... the internal pilot passage.

@Autogurukul
Pressure Relief Valve - SYMBOL

The zig-zag line

represents . . .

. . . the spring.

@Autogurukul
Pressure Relief Valve - SYMBOL

The arrow
traversing
the spring
represents
...

. . . the
adjusting screw.

@Autogurukul
Diagnostic Equipment Required To Audit
Pressure Control Department

ISO/ANSI Symbol

@Autogurukul
 Potential Hazard Alert!

Backing A Pressure Relief Valve Adjusting Screw Out

WARNING
Never back a pressure relief
valve adjusting screw all the
way out while there is
pressure in the system.
Some pressure relief valve
designs permit the entire
assembly to come out of the
valve body.

@Autogurukul
Hydraulic System Departments

Department 2
SPEED DEPARTMENT

@Autogurukul
What component(s)
determines the
speed output of
the actuators?

@Autogurukul
Department 2

@Autogurukul
Fixed Displacement Pump - SYMBOL

DEFINING CHARACTERISTICS:
- Solid
arrow pointing out of circle -
Hydraulic pump.

- No arrow drawn through circle -

Fixed displacement.

@Autogurukul
Fixed Displacement Pump - SYMBOL

The circle
represents . . .

. . . the pump
body.

@Autogurukul
Fixed Displacement Pump - SYMBOL

The line on the

opposite side
of the triangle
represents . . .

. . . the inlet
port.

@Autogurukul
Fixed Displacement Pump - SYMBOL

The
darkened
triangle
represents . . .

. . . the outward
direction of flow.

@Autogurukul
Fixed Displacement Pump - SYMBOL

The line
perpendicular
to the triangle
represents . . .

. . . the input drive

shaft.

@Autogurukul
Variable Displacement Pump - SYMBOL

DEFINING CHARACTERISTICS:
- Solidarrow pointing out of circle -
Hydraulic pump.
- Arrow drawn through circle -
Variable displacement.

COMPLETE SYMBOL

SIMPLIFIED SYMBOL

@Autogurukul
Variable Displacement Pump - SYMBOL

The circle represents

...

. . . the pump
body.

@Autogurukul
 Variable Displacement Pump - SYMBOL

The darkened triangle

represents . . .

. . . the
outward
direction of
flow.

NOTE:
1. The darkened triangle (arrow) points outward in a pump and inward in a motor.
2. The arrow is darkened when it represents a liquid. It is an outline when it
represents a gas (compressor). @Autogurukul
Variable Displacement Pump - SYMBOL

The line on the

opposite side of the
triangle represents . .
.

. . . the inlet
port.

@Autogurukul
Variable Displacement Pump - SYMBOL

The line
perpendicular to the
triangle represents . .
.

. . . the input
drive shaft.

@Autogurukul
Variable Displacement Pump - SYMBOL

The arrow represents

...

. . . that the size of the

pumping chamber can be
changed to vary the flow
-
Variable flow output.

@Autogurukul
Variable Displacement Pump - SYMBOL

The rectangle
represents . . .

. . . manual
adjustment.

@Autogurukul
Variable Displacement Pump - SYMBOL

The dashed line

represents . . .

. . . that the
internal leakage
is externally
drained.

@Autogurukul
Variable Displacement Pump - SYMBOL

The arrow represents

...

. . . the
direction
of shaft
rotation.
Clock-wise or
right-hand rotation.

@Autogurukul
Prime Movers - SYMBOLS

ISO/ANSI SYMBOL Diesel engine

(electric motor) Electric Motor

ISO/ANSI SYMBOL
(heat engine) Gas engine

Turbine

@Autogurukul
Non-Positive Displacement -VS- Positive Displacement

Nozzle NON-POSITIVE
DISPLACEMENT
Impeller

POSITIVE
DISPLACEMENT
Power is transmitted
by pushing on a
confined liquid

@Autogurukul
 Positive Displacement
Displaces an Equal Volume for Each Revolution

@Autogurukul
 How To Calculate Flow

1. Determine from the pump part number or the manufacturer’s specifications,

pump displacement.
2. Determine pump shaft speed.
FLOW = DISPLACEMENT x SHAFT SPEED
231 (1000 metric)

Where: FLOW = Gallons per minute (GPM) / litres per minute (LPM)
3
DISPLACEMENT = Cubic inches per revolution (in.3 /rev.)
Cubic centimetres per rev. (cm /rev.)
SHAFT SPEED = Revolutions per minute (RPM)
3 3
231 in. = 1 US gallon 1000cm = 1 litre
3 3
Example: DISPLACEMENT = 2.2 in. /rev. (36 cm /rev.)
SHAFT SPEED = 1750 RPM
3 3
2.2 in. /rev. (36 cm /rev.) x 1750 RPM
FLOW =
3 3
231 in. (1000 cm )

FLOW = 16.67 GPM (63.1 LPM)

@Autogurukul
 Pump Flow Determines Speed

Pump flow
determines speed

To reduce speed -
reduce flow

@Autogurukul
 Input Horsepower (HP) to drive a Hydraulic Pump:
GPM x PSI
HP =
1714

Example: 20 GPM x 2000 PSI

1714 = 23.3 HP

@Autogurukul
Fluid power (HP) to move load is useful work:
5 GPM x 2000 PSI
HP = 1714 = 5.8 HP

@Autogurukul
 Each horsepower (HP) minute that is not converted into
mechanical work is converted to heat:
1 HP = 42.4 BTU’s/min. (British Thermal Units)
Input = 23.3 HP
Useful Work = 5.8 HP 17.5 HP x 42.4 BTU’s
Horsepower Wasted = 17.5 HP = 742 BTU’s of heat per minute or 44,520
BTU’s per hour.

44,520 BTU’s/hour must be absorbed by the

hydraulic system and eventually dissipated
through the heat exchanger.
@Autogurukul
 Diagnostic Equipment Required To
Audit the Speed Delivery Department

FLOWMETER -
Required to monitor
pump flow ISO/ANSI Symbol

TACHOMETER -
Required to monitor
prime mover speed
ISO/ANSI Symbol

VACUUM GAUGE -
Required to monitor
pump inlet restriction
ISO/ANSI Symbol

@Autogurukul
 Calculations for Cylinder and Motor Speed
To find the speed of a cylinder when area size and GPM are known:

GPM x 19.25
A) Cylinder Speed (ft./min.) = 2
Piston Area (in. )

231
B) Cylinder Speed (in./min.) = GPM x 2
Piston Area (in. )

NOTE: (231 ÷ 12 = 19.25)

To find the speed of a motor when displacement and GPM are known:

231 x Flow rate (GPM)

A) Motor Speed =
Motor displacement (cu. in./rev.)

To find the flow required to deliver calculated speed when speed and displacement
are known:
Speed (RPM) x Motor displacement (cu. in./rev.)
B) GPM =
231

@Autogurukul
Hydraulic System Departments

Department 3
FORCE/TORQUE OUTPUT DEPARTMENT

@Autogurukul
What Component Determines
How Much Force or Torque
Output a How much torque
Hydraulic can this motor
System Will develop?
Deliver?

How much force

can this cylinder directional
develop? control valve

pressure
pump
relief valve

prime mover
reservoir

@Autogurukul
MIND EXERCISE

What will happen when

the pump is started?

@Autogurukul
MIND EXERCISE

3-Speed Transmission
Connect lines from the pump 1st
gear
to the cylinder to show how a
cylinder imitates a 3-speed
transmission.

2nd
gear

3rd
gear

@Autogurukul
Cylinder Areas

Major Area
Slow Speed
High Force

Intermediate Speed
Intermediate Force
Minor Area

High Speed
Low Force
Rod Area

@Autogurukul
Department 3

@Autogurukul
 Hydraulic Power Transmission

2. Transmission lines carry the fluid to actuators

1. The pump pushes the hydraulic fluid which are pushed to cause a mechanical output to
into the transmission lines. move a load.
LOAD

pump
LINEAR ACTUATOR

piston and rod

3. Some actuators operate in a straight line (linear actuators). They are

called cylinders or rams. They are used to lift weight, exert force, clamp,
etc. rotary driveshaft
pump motor

4. Rotary actuators or motors give

the system rotating output. They
can be connected to pulleys, gears,
rack-and-pinions, conveyors, etc. ROTARY ACTUATOR

@Autogurukul
Common Types
of Cylinders

Double-acting Single-acting, spring-return

Double-rod

Tandem Duplex

Telescoping Ram

@Autogurukul
Double-Acting, Single-Rod Cylinder - SYMBOL

DEFINING CHARACTERISTICS:
- Two
ports off cylinder tube -
Double-acting.

@Autogurukul
 Double-Acting, Single-Rod Cylinder - SYMBOL

The rectangle
represents . . .

. . . the cylinder tube.

@Autogurukul
Double-Acting, Single-Rod Cylinder - SYMBOL

The line
perpendicular to
the cylinder tube
represents . . .

. . . the piston.

@Autogurukul
 Page 4 of 5

Double-Acting, Single-Rod Cylinder - SYMBOL

The line
perpendicular
to the piston
represents . . .

. . . the cylinder rod.

@Autogurukul
Double-Acting, Single-Rod Cylinder - SYMBOL

The two short lines

protruding from the
cylinder tube
represents . . .

. . . the cylinder
ports.

@Autogurukul
 Double-Acting, Single-Rod Cylinder
PARTS IDENTIFICATION

Port Port
Rod Gland Seal

Rod

Wiper Seal

Piston
Blind (Closed) End
Piston Seals Live (Rod) End
Cylinder Body

@Autogurukul
Cylinder Travel Direction

EXTEND

RETRACT

@Autogurukul
 Fixed Displacement, Bi-directional Hydraulic Motor
SYMBOL

DEFINING CHARACTERISTICS:
- Solid
arrows pointing into circle -
Hydraulic motor.

- No arrows drawn through circle -

Fixed displacement.

@Autogurukul
Fixed Displacement, Bi-directional Hydraulic Motor
SYMBOL

The circle represents . . .

. . . the motor body.

@Autogurukul
 Fixed Displacement, Bi-directional Hydraulic Motor
SYMBOL

The darkened triangles

represent . . .

...the inward direction of flow.

Depending on which
side of the motor the oil enters
will determine in which
direction the shaft
rotates.

NOTE: A single triangle indicates uni-directional rotation.

@Autogurukul
Fixed Displacement, Bi-directional Hydraulic Motor
SYMBOL

The line entering the motor

through the triangles
represents . . .

. . . the work ports.

@Autogurukul
Fixed Displacement, Bi-directional Hydraulic Motor
SYMBOL

The line perpendicular

to the triangles represents . . .

. . . the output drive shaft.

@Autogurukul
 Variable Displacement, Bi-directional Hydraulic Motor
SYMBOL

DEFINING CHARACTERISTICS:
- Solid arrows pointing into circle -
Hydraulic motor.

- Arrow drawn through circle -

Variable displacement.

@Autogurukul
Variable Displacement, Bi-directional Hydraulic Motor
SYMBOL

The circle represents . . .

. . . the motor body.

@Autogurukul
Variable Displacement, Bi-directional Hydraulic Motor
SYMBOL

The line entering the motor

through the triangles represents . . .

. . . the work ports.

@Autogurukul
Variable Displacement, Bi-directional Hydraulic Motor
SYMBOL

The darkened triangles

represent . . .

. . . the inward
direction of flow.

NOTE: A single triangle indicates uni-directional rotation.

@Autogurukul
Variable Displacement, Bi-directional Hydraulic Motor
SYMBOL

The line perpendicular

to the triangles represents . . .

. . . the output drive

shaft.

@Autogurukul
 Variable Displacement, Bi-directional Hydraulic Motor
SYMBOL

The diagonal arrow represents .

..

. . . variable flow
output. (The size of
the pumping chambers
can be changed while the
output shaft is rotating).

@Autogurukul
 Calculations for FORCE and TORQUE
To calculate the force developed by a cylinder:

2
FORCE (lbs.) = PRESSURE (PSI) x Area (in. )

To calculate the torque developed by a motor:

3
PRESSURE (PSI) x Displacement (in. /rev.)
TORQUE (ft. lbs.) =
*75

*75 = (24 x π)

@Autogurukul
Hydraulic System Departments

Department 4
FLOW DIRECTION CONTROL DEPARTMENT

@Autogurukul
 actuator
(motor)

actuator
directional
What Component(s) (cylinder) control valve
Change
Flow Direction?

pump pressure
relief valve

reservoir
prime mover

@Autogurukul
Department 4

@Autogurukul
 Directional Control Valve

Directional
Control
Valve

pump

Relief
valve

pump

Relief
valve

Directional
Control
Valve

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 1:
... a position.
Each envelope (square)
represents . . .

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 2:
Each port in one
envelope (square)
represents . . . . . . the number of ports (ways) in the valve.
eg. 4 ports indicates a four “way” valve.

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 3:
The diagonal line enclosed by
a rectangle represents . . . . . . that the valve is being
driven by solenoids.

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 4:
The zig-zag line at each end . . . that the valve is centered
of the valve represents . . . (neutralized) by spring force.

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 5a: . . . the flow path in neutral.

The center envelope (square) eg. port “P” connects to port “T”
represents . . . and ports “A” and “B” are plugged.
(commonly called “tandem center”).

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 5b: . . . the flow path when the left solenoid

The left envelope (square) is energized. Port “P” is connected to
represents . . . Port “A” and Port “B” is connected to Port “T”.

@Autogurukul
 Directional Control Valve
SYMBOL

STEP 5c: . . . the flow path when the right

The right envelope (square) solenoid is energized.
represents . . . Port “P” is connected to Port “B” and
Port “A” is connected to Port “T”.

@Autogurukul
 Directional Control Valve
CENTER CONFIGURATIONS

A B

Tandem Center
P T
T A P B

A B

Closed Center
P T T A P B

A B

Float Center
P T
T A P B

A B

Open Center
P T
T A P B

@Autogurukul
 Directional Control Valve
IN-CIRCUIT

NEUTRAL

A B

P T

@Autogurukul
 Directional Control Valve
IN-CIRCUIT

LEFT
Solenoid
Energized

A B

P T

@Autogurukul
 Directional Control Valve
IN-CIRCUIT

RIGHT
Solenoid
Energized

A B

P T

@Autogurukul
Hydraulic System Departments
Department 5
PRESSURE DEPARTMENT

@Autogurukul
 actuator
(motor)

actuator
(cylinder)
directional
What Component(s) control valve
Generate Pressure
in a Hydraulic System?

pressure
pump
relief valve

reservoir
prime mover

@Autogurukul
Department 5

@Autogurukul
 1. Where does pressure come from?
MIND EXERCISE

RESISTANCE
2. Total comes from two
To determine total
resistance in a independent sources. What are they?
hydraulic system,
two elements Source 1:
have to be
Source 2:
considered:

S1:

S2:

@Autogurukul
Weight of Hydraulic Oil
The following example is based
upon standard hydraulic oil
with 0.9 specific gravity
at 220 SSU.

3
1 ft. of oil = 55-58lbs.
(0.0283 m3 ) (25-26kgs.)
3
55 gallons = 7.35 ft.
(208 litres) (0.208 m3 )

7.35 x 58 = 426lbs.
(0.208 x 26) (193 kgs.)

@Autogurukul
Specific Gravity

@Autogurukul
Liquid and Load
Resistance

@Autogurukul
 Pressure difference here is
500 PSI
caused
(34.38 bar)
by __________________
resistance.
500 PSI
5 PSI
(34.38 bar)
(0.34 bar)

System
and Load 250 PSI
Resistance (17.2 bar)

1500 PSI 1250 PSI 1000 PSI

(103.5 5 PSI (86.2 bar) (68.9 bar) is
bar) (0.34 bar) required to
push the load

Pressure difference here is caused by

___________ & __________
resistance.
@Autogurukul
 Simulator Checklists
1. Safety Checklist
Are you wearing your safety glasses?

Is the motor shaft safety guard (A) in place?

Is the safety guard (B) for cylinder rod C2 in place?

Is the weight mechanism safety guard (C) in place?

Is the floor around the simulator clean and oil-free?

Is the extension cord on the simulator rated for at

least 15 amps?

Remove the electrical plug and check that it has a

ground terminal.

Cover all power cords on the ground to prevent a

trip hazard.

Review school/company emergency policies, e.g.

emergency exits,
fire alarms, etc.

Identify location of nearest eyewash station. CONTENTS

Simulator Checklists

2. Simulator Pre-Start Checklist

Check oil level in sight glass.

Check gauges.

Check all safety covers.

Make sure weight is disengaged.

Make sure wheel brakes are applied.

3. Simulator Post-Start Checklist

Check filter bypass indicator (D).

Hoses are stored in hose caddy (E) while operating.

Check for unusual noise(s).

Are there any oil leaks?

NOTE: If there are any problems, notify the instructor immediately.

CONTENTS
@Autogurukul
THANK YOU

@Autogurukul