Hydraulic and Pneumatic

Circuits

Dr. Omar Mehrez

(PhD) Assistant Professor,

Mechanical Power Engineering Department,
Faculty of Engineering, Tanta University

1
 - About the Course -

❑ Introduction to Fluid Power

❑ Hydraulic Pumps
❑ Hydraulic Cylinders and Hydraulic Motors
❑ Hydraulic Valves
❑ Hydraulic Circuit Design and Analysis
❑ Basic Electrical Control of Fluid Power Systems

Reference:
Esposito, A. “Fluid Power with Applications”, England: PEARSON, 2014
2
 Hydraulic Pumps

❑ Pumping Theory
❑ Pump Classification
❑ Positive Displacement Pumps
❑ Pump Performance
❑ Pump Cavitation
❑ Pump Selection

3
 Pumping Theory
Definition
▪ A pump (heart of a hydraulic system) converts mechanical energy into
hydraulic energy.
▪ The mechanical energy is delivered to the pump via a prime mover
▪ Partial vacuum is created at the pump inlet
▪ Atmospheric pressure push the fluid out of the oil tank into the pump
▪ The pump mechanically pushes the fluid out of the discharge line
Fxv
Hydraulic
Cylinder

VxI Txω PxQ

Electric Hydraulic
Motor Pump
Txω
Hydraulic
Motor
4
 Pumping Theory
Operation
High Pressure
High Pressure Outlet
Outlet

Suction Compression

Atmospheric pressure Atmospheric Pressure

TANK
TANK

5
 Pumping Theory
Operation

Pump
hydraulic
symbol

Pumping action of a simple piston pump 7

 Pump Classification

Pumps

Dynamic Pumps Positive Displacement Pumps

Centrifugal
Fixed Displacement Variable Displacement
Axial
Gear Vane Pumps
(unbalanced)
Mixed Flow Balanced
Vane Piston
Unbalanced
Piston

8
 Pump Classification
Dynamic Pumps

▪ Used for low-pressure, high-volume applications

▪ They are of little use in fluid power systems
▪ Normally max. pressure capacities are limited to 250-300psi
(15-20bar)
▪ Mostly used for transporting fluids from one location to another
▪ Provide continuous flow, but their flow is reduced as circuit
resistance is increased

9
 Pump Classification
Dynamic Pumps

Centrifugal pump Axial Flow pump

Dynamic Pumps
10
 Pump Classification
Dynamic Pumps

Centrifugal pump construction

Press. vs. flow rate

11
 Pump Classification
Positive Displacement Pumps

▪ Used for fluid power systems

▪ Ejects a fixed amount of fluid into the hydraulic system per
revolution of pump shaft rotation
▪ Capable of overcoming the pressure resulting from:
1. mechanical loads on the system and,
2. flow resistance due to friction

12
 Pump Classification
Positive Displacement Pumps

Advantages
▪ High pressure capability
(800bar)
▪ Small and compact size
▪ High volumetric efficiency
▪ Great flexibility of performance
▪ Small changes in efficiency throughout the design
pressure range

13
 Pump Classification
Positive Displacement Pumps

Fixed Displacement Pumps

The amount of fluid ejected per revolution (displacement) cannot
be varied.

Variable Displacement Pumps

The displacement can be varied by changing the relationships of
various pump elements.

Pump displacement change Change in pump flow output

For the same pump speed

14
 Hydraulic Pumps

❑ Pumping Theory
❑ Pump Classification
❑ Positive Displacement Pumps
❑ Pump Performance
❑ Pump Cavitation
❑ Pump Selection

15
 Positive Displacement Pumps
Gear Pumps
Pumps

Dynamic Pumps Positive Displacement Pumps

Centrifugal
Fixed Displacement Variable Displacement
Axial Vane Pumps
Gear External gear pumps (unbalanced)
Mixed Flow Internal gear pumps
Vane Piston
Lobe pumps
Piston Gerotor pumps
Screw pumps
16
 Gear Pumps
External Gear Pumps

Theory of operation:
▪ External gear pump develops flow by carrying fluid between
the teeth of two meshing gears
▪ The suction side is where teeth come out of mesh bringing a
reduction in pressure to below atmospheric pressure
▪ The discharge side is where teeth go into mesh and here the
volume decreases between mating teeth

17
 Gear Pumps
External Gear Pumps

External Gear Pump

18
 Gear Pumps
External Gear Pumps

External Gear Pump 19

 Gear Pumps
External Gear Pumps
Features:
▪ Inexpensive and simple in design
▪ Wide range of speeds (500 to 6000rpm)
▪ Displacement volume: 0.2 to 200cm3
▪ Max. pressure: up to 300 bar (size dependent)
▪ High noise level at relatively high speeds (because of using
spur gears)
▪ Using helical gears to reduce noise level
▪ Limited to low pressure because of developing end thrust
20
 Gear Pumps
External Gear Pumps

Volumetric Displacement and Theoretical Flow Rate

The volumetric displacement VD (m3/rev):
𝜋
𝑉𝐷 = 𝐷𝑜 2 − 𝐷𝑖 2 𝐿
4
Gear teeth outside Gear teeth inside
Do: Di: L: Width of gear teeth
diameter diameter

The theoretical flow rate QT:

𝑄𝑇 = 𝑉𝐷 (m3 /rev) × 𝑁(rpm)

Volumetric efficiency ηv:

𝑄𝐴
ηv =
𝑄𝑇 21
 Gear Pumps
External Gear Pumps

Volumetric Displacement and Theoretical Flow Rate

▪ Volumetric efficiency identifying the internal leakage or pump
slippage
▪ A small clearance exist between the teeth and pump housing
▪ Some of the oil at the discharge port can leak directly back
toward the suction port
▪ Internal leakage increases with pressure
▪ Volumetric efficiency is specified at the pump rated pressure

22
 Gear Pumps
External Gear Pumps

Flow versus speed Flow versus pressure

23
 Gear Pumps
Internal Gear Pumps

Theory of operation:
▪ Consists of an internal gear, a regular spur gear, a crescent-
shaped seal and external housing
▪ The motion of the gears draws fluid from reservoir and forces
it around both sides of the crescent seal (which acts as a seal
between the suction and discharge ports)
▪ When the teeth mesh on the side opposite to the crescent seal,
the fluid is forced to discharge out of pump

25
 Gear Pumps
Internal Gear Pumps

Internal Gear Pump

26
 Gear Pumps
Internal Gear Pumps

Internal Gear Pump 27

 Gear Pumps
Internal Gear Pumps

Features:
▪ Inexpensive and simple in design
▪ Very low noise level
▪ Wide range of speeds (500 to 3000rpm)
▪ Displacement volume: 3 to 250cm3
▪ Max. pressure: up to 300 bar (size dependent)

28
 Gear Pumps
Lobe Pumps

Theory of operation:
▪ Operate in a way similar to external gear pump
▪ Both lobes are driven externally so they do not actually contact
each other
▪ Volumetric displacement is greater than that for other types of
gear pumps
▪ Lobe pump output has greater amount of pulsation due to
smaller number of mating parts

29
 Gear Pumps
Lobe Pumps

Lobe Pump

30
 Gear Pumps
Gerotor Pumps

Theory of operation:
▪ Operate in a way similar to internal gear pump
▪ The inner gear rotor (gerotor element) is power driven and
draws the outer gear rotor as they mesh together
▪ The inner gear has one tooth less than the outer gear
▪ The displacement volume is determined by the space formed
by the extra tooth in the outer rotor

31
 Gear Pumps
Gerotor Pumps

Gerotor Pump

32
 Gear Pumps
Screw Pumps

Theory of operation:
▪ Axial flow positive displacement units
▪ Three precision ground screws meshing within a close-fitting
house deliver non-pulsating flow
▪ Idler rotors are in rolling contact with the central power rotor
▪ There are no radial bending loads
▪ Axial hydraulic forces on the rotor set are balanced
▪ Rated at 200bar
▪ Displacement volume: 15 to 3500 cm3
33
 Gear Pumps
Screw Pumps

Screw Pump
34
 Positive Displacement Pumps
Vane Pumps
Pumps

Dynamic Pumps Positive Displacement Pumps

Centrifugal
Fixed Displacement Variable Displacement
Axial Vane Pumps
Gear (unbalanced)
Mixed Flow Balanced
Vane Piston
Unbalanced
Piston

35
 Positive Displacement Pumps
Vane Pumps
Theory of operation:
▪ The rotor, has a radial slots is splined to drive shaft and rotates
inside a cam ring
▪ A vane is designed to mate the cam ring as the rotor turns
▪ During one-half revolution of the rotor, the volume increases
between the cam ring and rotor causing a volume expansion
and hence fluid flow through the inlet port
▪ During the second half revolution, the cam ring surface pushes
the vanes in their slots causing ejection of the trapped fluid
through the discharge port 36
 Positive Displacement Pumps
Vane Pumps

Vane Pump
37
 Positive Displacement Pumps
Vane Pumps

Vane Pump 38
 Positive Displacement Pumps
Vane Pumps

Vane Pump
39
 Positive Displacement Pumps
Vane Pumps

Volumetric Displacement and Theoretical Flow Rate

▪ An eccentricity exist between the rotor and cam ring
centerlines.
▪ No flow exist for zero eccentricity

DC: Cam ring Diameter DR: Rotor Diameter

L: Rotor width e: eccentricity
VD: Volumetric displacement emax: max. possible eccentricity
VDmax: max. possible volumetric displacement

40
 Positive Displacement Pumps
Vane Pumps
Volumetric Displacement and Theoretical Flow Rate
The maximum eccentricity emax (m):
(𝐷𝐶 − 𝐷𝑅 )
𝑒max =
2
produces maximum volumetric displacement VDmax (m3/rev):
𝜋 2 2 𝜋
𝑉𝐷max = 𝐷𝐶 − 𝐷𝑅 𝐿 = 𝐷𝑐 − 𝐷𝑅 𝐷𝑐 + 𝐷𝑅 𝐿
4 4
𝜋
𝑉𝐷max = 𝐷𝑐 + 𝐷𝑅 𝑒max 𝐿
2
The actual volumetric displacement VD (m3/rev):
𝜋
𝑉𝐷 = 𝐷𝑐 + 𝐷𝑅 𝑒𝐿
2 41
 Positive Displacement Pumps
Vane Pumps

Features:
▪ Very low noise level
▪ Displacement volume: 5 to 100cm3
▪ Max. pressure: up to 100bar
▪ Range of speeds: 1000 to 2000rpm
▪ Variable displacement
▪ Like gear pump, hydraulically unbalanced

42
 Positive Displacement Pumps
Vane Pumps

Pressure-compensated vane pump

43
 Positive Displacement Pumps
Vane Pumps

Pressure-compensated vane pump

P-Q Curve of a
pressure compensated
vane pump

44
 Positive Displacement Pumps
Vane Pumps
Pressure-compensated vane pump

▪ The pressure at which the hydraulic piston force is equal to

the compensator spring force is called the cutoff pressure,
Pcutoff. The eccentricity is below its maximum value at a
pressure above Pcutoff.

▪ The pressure at which the eccentricity is zero is called the

dead head pressure, Pdeadhead. At dead head pressure, no
pumping occurs, no power is wasted, and fluid heating is
reduced.
45
 Positive Displacement Pumps
Vane Pumps
Balanced vane pump

▪ A balanced vane pump is one which has two intakes and two
outlets diametrically opposite each other.

▪ This produces complete hydraulic balance and minimum side

load is exerted on the bearings. This permits the pump to
operate at a higher pressure.

▪ One disadvantage of a balanced vane pumps is that it can not

be designed as a variable displacement unit.
46
 Positive Displacement Pumps
Vane Pumps
Balanced vane pump

47
 Positive Displacement Pumps
Vane Pumps
Example:

A fixed displacement vane pump delivers 1000psi oil to an extending

hydraulic cylinder at 20gpm. When the cylinder is fully extended, oil leaks
past its piston at a rate of 0.7gpm. The pressure relieve valve setting is
1200psi. If a pressure compensated vane pump were used it would reduce
pump flow rate from 20gpm to 0.7gpm when the cylinder is fully extended to
provide the leakage flow at the pressure relief valve setting of 1200psi. How
much hydraulic horse power would be saved by using the pressure
compensated pump?

48
 Positive Displacement Pumps
Piston Pumps
Pumps

Dynamic Pumps Positive Displacement Pumps

Centrifugal
Fixed Displacement Variable Displacement
Axial Vane Pumps
Gear (unbalanced)
Mixed Flow
Piston
Vane
(Radial/Axial)
Axial
Piston Bent-Axis Design
Radial
In-line (Swash Plate Design)
 Positive Displacement Pumps
Piston Pumps

Theory of operation:
▪ a reciprocating piston can draw in fluid when it extends out of
a cylinder bore, and discharges it when it retracts into the bore.
▪ This principle can be applied to pump fluid, but the resulting
flow will suffer from large pulsations.
▪ To reduce pulsations, a series of reciprocating pistons working
with a time shift between them.
▪ The basic question is how to mechanize this series of
reciprocating pistons.
50
 Positive Displacement Pumps
Piston Pumps

Suction
Compression

Basic principle of piston pumps

51
 Positive Displacement Pumps
Types of Piston Pumps
Axial Type:
Having pistons that are parallel to the axis of the cylinder block
Bent Axis Design / Swash Plate Design

Radial Type:
Pistons are arranged radially in the cylinder block

52
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)
Theory of operation:

▪ The centerline of the cylinder block is set in an offset

angle relative to the centerline of the drive shaft.
▪ The cylinder block rotates with the drive shaft.

▪ The cylinder block contains a number of pistons arranged

along a circle.

▪ The piston rods are connected to the drive shaft flange by

ball and socket joints.
53
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)
▪ The pistons are forced in and out of their bores as the
distance between the drive shaft flange and cylinder
block changes.
▪ A universal link connects the block to the drive shaft to
provide alignment and positive drive.

54
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)

Bent Axis Axial

Piston Pump
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)

Bent Axis Axial Piston Pump

56
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)

Variable displacement Bent Axis Axial Piston Pump

57
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)

Volumetric Displacement and Theoretical Flow Rate

▪ The volumetric displacement of the pump varies with the offset
angle, α.

▪ No flow is produced when the cylinder block centerline is

parallel to the drive shaft centerline, (α = 0)

▪ The offset angle can vary between 0⁰ to a maximum of about

30⁰. Fixed displacement units are usually provided with 23⁰ or
30⁰ offset angle.
58
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)
Volumetric Displacement and
Theoretical Flow Rate

 = offset angle, ()

S = piston stroke, (m)
D = piston circle diameter, (m)
Y = number of pistons
A = piston area (m 2 )
VD = volumetric displacement (m 3 )
QT = theortical flow rate (m 3 /min)

59
 Positive Displacement Pumps
Axial Pumps (Bent-Axis Design)
Volumetric Displacement and
Theoretical Flow Rate

tan ( ) =
S
D α α

S = D tan ( )

The volumetric displacement VD is:

VD = YAS = YAD tan ( )
The theoretical flow rate QT is given as:
QT = VD N = DANY tan ( )
60
 Positive Displacement Pumps
In-Line Piston Pumps (Swash Plate Design)

Theory of operation:
▪ The cylinder block and the drive shaft are located on the same
centerline.

▪ The pistons are connected to a shoe plate

▪ As the cylinder rotates, the pistons reciprocate (piston shoes

follow the angled swash plate)

▪ The inlet and outlet ports are located in the valve plate

61
 Positive Displacement Pumps
In-Line Piston Pumps (Swash Plate Design)

Swash plate Piston Pump

62
 Positive Displacement Pumps
In-Line Piston Pumps (Swash Plate Design)

Swash plate Piston

Pump

63
 Positive Displacement Pumps
In-Line Piston Pumps (Swash Plate Design)
Variable Displacement Pump:
▪ The swash plate is mounted in a movable yoke
▪ Yoke positioning is accomplished by manual operation, servo
control or compensator control
▪ The max. swash plate angle is 17.5º by construction

64
 Positive Displacement Pumps
In-Line Piston Pumps (Swash Plate Design)
Variable Displacement Pump:

Compensated Swash Plate Piston Pump 65

 Positive Displacement Pumps
Radial Pumps
Theory of operation:
▪ Consists of a pintle, a cylinder barrel with pistons, and a rotor
containing a retraction ring.
▪ Pistons remain in contact with retraction ring due to centrifugal
force and back pressure on the pistons.
▪ Eccentric movement of the reaction ring w.r.t. the shaft axis.
▪ As the cylinder barrel rotates, the piston on one side travel outward,
this draws some fluid
▪ When the piston passes the point of max. eccentricity, it is forced in
by the retraction ring causing the fluid to enter the discharge port66
 Positive Displacement Pumps
Radial Pumps

Radial Piston Pump 1, 2

67
 Positive Displacement Pumps
Piston Pumps

Features:
▪ Very low noise level
▪ Displacement volume: up to 250cm3
▪ Normal pressure: up to 450bar
▪ Range of speeds: up to 5000rpm
▪ Produce non-pulsating flow
▪ Variable displacement
▪ High power to weight ratio

68
 Hydraulic Pumps

❑ Pumping Theory
❑ Pump Classification
❑ Positive Displacement Pumps
❑ Pump Performance
❑ Pump Cavitation
❑ Pump Selection

69
 Pump Performance
Pump Efficiencies

1) Volumetric Efficiency ηv:

actual flow rate produced by the pump Q

v = = A
theoretica l flow rate produced by the pump QT

Pump Type ηv (%)

Gear Pump 80 – 90
Vane Pump 82 – 92
Piston Pump 90 – 98

70
 Pump Performance
Pump Efficiencies
2) Mechanical Efficiency ηm:
power produced by pump assuming no leakage PQT
m = =
power delivered to the pump TA N

Theoretical torque required to operate the pump TT

m = =
actual torque delivered to the pump TA

Theoretical Torque TT: VD (m 3 )  P(Pa)

TT ( Nm) =
2
Actual Torque TA:
actual power delivered to the pump(W)
TA ( Nm) =
N (rad/s)
71
 Pump Performance
Pump Efficiencies
3) Overall Efficiency ηo:

actual power produced by pump

o =
actual power delivered to the pump

QA PQT PQA
 o =  v m = =
QT TA N TA N

TAN: is the brake power

PQA: is the hydraulic power

72
 Pump Performance
Pump Performance Curves

73
 Pump Performance
Pump Performance Curves

Performance curves for 6in3 variable

displacement piston pump 74
 Pump Performance
Pump Performance Curves

Performance curves for radial piston pumps (2.4in3, 3in3, 4in3) 75

 Pump Performance
Pump Performance Comparison Factors

Pressure Rating Speed Rating Overall Eff. HP / LB Capacity Cost

Pump Type
(PSI) (RPM) (%) Ratio (GPM) ($ per HP)

External Gear 2000 – 3000 1200 – 2500 80 – 90 2 1 – 150 4–8

Internal Gear 500 – 2000 1200 – 2500 70 – 85 2 1 – 200 4–8

Vane 1000 – 2000 1200 – 1800 80 – 95 2 1 – 80 6 – 30

Axial Piston 2000 – 12,000 1200 – 3000 90 – 98 4 1 – 200 6 – 50

Radial Piston 3000 – 12,000 1200 – 1800 85 – 95 4 1 – 200 5 – 35

76
 Pump Performance
Example
𝑉𝐷 𝑄𝑎 𝑁
𝑃
A pump has a displacement volume of 100cm3/rev. it delivers 0.0015m3/s at 1000
rpm and 70bars. If the prime mover input torque is 120N.m, 𝑇𝐴
a) What is the overall efficiency of the pump?
b) What is the theoretical torque required to operate the pump?
If the pump is driven by an electric motor having an overall efficiency of 85%.
The hydraulic system operates 12hrs per day for 250days per year. The cost of
electricity is $0.11per kw.hr. Determine
c) The yearly cost of electricity to operate the hydraulic system
d) The amount of the yearly cost of electricity that is due to the inefficiencies of
the electric motor and pump

77
 Pump Performance
Example 𝑉𝐷 (m3 /rev)𝑁(rev/s)
a) the overall efficiency of the pump

b) theoretical torque required to operate the pump

c) The yearly cost of electricity to operate the hydraulic system

78
 Pump Performance
Example

d) The total kW loss equals the kW loss due to the electric motor plus the kW loss
due to the pump. Thus, we have:

Since 4.3/14.8 = 0.29, then 29% of the total cost of electricity is due to the
inefficiencies of the electric motor and pump.
79
 Hydraulic Pumps

❑ Pumping Theory
❑ Pump Classification
❑ Positive Displacement Pumps
❑ Pump Performance
❑ Pump Cavitation
❑ Pump Selection

80
 Pump Cavitation
Pump Cavitation
▪ Occur due to entrained air bubbles or vaporization of hydraulic fluid
▪ Occurs when pump suction lift is
excessive and pump inlet pressure
falls below vapor pressure (5psi
suction)
▪ Air or vapor bubbles are collapsed
when they reach the high pressure
discharge region

▪ This produces high fluid velocity and impact forces , eroding the metallic
components and shorten the pump life

81
 Pump Cavitation
Cavitation Control

▪ Keep suction line velocities low (below 1.2 m/s)

▪ Keep pump inlets lines as short as possible.
▪ Minimize the number of fittings in the inlet line.
▪ Mount the pump as close as possible to the reservoir.
▪ Use low pressure drop inlet filters of strainers.
▪ Use the proper oil as recommended by the pump
manufacturer.
▪ Use proper control on oil temperature (50°C to 65°C)

82
 Hydraulic Pumps

❑ Pumping Theory
❑ Pump Classification
❑ Positive Displacement Pumps
❑ Pump Performance
❑ Pump Cavitation
❑ Pump Selection

83
 Pump Selection
Pump Selection
𝑸
𝑽𝑫 Pump 𝑨
Pump dis. flow rate Actuator
volume size

𝑷
System 𝒗
pressure Load
velocity
𝑭
Load
force

84
 Pump Selection
Pump Selection
1) Select the actuator (hydraulic cylinder or motor) that is appropriate to the load

(𝐹 = 𝑃𝐴, the load 𝐹 is given and the pressure 𝑃 is selected, from which actuator
size 𝐴 is calculated)

2) Determine the flow rate requirements

(𝑄 = 𝑣𝐴, the load 𝐹 is to move by a specified velocity 𝑣, and from the actuator
size 𝐴 , the required flow rate 𝑄 is calculated)

3) Determine the pump speed and select the prime mover. This together with the
flow rate calculation, determines the pump size (volumetric displacement)
(𝑄 = 𝑉𝐷 𝑁, the prime mover speed 𝑁 is selected, and from the calculated flow
rate 𝑄 , the pump displacement volume 𝑉𝐷 is calculated)
85
 Pump Selection
Pump Selection

4) Select the pump type based on the application

5) Select the reservoir and the associated plumbing
6) Consider factors such as pump noise levels, power loss, need for a heat
exchanger,…
7) Calculate the overall cost of the system

86
 Summary

▪ Explain the operation of gear, vane and piston pumps

▪ Determine the flow rate delivered by positive displacement pumps
▪ Understand the difference between fixed and variable displacement
pumps
▪ Evaluate the performance of pumps
▪ Identify ways to avoid cavitation phenomenon in pumps
▪ Sequence of operations to select a pump for a given application

87
THANK YOU

88