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Lab 03
HYDRAULIC SYSTEM
CIRCUIT & BASIC APPLICATION

BFM3403 Fluid Drive System

Prepared By:
Mohd Azraai Razman
[email protected]

Fakulti Kejuruteraan Pembuatan, UMP

Checked by:
Rizal Ramedan

Lab Location
Hydraulic and Pneumatic FKP, UMP

Lab Objectives

By the end of this lab, students should be able to understand the specification of Hydraulics
components, cylinder, relays and valves. Basic understanding of electro-hydraulic are
imposed.

Group Information: GROUP NO ___

No Student ID Student Names Section

1
2
3
4

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In this lab, students are required to have an ample understanding of operating basic hydraulic
system. The objective of this lab exercise is to ensure students understanding of Hydraulic
system.

i. Fundamental of Hydraulic System components.

ii. PART A: Basic of Hydraulic system
iii. PART B: Integrating electro-hydraulic circuit
iv. References

SAFETY PRECAUTIONS – BE AWARE OF HIGH VOLTAGE!

DO NOT TURN ON THE POWER WHILE WIRING
FOLLOW THE STANDARD OF PROCEDURES (SOP) ON
OPERATING THE TANK COMPRESSOR

Fundamental of Hydraulic System components

Hydraulic involves the use of hydraulic fluids. Hydraulic fluids are most commonly used to
perform mechanical work. Mechanical work is necessary in order to carry out movements
and generate forces. The function of hydraulic drives is to convert the energy stored in
hydraulic fluid into kinetic energy.

The following are used as hydraulic drives:

 Hydraulic Cylinders (linear drives) for the generation of straight-linear movements
 Motors and semi-rotary actuators drive Hydraulic Motor (rotary drives) to generate
rotary movements.

Figure 1 hydraulic linear and rotary cylinder

Basic Operation of Power Unit

1. Open up the breather cap and slowly pump the hydraulic oil into the reservoir tank by
using manual plastic pump
2. Measure there is sufficient oil level by checking or view oil level slight glass
3. Counter clockwise to reduce the pressure relief valve setting to the minimum
4. Then switch on the power supply
5. Slowly adjust the pressure relief setting to required pressure range 50 bar (70 bar max)

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PART A: Basic of Hydraulic systems (12 Marks)

In this section students are required to install the given actuators and study the motion of each
independently. Linear and rotary cylinders will give specific power based on their
specifications.

1. Work out the equations (linear and rotary) and derive the hydraulic power for these
actuators. Describe the relations between pressure and Force

2. Complete the table for each actuator. Vary the pressure to the operatable value from
minimum to maximum

Linear Rotary

Pressure Force Pressure Force

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Figure 2 Pressure relief valve

3. What are the components parts of pressure relief valve?

1._____________________________________________
2._____________________________________________
3._____________________________________________
4._____________________________________________
5._____________________________________________
6._____________________________________________
P._____________________________________________
T._____________________________________________

4. What function does the 4/2 way solenoid valve have in the activation of a double-
acting cylinder
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
___________________________________________________________________

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PART B: Integrating electro-hydraulic circuit (18 Marks)

In this section students are required to assemble the previous actuators and develop a
hydraulic system integrating with PLC. The conditions are given as follows:

i. The mode sequence is [ A+ B+ B- A- ] where A is the linear and B is the rotary

actuator.
ii. The EMERGENCY STOP button is used to operate and shuts the entire systems.
iii. Normally Closed NC button is used to RUN the operation
iv. Normally Open NO button is used to RESET the operation
v. Used the INDICATOR (RED, GREEN, YELLOW) to specify the operation of the
system.
vi. CLEAR the system after A- has retracted for 3 seconds.
vii. RELAY and TIMER will be adopted in this part.
viii. Check with the instructor for inspection before operating.

Note: Installation are based on the station that each group operating. For Hydraulic station
based, use the linear or rotary cylinder that is initially installed. For groups which are
using external actuators, placed the actuators and limit switches accordingly. Some
groups may or may not require to uses the limit switches therefore TIMER is allowed
to complete the hydraulic system operation.
(Consult lab instructors for further assistance)

5. Why does the solenoid from the valve has to connect to a relay? Describe your
explanation in details.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

6. What type of oil that is used for the operating the hydraulic system in the tank
reservoir? What is the characteristics properties and why it is used for hydraulic
operation?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

7. Describe the ports on the valve (P,T, A and B) on their respective function.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
____________________________________________________________________

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5. Draw the hydraulic and electric circuit of the system

Case study

In a sorting system between non-metal and metal materials, a common problem occurs when
pressure was loss on the fluid system to drive the actuators. This problem will distrust the
entire process line in which the subsequent will assume that the process will continue despite
any indication of faulty.

Build a pneumatic/hydraulic system that integrate pressure loss indicator, in example if the
actuators do not reach to a certain point, the entire system will stop, and an indicator will turn
on to inform the operator of the faulty system. The system will restart from beginning after
pressure has been fix.

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BFM 3403 Fluid_Drive_System_Lab_Intro_Hydraulic Azraai-FKP-2018/2019