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This text-book provides an in-depth background in the field of Fluid Power, It covers Design, Analysis, Operation and Maintenance. The reader will find this book useful for a clear understanding of the subject and also to assist in the selection and troubleshooting of fluid power components and systems used in manufacturing operations, providing a systematic summary of the fundamentals of hydraulic power transmission.

* 431 *   54 *   52 * 285

Neatly drawn self-explanatory diagrams Useful Tables Worked examples Questions are given for preparation of examinations

It is hoped that this book will satisfy the need of the Mechanical Engineering students preparing for the B.Tech/B.E. examinations of almost all the Indian Universities, Diploma examinations conducted by various Boards of Technical Education, Certificate courses as well as for the A.M.I.E., U.P.S.C., G.A.T.E. and other similar competitive and professional Examinations. It should also be of an immense help to the practising Engineers.

Price	:	Rs. 200-00
Edition	:	First Edition : 2007
ISBN	:	81-85594-75-9
Book Size	:	170 mm × 240 mm
Binding	:	Paperback with Four Colour Jacket Cover
Pages	:	460 + 16

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Chapter 1   : INTRODUCTION – HISTORY

Chapter 2   : HYDRAULIC BASICS

Chapter 3   : HYDRAULIC PRINCIPLES

Chapter 4   : HYDRAULIC DEVICES

Chapter 5   : HYDRAULIC ACCESSORIES

Chapter 6   : HYDRAULIC CIRCUIT DIAGRAMS

Chapter 7   : TROUBLESHOOTING IN HYDRAULIC

Chapter 8   : HYDRAULIC ELECTRICAL DEVICES: TROUBLESHOOTING AND SAFETY

Chapter 9   : PNEUMATICS

Chapter 10 : COMPONENT OF PNEUMATICS

Chapter 11 : BASIC PNEUMATIC CIRCUITS

Chapter 12 : APPLICATION FOR PNEUMATICS

Chapter 13 : SERVO SYSTEMS, PROPORTIONAL VALVES AND PNEUMATIC SAFETY

Chapter 14 : FLUIDICS

Chapter 15 : DESIGN OF PNEUMATIC CIRCUITS

APPENDICIES

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Chapter 1 : INTRODUCTION – HISTORY

1-1 1-2 1-3

Hydraulics Development of hydraulics Advantages of fluid power Questions 1 Top>>

Chapter 2 : HYDRAULIC BASICS

2-1	Pressure and force
	(1)	Pressure
		(i) (ii) (iii)	Diagram A Diagram B Diagram C
	(2)	Force
2-2 2-3	Pascal’s law Flow
	(1) (2)	Velocity Flow rate
2-4	Energy, work, and power
	(1) (2) (3) (4) (5) (6)	Potential energy Kinetic Energy Heat energy and friction Relationship between velocity and pressure Work Power
2-5	Liquids at rest
	(1) (2) (3)	Pressure and force Computing force, pressure, and area Atmospheric pressure
2-6 2-7 2-8 2-9 2-10 2-11	Transmission of forces through liquids Density and specific gravity Pressure of a liquid is independent of direction Pressure and force in fluid power systems Multiplication of forces Law of conservation of energy
	(1) (2) (3) (4) (5) (6) (7) (8)	The continuity equation Bernoulli’s equation Newtonian laws Differential areas Volume and distance factors Liquids in motion Volume and velocity of flow Volume of flow and speed
2-12 2-13	Streamline and turbulent flow Factors involved in flow
		Inertia and force
2-14 2-15 2-16 2-17	Kinetic energy Relationship of force, pressure, and head Static and dynamic factors Bernoulli’s principle
		Minimizing friction
2-18 2-19 2-20 2-21	Operation of hydraulic components Hydraulic jack Hydraulic brakes Typical examples Questions 2 Top>>

Chapter 3 : HYDRAULIC PRINCIPLES

3-1 3-2 3-2-1	Introduction Properties Viscosity
	(1) (2)	Measurement of viscosity Viscosity index
3-2-2 3-2-3 3-2-4 3-2-5 3-2-6 3-2-7 3-2-8 3-2-9 3-2-10 3-3 3-3-1 3-3-2	Lubricating power Chemical stability Freedom from acidity Flash point Fire point Minimum toxicity Density and compressibility Foaming tendencies Cleanliness Types of hydraulic fluids Petroleum based fluids Synthetic fire resistant fluids
	(1) (2) (3)	Phosphate ester fire resistant fluid Silicone synthetic fire resistant fluids Light weight synthetic fire resistant fluids
3-3-3 3-4	Water based fire resistant fluids Fluid contamination
		Classification
3-4-1	Particulate contamination
	(1) (2) (3)	Organic contamination Metallic solid contamination Inorganic solid contamination
3-4-2	Fluid contamination
	(1) (2) (3) (4)	Air contamination Water contamination Solvent contamination Foreign fluids contamination
3-5	Origin of contamination
	(1) (2) (3) (4)	Particles originally contained in the system Particles introduced from outside sources Particles created within the system during operation Particles introduced by foreign liquids
3-6 3-7 3-8 3-8-1 3-8-2 3-8-3 3-8-4	Contamination control Hydraulic fluid sampling Measurement and pressure control devices Pressure gauges Bourdon tube gauges Spiral and helical bourdon tubes Bellows elastic elements
	(1) (2)	Simple bellows elements Dual bellows indicators
3-9 3-10 3-10-1 3-10-2 3-11	Pressure switches Temperature measuring instruments Bimetallic expansion thermometer Distant reading thermometer Temperature switches
		Gauge snubbers
3-12	Sealing devices and materials
		Historical backgrounds
3-12-1	Seals
	(1) (2)	Static seals Dynamic seals
3-12-2	Seal materials
	(1) (2) (3) (4) (5)	Cork Cork and rubbers Rubber Leather Metal
3-12-3	Types of seals
	(1) (2) (3)	Seals V-rings O-rings
3-13	Fluid lines and fittings
	(1) (2) (3) (4)	Types of lines Pipes and tubings Selection of pipes and tubing Sizing of pipes and tubing
			Materials
	(5) (6) (7) (8) (9) (10) (11) (12) (13)	Preparation of pipes and tubing Tube cutting and deburring Tube bending Hand tube bender Mechanical tube bender Tube flaring Flexible hose Sizing Cure date
			PFTE
	(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37)	Fabrication and testing Identification Installation Types of fittings and connectors Threaded connectors Flange connectors Welded connectors Brazed connectors Flared connectors Flareless tube connectors Warning Inspection Final assembly Connectors for flexible hose Piping connection side of hose fitting Hose connection side of hose fitting One-piece reusable socket Segmented, bolted socket Segmented socket, ring and band attached Segmented socket, ring and bolt attached Solid socket, permanently attached Quick disconnect couplings Manifolds Precautionary measures
	Questions 3 Top>>

Chapter 4 : HYDRAULIC DEVICES

4-1 4-2	Pumps Hydraulic pumps
	(1) (2)	Purpose Pump operation
4-3 4-3-1 4-3-2 4-3-3	Pump classifications Non positive displacement pumps Positive displacement pumps Characteristics
	(1) (2)	Performance Displacement
		(i) (ii)	Fixed displacement pump Variable displacement pump
	(3) (4)	Slippage Designs
4-3-4	Centrifugal pump
	(1) (2)	Volute pump Diffuser pump
4-4 4-4-1	Rotary pump Gear pumps
	(1) (2)	External Internal
4-4-2 4-4-3	Lobe pump Vane pumps
	(1) (2) (3) (4) (5) (6)	Characteristics Unbalanced vane pumps Balanced vane pumps Double pumps Two stage pumps Variable delivery vane pump
4-4-4 4-4-5 4-5 4-5-1 4-5-2	Screw pump Performance of screw pump Reciprocating pumps Hand pumps Piston pumps
	(1)	Radial piston pumps
		(i) (ii) (iii) (iv) (v)	Pintle Cylinder block Pistons Rotors Drive shaft
	(2)	Axial piston pumps
		(i) (ii) (iii) (iv)	In line pump Wobble plate in line pump Bent axis axial piston pump Strato power pump
4-6	Pump operational problems
	(1) (2) (3) (4)	Overloading Excess speed Cavitation Operating problems
		(i) (ii) (iii) (iv)	Pressure loss Slow operation No delivery Noise
4-7	Pump symbols
		Key equations
		(1) (2) (3)	Shaft power Fluid power Overall efficiency
4-8 4-9	Typical examples Self assessment exercise 1 Hydraulic valves
	(1) (2) (3) (4) (5) (6)	Introduction Pressure control valves Relief valves Simple type Compound type Pressure reducing valves
		(i) (ii)	X-series type XC-series type
	(7) (8) (9) (10)	Sequence valves Counter balance valves Pressure switches Pressure regulators
4-10 4-10-1 4-10-2 4-10-3	Directional control valves Poppet valve Sliding spool valve Check valves
	(1) (2) (3)	Standard type Restriction type Pilot operated type
4-10-4 4-10-5 4-10-6	Shuttle valve Two way valve Four way valves
	(1) (2) (3) (4)	Four way poppet type valve Four way sliding spool valve Manually operated four way valve Pilot operated, four way valve
4-10-7 4-10-8 4-11 4-11-1 4-11-2 4-11-3 4-11-4 4-11-5 4-11-6 4-12 4-13	Solenoid operated, two and four way valves Rotary spool Flow control valve Gate valve Globe valve Needle valve Restrictor Orifice check valve Flow equalizer Cartridge valves Valve installation
	(1) (2) (3) (4)	Meter in circuit Meter out circuit Bleed off circuit Compensated flow
4-14 4-14-1 4-14-2 4-14-3	Valve failures and remedies Servicing valves Disassembling valves Repairing valves
	(1) (2) (3) (4) (5)	Directional control valves Volume control valve Pressure control valve Valve seats and poppets Non adjustable, cartridge type relief valves
4-15 4-15-1 4-15-2	Valve assembly Trouble shooting valves Pressure control valves
	(1) (2) (3) (4)	Relief valves Pressure reducing valves Pressure sequence valves Unloading valves
4-15-3 4-15-4 4-16 4-17 4-17-1 4-17-2	Directional control valves Volume control valves Control methods Actuators Cylinders Ram type cylinders
	(1) (2) (3) (4)	Single acting ram Double acting ram Telescoping rams Dual rams
4-18	Piston type cylinders
	(1) (2) (3) (4)	Single acting cylinder Double acting cylinder Tandem cylinders Rack and pinion piston type rotary actuators
4-19 4-20	Construction and application Maintenance
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)	External leakage Internal leakage Creeping cylinder Sluggish operation Loose mounting Misalignment Lack of lubrication Abrasives on a piston rod Burrs on a piston rod Air vents
4-21	Motors
	(1) (2) (3)	Gear type motors Vane type motors Balanced vane motor
4-22	Piston type motors
	(1) (2) (3) (4) (5)	Radial piston motor Axial piston motor In line axis, piston type motors Bent axis, piston type motors Impulse turbine
			Impulse principle
4-23	Reaction turbine Self assessment exercise 2 Self assessment exercise 3 Questions 2 Top>>

Chapter 5 : HYDRAULIC ACCESSORIES

5-1	Reservoirs, strainers, filters: Reservoirs
	(1) (2) (3) (4)	Non pressurized reservoirs Pressurized reservoirs Fluid pressurized reservoir Air pressurized reservoirs
5-2	Filtration
	(1) (2) (3) (4) (5)	Strainers Filters Full flow filter Proportional flow filter Filter rating
5-2-1	Filter elements
	(1) (2) (3) (4)	5-micron non cleanable filter elements Woven wire mesh filter elements Micronic hydraulic filter elements Magnetic filters
5-2-2	Filter size and efficiency
		Beta rating (b)
5-2-3 5-3 5-3-1	Location Accumulators Types of accumulators
	(1) (2) (3) (4)	Piston type accumulators Bladder type accumulators Direct contact gas to fluid accumulators Diaphragm accumulators
5-3-2	Operation of accumulator
	(1) (2) (3) (4)	Operating conditions of bladder accumulators Operating conditions of piston accumulators Operating conditions of diaphragm accumulators Accumulators
5-3-3	Applications
		Control of usable volume 218
5-3-4 5-3-5 5-3-6 5-4 5-4-1 5-4-2 5-4-3 5-4-4 5-4-5 5-4-6 5-4-7 5-4-8 5-4-9 5-4-10 5-4-11 5-4-12 5-5 5-5-1 5-5-2 5-5-3 5-5-4 5-5-5 5-5-6	Maintaining pressure Developing flow Absorbing shock Selection of accumulator Failure modes Output volume Flow rate Fluid type Response time Shock suppression High frequency cycling Mounting position External forces Sizing information Certification Safety Sizing of accumulator Auxiliary power source Hydraulic line shock suppression Thermal expansion Piston pump pulsation dampening Existing accumulator output used in an auxiliary power source application Hydraulic power packs Questions 5 Top>>

Chapter 6 : HYDRAULIC CIRCUIT DIAGRAMS

6-1	Hydraulic-circuit diagrams
	(1) (2) (3) (4)	Block diagram Cutaway diagram Pictorial diagram Graphical diagram
6-2	United States of American Standards Institute (USASI) graphical symbols
	(1) (2)	Reservoir Lines
		(i) (ii) (iii) (iv)	Working line Pilot line Drain line Flexible line
	(3) (4) (5)	Pump Motor Cylinder
		(i) (ii) (iii) (iv)	Single-acting cylinder Double-acting cylinder Double-end rod cylinder Cushioned cylinder
	(6)	Pressure-control valves
		(i) (ii) (iii) (iv) (v)	Relief valve Sequence valve Check valve Counterbalance valve Pressure-reducing valve
	(7) (8)	Flow-control valves Directional control valves
		(i) (ii) (iii)	Unloading valve Four way direction control valve Mobile directional valve section
6-3	Typical mobile circuits
	(1) (2) (3)	Hydraulic lift circuit Power steering circuits Road patrol truck circuits
6-4 6-4-1 6-4-2 6-4-3 6-4-4 6-4-5 6-4-6 6-4-7 6-4-8 6-4-9 6-4-10	Different hydraulic circuit diagrams Control of double acting hydraulic cylinder Regenerative circuit Control of single hydraulic cylinder Pump unloading circuit Intensifier circuit Intensifier press circuit Counter balance valve application Hydraulic cylinder sequence circuit Automatic cylinder reciprocation circuit Synchronising circuits
		Tie cylinders Synchronising with flow control valves
6-4-11 6-4-12 6-4-13 6-4-14	Locked cylinder using pilot check valve Cylinder hooked in series–synchronization Safety circuits Two-hand safety control circuit
	(1) (2)	The circuit functions as follows Fail-safe control circuit using emergency cut-off valve
6-5	Typical examples — Design of hydraulic circuits Questions 6 Top>>

Chapter 7 : TROUBLESHOOTING IN HYDRAULIC

7-1	Troubleshooting
	(1) (2) (3) (4) (5) (6) (7)	Causes of improper operations Testing a hydraulic circuit Comparing test results with specifications Slippage Flow and pressure Other conditions Specific troubles, causes and solutions
7-2	10 Ways to increase hydraulic circuit cycle speed Questions 7 Top>>

Chapter 8 : HYDRAULIC ELECTRICAL DEVICES: TROUBLESHOOTING AND SAFETY

8-1 8-2	Hydraulics and electricity Troubleshooting electrical devices
	(1)	Procedure
		(i) (ii) (iii) (iv) (v)	Step one identify the symptom Step two analyze the symptom Step three isolate the single faulty function Step four isolate the faulty circuit Step five locate/verify the cause of the malfunction
	(2)	Testing devices
		(i) (ii) (iii) (iv) (v)	Potentiometer Solenoid coil Relay Transformer Diode
8-3	Ground
	(1) (2) (3) (4)	Earth ground Chassis or common ground Zero reference point Isolation between earth and chassis ground
8-4	Safety
	(1) (2)	Information Practices
	Questions 8 Top>>

Chapter 9 : PNEUMATICS

9-1 9-2 9-2-1 9-2-2 9-2-3 9-3 9-4 9-5 9-6 9-7 9-8 9-8-1 9-8-2 9-8-3 9-8-4 9-8-5	Development of pneumatics Characteristics of gases Density Temperature Pressure Compressibility and expansion of gases Kinetic theory of gases Boyle’s law Charles’s law General gas law Pneumatic gases Qualities Compressed air High-pressure air systems Medium-pressure air Low-pressure air
		Nitrogen
9-9 9-10 9-11	Contamination control Potential hazards Safety precautions Questions 9 Top>>

Chapter 10 : COMPONENT OF PNEUMATICS

10-1 10-1-1 10-1-2 10-1-3 10-2	Compressors Vane compressors Screw compressor Lobe compressor Selection of compressor
	(1) (2) (3)	System flow rate demand Standby capacity for emergencies Future air requirements
10-3 10-4 10-5 10-6	Air capacity rating of compressors Sizing of air compressor Power requied to drive a compressors Air conditioners
		Pneumatic gases
10-6-1 10-6-2	Removal of solids Removal of moisture
	(1) (2)	Refrigerated type dehydrators Desiccant type dehydrators
10-6-3 10-6-4 10-6-5 10-6-6 10-6-7 10-6-8 10-6-9 10-7 10-8	Air pressure regulator Air lubricator Air service unit Pneumatic silencer Pneumatic actuators Pneumatic semi rotary actuators Directional control valves Air pressure losses in the pipe line FRL unit
	(1) (2) (3)	Air-filter Pressure regulator Lubricator
10-9 10-10 10-11	Installation of FRL unit Quick exhaust valve Speed control
		Actuation of pneumatic motor
10-12 10-13 10-14 10-14-1 10-14-2 10-14-3	Air control valves Pneumatic circuit design considerations Hydro pneumatic Air-oil reservoir Air-oil cylinder Air-oil intensifier
		Extension Punching Retraction
	Questions 10 Top>>

Chapter 11 : BASIC PNEUMATIC CIRCUITS

11-1 11-2 11-3 11-4 11-5 11-6 11-6-1 11-6-2 11-7	Air pilot control of double acting cylinder Two step speed control system Control of air motor Deceleration air cushion cylinder Movement diagram Cascade system of pneumatic circuit design Principle and procedure Advantages of cascade system Use of karnaugh veitch map for pneumatic circuit design
		Venn diagram
11-8 11-9 11-10	K-V diagram Design of pneumatic circuit with K-V diagram Ladder diagrams
		Ladder logic Inputs Outputs Latches Counters Timers
11-11	Sequence charts
		Ladder diagram for actuating two cylinders
11-12 11-13 11-14 11-14-1 11-14-2 11-14-3 11-15 11-16 11-17	Cascade method Ladder-diagram design : cascade method Introduction to industrial automation Huffman method Sequential systems Ladder logic program Programmable logic control PLC history PLC construction
	(1) (2)	Central processing unit i/o module
11-18	Programming the PLC
	(1) (2) (3) (4) (5)	Ladder diagram based Low level language based on boolean operations Functional blocks High level langauage PLC operation
		(i) (ii) (iii)	Check input status Execute program Update output status
	Questions 11 Top>>

Chapter 12 : APPLICATION FOR PNEUMATICS

12-1	The advantages of compressed air
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)	Easily transported Easily stored Clean and dry Lightweight Safe to use Accident-proof Rational and economical Simple Overload-proof Fast work medium Fully adjustable
12-2	Pressure ranges
	(1) (2) (3) (4)	Low pressure range to 10 bar Medium pressure range to 15 bar High pressure range to 40 bar High pressure range to 400 bar
12-3 12-3-1	Possible applications for compressed air Tensioning and clamping with compressed air
		Tensioning and clamping
12-3-2 12-3-3 12-3-4 12-3-5 12-3-6 12-3-7 12-4	Conveyance by compressed air Pneumatic drive systems Spraying with compressed air Blowing and flushing with compressed air Testing and inspection with compressed air Using compressed air for process control Examples of specialized applications
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)	Construction trade Mining Chemicals industry Energy industry Health system The crafts Wood processing industry Steel mills and foundries Plastics industry Agriculture and forestry Food and semi-luxury food industry Paper-processing industry Textiles industry Environmental technology Traffic and communications
12-5	Fluid power technical specification
		Cost Health and safety
	Questions 12 Top>>

Chapter 13 : SERVO SYSTEMS, PROPORTIONAL VALVES AND PNEUMATIC SAFETY

13-1	Introduction
	(1) (2)	Pneumatics are potentially dangerous because they are fast Pneumatics develop significant forces
		(i) (ii)	Force in human terms Force in pneumatic terms
13-2 13-3	Safety considerations Servo valve
	(1) (2)	Two stage servo valves Flapper type servo valve
13-4	Proportional valves
	(1) (2)	Proportional and servo valves Loss of pitch control
13-5	Electro hydraulic servo valve
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)	Auxiliary relief valve Reducing valve Loss of hydraulic oil pressure Main relief valve Sequencing valve Major leak Cleaning and lubrication Alignments and adjustments Unloading valve Sequencing valve Reducing valve Auxiliary servo relief valve Main relief valve Mechanical alignment Electronic alignment Removal and replacement of components
	Questions 13 Top>>

Chapter 14 : FLUIDICS

14-1 14-2	Introduction Principles of fluidic logic control
		Basic fluidic devices
14-3	The coanda effect Questions 14 Top>>

Chapter 15 : DESIGN OF PNEUMATIC CIRCUITS

15-1	Introduction
		Drive forces
15-2	Choice of components
	(1) (2) (3) (4) (5) (6) (7) (8)	Pumps Pressure controls Flow control Directional controls Actuated end-use device Space requirements Speed of operation Pressure considerations
15-3	Choice of signal source and transmitting systems
	(1) (2) (3) (4)	Sensitivity required Available space and environment Dependability and service life required Economic limitations
	Summary
15-4	Fluid power advantages
	(1) (2) (3) (4) (5) (6) (7) (8) (9)	Trade-offs between hydraulic vs. pneumatic power Designing a fluid power system Pumps Cylinders Accumulator Plumbing Valves Motion controller Sensors/Transducers
15-5	Performance, precision and price make fluid power the right choice
	(1) (2)	Description of equipment Drive system
15-6 15-6-1 15-6-2	Model design Design of Hoist Design of ram type hydraulic press
	(1) (2)	Objective Construction and design principle
15-6-3	Hydraulic tilting for electric arc furnace
		Requirement
15-6-4	Design of hydro pneumatic spring
		Objective
15-6-5	Pneumatic sequencer
	(1) (2) (3)	Requirement Air consumption Specification of components
	Questions 15 Top>>

APPENDICIES

Appendix A Appendix B Appendix C

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Basic symbols of mechanical component, valve Glossary Model question papers Top>>