Cover
Title Page
Copyright Page
Dedication
Contents
Preface
CHAPTER 1 INTRODUCTION
1.1 What is Fluid Power
1.2 History of Fluid Power
1.3 Basic Law
1.4 Applications of Fluid Power
1.5 Advantages of Fluid Power Systems
1.6 Comparison of Hydraulic, Pneumatic and Electrical Systems
1.7 Types of Fluid Power System
1.7.1 Based on Control System
1.7.2 Based on the Type of Control
1.8 Fluid Power Industry in India
Solved Problems
Exercise
Review Questions
CHAPTER 2 HYDRAULIC FLUIDS AND PROPERTIES
2.1 Fluids: Liquids and Gases
2.2 Various Hydraulic Fluids
2.2.1 Water
2.2.2 Petroleum Oils
2.2.3 Water Glycols
2.2.4 Water-in-Oil Emulsion
2.2.5 Oil-in-Water Emulsion
2.2.6 Phosphate Esters
2.2.7 Silicones
2.3 Properties of Fluids
2.3.1 Viscosity
2.3.2 Viscosity Index
2.3.3 Oxidation Stability
2.3.4 Demulsibility
2.3.5 Lubricity
2.3.6 Rust Prevention
2.3.7 Pour Point
2.3.8 Flash Point and Fire Point
2.3.9 Neutralisation Number
2.4 Comparison of Properties
Solved Problems
Review Questions
CHAPTER 3 BASIC PRINCIPLES OF HYDRAULIC FLOW
3.1 Laminar and Turbulent Flow
3.2 Reynolds Number
3.3 Darcy–Weisbach Equation
3.4 Losses in Valves and Fittings
3.5 Circuit Calculations
Solved Problems
Exercise
Review Questions
CHAPTER 4 PUMPS
4.1 Basic Elements of an Oil Hydraulic System
4.1.1 Hydraulic Pump Unit
4.1.2 Control Valves
4.1.3 Hydraulic Motor (or) Cylinder
4.2 Pumps
4.3 Hydrodynamic or Non-Positive Displacement Pumps
4.4 Hydrostatic or Positive Displacement Pumps
4.4.1 Classification of Positive Displacement Pumps
4.5 Gear Pumps
4.5.1 External Gear Pumps
4.5.2 Internal Gear Pumps
4.5.3 Lobe Pumps
4.5.4 Gerotor Pump
4.5.5 Screw Pumps
4.6 Vane Pumps
4.6.1 Unbalanced Vane Pump
4.6.2 Pressure Compensated Variable Delivery Pump
4.6.3 Balanced Vane Pump
4.7 Piston Pumps
4.7.1 Bent Axis Type Piston Pump
4.7.2 Swash Plate Type Piston Pump
4.7.3 Radial Piston Pump
4.8 Pump Performance
4.8.1 Volumetric Efficiency
4.8.2 Mechanical Efficiency
4.8.3 Overall Efficiency
Solved Problems
Exercise
Review Questions
CHAPTER 5 HYDRAULIC ACTUATORS
5.1 Hydraulic Motors
5.1.1 Gear Type Motors
5.1.2 Vane Type Motors
5.1.3 Piston Type Motors
5.1.4 Hydraulic Motor Efficiencies
5.2 Semi-Rotary Actuators
5.2.1 Vane Type Actuators
5.2.2 Piston Type Semi-Rotary Actuator
5.2.3 Helical Screw Semi-Rotary Actuator
5.3 Hydraulic Cylinders
5.3.1 Single Acting Cylinders
5.3.2 Double Acting Cylinders
5.3.3 Special Type Cylinders
5.3.4 Mounting Configurations
5.3.5 Methods of Applying Linear Motion
Solved Problems
Exercise
Review Questions
CHAPTER 6 HYDRAULIC VALVES
6.1 Pressure Controls
6.1.1 Pressure Relief (Spring Loaded Type) Valve
6.1.2 Compound Relief Valve
6.2 Direction Control Valves
6.2.1 Classification of Direction Control Valves
6.2.2 Two Way Valves
6.2.3 Actuating Devices
6.2.4 Rotary Spool Valves
6.3 Unloading Valve
6.4 Sequence Valve
6.5 Counterbalance Valve
6.6 Brake Valve
6.7 Pressure Reducing Valve
6.8 Flow Control Valve
6.8.1 Non-Pressure CompensatedFlow Control Valve
6.8.2 Pressure CompensatedFlow Control Valve
6.8.3 Location of Flow Control Valves
6.9 Flow Dividers
6.9.1 Valve Type
6.9.2 Motor Type
6.10 Deceleration Valve
6.11 Modular Valves
6.12 Cartridge Valves
6.12.1 Cartridge Insert Valves
6.12.2 Cartridge Logic Valves
Solved Problems
Exercise
Review Questions
CHAPTER 7 SEALS AND FILTERS
7.1 Seals
7.1.1 Static Seals
7.1.2 Dynamic Seals
7.1.3 Materials for Seals
7.1.4 Conditions Affecting theSelection of Sealing Devices
7.2 Fluid Contamination
7.2.1 Cleanliness Standards
7.3 Filtration of Fluids
7.3.1 Strainers
7.3.2 Filters
7.3.3 Filter Media
7.3.4 Types of Filters
7.3.5 Filter Location
Solved Problem
Review Questions
CHAPTER 8 ACCUMULATORS
8.1 Weight Loaded Type Accumulator
8.2 Spring Loaded Accumulator
8.3 Gas Loaded Type Accumulator
8.3.1 Non-separator Type
8.3.2 Separator Type
8.3.3 Gas Loaded Accumulator Operation
8.3.4 Bellows Type Accumulator
8.4 Accumulator Circuits
8.4.1 Leakage Compensation
8.4.2 Auxiliary Power Source
8.4.3 Emergency Source of Power
8.4.4 Shock Suppressor
8.4.5 Thermal Expansion Compensator
8.5 Sizing of Accumulator
Solved Problems
Exercise
Review Questions
CHAPTER 9 SERVO VALVES AND PROPORTIONAL VALVES
9.1 Mechanical Hydraulic Servo Valve
9.2 Electro Hydraulic Servo Valves
9.2.1 Single Stage Servo Valves
9.2.2 Two Stage Servo Valves
9.2.3 Flapper Type Servo Valve
9.2.4 Jet Pipe Servo Valve
9.2.5 Speed Control Circuit with a Servo Valve
9.3 Proportional Valves
9.3.1 Control of Proportional Valves
9.3.2 Spool Position Control
9.4 Proportional Pressure Relief Valves
9.5 Proportional Pressure Reducing Valve
9.6 Proportional Direction Control Valve
9.6.1 Speed Control Circuit with a Proportional Valve
9.7 Comparison of Proportional and Servo Valves
Review Questions
CHAPTER 10 INDUSTRIAL HYDRAULIC SYSTEMS
10.1 Intensifier Circuit
10.1.1 Intensifier Press Circuit
10.2 Regenerative Circuit
10.2.1 Drilling Machine Application
10.3 Synchronising Circuits
10.4 Automatic Cylinder Reciprocation Circuit
10.5 Multiple Circuitry using Banked Units
10.6 Sequencing Circuits
10.6.1 Sequence Operation using Sequencing Valve
10.6.2 Sequence Operation by use of Cam Valve
10.7 Circuits for Operations of Machine Tools
10.7.1 Hydraulic Operation of a Planning Machine
10.7.2 Hydraulic Operation of a Vertical Milling Machine
10.7.3 Hydraulic Operation of a Surface Grinding Machine
10.7.4 Hydraulic Operation of a Press
10.8 Safety Circuits
10.8.1 Two-hand Safety Control Circuit
10.8.2 Fail-safe Control Circuit Using Emergency Cut-off Valve
10.9 Hydraulic Circuit for a Robot Arm
10.10 Hydrostatic Transmission
10.10.1 Open Circuit Transmission
10.10.2 Closed Circuit Transmission
10.10.3 Applications
10.11 Power Pack
Solved Problems
Exercise
Review Questions
CHAPTER 11 DESIGN OF HYDRAULIC CIRCUITS
11.1 Design Informations Required
11.2 Selection of a Hydraulic Cylinder
11.2.1 Preferred Sizes
11.2.2 Piston Rod Buckling
11.3 Selection of Hydraulic Motors
11.3.1 Hydrostatic Drives
11.3.2 Hydrostatic Drive Characteristics
11.3.3 Braking of Hydrostatic Drives
11.3.4 Hydraulic Motor Characteristics and Performance Curves
11.3.5 Matching Motor to Load
11.4 Selection of Control Valves
11.4.1 Selection of Relief Valves
11.4.2 Selection of Flow Control Valve
11.4.3 Selection of DirectionControl Valve
11.5 Selection of Filters
11.6 Selection of Hydraulic Conduits
11.6.1 Tubing
11.6.2 Hoses
11.7 Pressure Losses
11.7.1 Pressure Drop in Pipelines
11.7.2 Pressure Losses in Valves and Filters
11.8 Selection of Pump
11.9 Reservoir
11.9.1 Functions of a Fluid Reservoir
11.9.2 Reservoir Design
11.10 Sizing of Accumulator
Solved Problems
Exercise
Review Questions
CHAPTER 12 PNEUMATICS
12.1 Comparison of Pneumatic System with Hydraulic System
12.2 Properties of Air
12.3 Basic Pneumatic System
12.4 Compressors
12.4.1 Piston Compressors
12.4.2 Vane Compressors
12.4.3 Screw Compressors
12.5 Primary Air Treatment
12.6 Receiver
12.7 Air Filter
12.8 Pressure Regulator
12.9 Lubricator
12.10 Pneumatic Valves
12.10.1 Direction Control Valves
12.10.2 Pneumatic Check Valve
12.10.3 Flow Control Valve
12.10.4 Pneumatic Shuttle Valve or ‘OR’ Type Valve
12.10.5 ‘AND’ Type or Two-Pressure Valve
12.10.6 Quick Exhaust Valve
12.10.7 Time Delay Valve
12.11 Pneumatic Actuators
12.11.1 Pneumatic Cylinders
12.11.2 Air Motors
12.11.3 Vacuum Suction Cups
12.12 Mufflers
12.13 Pneumatic Circuits
12.13.1 Basic Pneumatic Circuit
12.13.2 Speed Control Circuit
12.13.3 Quick Exhaust Circuit
12.13.4 Two Step Feed Control Circuit
12.13.5 Time Delay Circuit
12.13.6 Automatic Cylinder Reciprocation Circuit
12.13.7 Two Hand Safety Control Circuit
12.14 Selection of Pneumatic Components
12.14.1 Selection of Pneumatic Cylinders
12.14.2 Selection of Air Motors
12.14.3 Sizing of Control Valves
12.14.4 Pressure Losses in Pipes
12.14.5 Selection of Filter, Regulator, Lubricator
12.14.6 Sizing of Compressors
Solved Problems
Exercise
Review Questions
CHAPTER 13 HYDROPNEUMATICS
13.1 Air-Oil Reservoir
13.2 Air-Oil Cylinder
13.3 Air-Oil Intensifier
13.4 Comparison of Hydropneumatic, Hydraulic and Pneumatic System
Review Questions
CHAPTER 14 PNEUMATIC LOGIC CONTROLS
14.1 Pneumatic Sensors
14.2 Position Sensors
14.2.1 Pneumatic Limit Valves
14.2.2 Back Pressure Sensor
14.2.3 Proximity Sensor
14.2.4 Gap Sensor or Interruptible Jet Sensor
14.2.5 Limit Switch
14.2.6 Comparison between the Different Position Sensors
14.3 Pressure Sensors
14.4 Switching Elements
14.4.1 Miniature Control Valves
14.4.2 Moving-Part Logic Elements
14.4.3 Fluidic Element
14.4.4 Comparison between the Different Switching Elements
Review Questions
CHAPTER 15 DESIGN OF PNEUMATIC LOGIC CIRCUITS
15.1 Classic Method
15.2 Cascade Method
15.3 Step-counter Method
15.4 Logic Circuit Design with Karnaugh-Veitch Mapping Method
15.5 Combinational Circuit Design
Solved Problems
Exercise
Review Questions
CHAPTER 16 ELECTRICAL CONTROL OF FLUID POWER
16.1 Components of Electrical Controls
16.1.1 Switches
16.1.2 Solenoids
16.1.3 Relays
16.1.4 Timers
16.2 Electro-Hydraulic / Pneumatic Circuits
16.2.1 Reciprocation of a CylinderUsing Pressure Switches
16.2.2 Control of a Cylinder Using a Single Limit Switch
16.2.3 Dual Cylinder Sequencing Circuit
16.2.4 Regenerative Circuit
16.3 Cascade Method for Electropneumatic Circuits
Review Questions
CHAPTER 17 MICROELECTRONIC CONTROL OF FLUID POWER
17.1 PLC Construction
17.1.1 Central Processing Unit
17.1.2 Memory
17.1.3 I/O Module
17.2 Programming the PLC
17.2.1 Ladder Diagram Based
17.2.2 Low-level Language Based on Boolean Functions
17.2.3 Functional Blocks
17.2.4 High-level Languages
17.3 PLC Operation
17.4 Microprocessor Construction
17.4.1 Microprocessor
17.4.2 Memory
17.4.3 Input/Output
17.4.4 DC Power Supplies
17.4.5 Bus
17.4.6 Interfacing
17.5 Programming the Microprocessor
17.5.1 Low-level Language Programming
17.5.2 High-level Language Programming
17.6 Microprocessor Operation
17.7 Difference between PLCs and Microcomputers
Exercise
Review Questions
CHAPTER 18 INSTALLATION, MAINTENANCE AND TROUBLESHOOTING OF FLUID POWER SYSTEMS
18.1 Installation of Hydraulic Systems
18.1.1 Installation of Pumps
18.1.2 Installation of Cylinders
18.1.3 Installation of Valves
18.1.4 Installation of Tubing
18.1.5 Power Pack Installation
18.1.6 Filling the System
18.2 Maintenance of Hydraulic Systems
18.2.1 Maintenance Schedule
18.3 Troubleshooting of Hydraulic System
18.3.1 Fault Finding Procedure
18.4 Trouble — Possible Causes and Remedies
18.4.1 Pumps
18.4.2 Relief Valves
18.4.3 Directional Valves
18.4.4 Sequence Valves
18.4.5 Unloading Valves
18.4.6 Counterbalance Valves
18.4.7 Flow Control Valves
18.4.8 Remote Flow Control Valves
18.4.9 Hydraulic Motors
18.4.10 Hydraulic Cylinders
18.4.11 Accumulators
18.4.12 General Circuit Problems
18.5 Installation of Pneumatic Systems
18.5.1 Installation of FRL Unit
18.5.2 Installation of Pneumatic Cylinder
18.5.3 Installation of Pipelines
18.5.4 Installation of Compressor
18.6 Maintenance of Pneumatic System
18.6.1 Maintenance Schedule
18.7 Troubleshooting of Pneumatic Systems
18.8 Trouble — Possible Causes and Remedies
18.8.1 Compressor
18.8.2 FRL Unit
18.8.3 Air Cylinders and Air Motors
18.8.4 Valves
18.8.5 Pipe Lines and Hoses
Review Questions
CHAPTER 19 LOW – COST AUTOMATION
19.1 Concepts of Low-cost Automation
19.2 Technologies Used for LCA
19.3 Applications
Appendices
Two-mark Questions and Answers
References
Index
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