UNIT -3

Fluid power symbols

REGENERATIVE CIRCUIT

A Regenerative circuit that is used to speed of the extending force of a double

acting hydraulic cylinder. Notice that the pipe lines to both ends of the
hydraulic cylinder are connected in parallel and that one of the port of a four
way valve is blocked. The operation of the cylinder during the retraction stroke
as shaft of a regular double acting cylinder. Fluid flows thorough the DCV via
the right hand envelope during retraction. In this mode, fluid from the pump
bypasses the DCV and enters the rod end of the cylinder. Fluid in the blank
end drain back to the tank through the DCV as the cylinder retracts.
 When the DCV is shifted into the left envelope configuration, the
cylinder extends. The force of extension is greater than that for a regular
double acting cylinder. Because flow from the rod end regenerates with the
pump flow to provide a total flow rate which is greater than the pump flow
rate to the blank end of the cylinder.

Regenerative circuit

INTENSIFIER:
A Hydraulic intensifier for oil well fracturing , erosion drilling, in which a pair of
working rams are sequentially operated by a corresponding pair of hydraulic cylinder
motor each having a piston forming a working face side an opposed return face side
of lesser operative area than said position of said motors being movable
and supplying it to said source for increasing fluid flow from said sources to
the working face side of said motors during the movement from said
retracted position to said extended position or the expelling fluid from said
return face side and not returning it to said source during movement from
said retracted position to said extended position and means for supplying
hydraulic fluid to return face side of said motors to said retracted position.

METER - IN CIRCUIT:
A figure shows the pipes are connected to meter the fluid in to the cylinder when the
directional control valve is shifted to direct fluid to the cylinder rod end. Feed
direction is shown by the arrow. The fluid must pass through the compensated flow
control valve. Before entering the rod end of the cylinder. Exhaust fluid is directed
freely to the reservoir. When the spool is shifted to the alternate flow path
configuration, the flow is directed to the head end of the cylinder. The fluid
from the rod end pass through the integral check valve and the rod can
move rapidly to the extended position. It should be noted that a fluid must
pass through the compensated flow control valve before entering the rod
end of the cylinder. The exhaust cylinder directed freely to the reservoir.

Meter in Circuit

BLEED OUT CIRCUIT:

Bleed out Circuit

 The third basic type of control circuit uses the flow control valve to divert
the fluid to the tank or another lower pressure area. The bleed of function is
not show widely used as the meter in and meter out types. The bleed of valve
as shown in figure is connected in the pressure line. This valve may be
connected in either in pressure line or in cylinder line , depending on whether
it is desirable to have the speed control in both directions of flow or on a
specific line and limits speed in only one direction of the cylinder travel.
Bleed off the circuits are widely used in broaching machines
sharpers, planners and similar machines were a fairly large quantity of fluid
is to be used. The degree of accuracy of bleed of circuit is adequate for
large flows. A bleed off circuits may not be sensitive enough to compensate
for very small flows success those encounter in precise boring operations.
SPEED CONTROL CIRCUITS:

The operational speed of an actuator is determined by the fluid flow

rate and the actuator area. The physical dimensions are generally fixed for
an actuator, so speed is control by adjusting the flow to the actuator. There
are basically three ways which speed can be achieved. These are called
speed control circuit and are as given below.
(i) Meter – out circuit

(ii) Meter – in circuit

(iii) Bleed out circuit

METER – OUT CIRCUIT:

 The Meter – out circuit is commonly used in machine tools that
require precise control of the fluid on the discharge or exhaust side of the
cylinder. This circuit gives the control extension speed and full retraction
speed. Machine tools often require large re straining forces to prevent
excessive pull on the cylinders. Milling cutters and drills passing through
the work piece often tend to drag the entire tool unit forward. Considerable
force may be required to push the tool during the cutting cycle.
Metering the fluid out of the cylinder as shown in the figure, prevention this
break through condition from the affecting speed of drill feed. The integral
check valve permits the full retraction that results a rapid travel of the tool
to the start position ready for the next cycle.
FORCE CONTROL CIRCUIT VEHICLE SUSPENSION SYSTEM:
AFC loop is designed to compensate for the unknown disturbances. The efficiency
of the AFC strategy relies on the mass estimator as the body acceleration and the
actuator force are easily obtained. Sugeno type of Fuzzy Inference System (FIS) is
used to estimate the mass. The main aim of using the fuzzy logic in the study is to
estimate the mass intelligently so that it can be utilized by AFC mechanism to effect
its control strategy. Input to the mass estimation FLC is sprung mass acceleration
(Gaussian membership function) and the output is a singleton value of the estimated
mass. Once FLC is designed, it is embedded in the overall control strategy for online
estimation of the mass and thereafter estimates force. The estimated force is fed
forward through a transfer function block (inverse dynamics of actuator) so that
controller output cancels the disturbance force.

AFC loop is designed to compensate for the unknown disturbances. The efficiency
of the AFC strategy relies on the mass estimator as the body acceleration and the
actuator force are easily obtained. Sugeno type of Fuzzy Inference System (FIS) is
used to estimate the mass. The main aim of using the fuzzy logic in the study is to
estimate the mass intelligently so that it can be utilized by AFC mechanism to effect
its control strategy. Input to the mass estimation FLC is sprung mass
acceleration (Gaussian membership function) and the output is a singleton value
of the estimated mass. Once FLC is designed, it is embedded in the overall
control strategy for online estimation of the mass and thereafter estimates force.
The estimated force is fed forward through a transfer function block (inverse
dynamics of actuator) so that controller output cancels the disturbance force.

Hydraulic Press:

This System is capable of applying several different forces to complete an

operation. This circuit is designed to change operating pressure in various
parts of the system.
This system used to press fit (Light Press) cylinder liners into cylinder bodies. The
main operating pressure of the system is controlled by a relief valve N on the power
unit. The pressure reducing valve F controls the pressure to cylinder C. The
pressure reducing valve G controls the pressure to the upper end of cylinder A. To
operate the circuit, the operator loads the liner into a fixture and momentarily
depresses push button X. This momentarily energises solenoid one of valve M, and
spool of the valve M shifts directing oil to the valve F and onward to the blind end of
the cylinder C on the pressure switches D and E are place d in this line.

A green indicated light is connected to the pressure switches D and the red
indicated light is connected to pressure switch is E. A satisfactory press fit is
indicated by the green light (switch D ) and a press fit to tight indicated by the red
light indicator C begins to move low pressure oil cylinder D and since there is
large difference in piston areas between cylinder C and B, the oil is directed to
the top of the pressing cylinder A and piston A Advances. S is contacted and if
the press is too tight (red light has been ON) solenoid 2 and 5 are energicise and
the piston of the cylinder is A retracted, the piston of the cylinder K advances at
the pressure level set by valve N. If the green indicator light is ON when switch S
is connected, solenoid 3 closes valve H, solenoid valve J and pressure set by
valve G is applied top side of the cylinder A to finish the operation and operated
momentarily depresses push button Y solenoid 2 is energyse, and spool of the
valve M is returned to the normal position. Oil is directed end of the cylinder A,
and piston retracts completing the cycles.
Principles of pneumatic control
(a) Pneumatic circuit
Pneumatic control systems can be designed in the form of pneumatic
circuits. A pneumatic
circuit is formed by various pneumatic components, such as cylinders,
directional control valves,
flow control valves, etc. Pneumatic circuits have the following functions:

1. To control the injection and release of compressed air in the cylinders.

2. To use one valve to control another valve.
(b) Pneumatic circuit diagram
A pneumatic circuit diagram uses pneumatic symbols to describe its
design. Some basic rules
must be followed when drawing pneumatic diagrams.

(i) Basic rules

1. A pneumatic circuit diagram represents the circuit in static form and

assumes there is no
supply of pressure. The placement of the pneumatic components on
the circuit also follows
this assumption.
2. The pneumatic symbol of a directional control valve is formed by one
or more squares. The
inlet and exhaust are drawn underneath the square, while the outlet is
drawn on the top.
Each function of the valve (the position of the valve) shall be
represented by a square. If
there are two or more functions, the squares should be arranged
horizontally in Fig
3/2 directional control valve 3/2 directional control valve

3. Arrows "↓↖" are used to indicate the flow direction of air current. If
the external port is
not connected to the internal parts, the symbol “-” is used. The
symbol “⊙ ” underneath
the square represents the air input, while the symbol “▽” represents the
exhaust. Fig
shows an example of a typical pneumatic valve.
4. The pneumatic symbols of operational components should be
drawn on the outside of the
squares. They can be divided into two classes: mechanical and manual

Basic principles
Fig. 21 shows some of the basic principles of drawing pneumatic circuit
diagrams, the
numbers in the diagram correspond to the following points:

Basic principles of drawing pneumatic circuit diagrams

When the manual switch is not operated, the spring will restore the
valve to its original
position.
2. From the position of the spring, one can deduce that the block is
operating. The other block
will not operate until the switch is pushed.
3. Air pressure exists along this line because it is connected to the
source of compressed air.
4. As this cylinder cavity and piston rod are under the influence of
pressure, the piston rod is
in its restored position.
5. The rear cylinder cavity and this line are connected to the exhaust, where air is
released.

Different kinds of basic circuits

A basic circuit is a pneumatic circuit designed to perform basic tasks, such
as flow amplification, signal inversion, memory, delay, single acting
cylinder control, double acting
cylinder control, etc.

(a) Flow amplification

Cylinders with a large capacity require a larger flow of air, which can be
hazardous to users. It
is unsafe to manually operate pneumatic directional control valves with large
flow capacity. Insteadwe should first operate manually a small control valve
and use it to operate the pneumatic control system with large flow capacity.
This is called flow amplification, which can greatly ensure the safety of the
operators. During operation, valves with large flow capacity should be placed
near the cylinder, while valves with smaller flow capacity should be placed on
control boards some distances away. Fig. shows a basic flow amplification
circuit. Notice how different components are placed on different levels.
 Flow amplification system

(b) Signal inversion

The pneumatic diagram in Fig shows how directional control valves can
be switched.
When operating control valve , control valve will stop producing
pressure output. When
control valve ceases operation and is restored to its original position,
control valve will
resume its output. Therefore, at any given time, the pressure output of
control valve is the exact opposite of that of control valve .

Signal inversion system

(c) Memory Function
Memory is a common basic function. It can keep a component at a
certain state permanently until there is a change of signals. Fig shows a
memory function circuit. When
control valve is operated momentarily (that is, pressed for a short time), the
output signal of the5/2 directional control valve will be set to ON. The signal
will stay that way until control valve is operated momentarily and generates
another signal to replace it, causing it to stay permanently at OFF.

Memory function circuit

(d) Delay function

A pneumatic delay circuit can delay the operating time of the next control
valve. Its principle
of operation involves the use of an orifice to slow down the flow of air and
control the time of
pneumatic operation. Delay functions can be divided into two classes:
ON-signal delay and OFFsignal delay.

(i) ON-signal delay

Fig shows the circuit diagram of an ON-signal delay circuit, which delays
the output of the
next control valve. When control valve is operated, the one way flow
control valve will slow
down the flow of air, thus delaying the signal output of the outlet of control valve
(A), resulting in a persistent ON-signal. The time when control valve will be
restored to its original position is not affected.
 Circuit diagram of an ON-signal delay
circuit (ii) OFF-signal Delay
Fig shows the circuit diagram of an OFF-signal delay circuit, which delays
the output of
the next control valve. This circuit is similar to an ON-signal delay circuit. The only
difference is that the one way flow control valve is connected in the opposite
direction. Therefore, when control valve is operated, the outlet of control valve
(A) will continue to output signals. However, when control valve is
restored to its original position, the release of air is slowed down by the
one way flow control valve, resulting in a persistent OFF-signal.

Circuit diagram of an OFF-signal delay circuit

(e) Single acting cylinder control
Single acting cylinders can be controlled manually. However, they can
also be controlled by
two or more valves. This is called logic control. Examples of logic control
include ‘OR’ function,‘AND’ function, ‘NOT’ function, etc.

(i) Direct control and speed control

If a single acting cylinder is connected to a manual 3/2 directional control
valve, when the
control valve is operated, it will cause the cylinder to work . Therefore,
the circuit allows the cylinder to be controlled manually.

Direct control of a single acting cylinder

The only way to change the extension speed of the piston of a
single acting cylinder is to
restrict the flow of air at the inlet and use the spring to determine the
speed of retraction. Therefore,a one way flow control valve is placed
in the circuit to control the speed.

(ii) OR Function
The single acting cylinder in Fig can be operated by two different
circuits. Examples
include manual operation and relying on automatic circuit signals, that is,
when either control valve or control valve is operated, the cylinder will work.
Therefore, the circuit in Fig. 29 possesses the OR function. However, if the
output of two 3/2 directional control valves are connected through the port of
a triode, the air current from control valve will be released through the
exhaust of control valve , and so the cylinder will not work. This problem can
be solved by connecting a shuttle valve to the port of the triode.
 Circuit diagram of an OR function circuit

(iii) AND Function

Another name for an AND function is interlock control. This means

control is possible only
when two conditions are satisfied. A classic example is a pneumatic system
that works only when its safety door is closed and its manual control valve is
operated. The flow passage will open only when both control valves are
operated. Fig shows the circuit diagram of an AND function circuit. The
cylinder will work only when both valve and are operated.
 Circuit diagram of an AND function circuit
(iv) NOT Function
Another name for a NOT function is inverse control. In order to hold or
lock an operating
conveyor or a similar machine, the cylinder must be locked until a signal for
cancelling the lock is received. Therefore, the signal for cancelling the lock
should be operated by a normally open type control valve. However, to
cancel the lock, the same signal must also cancel the locks on other
devices, like the indication signal in Fig. 31. Fig. 31 shows how the
normally closed type control valve can be used to cut off the normally open
type control valve and achieve the goal of changing the signal.

Circuit diagram for a NOT function circuit

(f) Double acting cylinder

(i) Direct control
The only difference between a single acting cylinder and a double acting
cylinder is that a
double acting cylinder uses a 5/2 directional control valve instead
of a 3/2 directional control valve
Usually, when a double acting cylinder is not operated, outlet ‘B’ and
inlet ‘P’ will be
connected. In this circuit, whenever the operation button is pushed
manually, the double acting
cylinder will move back and forth once.
 Circuit diagram of a double acting cylinder direct control circuit

In order to control the speed in both directions, flow control valves are
connected to the inlets
on both sides of the cylinder. The direction of the flow control valve is
opposite to that of the
release of air by the flow control valve of the single acting cylinder.
Compared to the throttle inlet,the flow control valve is tougher and more
stable. Connecting the circuit in this way allows the input of sufficient air
pressure and energy to drive the piston.

(ii) Single control

A cylinder always has to maintain its position in a lot of situations, even
after the operational signal has disappeared. This can be achieved by
the use of a circuit that possesses
the memory function. As shown in Fig the extension path of a double
acting cylinder is
activated by control valve , while retraction is governed by control
valve . Control valve ,
on the other hand, maintains the position of the cylinder by maintaining its own
position.
Control valve will be changed only when one of the manual control valves is
pushed. If both
control valves and are operated at the same time, control valve will be
subject to the
same pressure and will remain in its original position.
Circuit that maintains the position of a double acting cylinder

TEMPERATURE CONTROL IN HYDRAULIC CIRCUIT

Hydraulic machines power the moving parts of many kinds industrial machines
by applying the force of a fluid under pressure. Some systems are very small
,simple and straight-forward over large ,high pressure systems with a complex
array of servo valves and pumps. No matter the size or complexity, proper
maintenance of BOTH the system and the hydraulic oil is crucial in
maximizing uptime and reducing repair costs.

Typical industrial hydraulic system temperatures often range between

110to150ºF. system temperatures can operate upto 250ºF .Selection of ,high
temperature protection and to obtain the optimum system eficiency. Keep
systems which operate on a water based fluid below 140ºF event the water
from evaporating.
The -tolerance servo valves to seize and seperate sluggishly. To allow heat to
radiate from the system ,keep the outside of the reservoir clean and the
surrounding .Make sure the oil cooler is functioning properly and keep air-
cooled radiators free o f dirt. Normal temperature drop form oil coolers
Is 5to10ºF. Reservoirs should be filled to the proper level to allow enough
fluid residence time for the heat to dissipate and to shed water and dirt.

In modern equipment using servo valves ,oil degradation can be even more
damaging. High pressure (upto4000psi),high temperatures ,and small
reservoirs stress the f luid .With minim al residence time and high pressures,
entrained air bubbles can cause

Extreme localized heating of the hydraulic fluid.This, when combined with oil
oxidation,canformdepositswhichwillplugoililtersandcauseservovalvestostick.

KeepSystemsClean—
Evennewsystemsmaybecontaminatedandshouldbecleanedbeforeuse.Preven
tcontaminantssuchasdirt,water,cuttingluids,andmetalparticlesfromenteringthe
systemaroundthereservoircover,openingsforsuctionanddrainlines,throughbre
atherillopenings,pastpistonrodpacking,andthroughleaksinpumpsuctionlines.

Keep the Fluid Clean— Keeping hydraulic fluids clean begins with good
storage and handling practices. To prevent
contaminationbeforeuse,storenewluidinaprotectedareaanddispenseitinclean,
DEDICATEDcontainers.Cleantheillcapbeforeremovingittoaddhydraulicluid.On
criticalNCsystems,usequickdisconnecthosesandilteralloiladdedtothereservoirt
hrougha5micron filter
These filters are often forgotten and going to by pass mode, thus allowing
dirty oil to circulate. Inspect fluid f ilters frequently and change
orcleanthembeforetheygointobypassmode.Portableilterswillsupplement
permanently installed. Systems should be filtered long enough to pass the
total volume of oil through the filter atleleast 10times. Portable filters should
be used when transferring new oil from drums or storage tank.

Control the Temperature—Heat develops in the fluid as it is

forcedthroughthepumps,motortubing,andreliefvalves.Inconventionalsystems
,excessive temperatures will oxidize the oil and can lead
To varnish and sludge deposit s in the system .Conversely ,running the
temperature tool will allow condensation in there servo ir and increase the like
li hood of pump cavitation. Typical industrial hydraulic system temperatures
often range between 110to150ºF . Mobil hydraulic system temperatures can
operate upto 250ºF .Selection of the proper grade of hydraulic oilis critical to
ensure cold start, high temperature protection and to obtain the optimum
sytemeticcally Keep systems which operate on a water based fluid
below140ºF to prevent the water from evaporating The deposits caused by oil
degradation can plug valves and suction screens and cause high-tolerance
servo valves to seize and/ or operate sluggishly . To allow heat to radiate from
the system ,keep the outside of the reservoir clean and the surrounding are a
clear of obstructions. Make sure the oil cooler is functioning properly and keep
air-cooled radiators free o f dirt .Normal temperature drop form oil coolers
Is 5to10ºF. Reservoirs should be filled to the properly to allow enough fluid
residence time for the shed water and dirt In modern equipment using
servo valves ,oil degradation can be even more damaging .High pressure
(upto4000psi) ,high temperatures, and small reservoirs stress the fluid
.With minimal residence time and high pressures, entrained air bubbles can
cause