Hydraulic and Pneumatic

Actuators
Fluid Power: Pneumatics vs. Hydraulics

• Fluid power denotes the use of a pressurized fluid to

drive linear or rotary actuators.
• The subject can be broadly divided into two fields:
pneumatics and hydraulics.
• In the first, the working fluid is compressed air, and
in the second, it usually is oil (sometimes water-oil
emulsions).
• The two fields have a great deal in common, but
there are also some basic differences:
 Differences Between Pneumatics vs.
Hydraulics System
• Pressure Levels:
– In industrial pneumatic circuits range from 5 to 10 bar,
– whereas hydraulic circuits commonly operate at pressures up to
200 bar or even much higher.
• Actuating Forces:
– Because of the relatively low air pressures used, pneumatic
actuators can produce only low or medium size forces,
– whereas hydraulic actuators are suitable for very high loads.
• Element Cost:
– Hydraulic cylinders and valves can cost from 5 to 10 times more
than similar size pneumatic elements.
 Differences Between Pneumatics vs.
Hydraulics System
• Transmission Lines:
– Hydraulic transmission lines are usually made of metal
tubing needed to withstand the high working
pressures and to avoid leaks.
– In pneumatics, flexible plastic tubing is used, and the
fittings can usually be connected by hands.
– Also, in hydraulic systems, return lines are needed to
return the oil from each cylinder back to the reservoir.
– In pneumatic systems, only a single line is needed,
since the air is simply exhausted back to the
atmosphere after it has done its job.
 Differences Between Pneumatics vs.
Hydraulics System
• Speed Control:
– Because of the compressibility of air, it is difficult to control the
speed of pneumatic cylinders or motors accurately.
– Therefore, whenever constant actuator speeds are required-
despite sudden load changes-a hydraulic system should be used.

• Actuation Speeds:
– Since compressed air expands very quickly the piston velocities
in pneumatic cylinders are usually very high provided the
actuating valves and air supply tubing are properly sized.
– In hydraulic cylinders, piston velocity is usually low being
determined by the flow rate of the pump.
 Differences Between Pneumatics vs.
Hydraulics System
• The Power Source:
– In hydraulic systems, constant displacement pumps are
used, so that the oil flow rate is constant, regardless of
load pressure. The pump does not produce pressure, but
rather a constant flow. The pressure developed in the
system depends on the opposing load.
– The situation is exactly the opposite in pneumatic systems:
a pressure regulator connected at the compressor-receiver
outlet keeps air pressure essentially constant, whereas the
air flow rate into any given cylinder is determined by the
load.
 Components of Hydraulic and
Pneumatic System
➢Power supply

➢Directional control valves

➢Pressure control valves

➢Cylinders

➢Process control valves

 Typical Hydraulic Power System
✓ With a hydraulic system,
pressurized oil (fluid) is provided by
a pump driven by an electrical
motor.
✓ The pump pumps oil from a sump
through a non return valve,
pressure relief valve and an
accumulator to the system, from
which it return to the sump.
✓ The pressure relief valve is used to
release the pressure if it rises
above a safe level,
✓ The accumulator is used to smooth
out any short term fluctuations in
the output oil pressure.
 Accumulator
• Accumulator is used to Smooth out any
short term fluctuations in the output
oil pressure.
– If the oil pressure rises then the bladder
contracts increase the volume the oil can
occupy and so reduces the pressure.
(If pressure ↑, bladder vol. ↓, liquid vol. ↑, pressure ↓)
– If the oil pressure falls the bladder
expands to reduce the volume occupied
by the oil and so increases its pressure.
(If pressure ↓, bladder vol. ↑. liquid vol. ↓, pressure ↑)
 Hydraulic System
• Hydraulic pump driven by electric motor or an internal combustion
engine.
• Fluid pressure generated by the pumps in heavy equipment are
6.89 MPa to 20.7 Mpa
• Hydraulic fluid is selected based on
– Good lubrication.
– Corrosion resistance.
– Incompressibility to provide rapid response.
• Most hydraulic pumps actuated by +ve displacement, i.e., they
deliver a fixed volume of liquid with each cycle.
• Three main types of pumps used are, Gear pump, vane pump and
piston pump (Radial Piston Pump & Axial Piston Pump).
Gear Pump
Vane Pump
Radial Piston Pump
Axial Piston Pump
 Typical Pneumatic Power System
• An air receiver
increases the
volume of air
in the system
and smoothen
out any short
term pressure
fluctuations
 Pneumatic System
• Commonly used air compressors are ones in
which successive volumes of air are isolated
and then compressed.
• These are Reciprocating compressor, Rotary
vane compressor and Screw compressor.
Reciprocating compressor
Rotary vane compressor
Screw compressor
 Directional Control Valves
• Direct the fluid
flow through a
system
• They are either
completely open
or closed i.e.,
ON/OFF devices.
1. Spool valve
2. Poppet valve
 Directional Control Valves
• Poppet valve
• Normally closed
• Two position
– One with button
pressed (ON).
– One with not
pressed (OFF).
 Valve Symbols

• Port's number or a letter according to their

function.
– 1 or P. Pressure supply.
– 3 or T- For hydraulic return port
– 3 or 5 (or R or S) – Pneumatic exhaust port.
– 2 or 5 (or B or A) - Output ports.
Valve Symbols
Valve Symbols
 Solenoid operated spool valve
➢ The valve is actuated by a current passing through the
solenoid and return to its original position by spring.
 Application of Valves
• Pneumatic lift
system
• Two push button
2/2 valves used
 Pilot Operated Valve
• Force required to move the
balls or shuttle in a valve is
often too large for manual or
solenoid operation.
• To overcome this problem a
pilot operated system is used
where one valve is used to
control the other valve.
• The pilot valve is small
capacity and can be operated
manually or by a solenoid. It
allows the main valve to be
operated by the system
pressure.
 Directional Valves
• Free flow can only occur in one direction through the
valve, flow in the other direction is blocked by spring
forcing the ball against its seat.
 Pressure Control Valve
➢ Three principals types
1. Pressure regulating valves: Regulates operating
pressure and maintain it at a constant value.
 Pressure Control Valve
2. Pressure limiting valves
✓Safety device.
✓Limits pressure below some safe value.
✓Valve open & vent to atm. or back to sump.
 Pressure Control Valve
3. Pressure sequence valves
✓These valves are used to sense the pressure of an
external line and give a signal when it reaches a
preset value.
 Hydraulic / Pneumatic linear
actuators, Cylinders
➢ Both hydraulic and pneumatic actuators have the
same principles, differences being in size
➢ The cylinder consists of a cylindrical tube along
which a piston/ram can slide
➢ They are of two types:
✓Single acting and
✓Double acting
 Cylinders: Single acting
➢Single acting: the control pressure is applied
to one side of the piston.
Cylinders: Single acting
 Cylinders: Double acting
➢ Are used when control pressure are applied to both
side of the piston. A different in pressure between
the two sides results in motion of the piston (No
spring).
 Cylinders: Double acting
➢Current through one solenoid causes the
piston to move in one direction.
 Process Control Valve
➢ Used to control the fluid flow rate
➢ A common form of pneumatic actuator
used with process control valve is the
diaphragm actuator.
➢ The diaphragm is made of rubber which
sandwiched in it is centre between two
circular steel discs.
➢ The effect of changes in the input
pressure is to move the central part of
the diaphragm. The force F on the shaft is
the force that acting on the diaphragm =
PxA
Where P: gauge pressure = Control
pressure - atmospheric pressure
A: diaphragm area
➢ The restoring force is provided by spring,
so kx=PA
 Process Control Valve
➢ Fig shows a cross section of valve
for the control of rate of flow of a
fluid.
➢ The plug restricts the fluid flow
and so its position determines
the flow rate
 Process Control Valve
➢ Forms of Valve Body & Plug
✓Single seated: closed more tightly but required more
force
✓Double seated: less force is required, less tightly
 Process Control Valve
➢ Shape of the Plug: determines the relation between the
stem movement and the effect on the flow rate
➢ 3 types are commonly used
1. Quick opening
✓ Flow rate changes for small movement of valve stem
✓ Used for on/off control
2. Linear contoured type
✓ Change of flow rate proportional to change in stem
displacement
✓ Q/Qmax=S/Smax
3. Equal percentage
✓ Equal percentage in flow rate occur for equal change in valve
stem position.
 Process Control Valve
• Fig shows the relation between the stem
displacement & flow rate as % of maximum
 Rotary actuators
• A linear cylinder can, with
suitable mechanical linkage be
used to produce rotary
movement through angles less
than 3600

• Another alternative is shown in

Fig. is called: vane type semi
rotary. A pressure difference
between the two parts causes
the vane to rotate.
 Rotary actuators
✓ Vane motor is used for rotation
through angles > 360°
✓ In this an eccentric rotor has
slots in which vanes are forced
outwards against the walls of
the cylinder by the rotation.
✓ The vanes divide the chamber
into separate compartments
which increase in size from the
inlet to the exhaust port.
✓ The air entering such a
compartment exerts a force on
a vane and causes the rotor to
rotate.