Hydraulic and Pneumatic

Power Systems

Power Supply Control System Work Actuator

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Power Unit
 Provides Energy for operation of the system
 Moves the fluid through the system
 Provides a safe maximum limit on system pressure.
 Assists to maintain proper system operating temperature and fluid
cleanliness.
 Consist of Prime mover, Coupler, Pump, Storage, Pressure control
valve, Filters and Strainers

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 Power Unit

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 Hydraulic Power Unit

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 Components
 Prime Mover
 Pump
 Coupler
 Reservoir
 Pressure control valve
 Filters and strainers

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 Hydraulic Pump
 The device that causes the fluid to move through the system
carrying the energy to the point where it is needed.
 Selection of the pump depends on the
 System flow rate
 System operating pressure
 Other requirements

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Classification
 Displacement – Positive or Non-positive
 Pumping motion – Rotary or Reciprocating
 Fluid delivery characteristics – Fixed-delivery or
Variable delivery
 Positive or Non-positive
Displacement
 Centrifugal pump: no specific
 Positive displacement pump amount of fluid flow per
(Gear Pump): a specific amount rotation; flow depends on speed
of fluid passes through the pump of blades
for each rotation

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 Types
 Gear Pump
 Vane Pump
 Piston Pump
 Screw Pump
 Lobe Pump
 Centrifugal Pump
 Propeller Pump
 Jet Pump

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 Pump and Power Unit Design
 Design of the Power unit involve selection of adequately sized pump,
prime mover and plumbing to assure that the expected task can be
performed.
 Three concepts are needed
 Reading pump specification
 Calculating system power requirement
 Designing pump inlet line to eliminate cavitation

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 SHAFT POWER
 The shaft power of a pump is the mechanical power transmitted to it
by the motor/prime mover.
 It is the product of peed and torque:
S.P. = Tɷ
 ɷ is the angular speed of the shaft in radians/s and
 T is the torque transmitted in Nm.
 Since speed is more usually measured in rev/min , N
S.P. = (2πN/60)T
 FLUID POWER

 Fluid power is the energy per second carried in the fluid in the form
of pressure and quantity.
 It is defined mathematically as
F.P. = Q Δp
 Q is the flow rate in m3 /s and
 Δp the change in pressure over the pump in N/m2 .

 OVERALL EFFICIENCY

 The overall efficiency is the ratio of output power (Fluid Power) to

input power (Shaft Power).
 Because of friction and internal leakage, the power input to a pump is
larger than the fluid power (added to the fluid). The overall efficiency
of the pump is hence:
η = F.P./S.P.
 Pump Selection Factors
 Cost
 Pressure ripple and noise
 Suction Performance
 Contaminant sensitivity
 Speed
 Weight
 Fixed or Variable displacement
 Maximum Pressure and flow or Power
 Fluid type

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 Flow rate
 For the ideal Machine with no leakage, the displacement of the
machine and its speed of rotation determine the flow rate Q

Q  D

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Torque and Pressure Relation
 For the ideal machine, the mechanical Power is entirely converted to
fluid power

Power  T   PQ
PQ
T

T  PD
T  P

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 Volumetric Efficiency
 The internal flow leakage in pumps affects the relationship between
flow and speed

Q  v D
 The volumetric efficiency varies with fluid viscosity, pressure
and rotating speed

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 Mechanical Efficiency
 The presence of friction between moving parts creates
mechanical losses that are represented by the mechanical
efficiency
PD
 Input torque: T
m
 The mechanical efficiency varies with fluid viscosity, pressure
and rotating speed

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 Power Input
PQ
 The power input to a pump is H
vm

 With total machine efficiency

T  vm
PQ
H
T

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Pump characteristics
Pump characteristics
 Power Unit efficiency

𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑢𝑚𝑝 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑉𝑒 = × 100
𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑝𝑢𝑚𝑝 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝐻𝑃 𝑛𝑒𝑒𝑑𝑒𝑑 𝑡𝑜 𝑜𝑝𝑒𝑟𝑎𝑡𝑒 𝑝𝑢𝑚𝑝

𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑀𝑒 = × 100
𝑎𝑐𝑡𝑢𝑎𝑙 𝐻𝑃 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑜𝑝𝑒𝑟𝑎𝑡 𝑝𝑢𝑚𝑝

𝑉𝑒 × 𝑀𝑒
𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑂𝑒 =
100

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 Data from Manufacturer
 General Specification
 Displacement per revolution
 Flow at rated speed and pressure
 Maximum rated speed
 Continue rated operating pressure
 Allowable inlet line vacuum
 Performance Data
 Overall pump efficiency
 Volumetric efficiency
 Installation Drawing
 Information about shape and size of pump
 Application Information
 General information about pump installation and operation

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 Reservoir
 The reservoir has four basic
purposes:
 holds a reserve supply of oil
for the hydraulic system,
 dissipates heat from the
hydraulic system,
 settles larger contaminates
from the system oil and
 helps dissipate air from the
system oil.
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 Reservoir

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 Reservoir
 The reservoir must be large enough to handle the fluctuation of oil
volume used in the system when extending and retracting cylinders.
 Single action cylinders require the most oil because there is normally
no return oil from the cylinder as it is being extended. The larger the
cylinder, the more oil volume required.
 Maintaining the proper oil level in the reservoir is of utmost
importance for satisfactory operation of a Power Unit.
 Too high an oil level may cause messy overflow, blow the seal between
the reservoir and adaptor, clog the breather and foam. causing
cavitation of the pump
 Foaming will lead to poor pump performance and eventual damage to
the pump and other components in the hydraulic system.
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Reservoir shape
 High reservoir is good for heat dissipation
 Wide reservoir is good for air separation
 Intake and return lines should be as far as possible
and beneath lowest oil level
 Baffle & Separation plate between intake and
return areas.
 Base plate should slope down to drain screw.
 Ventilation & exhaust to balance the pressure in
case of fluctuating oil level. Not necessary in case
of closed reservoirs

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Problems Associated with Reservoirs
 MOTOR AND PUMP RUNS BUT HYDRAULIC SYSTEM
DOES NOT FUNCTION.
 Check oil level in reservoir, fill reservoir to proper fluid level with
recommended hydraulic fluid.
 SLOW OPERATION OF HYDRAULIC SYSTEM.
 Check oil level in reservoir, low oil supply could cause erratic operation
of system. Fill to proper level.
 Caution! Overfilling may cause foaming and poor performance.
 HYDRAULIC SYSTEM OIL TOO HOT
 Check fluid level in reservoir, low oil supply can prevent heat dissipation.
Fill to proper level.

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 Pneumatic Power Unit

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Compressed air Unit
 Provide the prime mover energy needed to compress air
 Control air temperature, retained water vapour and entrapped dirt.
 Provides means of controlling maximum air pressure in the system
 Store and condition air until needed at the workstation.

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Components
 Prime mover
 Compressor
 Receiver
 Capacity limiting system
 Safety valve
 Air filter
 Cooler and dryer

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Compressor types
 Reciprocating-piston compressors
 Single-Acting
 Double-Acting
 Rotary, sliding vane compressors
 Rotary screw compressors
 Dynamic compressors
 Lobe-type compressors

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 Reciprocating-piston compressors

Ideal

Actual
 Selecting a Compressor Package
 Establish needed capacity for the pneumatic system – requires listing
of all tools and equipment to be operated.
 Estimate increases in system demand
 Select a compressor type
 Select a system prime mover
 Determine the regulation method to control volume of air delivery.
 Select auxiliary components

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