HYDRAULICS & PNEUMATICS

MODULE – 2

Dr. ANIL KUMAR B N

Assistant Professor
Mechanical Engg.
Atria IT
 What is a Gear Pump?

•A type of Positive Displacement (PD) Pump.

•Moves a fixed amount of fluid with each revolution.
•Ideal for viscous fluids (oils, fuels, polymers, adhesives).
•Known for simplicity, reliability, and smooth flow.

Key Applications

•Content (Use icons for each bullet point):

• 🔄 Hydraulic Systems: Power steering,
excavators, machine tools.
• ⛽ Fuel Transfer: Moving gasoline, diesel,
lube oil.
• 🧪 Chemical Processing: Pumping
polymers, resins, solvents.
• 🏭 Industrial Manufacturing: Paints, inks,
soaps, plastics, food products (e.g.,
chocolate).
EXTERNAL GEAR PUMPS:
• An External Gear Pump is a type of positive displacement hydraulic pump that uses two meshing gears to pump fluid.
• It is widely used in hydraulic systems because of its simple design, reliability, and ability to handle a wide range of fluids.

Construction
•Two gears (driving gear & driven gear) mounted inside a closely fitted casing.
•Casing (housing): encloses the gears with very small clearance to reduce leakage.
•Inlet port: where fluid enters due to the suction created by gear rotation.
•Outlet port: where pressurized fluid is discharged.
•Bearings & shaft: support the gears and allow rotation.

Working Principle
1.The driving gear (connected to a motor/engine) rotates the driven gear.
2.As the gears unmesh at the inlet, a low-pressure zone is created, and fluid is drawn into the pump.
3.Fluid gets trapped between the gear teeth and casing walls, then carried around the outside of the gears.
4.At the outlet, gears mesh together again, forcing the fluid out at high pressure.
5.Since it is a positive displacement pump, a fixed volume of fluid is delivered per revolution.
 Disadvantages
characteristics
 Noisy at high speeds.
•Flow rate depends on gear size, speed, and width.
 Limited to medium pressure applications (not
•Delivery pressure: typically up to 210 bar (3000 psi).
suitable for very high pressure).
•Speed range: usually up to 3000 rpm.
 Fixed displacement (flow rate can’t be easily
•Efficiency: High volumetric efficiency, but leakage increases with
varied).
wear.
 Wear increases internal leakage and reduces
efficiency.
Advantages
•Simple and robust construction.
Applications
•Low cost compared to other hydraulic pumps.
 Hydraulic systems in machine tools, agricultural
•Capable of handling a wide range of viscosities.
machinery, and construction equipment.
•Steady flow with minimal pulsations.
 Lubrication systems.
•Suitable for medium-pressure applications.
 Oil transfer in engines and gearboxes.
 Automotive power steering systems.
INTERNAL GEAR PUMPS:
• An internal gear pump is a positive displacement pump that uses two gears (one internal and one external) along
with a crescent-shaped partition to pump fluid.
• It is widely used because of its quiet operation, ability to handle thick fluids, and compact design. Internal gear
pumps are commonly found in hydraulic systems, fuel transfer, lubrication, and food processing industries.

Construction
•Two gears:
• Internal gear (larger gear): Has teeth on the inside surface.
• External gear (idler gear): Smaller, meshes with the internal gear.
•Crescent-shaped partition (crescent seal): Placed between the gears, helps separate suction and discharge sides.
•Housing (casing): Encloses the gear assembly with close clearances.
•Inlet port & Outlet port for suction and delivery.
Working Principle
1.The internal gear (driving gear) rotates and drives the external gear (idler).
2.At the inlet side, as the gears unmesh, a vacuum is created, drawing fluid into the pump.
3.The fluid is carried in the spaces between the gear teeth and the crescent partition.
4.As the gears rotate toward the outlet side, they begin to mesh again, squeezing the trapped fluid and
forcing it out under pressure.
5.This process delivers a smooth, continuous flow of fluid.
Characteristics
•Positive displacement pump (delivers fixed volume per revolution).
•Capable of high efficiency with good suction characteristics.
•Low speed operation possible, which makes it quieter compared to external gear pumps.
Advantages
Handles a wide range of viscosities (from thin liquids to thick oils).
•Operates quietly (less noise compared to external gear pump).
•Self-priming capability.
•High volumetric efficiency.
•Compact design with fewer moving parts.
 vane pump
A vane pump is a positive displacement pump that uses sliding vanes mounted on a rotor to move fluids.
The vanes create suction at the inlet and discharge at the outlet by varying chamber volumes.
It is widely used in hydraulic systems, automotive, and industrial applications.

Applications of Vane Pump:

•Hydraulic systems (industrial machinery, presses, injection molding).
•Automotive systems ( automatic transmissions).
•Aviation (fuel transfer, de-icing, lubrication systems).
•Refrigeration and air-conditioning (handling refrigerants).
•Oil & gas industries (pumping fuels, solvents, LPG).
•Machine tools (coolant circulation, lubrication).

Vane Pumps are classified into

1. Unbalanced vane pump
• Fixed displacement type
• Pressure compensated variable displacement type
2. Balanced vane pump
UNBALANCED FIXED DISPLACEMENT VANE PUMP:
Unbalanced Fixed Displacement Vane Pump –
 An unbalanced fixed displacement vane pump is a type of positive displacement pump where the rotor is mounted
off-center inside a cam ring. Because of this offset, the pressure acts more on one side of the rotor, making it
unbalanced.
 Fixed displacement means it delivers a constant flow per revolution of the pump, regardless of load pressure.
 It uses sliding vanes in slots of the rotor to trap and move fluid from the inlet to the outlet.
 Commonly used in hydraulic power packs, machine tools, and low-to-medium pressure systems.

Construction
 Casing (Pump housing): Contains all the parts and forms the outer cover.
 Rotor: Mounted off-center inside the cam ring, has radial slots for vanes.
 Van es: Flat plates placed in rotor slots, free to slide in and out.
 Cam ring (Stator): Stationary ring inside the casing, against which vanes maintain contact.
 Inlet port: Larger space created between vanes draws in fluid.
 Outlet port: Smaller space forces fluid out.
 Shaft: Connected to motor/engine to rotate the rotor.
Working Principle
Suction stroke:
1. As the rotor rotates, centrifugal force and sometimes springs push vanes outward to stay in contact
with the cam ring.
2. On the inlet side, volume between vanes increases → fluid is drawn into chambers.
Transfer:
3. Vanes carry trapped fluid from inlet side to outlet side.
Discharge stroke:
4. On the outlet side, space between vanes decreases → fluid is forced out under pressure.
Unbalanced nature:
5. Since inlet and outlet pressures act on different sides of the rotor, a side load is created on the shaft
(making it "unbalanced").

Applications
•Hydraulic power steering systems
•Machine tools (lubrication & hydraulic actuation)
•Aircraft fuel & lubrication pumps
•Medium-pressure industrial hydraulic systems
UNBALANCED PRESSURE COMPENSATED VARIABLE DISPLACEMENT VANE PUMP:
 A Unbalanced Pressure Compensated Variable Displacement Vane Pump is a positive displacement pump in
which the rotor is mounted off-center inside a cam ring, creating an unbalanced pressure on the shaft.
 It has a variable displacement feature, where the cam ring shifts its position to change the flow rate.
 A pressure compensator mechanism automatically adjusts the displacement to maintain constant system
pressure, improving efficiency and preventing overload.

Components (short): Casing, rotor with vanes, cam ring, inlet & outlet ports, pressure compensator (spring +
control piston).
working
 As the rotor rotates,
 vanes slide out and maintain contact with the cam ring, creating variable chambers.
 On the inlet side, chamber volume increases → fluid is drawn in.
 On the outlet side, chamber volume decreases → fluid is forced out under pressure.
 The pressure compensator senses system pressure.
 When pressure reaches the preset value, it shifts the cam ring toward the rotor center → reduces chamber size
→ decreases pump displacement and flow.
 This maintains constant pressure and prevents energy loss.
Balanced Vane Pump – Introduction
A balanced vane pump is a positive displacement pump designed with two inlet ports and two outlet ports
placed opposite each other. This arrangement balances the hydraulic forces acting on the rotor, so no side
load is created on the shaft.

Construction :
•Pump casing
•Rotor with slots and sliding vanes
•Cam ring (symmetrical, elliptical shape)
•Two inlets and two outlets placed 180° apart
•Shaft

Working
•As the rotor rotates, vanes slide outward and trap fluid at the inlet.
•Fluid is carried between the vanes and discharged at the outlet.
•Since opposite sides of the rotor experience equal pressure, forces are balanced → smoother operation
and less wear.
Applications (short):
•Hydraulic power units
•Mobile equipment (loaders, excavators)
•Machine tools
•Aircraft fuel & lubrication systems
piston pump

• A piston pump is a type of positive displacement pump that uses one or more reciprocating pistons to
move fluid by suction and discharge.
• It can handle high pressures with precise flow control, making it suitable for heavy-duty hydraulic systems.
Commonly used in hydraulic presses, mobile equipment, aerospace, and industrial machinery.

Classification of Piston Pumps

Piston pumps are classified as follows:
1.Based on Axis of Piston Movement
1. Axial Piston Pump – Pistons are arranged parallel to the drive shaft.
2. Radial Piston Pump – Pistons are arranged radially (perpendicular) around the drive shaft.

2.Based on Displacement Control

1. Fixed Displacement Pump – Delivers constant flow per revolution.
2. Variable Displacement Pump – Flow can be varied by changing piston stroke or swash plate angle.

3.Based on Stroke Mechanism (for axial type)

1. Swash Plate Type (most common).
2. Bent Axis Type.
 SWASH PLATE TYPE PISTON PUMP

Introduction:
A swash plate type piston pump is an axial piston pump where pistons are arranged parallel to the shaft, and their
reciprocating motion is produced by an angled swash plate.
 Construction Applications (short):
•Cylinder block with several pistons. •Hydraulic presses
•Swash plate (tilted, fixed or variable). •Aircraft hydraulic systems
•Drive shaft (rotates the cylinder block). •Excavators and loaders
•Valve plate with inlet & outlet ports. •Machine tools and industrial hydraulics
•Housing.

Working
•The drive shaft rotates the cylinder block carrying pistons.
•As pistons move against the inclined swash plate, they reciprocate.
•During backward stroke → piston moves out → creates suction → fluid enters.
•During forward stroke → piston moves in → fluid is compressed & discharged.
•By changing the swash plate angle, the piston stroke (and hence displacement) can be varied.
 BENT AXIS TYPE PISTON PUMP:

A bent axis type piston pump is an axial piston pump where the cylinder block is placed at an angle to the
drive shaft, creating a "bent axis." This angle causes pistons to reciprocate as the shaft rotates.
 Applications (short):
Construction (short):
High-pressure hydraulic systems
•Drive shaft
Aircraft and aerospace hydraulics
•Cylinder block (with multiple pistons)
Mobile equipment (excavators, cranes)
•Pistons with connecting rods/ball joints
Industrial hydraulic machinery
•Valve plate (inlet & outlet ports)
•Pump housing

Working (short):
•As the drive shaft rotates, the angled connection between the shaft and cylinder block makes pistons
move back and forth.
•On the suction stroke, piston moves outward → fluid enters the cylinder.
•On the delivery stroke, piston moves inward → fluid is forced out through the outlet port.
•By changing the angle between shaft and cylinder block, the pump displacement can be varied.
Factors Affecting Pump Selection
When selecting a pump for any application, the following factors must be considered:
1.Type of Fluid – Clean, dirty, viscous, corrosive, abrasive, or containing solids.
2.Flow Rate Requirement – The quantity of fluid to be delivered (L/min, m³/hr).
3.Operating Pressure/Head – The pressure or height to which the fluid needs to be pumped.
4.Temperature of Fluid – Determines material and seal selection.
5.Efficiency & Power Consumption – Energy saving and operating cost.
6.Pump Type – Positive displacement (gear, vane, piston) or dynamic (centrifugal) based on application.
7.Maintenance & Reliability – Ease of service, spare parts availability, durability.
8.Installation Space & Orientation – Size, weight, and mounting arrangements.
9.Cost – Initial cost vs. long-term operating cost.
10.Application Requirement – Continuous/Intermittent duty, speed control, noise limits, safety standards.
PUMP PERFORMANCE:
Accumulator

An accumulator is a hydraulic or pneumatic device used to store energy in the form of pressurized fluid
(usually hydraulic oil or gas) and release it when required to maintain system pressure, absorb shocks, or
provide emergency power.
 Actuator
• An actuator is used to convert the energy of fluid back into the mechanical power.
• The amount of output power developed depends upon the flow rate, the pressure drop across the actuator and its
overall efficiency.
• Thus, hydraulic actuators are devices used to convert pressure energy of the fluid into mechanical energy.

Depending on the type of actuation, hydraulic actuators are classified as follows:

1) Linear actuator: For linear actuation (hydraulic cylinders)
2) Rotary actuator: For rotary actuation (hydraulic motor)
SINGLE-ACTING CYLINDERS:
 Figure shows the operation of a double-acting cylinder with a piston rod on one side. To extend the cylinder, the
pump flow is sent to the blank-end port as in Fig.(a).

 The fluid from the rod-end port returns to the reservoir. To retract the cylinder, the pump flow is sent to the rod-
end port and the fluid from the blank-end port returns to the tank as in Fig.(b).