CIM and Automation Laboratory Manual MEL77

DON BOSCO INSTITUTE OF TECHNOLOGY

DEPARTMENT OF
MECHANIACL ENGINEERING

Laboratory Manual
for
CIM and Automation
(06MEL77)

Compiled By

Hareesha N G
Lecturer

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

Simulation of Tool Path for Turning Operations

1) Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes.

The dimensions are shown in mm

Creating the Profile

You first need to start a new document in EdgeCAM and then invoke the ZX
environment and create the profile using the Line, Fillet, and Chamfer tools.

1) Start a new EdgeCAM document.

2) Invoke the ZX environment by choosing the XY button at the bottom right corner of
the EdgeCAM screen.
3) Draw one half of the turn profile above the horizontal axis, using the Line, Fillet, and
Chamfer tools. The profile drawn is shown in Figure
CIM and Automation Laboratory Manual MEL77

Creating the Stock

1) Choose the Stock/Fixtures button from the Design toolbar.
2) In the Stock/Fixtures dialog box, select the Automatic Stock check box and the
Cylinder option from the Shape drop-down list.
3) Enter 5 in the Start Extension, End Extension, and Radius Extension edit boxes
and choose the OK button.

Creating the Straight Turn Toolpath

Next, you need to invoke the manufacturing mode to create the straight turn toolpath.
1) Choose the Switch to Manufacture Mode button on the top right corner of the screen.
2) In the New Sequence dialog box, select the Turn option from the Discipline and the
Initial CPL drop-down lists. Select the fanuc2x-in.tcp option from the Machine Tool
drop-down list. Choose the Lathe Setup tab and make sure the Mirror View check box
is cleared and choose the OK button to exit the dialog box.
3) Create a new layer with the name Facing.
4) Choose the Turn button from the Main toolbar; the Turning Tool dialog box is
displayed. Choose the Find button and select the CSKPR-2020 K12-General Turn
GC 4015 tool and choose the Select button.
5) Set 1 in the Position spinner. Enter 88 in the Side Angle edit box.
6) Choose the More tab and select the Facing option from the Layer drop-down list.
Choose the OK button.
7) Choose the Straight Turn button from the Turn toolbar; the Straight Turn dialog
box is displayed. Set the following parameters:
Feeddrate (mm/rev): 0.5 Speed (RPM): 2500
Cut Increment: 1 Link Type: Rapid
Digitise Start: Select the check box
Safe Approach: Select the check box
8) Select Face from the Cut Direction drop-down list. If this list is not available, you
will select the cut direction from the model. Choose OK; you are prompted to select
the start point of the cut. Select the right top corner of the stock, as shown in Figure

9) You are prompted to select the destination point of the cut. Select the point at the end
of the profile, as shown in Figure above. If the point is not highlighted, press the TAB
key until it is highlighted. After selecting the point, right-click; the toolpath is
generated and displayed.

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Creating the Rough Turn Toolpath

In this section, you will select the appropriate tool for the rough turn and generate the rough
turn toolpath.

1) Create a new layer with the name Rough Turn.

2) Hide the Facing layer by double-clicking Yes next to Facing in the Layers window.
3) Choose the Turn button from the Main toolbar. In the Turning Tool dialog box,
choose the Find button. Select the PCLNL-2525-M12-0.8 General Turn GC1015
option and choose the Select button.
4) Choose the More tab, select the Rough Turn option from the Layers drop-down list
and choose the OK button.
5) Choose the Rough Turn button from the Turn toolbar; the Rough Turning dialog
box is displayed.
6) In the General tab, set the parameters as follows:

Feedrate (mm/sec): 0.5 Speed (RPM): 2500

Cut Increment: 1 Z Offset: 0.3
X Offset: 0.1 Finish At: Cycle Start
Rough Cuts Only: Select the check box Cut Direction: Turn
Safe Approach: Select the check box
7) Choose the OK button; you are prompted to select the profile. Select the profile by
dragging a selection box, as shown in Figure. Right-click to accept the selection

8) You are prompted to digitise the start and the end of the cycle. Right-click to accept
the default start point and the endpoint, as shown in Figure.

9) You are prompted to digitise the billet or the start point of the cycle. Select the top
right-corner of the stock. The rough turning toolpath will be generated.

Generating the Finish Turn Toolpath

In this section, you will select the appropriate tool for the finish turn and generate the finish

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turn toolpath.
1) Create a new layer with the name Finish Turn.
2) Hide the Rough Turn layer by double-clicking Yes next to rough turn in the Layers
window.
3) Choose the Turn button from the Main toolbar. In the Turning Tool dialog box,
choose the Find button. Select the SVLBL-2020-K16 0.4 Finish Turn GC 4015
option and choose the Select button.
4) Choose the More tab; select the Finish Turn option from the Layers drop-down list
and choose the OK button.
5) Choose the Finish Turn button from the Turn Tools toolbar; the Finish Turning
dialog box is displayed.
6) In the General tab, set the parameters as follows:
Feedrate (mm/rev): 0.3 Speed (RPM): 2500
Digitise Start: Select the check box Safe Approach: Select the check box
7) Choose the OK button; you are prompted to select the profile. Select the profile by
dragging a selection box similar to the one you defined in the previous section. Right-
click to accept the selection.
8) You will notice an arrow indicating the start point of the cycle. Right-click to accept
it.
9) You will notice a star at the endpoint of the selected profile. Right-click to accept it.
10) You are prompted to select the cycle start point. Right-click to accept the default
value; the final toolpath will be generated. You can select the toolpath from the right
to highlight it.
11) Invoke the Layers window and right-click. Select the Show-all option from the
shortcut menu. The wireframe model with all the toolpaths is displayed.

Run the EdgeCAM Simulator

1) To run the EdgeCAM simulator, choose the Simulate Machining button from the
Main toolbar. If the Select Sequence window is displayed, select the sequence and
choose the Add button. Next choose OK; the Simulator window is displayed.
2) Choose the Start button to begin the simulation. You can choose the Toggle Speed
Control tool to modify the speed of simulation.
3) Choose the Return to EdgeCAM button from the Main toolbar to revert to the
Manufacture mode.

You can use this stepwise procedure to do the Turning and

related operations
Turning Operation
1) On the Operations toolbar, click Turning Operation .
2) Now select the profile by holding down the left mouse button and dragging the
window to define the opposite corners. Right-click to finish the selection
3) Right-click to accept the default start point on the profile.
4) Right-click to accept the default start point of the cycle.
5) The dialog for the Turning Operation is now displayed.

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Turning - General Tab

6) On the General tab, set these parameters: Tool Orientation (Turn), Cut Direction
(Turn), Spindle Direction (Forward), CSS Check to use constant surface speed (Uncheck),
Canned Cycle (Uncheck), Prevent Undercuts (Check), Click the Roughing tab, but
do not click OK yet.
Turning - Roughing Tab
7) On the Roughing tab set these parameters: Strategy (Rough Turn), Rough Cuts
Only (uncheck), Pathcomp Compensation (Uncheck), Cut Increment (6), Z Offset
(0.3) and X Offset (0.5). Click the Find button to open the ToolStore. Click PCLNL-
2525 M12 0.8 General Turn CG1015 tool and click Select. Click the Finishing tab,
but do not click OK yet
Turning - Finishing Tab
8) On the Finishing tab set these parameters: Strategy (Finish Turn), Compensation
(Pathcomp) and Use Roughing Tool (Checked). All other settings can be left as they
are. Click OK to generate the roughing and finishing toolpaths.

Grooving

On the Operations toolbar, click Grooving Operation .

Hold down the left mouse button and drag to pick the groove profile. Right-click to
finish the profile selection and right-click again to accept the profile's start point.
Right-click again to accept the default cycle start point. The operation dialog now
opens.

Grooving - General Tab

1) On the General tab, set these parameters: Type (External), CSS (Checked), Spindle
Direction (Forward), Profile Extension Start (0) and Profile Extension End (0).
2) Click the Roughing tab, but do not click OK yet.
Grooving - Roughing Tab
3) On the Roughing tab set these parameters: Strategy (Sequential), %Stepover (50), Z
Offset (0.3) and X Offset (0.5).
4) Click the Find button to open the ToolStore. Pick the Groove tool and click Select.
All other settings can be left blank.
5) Click the Finishing tab, but do not click OK yet.
Grooving - Finishing Tab
6) On the Finishing tab set these parameters: Strategy (Finish Groove) and Use
Roughing Tool (Checked). All other settings can be left blank.
7) Click OK to generate the roughing and finishing grooving toolpaths

Face Groove
1) On the Operations toolbar, click Grooving Operation .
2) Window the Face groove profile and right-click to finish profile selection.
3) Right-click to accept the profile start point.
4) Right-click again to accept the default start point for the cycle. The dialog for the
operation now appears.
Face Groove - General Tab
5) Set these General parameters: Type (Face), CSS (Checked), Spindle Direction
(Forward), Profile Start Extension (1) and Profile End Extension (1). Move to the
Roughing tab, but do not click OK yet.

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Face Groove - Roughing Tab

6) On the Roughing tab, set these parameters: Strategy (Centre Alternate), % Stepover
(50), Z Offset (0.3) and X Offset (0.5).
7) Click the Find button to open the ToolStore. Click MBS4-151.21-035B-20 Face -
GC225 and click Select. All other settings can be left blank. Click the Finishing
tab, but do not click OK yet.
Face Groove - Finishing Tab
8) On the Finishing tab, set these parameters: Strategy (Finish Groove) and Use
Roughing Tool (Checked).
9) All other settings can be left blank. Click OK to generate the roughing and finishing
grooving toolpaths.

2) Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes.

The following steps are required to create the turn toolpath:

CIM and Automation Laboratory Manual MEL77

1) Draw the profile in the drawing area

2) Create the stock by choosing the Stock/Fixtures button.
3) Select the turn tool and generate the straight turn toolpath.
4) Select the turn tool and generate the rough turn toolpath.
5) Select the turn tool and generate the finish turn toolpath.
6) Select the grove tool and generate the rough groove toolpath.
7) Select the grove tool and generate the finish groove toolpath.
8) Run the EdgeCAM simulator.
9) Save the model.

3) Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes.
CIM and Automation Laboratory Manual MEL77

4) Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes.

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CIM and Automation Laboratory Manual MEL77

Simulation of Tool Path for Milling Operations

Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes. Assume t=10mm

Use the following steps to crate the tool path simulation

1. Start a new EdgeCAM document.

2. Create the profile as shown in figure
3. Create the stock.
4. Generate the machining toolpaths using the profiling mill cycles.
5. Run the simulation.
6. Save the file

Create the profile

Create the profile as shown in the figure above.

Create the stock

1. To create the stock, choose Geometry > Stock/Fixture from the menu bar; the Stock
dialog box is displayed.
2. Select the Automatic Stock check box. Next, select the Box option from the Shape
drop-down list; the Box Offset area is available.
3. Enter the value of 5 in the X Min and X Max edit boxes, respectively.
4. Enter the value of 5 in the Y Min and Y Max edit boxes, respectively.
5. Enter the value of 10 (Thickness) in the Z Min and 0 in the Z Max edit boxes,
respectively.
6. Choose the OK button; a box shaped wireframe stock will be created around the
model.

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Invoking the Manufacture Mode

1. Choose the Switch to Manufacture Mode button on the top-right corner of the
window; the Machining Sequence dialog box is displayed.
2. Enter the Sequence Name as Mill exercise 1. Select Mill from the Discipline drop-
down list. From the Machine Tool drop-down list, select fanuc3x.mcp. From the
Initial CPL drop-down list, select Top. From the Datum Type area, select the
Absolute radio button. Choose OK.

Generating the Profiling Toolpath

The first operation to be performed on the stock is the profiling operation.
1) From the menu bar dropdown list choose operation  Profiling as shown in figure
below.

2) Select the part profile ( Double click the profile to select)  Press Enter ( Or right
click)  Select the starting point as shown in figure  If inside profile is selected,
select outside profile by clicking outside the profile  Press Enter  Press Enter 
The following window will be displayed. Enter the values as shown (Do not press ok)

3) Go to tooling, Select 10 mm end milling cutter . ( Tool store  Find  mill  10

mm end milling cutter  Select), Enter the values as shown. (Do not press ok)

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4) Go to depth and enter the values as shown in figure. Press OK. The cut path will be
created.

Running the EdgeCAM Simulator

1) Choose the Simulate Machining button from the Main toolbar; the Simulator
window is displayed.
2) Choose the Start button from the Main toolbar to begin the simulation.
3) After completing the simulation, choose the Return to EdgeCAM button from the
Main toolbar to return to the Manufacture mode. The model, after simulation, is
shown in figure.

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Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes. Assume t=10mm

Use the following steps to crate the tool path simulation

1. Start a new EdgeCAM document.
2. Create the profile as shown in figure
3. Create the stock.
4. Generate the machining toolpaths using the profiling mill cycles.
5. Run the simulation.
6. Save the file

Write Manual part program for the part shown below and generate the
tool path for the same. Also generate NC codes.

1. Start a new EdgeCAM document.

2. Create the profile as shown in figure below.
CIM and Automation Laboratory Manual MEL77

Create the stock

To create the stock, choose Geometry > Stock/Fixture from the menu bar; the Stock dialog
box is displayed.
1. Select the Automatic Stock check box. Next, select the Box option from the Shape
drop-down list; the Box Offset area is available.
2. Enter the value of 5 in the X Min and X Max edit boxes, respectively.
3. Enter the value of 5 in the Y Min and Y Max edit boxes, respectively.
4. Enter the value of 12 (Thickness) in the Z Min and 0 in the Z Max edit boxes,
respectively.
5. Choose the OK button; a box shaped wireframe stock will be created around the
model.

Invoking the Manufacture Mode

1. Choose the Switch to Manufacture Mode button on the top-right corner of the
window; the Machining Sequence dialog box is displayed.
2. Enter the Sequence Name as Mill exercise 1. Select Mill from the Discipline drop-
down list. From the Machine Tool drop-down list, select fanuc3x.mcp. From the
Initial CPL drop-down list, select Top. From the Datum Type area, select the
Absolute radio button. Choose OK.

Generating the Profiling Toolpath

The first operation to be performed on the stock is the profiling operation.
1) From the menu bar dropdown list choose operation  Profiling as shown in figure
below.

2) Select the part profile ( Double click the profile to select)  Press Enter ( Or right
click)  Select the starting point as shown in figure  If inside profile is selected,
select outside profile by clicking outside the profile  Press Enter  Press Enter 
The following window will be displayed. Enter the values as shown (Do not press ok)

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3) Go to tooling, Select 10 mm end milling cutter . ( Tool store  Find  mill  10

mm end milling cutter  Select), Enter the values as shown. (Do not press ok)

4) Go to depth and enter the values as shown in figure. Press OK. The cut path will be
created.

To create pocketing (Roughing)

1) To create pocketing, Operations  Roughing as shown in figure.

2) Double click the inside profile for pocketing  Press Enter  Press Enter  The
Roughing Operation dialog appears.
3) In the General tab, set Rest Rough to Unchecked, Mill Type to Climb, % Step
over to 50, Tolerance to 0.01, and Digitise Stock to Unchecked. All other settings
can be left blank.
4) Click the Tooling tab. Click the Find button to open the ToolStore. In the tooling list
click 10mm Endmill - short series to select it and click Select. (If you cannot see
the tool in the list, click Use Filters on the right side of the ToolStore dialog.) Feed =
400mm/min, Plunge Speed to 600 and Speed = 2000rpm. All other settings can be left
as they are.
5) Click the Depth tab and set Clearance to 10, Level to 0, Depth to -5 and Cut
Increment to 1.
6) Click OK to close the dialog and generate the toolpath.

To create pocketing (Finishing)

1) To create pocketing, Operations  Profiling
2) Double click the inner profile  Enter  Click inside if outside milling is selected
(Arrow mark should be inside the profile)  Enter  Enter

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3) In the General tab, set Rest Rough to Unchecked, Mill Type to Climb, % Step
over to 50, Tolerance to 0.01, and Digitise Stock to Unchecked. All other settings
can be left blank.
4) Click the Tooling tab. Click the Find button to open the ToolStore. In the tooling list
click 2 mm Endmill - short series to select it and click Select. (If you cannot see the
tool in the list, click Use Filters on the right side of the ToolStore dialog.) Feed =
400mm/min, Plunge Speed to 600 and Speed = 2000rpm. All other settings can be left
as they are.
5) Click the Depth tab and set Clearance to 10, Level to 0, Depth to -5 and Cut
Increment to 1.
6) Click OK to close the dialog and generate the toolpath.

To drill the Hole:

1) I n the Operations toolbar, click Hole for Milling.
2) Rest the cursor on one of the holes to highlight it (a box appears around it), then click.
Repeat for the other holes. Right-click to finish the selection.
3) In the Hole Operation dialog that appears click the General tab and set Clearance to
10, Retract to 0 (or blank), Level to 0 , Termination to Trough , and Optimise
Path to Closest Next.
Do not click OK yet.
4) Select Centre/spot  Enter the Values as shown below. (Select 3mm X 60 Centre
Drill)

Do not click OK yet.

5) Select Preparation  Enter the values as shown in figure

Do not click OK yet.

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6) Roughing the Hole, Select Roughing  Enter The values as shown in figure

Do not click OK yet.

7) Select Finishing  No finishing  OK

Running the EdgeCAM Simulator

1) Choose the Simulate Machining button from the Main toolbar; the Simulator
window is displayed.
2) Choose the Start button from the Main toolbar to begin the simulation.
3) After completing the simulation, choose the Return to EdgeCAM button from the
Main toolbar to return to the Manufacture mode. The model, after simulation, is
shown in figure.

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CIM and Automation Laboratory Manual MEL77

ROBOT PROGRAMMING

According to RIA (Robotics Industries Association) the definition of robot is “An

industrial robot is a reprogrammable, multifunctional manipulator designed to move
materials, parts, tools or special devices through variable programmed motions for the
performance of a variety of tasks”.
A robot can perform a task, only when appropriate instructions are given to it.
Programming or teaching the robot does this. There are two types of robot program On-line
programming and Off-line programming.
CONCEPTS OF ON-LINE PROGRAMMING
On-line programming is accomplished through teach programming methods. Teach
programming is a means of entering a desired control program into the robot controller. The
robot is manually led through a desired sequence of motions by an operator who is observing
the robot and robot motions as well as other equipment within the workcell. The teach
process involves the teaching, editing, and replay of the desired path. The movement
information and other necessary data are recorded by the robot controller as the robot is
guided through the desired path during the teach process. At specific points in the motion
path the operator may also position or sequence related equipment within the work envelope
of the robot. Program editing is used to add supplemental data to the motion control program
for automatic operation of the robot or the associated production equipment. Additionally,
teach-program editing provides a means of correcting or modifying an existing control
program to change an incorrect point or compensate for a change in the task to be performed.
During the teach process the operator may desire to replay various segments of the program
for visual verification of the motion or operations.
In on-line programming two basic approaches are taken to teach the robot a desired
path:
1. Teach pendant programming and
2. Lead-through programming.
Teach pendant programming involves the use of a portable, hand-held programming
unit referred to as a teach pendant. Teach pendant programming is normally associated with
point-to-point motion and controlled path motion robots. When a continuous path has to be
achieved, lead-through programming is used for teaching the desired path. The operator
grasps a handle secured to the arm and guides the robot through the task or motions.
Lead-through programming is used for operations such as spray painting or arc
welding. Lead-through programming can also be utilized for point-to-point motion
programming. Whether the robot is taught by the teach pendant method or the lead-through
method, the programming task involves the integration of three basic factors:

TEACH PENDANT PROGRAMMING

Teach pendant programs involve the use of a portable, hand-held programming unit
that directs the controller in positioning the robot at desired points. This is best illustrated by
the example shown in Figure 2. In this example a robot is required to pick up incoming parts
from the conveyor on the left, place them into the machining center, and then carry them to
the finished parts conveyor on the right. Twin grippers on the end of the arm allow unloading
of a finished part followed immediately by loading of a new part, thus reducing wasted
motion and overall cycle time. The robot is interfaced to the machining center and to both
part conveyors. An operator will lead the robot step by step through one cycle of the
operation and record each move in the robot controller. Additionally, functional data and

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motion parameters will be entered as the points are programmed. The teach pendant is used to
position the robot, whereas the controller keyboard may be required for specific data entry.

LEAD-THROUGH TEACH PROGRAMMING

Lead-through teach programming is used primarily for continuous-path motion-
controlled robots. During the lead-through teach process an operator grasps a removable
teach handle, which is attached directly to the arm and leads the robot through a desired
sequence of operations to define the path and relative velocity of the arm. While the operator
is teaching the robot, position transducers measure the joint angles associated with each robot
axis, and the robot control unit records this information for use during production replay.
Automatic replay of the digitized data provides the continuous path motion necessary for
precise duplication of the motion and technique utilized by the human operator. Lead-through
teach programming and continuous path motion-controlled robots are well suited for
operations such as spray painting. sealant application, and arc welding.

OFF - LINE PROGRAMMING

INTRODUCTION
What Is Off-Une Programming?
Off-line programming may be considered as the process by which robot programs arc
developed, partially or completely, without requiring the use of the robot itself. This includes
generating point coordinate data, function data, and cycle logic. Developments in robot
technology, both hardware and software, are making off-line programming techniques more
feasible. These developments include greater sophistication in robot controllers, improved
positional accuracy, and the adoption of sensor technology. There is currently considerable
activity in off-line programming methods, and these techniques are employed in
manufacturing industries.
Why Should Off-Line Programming Be Used?
Programming a robot by teaching can be time-consuming—the time taken quite often
rises disproportionately with increasing complexity of the task. As the robot remains out of

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production, teach programming can substantially reduce the utility of the robot, sometimes to
the extent that the economic viability of its introduction is questioned.
In off-line programming the robot is programmed indirectly with the help of robot
programming languages and does not require the use of robot in the preparation of
instructions. On-line teaching of robots is sufficient for many applications. But it can be
become tedious when hundreds of points must be programmed individually on PTP or robots.
In such cases programming languages are used. The robot programming languages are
concerned with the generation of all data required to move the robot end effector along a
required path in order to perform a specific task. Some of the robot programming languages
are WAVE, AL, VAL, VALII, AML, MCL, RAIL, HELP, RPL, ROBEX, PART,
AUTOPASS, etc.
The VAL language:- Victor’s assembly language. This was developed for PUMA robot of
unimation Inc.
In VAL program, the point co ordinates can be determined by manually leading the
manipulator to each required point and recording its co ordinates, and motion sequence can
be defined by using service of one word commands.
Motion instructions in robot programming languages contain following data;

1.Positional information:- The start and end points of the each trajectory.
2.Trajectory type:- Linear in CP/ quickest path in PTP
3.Velocity:- Velocity values for each motion
4.Functions to be performed at a point:- Inverse Kinematics, time delay , tool manipulation,
send / receive signals.
5.Gripper status:- Open or Close.
VAL statements are divided into two categories monitor commands and programming
instructions.

Programming Instructions:-
These are a motion and action statement, which directs the sequence of motions of the PUMA
robot. Program instructions include,
Move to a point
Move to a point in a straight line motion
Open gripper
Close gripper
Example:- MOVE, MOVES SPPRO, APPROS, DEPART, OPENI and CLOSEI, EXIT
SPEED
MOVE (Location) - PTP motion command
MOVES (Location) - Straight-line interpolation command (CP)

Example:-* PROGRAM DEMO

1. APPRO PART, 50
2. MOVES PART,50
3. CLOSE I
4. DEPARTS 150
5. APPROS BOX. 200
6. MOVE BOX
7. OPEN I
8. DEPART 75

1.Move to a location 50 mm above the part in the chute.

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2.Move along a straight line to the part

3.Close the gripper jaws ‘I’ – a short delay before next statement
4.With draw the part to a point 150 mm above the chute along straight line path
5.Move along a straight line to a location 200 mm above the box
6.Move the part into the box
7.Open the gripper jaws
8.With draw to a point 75 mm above the box

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CIM and Automation Laboratory Manual MEL77

A hydraulic system
A suitable hydraulic system is shown in Figure. The system requires a liquid fluid to
operate: expensive and messy and, consequently, the piping must act as a closed loop, with
fluid transferred from a storage tank to one side of the piston, and returned from the other
side of the piston to the tank. Fluid is drawn from the tank by a pump which produces fluid
flow at the required 150 bar. Such high pressure pumps, however, cannot operate into a dead-
end load as they deliver constant volumes of fluid from input to output ports for each
revolution of the pump shaft. With a dead-end load, fluid pressure rises indefinitely, until a
pipe or the pump itself fails. Some form of pressure regulation, as shown, is therefore
required to spill excess fluid back to the tank.

Hydraulics symbols used

continuous line - flow line dashed line - pilot, drain
large circle - pump, motor small circle - Measuring devices
one square - pressure control function two or
semi-circle - rotary actuator
three adjacent squares -directional control
Spring Flow Restriction
solid - Direction of Hydraulic Fluid Flow open - Direction of Pneumatic flow
Fixed Displacement hydraulic pump Bi
Fixed Displacement hydraulic pump unidirectional
directional

Compressor Pneumatic motor -unidirectional

Pneumatic motor -bidirectional Rotary Actuator pneumatic

Single acting cylinder returned by spring or

Rotary Actuator hydraulic
extended by spring force

Single acting cylinder returned by external force Double acting cylinders double ended piston rod

Normally closed directional control valve with 2

Double acting cylinders single piston rod
ports and 2 finite positions.
Directional control valve (2 ports / 2 positions) Directional control valve (2 ports / 2 positions)
Normally open directional control valve with 2 Normally open directional control valve with 2
ports and 2 finite positions ports and 2 finite positions
CIM and Automation Laboratory Manual MEL77

Directional control valve (3 ports / 2 positions) Directional control valve (3 ports / 2 positions)
Normally closed directional control valve with 3 Normally open directional control valve with 3
ports and 2 finite positions. ports and 2 finite positions
Directional control valve (4 ports / 3 positions) -
Directional control valve (4 ports / 2 positions)
directional control valve with 4 ports and 3 finite
directional control valve with 4 ports and 2 finite
positions
positions
-(center position can have various flow paths)
Manual Control general symbol (without showing
pushbutton
the control type)

lever foot pedal

Mechanical Control plunger or tracer spring

roller roller(one direction only)

Electrical Control Solenoid (the one winding) Pilot Operation pneumatic

check valve -free flow one direction, blocked flow

Pilot Operation hydraulic
in other direction
Pressure Relief Valve (safety valve) normally
Shuttle valve to isolate one part of a system from
closed line pressure is limited to the setting of the
an alternate part of circuit
valve; secondary part is directed to tank.

Proportional Pressure Relief line pressure is limited pressure downstream of valve is limited to the
to and proportional to an electronic signal setting of the valve

Sequence Valve when the line pressure reaches the

setting of the valve, valve opens permitting flow to
Throttle valve adjustable output flow
the secondary port. The pilot must be externally
drained to tank.
with fixed output and relief port to reservoir with
Flow Control valve with fixed output (variations in
relief for excess flow (variations in inlet pressure
inlet pressure do not affect rate of flow)
do not affect rate of flow)

Shut-Off Valve Simplified symbol Accumulators

HYDRAULIC CIRCUIT DESIGN

Control of a single acting hydraulic cylinder

Figure 5.1 shows how a two-position, three-way, manually
actuated, spring-offset directional control valve (DCV) can be
used to control the operation of a single acting cylinder.
In the spring-offset mode, full pump flow goes to the tank
via the pressure relief valve. The spring in the rod end of the
cylinder retracts the piston as oil from the blank end drains
back to the tank. When the valve is manually actuated into its
left envelope flow path configuration, pump flow extends the
cylinder. At full extension, pump flow goes through the relief
Figure 5.1: control of a single valve. Deactivation of the DCV allows the cylinder to retract as
acting hydraulic cylinder the DCV shifts into -its spring-offset mode.
CIM and Automation Laboratory Manual MEL77

Control of a double acting hydraulic cylinder

Figure 5.2 gives a circuit used to control a double-
acting hydraulic cylinder. The operation is described
as follows:
1) When the four-way valve is in its spring-centered
position, the cylinder is hydraulically locked.
Also the pump is unloaded back to the tank at
essentially atmospheric pressure.
2) When the four-way valve is actuated into the flow
path configuration of the left envelope, the
Figure 5.2: control of a single acting cylinder is extended against its load force Fload as
hydraulic cylinder oil flows from port P through port A. Also, oil in
the rod end of the cylinder is-free to flow back to
the tank via the four-way valve from port B
through port T. Note that the cylinder could
not extend if this oil were not allowed to leave the rod end of the cylinder.
3) When the four-way valve is deactivated, the spring-centered envelope prevails, and the
cylinder is once again hydraulically locked.
4) When the four-way valve is actuated into the right envelope configuration, the cylinder
retracts as oil flows from port P through port B. Oil in the blank end is returned to the
tank via the flow path from port A to port T.
5) At the end of the stroke, there is no system demand for oil. Thus, the pump flow goes
through the relief valve at its pressure-level setting unless the four way valve is
deactivated. In any event, the system is protected from any cylinder overloads.

A pneumatic system
Figure shows the components of a pneumatic system. The basic actuator is again a
cylinder, with maximum force on the shaft being determined by air pressure and piston cross
sectional area. Operating pressures in pneumatic systems are generally much lower than those
in a hydraulic systems; 10 bar being typical which will lift 10 kg cm-2 of piston area, so a 16
cm diameter piston is required to lift the 2000 kg load specified in the previous section.
Pneumatic systems therefore require larger actuators than hydraulic systems for the same
load. The valve delivering air to the cylinder operates in a similar way to its hydraulic
equivalent. One notable difference arises out of the simple fact that air is free; return air is
simply vented to atmosphere.

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

Dept. of Mech Engg DBIT, Bengaluru-74

CIM and Automation Laboratory Manual MEL77

DRAWINGS FOR PRACTICE FOR MILLING OPERATIONS

CIM and Automation Laboratory Manual MEL77
CIM and Automation Laboratory Manual MEL77
CIM and Automation Laboratory Manual MEL77
CIM and Automation Laboratory Manual MEL77

DRAWINGS FOR PRACTICE FOR TURNING OPERATIONS

CIM and Automation Laboratory Manual MEL77
CIM and Automation Laboratory Manual MEL77
CIM and Automation Laboratory Manual MEL77