Basic of Hydraulics

Module 1: Introduction to
Hydraulics
• Module Objectives
After the completion of this module, the student will be able to:
• Identify the common uses of hydraulic systems.
• Determine that liquids are incompressible.
• Identify the fundamental parts of a hydraulic system.
• Observe how hydraulic components can be connected together to
construct a hydraulic circuit.
• Identify the main components of the hydraulic work station TP 501.
• Explain the main parts of the hydraulic power pack.
• Explain the importance of using standard hydraulic symbols.
• Identify the basic hydraulic laws.
• Calculate the piston area, force, and pressure.
• Describe how to read a pressure gauge in the US and SI units.
• Set the pressure gauge of the hydraulic power pack to a certain
pressure.
 Module 1: Introduction to Hydraulics
All machines require some type of power source and a
way of transmitting this power to the point of
operation.
The three methods of transmitting power are:
• Mechanical
• Electrical
• Fluid

• In this course we are going to deal with the third type

of power transmission which is the Fluid Power
 Module 1: Introduction to Hydraulics
• Fluid power is the method of using
pressurized fluid to transmit energy.

• Liquid or Gas is referred to as a fluid.

Accordingly, there are two branches of fluid
power; Pneumatics, and Hydraulics.

• Hydraulic systems use liquid to transfer

force from one point to another.
• Pneumatic systems use air to transfer force
from one point to another. Air is
 Module 1: Introduction to Hydraulics
• Air is Compressible:
(This describes whether it is possible to force an
object into a smaller space than it normally
occupies. For example, a sponge is compressible
because it can be squeezed into a smaller size).

• liquid is Incompressible:
(The opposite to compressible. When a “squeezing”
force is applied to an object, it does not change to a
smaller size. Liquid, for example hydraulic fluid,
possesses this physical property).
 Module 1: Introduction to Hydraulics
• Hydraulic systems are commonly used
where mechanisms require large forces and
precise control.

• Examples include vehicle power steering

and brakes, hydraulic jacks and heavy earth
moving machines.
 2.Uses of hydraulics

• Hydraulics plays an important role in many

industries; there are a lot of hydraulic
applications in manufacturing, transportation,
and construction sectors.

• Hydraulics systems are used where large,

precise forces are required.
 2.1 Common examples of hydraulic systems include:

2.1.1 Vehicle brake hydraulic systems

Brake pedal
The function of a vehicle
braking system is to stop or Master
cylinder
slow down a moving vehicle.
When the brake pedal is
pressed as illustrated in Fig.
1.1, the hydraulic pressure is
transmitted to the piston in the Brake
brake caliper of the brakes. lines
The pressure forces the brake
pads against the brake rotor, Front
brake
which is rotating with the calipers
wheel.
Rear wheel
The friction between the brake cylinder
pad and the rotor causes the pistons
wheel to slow down and then Pads
Rotor
stop.

Tip: Watch the hydraulic brake Fig.1.1: A schematic diagram of the vehicle’s hydraulic
brake system.
system video.
2.1 Common examples of hydraulic systems include:
 2.1 Common examples of hydraulic systems include:
2.1.2 Vehicle power steering

• The vehicle power

steering system uses
hydraulic oil, the Hydraulic pump

hydraulic pump supplies

the oil through the
control valves to the
power cylinder as shown
in Fig. 1.2. The major Control
Power cylinder valve
advantage of using this
system is to turn the
vehicle’s wheels with less
effort. Fig.1.2:Vehicle hydraulic power
steering system
 2.1 Common examples of hydraulic systems include:
2.1.3 Hydraulic jack

• In a hydraulic jack, a small

piston (pumping piston)
transmits pressure (a) Hydraulic jack
through the oil to a large
piston (power piston) Oil reservoir Handle

through a check valve,

resulting in the weight Weight

being lifted as shown in Inlet check

valve (allows
Pumping piston
Power
piston

Fig.1.3. the oil to

move in only
one direction)
Outlet check valve
(allows the oil to move
in only one direction)

• Tip: Watch the hydraulic

jack video. (b) Hydraulic jack schematic
diagram
Tip: Watch the hydraulic jack video.
 2.1 Common examples of hydraulic systems include:
2.1.4 Aircraft hydraulic systems

• All modern aircraft contain

hydraulic systems to operate
mechanisms, such as:
• Flaps (Fig. 1.4a)
• Landing gear (Fig. 1.4a)
• The hydraulic pump that is coupled
to the engine provides hydraulic Landing gears Flaps
power as illustrated by Fig. 1.4b.
(a) Landing gears and flaps
• Power is also distributed to Transmission
systems through the aircraft by lines

transmission lines. Hydraulic

Landing
pump
• Hydraulic power is converted to gear

mechanical power by means of an Actuating

Cylinder
actuating cylinder or hydraulic
motor.
Engine
power

(b) Landing gear schematic diagram

 3 Hydraulic system components

• All industrial hydraulic systems consist of the following basic components

• Power input device:
The pump and motor together are called the power input device; the pump
provides power to the hydraulic system by pumping oil from the
reservoir/tank. The pump’s shaft is rotated by an external force which is
most often an electric motor as illustrated in Fig 1.5.

Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Power output device

Actuator
 3 Hydraulic system components
• Control device: Valves control the direction,
pressure, and flow of the hydraulic fluid from the
pump to the actuator/cylinder.
• Power output device: The hydraulic power is
converted to mechanical power inside the power
output device. The output device can be either a
cylinder which produces linear motion or a motor
which produces rotary motion.
• Liquid: the liquid is the medium used in hydraulic
systems to transmit power. The liquid is typically oil,
and it is stored in a tank or reservoir.
• Conductors: The conductors are the pipes or hoses
needed to transmit the oil between the hydraulic
components.
Tip: “Watch the hydraulic system video”
 3.1 Hydraulic power pack
• The hydraulic power pack combines the pump,
the motor, and the tank. The hydraulic power
pack unit provides the energy required for the
hydraulic system. The parts of the hydraulic
power pack unit are shown in Fig. 1.6.

.1.6: The main parts of the hydraulic power pack

3.2 Activity 1: Hydraulic station component identification

• In this activity, you will identify the

components of the Festo Hydraulic work
station in your lab:
• Locate the power pack unit and identify its
parts.
• Locate the out put device (actuators).
• Locate the control devices (valves).
• Locate the conductors (hoses).
 3.3 Hydraulic symbols
• The way hydraulic components direct
and control liquid around a circuit can
be complex.
• This would cause difficulty for one (a) Electric motor
engineer explaining to another engineer
how the circuit works.
• A common form of representing
components and circuits is used to more
easily explain what is happening. (b) Hydraulic pump
• This form of representation uses
common symbols to represent
components and the ways in which they
are connected to form circuits. Fig. 1.7
shows some of the components’ (c) Tank or reservoir
symbols used in hydraulics.
• The symbols don’t show the component
construction, or size, however, it is a
standard form that is used by all
(d)Pressure relief valve
engineers to represent that specific
component. Fig.1.7: (a) Electric motor. (b) Hydraulic pump.
(c) Tank or reservoir. (d) Pressure relief valve.
 Power Pack Symbols
• The simplified and detailed symbols of the
hydraulic power pack are shown in Fig. 1.8.

(a) Simplified

(b) Detailed
Fig.1.8: (a) Simplified symbol of the hydraulic power pack.
 4- Fundamental laws of Hydraulics

• All hydraulic systems operate

following a defined relationship
between area, force and
pressure.

• Laws have been established to

explain the behavior of
hydraulic systems.

• Hydraulic systems use the ability

of a fluid to distribute an
applied force to a desired
location.
 4- Fundamental laws of Hydraulics
4.1 Pressure

• When a force (F) is applied on

an area (A) of an enclosed
liquid, a pressure (P) is
produced as shown in Fig.
• Pressure is the distribution of a
given force over a certain area.
• Pressure can be quoted in bar,
pounds per square inch (PSI) or
Pascal (Pa) .
 4.1 Pressure

Where
Force is in newtons (N) and
Area is in square meters (m2).
1 Pascal (Pa) =1 N/m2.
1 bar= 100,000 Pa= 105 Pa.
10 bar= 1 MPa (mega Pascals)
 4.1 Pressure
• If the pressure is calculated using a force in
Newton, and area in square millimeters,
the pressure in bar can be calculated.
Example 1-1.
A cylinder is supplied with 100 bar pressure;
its effective piston surface is equal to 700
mm2. Find the maximum force which can
be attained.
• P= 100 bar = 100X100000 N/m2.
• A= 700/1000000=0.0007 m2.
• F= P.A= 100X100000X0.0007= 7,000 N
 4.2 Pascal’s Law
• Pascal’s law states that: “The
pressure in a confined fluid is
transmitted equally to the
whole surface of its container”

• When force F is exerted on area

A on an enclosed liquid,
pressure P is produced. The
same pressure applies at every
point of the closed system as
shown in Fig. 1.10a.
Fig.1.10: (a) Pascal’s law.
 4.3 Liquid flow
4.3.1 Flow rate versus flow velocity
The flow rate is the volume of fluid that moves through the system in a
given period of time.
Flow rates determine the speed at which the output device (e.g., a
cylinder) will operate.
The flow velocity of a fluid is the distance the fluid travels in a given
period of time.
These two quantities are often confused, so care should be taken to
note the distinction. The following equation relates the flow rate and
flow velocity of a liquid to the size (area) of the conductors (pipe,
tube or hose) through which it flows.
Q=V x A
Where:
Q= flow rate ( m³ /s )
V= flow velocity (m / s )
A= area (m² )
 4.3 Liquid flow

This is shown graphically in Fig. 1.11.

Arrows are used to represent the fluid flow.
It is important to note that the area of the
pipe or tube being used.
Q, V
A

Fig.1.11: Flow velocity and flow rate

 5 Reading the pressure gauge

• The pressure gauge indicates the amount of

pressure in a system. Technicians read
these gauges to determine if a machine is
operating properly.
• Most pressure gauges have a face plate that
is graduated either in US units (psi) or SI
units (Pascal or bar) note that;
1 bar=0.1 mega pascals as explained
 5 Reading the pressure gauge

• A pointer rotates on the

graduated scale as the Face plate

pressure changes to Pointer

indicate the pressure in
the system. The pressure
gauge used in the
hydraulic power pack is
shown in Fig. 1.13. The psi
bar
outer black scale indicates
Minimum SI units US units
pressure units of bar, and reading
Maximum
reading

the inner red scale

indicates pressure units in
psi Fig. 1.13: A pressure gauge.
 5 Reading the pressure gauge

• Each scale is graduated with a series of numbers ranging

from 0 to a maximum number. In case of the gauge shown,
it is graduated from 0 to a maximum reading of 100 bar or a
maximum reading of 1450 psi. The maximum reading is
always called the range of the gauge.

• To read the pressure gauge, you only need to read the inner
red scale or the outer red scale to which the pointer points.
If the pointer points to a position between the two
numbers, you read the gauge to the closest graduation.

• In the bar scale there are 4 graduations between 0 and 20;

this means the value of each graduation is 20/4=5 bar. In
the psi scale there are 4 graduations between 0 and 200;
this means the value of each graduation is 200/4=50 psi.
 5.1 Activity 2: Setting the hydraulic pressure to 30 bar.

Procedures:
1- Switch on the electrical power supply
first and then the hydraulic power
pack.
2- Use the pressure relief valve to set
the pressure to 30 bars.
3- While you are adjusting the pressure
observe the pressure gauge.
4- When the pressure gauge indicates 30
bar, switch off the hydraulic power
pack first, and then the electrical
power supply
Fig. 1.13: The hydraulic
power pack.
For more information, refer to the
movie section