Unit-5 Ae

Kongu Engineering College
Department of Automobile Engineering
20AUE05 – HYDRAULICS AND PNEUMATICS

Unit V
Industrial Circuits and Maintenance
 Construction of hydraulic circuits - Counter balance circuit - Fail safe circuit

- Regenerative circuit - Pressure intensifier circuits -Accumulator circuits.
Construction of pneumatic circuits: Cascade method - Sequence circuit.
Electro-pneumatic circuit - Basics of fluidics.
 Sealing devices: Types and materials
 Safety aspects in fluid power system, installation, maintenance and
troubleshooting of fluid power systems.
Accumulator
Definition: A hydraulic accumulator is a pressure storage
reservoir in which a non-compressible hydraulic fluid is held
under pressure that is applied by an external source
Weighed loaded accululator

Spring loaded accumulator
Piston-type accumulator
Diaphragm type accumulator
Bladder type accumulator
Auxiliary power source
Leakage compensator
Emergency power source
Thermal expansion compensator
Double acting Tie-rod cylinder
Dual cylinder sequencing circuit (Electro-Pneumatic)
Sealing devices
 Any hydraulic system is associated with a major problem, that is, leakage.
 This reduces efficiency and increases the power losses.
 Hence, sealing devices play a vital role in a hydraulic system by increasing the efficiency and decreasing the
power losses.
 Leakage can be overcome by proper maintenance of the system and proper selection of seals and sealing at the
design stage
Internal leakage:
 This occurs in hydraulic components built with operating clearances.
 Moving parts need to be lubricated and leakage path may be designed solely for this purpose.
 Internal leakage does not cause loss of fluid because the fluid returns to the reservoir.
 This leakage increases the clearances between mating parts due to wear.
External leakage:
• External leakage represents loss of fluid from the system.
• It also represents a safety hazard.
• Improper assembly of pipe fittings is the most common cause of external leakage.
• Over tightened fittings may become damages or vibrations can cause properly tightened fittings
to become loose.
Functions of Seals
Seals are used in hydraulic systems to prevent excessive internal and
external leakage and to keep out contamination. Various functions of seals
include the following:
1. They prevent leakage both internal and external.
2. They prevent dust and other particles from entering into the system.
3. They maintain pressure.
4. They enhance the service life and reliability of the hydraulic system
Classification of Hydraulic Seals
Hydraulic seals can be classified as follows:
1. According to the method of sealing:
Positive sealing: A positive seal prevents even a minute amount of oil from getting past. A positive seal does
not allow any leakage whatsoever (external or internal).
Non positive sealing: A non-positive seal allows a small amount of internal leakage, such as the clearance of
the piston to provide a lubrication film.
2. According to the relative motion existing between the seals and other parts:
Static seals: These are used between mating parts that do not move relative too another. Typical examples are
flange gaskets and seals, o-rings, etc. These are relatively simple. They are essentially non-wearing and
usually trouble free if assembled properly.
Dynamic seals: These are assembled between mating parts that move relative to each other. Hence, dynamic
seals are subject to wear because one of the mating parts rubs against the seal.
2. V-ring seal and U-ring seal
3. According to geometrical cross-section:
1. O-ring seal:
1. O-ring is the most widely used seal for hydraulic

systems.
2. It is a molded synthetic rubber seal that has a round
cross-section in its free state
3. O-ring can be used for the most static and dynamic
conditions.
2. V-ring seal and U-ring seal
1. V- and U-ring seals are compression-type seals used in
virtually in all types of reciprocating motion
applications .
2. These include piston rods and piston seals in pneumatic
and hydraulic cylinder, press rank, jacks and seals on
plungers and piston in reciprocating pumps.
T-ring seal:
T-ring seal isa dynamic seal that is extensively used to seal cylinder-
pistons, piston rods and other reciprocating parts
Piston cup packings:
1. Piston cup packings are designed specifically for pistons Cup packing – single acting
in reciprocating pumps and pneumatic and hydraulic
cylinders.
2. They offer the best service life for this type of
application, require a minimum recess space and
minimum recess machining, and can be installed easily
and quickly.
cup packing –double acting
•4. According to the type of seal material used
Hydraulic seals may be classified according to the type of seal material used.
• Seals are manufactured from a variety of natural and synthetic materials.
• Earlier leather, cork and impregnated fibers were used in hydraulic systems.
• But nowadays, these are replaced by plastic and synthetic rubber materials.
• Synthetic rubbers (elastomers) are compatible with oil. Elastomers can be made in
various compositions to meet various operating conditions:
1. Neoprene (chloroprene).
2. Buna-N.
3. Silicone (Teflon).
4. Tetrafluoroethylene.
5. Viton.
Installation of hydraulic systems
 Installation of pumps
 The installation of pumps with respect to its reservoir is very important because it
affects the performance of the pump.
 The pump should be mounted on a strong foundation
 Enter of the air should be prevented because this will reduce the life of the pump
 For the range of operating pressures, temperature and speeds, manufacturer’s
recommendations should be always followed.
 The lubrication of the internal moving parts is very important.
Installation of Cylinders
 The hydraulic cylinder should be installed using proper mountings.
 During installation, particular attention must be paid to cleanliness.
 The cylinder must be installed free of tension and in particular free of radial force
 Eccentric loading should be avoid
 Front flange or rear flange mounted cylinders with long strokes should be installed
with provision for support at the opposite the mounting.
 Trunnion-mounted cylinder application must be furnished.
Installation of Valves
 A relief valve is mounted just after the hydraulic pump.
 The relief valve is always mounted vertically, keeping the return port downwards.
 The axis of the sliding type direction control valve is generally kept horizontal.
 The drain connections of flow control valve should be connected to the reservoir.
Installation of Tubing
 Maintained the high standard of cleanliness at all times.
 Protect the bore of pipe with the thin film of mineral oil
 Keep tubes plugged until are to be cut or manipulated.
 After cutting, remove any flask and debris
 Inspect threaded fittings and remove any flash before assembling.
Power pack installation

• Clean the inside of the reservoir. Check if the sealing gaskets are in place to stop the
entry of dirt and air.
• Position the clean reservoir on suitable antivibration materials
• Check whether the pump motor assembly is correct with the pump and motor shaft
connected by a suitable flexible coupling or by a similar device.
Maintenance of hydraulic system
Maintenance schedule
 Operator tasks
 Visual examination of system for damaged or leaking pipes, fittings and components
 Visual examination of fluid level in reservoir and the fluid condition
 Visual check of operating pressures, filter condition indicators
 Check whether guards are in place.
 Check the operation of system and the work produced.
 Periodic maintenance
 Carry out operator tasks
 Check fixing of all units
 Check pressure readings at the test point of the system
 Check the pumps for noise level and operating temperatures
 Check for correct operation of interlocks
C. Annual maintenance
 Empty fluid reservoir and check fluid condition
 Clean reservoir internally and externally
 Examine all hoses, pipe works and fittings for damage, wear and leaks.
 Examine electric motor
 Examine the flexible coupling between pump and motor
 Check filter elements, replace ant which have been in service for 12 months
 Clean filter bowl
 Clean filter condition indicator for correct operation
 Check leakage of pumps and motor by running them under normal condition.
 Check leakage across the piston seal of cylinders, re-seal as required.
Trouble –possible causes and remedies
 Pump
Relief Valves
Directional valves
Sizing of the Reservoir
The reservoir capacity should be adequate to cater for changes in fluid volume within the system, and with
sufficient surface area to provide system cooling.
The sizing of a reservoir is based on the following criteria:
1. The minimum reservoir capacity should be twice the pump delivery
per minute. This must be regarded as an absolute minimum and may not
be sufficient to allow for the volume changes in the system.
2. The reservoir capacity should be three to four times the pump delivery
per minute. This may well be too high a volume for mobile application.
3. The reservoir capacity should be 2–15 L per installed horse power.
This may result in very large reservoirs when high-pressure systems are
used.
4. It must make allowance for dirt and chips to settle and for air to escape.
5. It must be able to hold all the oil.

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Kongu Engineering College

Department of Automobile Engineering

20AUE05 – HYDRAULICS AND PNEUMATICS

 Construction of hydraulic circuits - Counter balance circuit - Fail safe circuit

Weighed loaded accululator

1. O-ring is the most widely used seal for hydraulic

Piston cup packings:

Power pack installation

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