UNIT 11: ASSIGNMENT 1

CONSTRUCTION AND
OPERATION OF FLUID
POWER DEVICES
James Baggaley

Task 1
a) A pneumatic storage tank reduces the need to run a pneumatic compressor continuously as the
storage tank can hold compressed air. This reduces the strain on the compressor as it can store
compressed air, instead of being used every time a supply is needed. This reduces wear and
tear on the compressor. A pneumatic storage tank uses a one way valve called a check valve
that stops air going back to the pump. Electronic sensors such as pressure sensors are used to
 monitor the storage tank’s pressure. When the pressure reading reaches a certain level, the
compressor can stop. As the air supply is used, the pressure in the tank will drop, closing the
circuit for the compressor to refill the tank to the required level.

b) A linear electro hydraulic actuator operates a piston with pressurised oil. An electric motor
powers a pump which sends fluid from a reservoir to the opposite sides of the cylinder. This
creates very strong accurate force and movement. The input pressure from the fluid
determines the thrust of the piston. These systems may be used to move valves and can be
found in both low and high torque situations.

https://www.google.co.uk/url?sa=i&url=ht 2

Task 2
Pneumatic

Component Function
Single acting cylinder Converting air pressure to
physical movement.
One way flow control valve Ensures that the flow cannot
flow backwards. Can also
adjust the flow rate.
3/2 way valve with pushbutton Direct the air flow to the
output when the push button is
pressed.

Compression Return
This circuit
directs
compressed air
flow through a
3/2 valve
through to a one
way flow control
valve, which
controls the flow
to the single
acting cylinder.
The compressed
air pushes
against a piston,
creating
movement of the
shaft. When the
3/2 valve button
is pushed, the
internals of the
valve change,
creating an open
channel for air to
flow out of the output. When the push button is released, the path to the output is blocked, creating a
path for the compressed air to exhaust through. As the single acting cylinder is spring loaded, the
piston will return to its normal position, exhausting any pressurised air in the system through the
exhaust of the 3/2 valve. The one way control valve also allows you to change the flow rate, allowing
for a slow/fast extension of the cylinder, as the air flow can be slowed down or sped up by increasing
or decreasing the obstruction to air flow.

BMW GROUP
This circuit could be used for stamping manufactured objects within a conveyor system, such as in
food production.

Task 3
Pneumatic

This pneumatic circuit was constructed using a double acting cylinder and a 5/2 valve to create a
separate circuit for extending and contracting the cylinder. The circuit also uses one way valves at the
inlets to the cylinder. These valves can be adjusted to regulate the air flow.
The air is supplied from an air compressor system.
The air supply is regulated by the flow control valve, which then sends the air to the manifold. The air
is distributed evenly to the 5/2 valve and switches. These switches then direct power to the 5/2 valve
which directs the pressure to each inlet of the cylinder individually, depending on which button is
pressed.
Hydraulic

This hydraulic circuit features a double acting cylinder, a shut off valve and a directional control valve
with a lever. This is a closed loop circuit which picks up and returns hydraulic fluid to a tank under
the rig. The fluid is pressurised by a hydraulic pump. The lever valve will send pressurised fluid to
either side of the cylinder. When one side is pressurised, the fluid on the other side will be forced back
into the tank. The pressure can be monitored by the pressure gauge at the tank manifold.
Comparison
Both systems require a pump and valves to control the flow of the fluid, but there are many
differences which mean that one system may be more suitable than the other.
Hydraulic systems use fluid such as mineral oil to transmit power. This method of transmitting power
can allow for more than 10,000 psi to be transmitted. As hydraulic systems operate at much higher
pressures than pneumatic systems, the hardware and couplings need to be much stronger. This is why
hydraulic systems often use quick release couplings and pneumatic systems use push fit couplings.
Hydraulic systems require a tank or bath to store the oil, unlike most air systems which can take in
atmospheric air and purify it. For this reason, a pneumatic system could be safer in a workshop
environment as oil does not need to be changed transported, reducing the risk of slip hazards.
Unlike pneumatic systems, hydraulic fluid cannot be compressed. This means that pneumatic systems
can suffer from a delay of movement and required force, therefore being less accurate.
When maintaining fluid systems, there are several differences which need to be considered. A
hydraulic circuit is normally a closed circuit, meaning that the oil is re used through a pickup and
pump, then dumped into a bath or tank. The hydraulic oil needs to be changed at regular intervals as it
can lose its compressive properties and become contaminated. As the fluid system needs to be free
from contaminants such as air and moisture, it must be bled to ensure that the hydraulic lines only
contain hydraulic fluid.
Pneumatic systems are usually less labour intensive to maintain as air is collected from the
atmosphere. When air is collected, it must pass through a filter to ensure that the air is free of
contaminants such as dust or water droplets. This filter must be changed regularly to ensure that the
air is of high quality.
Pneumatic systems rely on a compressor and storage tank to create and hold the air pressure. This
ensures that the air compressor does not need to be run constantly.
Hydraulic systems use a pump to create the pressure for the system.
Uses:
Hydraulic
- Car lift
- Car braking system

Pneumatic
- Tools (drills, impact drive)
- Truck braking system

Task 4

- Pneumatic storage tank

ISO 3857-1:1977 (Compressors, pneumatic tools and machines)

This ISO regulation covers the pressures and temperatures regulations of using pneumatic machinery.
This is relevant to the storage tank as there must be an acceptable maximum pressure within the tank
before a valve releases it.
ISO 2151:2004 (Acoustics — Noise test code for compressors and vacuum pumps)
This regulation specifies the acceptable noise emission from
pneumatic equipment such as compressors. This is relevant as a
storage tank is usually combined with a compressor. The noise
emitted from the compressor could damage people’s hearing if the
noise level is too high, causing health and safety problems within
a workplace.

- Electro hydraulic actuator

ISO 18387:2019 (Linear hydraulic utility actuator — General)

This regulation covers the standards and regulations for electrohydraulic actuators with a force up to
5000 psi, covering design and test requirements, such as minimum and maximum operating
temperatures and reliability. This ensures that the actuator can operate to its specification reliably and
safely.

- Single acting pneumatic cylinder + double acting

ISO 3857-1:1977 (Compressors, pneumatic tools and machines)

This regulation is relevant as it covers the maximum pressures and air temperatures for pneumatic
machines and tools. High pressures may result in seals being damaged or dangerous releases of air.
Hot or cold air will change the volumetric properties of the air.

- One way flow control valve

ISO 19973-1:2015(en) Pneumatic fluid power — Assessment of component reliability by testing

This regulation is relevant as it covers the testing and assessment of
reliability for pneumatic valves and components. This testing
ensures that the operation of the one way flow valve is reliable and
will not cause a problem in a pnumatic circuit.

- 3/2 way valve with pushbutton

ISO 19973-1:2015(en) Pneumatic fluid power — Assessment of component reliability by testing

This regulation is also relevant to the 3/2 valve as it covers the testing and assessment of reliability for
pneumatic valves and components. The valve has to operate correctly and be constructed to a high
standard to achieve a long working life. These tests and regulations will also ensure that the valve can
work at varying pressures and temperatures.

- Double acting hydraulic cylinder

ISO 4413:2010 Hydraulic fluid power

This regulation ensures that the construction of the hydraulic system and its components are reliable
and operate to their intended use. It also ensures that components are economical to maintain and
repair. It ensures that components are not hazardous when in use.

- Hydraulic directional control valve + Shut off valve

ISO 4411:1986 Hydraulic fluid power; Valves; Determination of pressure differential/flow
characteristics.
This regulation specifies the requirements for test installations, procedures and presentation of results.
Testing includes the determination of pressure and the characteristics of flow through the valve.

ISO 4413:2010 Hydraulic fluid power — General rules and safety requirements
This regulation ensures that the construction of the hydraulic system and its components are reliable
and operate to their intended use. It also ensures that the directional control valve and shut off valve
are not hazardous when in use at high pressures.