Engineering Basics

This article is the first in our series on hydraulic oil analysis programs. Hydraulic oil is the lifeblood of your hydraulic system, circulating primarily as a power transmission medium but also acting to lubricate, cool, seal and help remove contamination. Without oil, your hydraulic system is just a comatose pneumatic system, lying lifeless with no […]

The term hydrostatic refers to the fundamental concept we hold dear in fluid power, which is that confined hydraulic fluid under pressure exists in equilibrium and balance. Although hydraulic fluid does no more than hold objects stationary without the active application of force through a pumping device, the concept is entirely different than hydrodynamics, which […]

Spring is around the corner, although if you’re located near the Great Lakes, you might need convincing that winter ever came this year at all. Regardless, the page on my desktop calendar is March, which makes a perfect time to schedule a spring maintenance session for your industrial hydraulic equipment. Even if you enjoy a…

I’ve written much about pressure lately, discussing subjects such as the upper reasonable limits in hydraulics to shockingly high-pressure fuel injection systems. Regarding current or conceivable limits, I see no reason we can’t exceed 7,000 bar with commercially available machinery, such as water jet cutters. For the sake of simplicity and lower digits, I’m expressing…

By Josh Cosford, Contributing Editor There are very few hydraulic systems operating without directional valves, and aside from modern technologies that can make do with a servo-driven pump and a single actuator, you’ll be hard-pressed to think of a way to control actuators without them. They are responsible for managing the flow and direction of…

Machinery builders and OEMs save space and improve functionality by applying electro-pneumatic I/O and solenoid systems throughout their equipment. By: Chip McDaniel, AutomationDirect For machine builders and original equipment manufacturers (OEMs) alike, there is an increasing push to deliver smarter, more modular, and physically compact systems. Among the many design choices required to make this […]

By Josh Cosford, Contributing Editor Hydraulic hoses are crucial in various fluid power industries, helping power heavy machinery and equipment by providing the very conduit through which hydraulic fluid flows. The integrity of these systems relies heavily on the proper connection and disconnection of hydraulic hoses, as mishandling hydraulic hoses can lead to severe accidents […]

By Josh Cosford, Contributing Editor In the dynamic and intricate world of aviation, where precision and reliability are paramount, hydraulics plays a pivotal role in ensuring the smooth functioning of various aircraft systems. Hydraulics, the science of transmitting force through liquids, finds extensive application in aviation due to its ability to generate powerful and controlled…

By Josh Cosford, Contributing Editor Vacuum technology is the quintessential method for safe and careful material handling in various industries, from packaging to glass manufacturing. Vacuum cups and pads are gentle and soft, lifting even the largest material while barely contacting the surface. By creating a vacuum inside the cup, the pressure differential draws the […]

By Josh Cosford, Contributing Editor We don’t hear much anymore regarding sequence valves, and probably for good reason. A sequence valve is like a self-regulating inline relay that opens when work pressure overrides the spring setting. It’s a form of hydraulic automation that provides sequential operation for two or more functions using one fluid supply…

If you are carefully selecting your new compressors by looking at Compressed Air & Gas (CAGI) data sheets, you should be commended. Use of these sheets are a great way to compare compressor energy and flow characteristics between brands of compressors. In this way, you can choose the most efficient machine for your use and […]

By Josh Cosford, Contributing Editor Technically speaking, hydraulic hose is often also industrial hose, but for the sake of this article, I will define what makes them different in both construction and application. We could call out industrial hose for its use in mobile machinery as well, although I’m not here to make beef, so […]

Hydraulic cylinder column strength is essential in most applications. Here, we go into some basic specifications to consider when selecting, mounting and using hydraulic cylinders. By Josh Cosford, Contributing Editor As someone who helps run a cylinder manufacturing company, I can tell you that hydraulic cylinder column strength is a poorly understood concept by designers…

By Josh Cosford, Contributing Editor Hydraulic cylinders are unique in that they’re nearly 100% volumetrically efficient, although they are subjected to losses from mechanical efficiency. This means that nearly all the fluid stuffed into them results in proportional linear movement, but only some of the pressure required by them is to move their loads. Regardless,…

By Josh Cosford, Contributing Editor In the case of hydraulic systems, efficiency and reliability are paramount, and these systems, used in various industries, rely on the seamless flow of hydraulic fluid to power heavy machinery and equipment. One crucial component that ensures the reliable operation of the pumps, valves and actuators is the hydraulic filter. […]

Contributed by Robert Sheaf  •   Founder of CFC Industrial Training In this month’s Troubleshooting Challenge, a truck assembly line has a lift system to elevate the transmission into position for bolting it to the engine. The operator complained to the maintenance department that the system was very sluggish to respond to the forward and…

By Josh Cosford, Contributing Editor Oversizing your hydraulic pump is a relatively common error by beginner fluid power professionals or, more likely, entirely untrained individuals tasked with maintaining machinery. Everyone wears many hats these days, so don’t take it personally if you’ve inherited a role that requires skills above your pay grade. More than once […]

By Josh Cosford, Contributing Editor Hydraulic systems are the workhorses of many industries, powering everything from heavy machinery to manufacturing equipment. The lifeblood of these machines is hydraulic oil, which transmits power, dissipates heat, carries away contamination and lubricates components. However, just like any other fluid-based system, hydraulic systems are susceptible to unique issues, including […]

By Josh Cosford, Contributing Editor Pneumatic cylinders are essential in various industrial applications, providing the mechanical force needed to move loads, automate equipment, and perform countless other tasks. However, pneumatic cylinders encounter issues that impede their performance like other machine components. When your pneumatic cylinder isn’t working as expected, it can lead to downtime, reduced […]

By Josh Cosford, Contributing Editor Hydraulic pumps are a fundamental component in hydraulic machinery and they play a pivotal role in ensuring everything runs with the force and reliability you expect from hydraulics. Over time, though, pumps might show signs of wear and tear, just like any other piece of equipment. And just like most…

What if you could reduce all your leaks without turning a wrench? Well, it is possible with good pressure control. And sometimes it is as easy as turning a knob. The principle is shown in the following orifice chart, Fig. 1. As the pressure to a leak reduces by 1 psi, the flow consumed by […]

Hydraulic piston pumps are the current standard for power, control and efficiency, but such a position in the hierarchy comes with more significant investment and responsibility. Piston pumps are expensive, complicated and involved compared to their lessor counterparts, such as the venerable gear pump. Inexpensive piston pumps still start in the four-figure range, and once…

By Anton Zhukov, Electrical Engineer, an expert in uninterrupted power solutions To curb the limited supply and high price of battery-grade lithium, alternative sodium-ion batteries are one of the most developed technologies that can potentially become a viable option in many applications. However, new battery technology requires years of engineering for successful commercialization — and […]

By Josh Cosford,  Contributing Editor How long a hydraulic hose should last depends on many factors, not the least of which is who you ask. Some standards want to see hoses changed every few years, yet others are okay up to ten years (such as with the SAE). But do we even need to apply […]