Dr. D.Y.

Patil Institute of Technology

Pimpri, Pune - 411 018

Department of Mechanical Engineering

Lab Manual

Subject: Fluid Power and Control

lllla Lab

Labrotary

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Course Syllabus: -
Savitribai Phule Pune University, Pune
Third Year of Mechanical (2019 Course)
Subject: - Fluid Power and Control laboratory (302054)
Practical: 02 Hours/Week Term Work: 50 Marks

Course Objectives: -
1. UNDERSTAND working principles of control devices and accessories.
2. SELECT different components from manufactures’ catalogues.
3. DEMONSTRATE the capabilities to simulate and design fluid power systems.
4. UNDERTAKE digitalization of fluid power system.

Course Outcomes: -
DEFINE working principle of components used in hydraulic and pneumatic
CO-1
systems
CO-2 IDENTIFY & EXPLAIN various applications of hydraulic and pneumatic systems.
CO-3 SELECT an appropriate component required for hydraulic and pneumatic systems
using manufactures’ catalogues
CO-4 SIMULATE & ANALYSE various hydraulic and pneumatic systems for
industrial/mobile applications
CO-5 DESIGN a hydraulic and pneumatic system for the industrial applications
CO-6 DESIGN & DEMONESTRATE various IoT, PLC based controlling system using
hydraulics and pneumatics

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 Dr. D. Y. Patil Institute of Technology Pimpri, Pune – 411 018
Department of Mechanical Engineering
Academic Year: 2022-2023
Subject: Fluid Power and Control Laboratory

Date of Page No. Sign. of

Sr. Title of the Experiment Remarks
Performance From To Teacher
No.
Study of fluid power control systems
1.

2. Study and trial on actuators

3. Study and trial on Gear/Vane/Piston pump

Study and design of compressed air

4. generation and distribution system

5. Study of control valves

Study of accessory used in hydraulic
6. systems
Following experiments to be done on
7. pneumatic trainer
a. Automatic reciprocating circuit
b. Speed control circuit/Flow control valve
c. Pneumatic circuit involving Shuttle
valve/ Quick exhaust valve / Two pressure
valve
d. Electro pneumatic circuits
Design of industrial hydraulic and
8.
pneumatic circuits, selection of
components using the manufacturer’s
catalogue and analysis using any open
source/free/commercial software or
application.
Industrial visit. (Automotive workshop,
9.
small or medium scale /automation
industry)
Study and implementation of IoT based
10.
system to operate electro
pneumatic/hydraulic circuit from a remote
location. i.e. Demonstration of one cycle
of operation of cylinder extension by
actuation of solenoid and then retraction
by deactivation of the solenoid through
proximity sensor.

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 Experiment No. 1
Title: Study of fluid power control system.

Aim: To Study the fundamentals and components of fluid power system.

Objective:

 To study the fundamentals of fluid power systems and understand their

role in the industrial automation.
 To study the basic components of the fluid power.

Introduction

In the industry we use three methods for transmitting power from one point to
another. Mechanical transmission is through shafts, gears, chains, belts, etc.
Electrical transmission is through wires, transformers, etc. Fluid power is through
liquids or gas in a confined space. In this chapter, we shall discuss a structure of
hydraulic systems and pneumatic systems. We will also discuss the
advantages and disadvantages and compare hydraulic, pneumatic, electrical and
mechanical systems.

Fluid Power and It’s Scope

Fluid power is the technology that deals with the generation, control and
transmission of forces and movement of mechanical element or system with the
use of pressurized fluids in a confined system. Both liquids and gases are
considered fluids. Fluid power system includes a hydraulic system (hydra
meaning water in Greek) and a pneumatic system (pneuma meaning air in
Greek). Oil hydraulic employs pressurized liquid petroleum oils and synthetic
oils, and pneumatic employs compressed air that is released to the atmosphere
after performing the work. Perhaps it would be in order that we clarify our
thinking on one point. By the term “fluid” we refer to air or oil, for it has been
shown that water has certain drawbacks in the transmission of hydraulic
power in machine operation and control. Commercially, pure water contains
various chemicals (some deliberately included) and also foreign matter, and
unless special precautions are taken when it is used, it is nearly impossible to

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 maintain valves and working surfaces in satisfactory condition. In the cases
where the hydraulic system is closed (i.e., the one with a self-contained unit that
serves one machine or one small group of machines), oil is commonly used,
thus providing, in addition to power transmission, benefits of lubrication not
afforded by water as well as increased life and efficiency of packings and
valves.

It should be mentioned that in some special cases, soluble oil diluted with
water is used for safety reasons. The application of fluid power is limited only
by the ingenuity of the designer, production engineer or plant engineer. If the
application pertains to lifting, pushing, pulling, clamping, tilting, forcing,
pressing or any other straight line (and many rotary) motions, it is possible that
fluid power will meet therequirement.

Fluid power applications can be classified into two major segments:

Table 1.1 More applications of fluid power

Agriculture Tractors; farm equipment such as mowers, ploughs,

chemical and water sprayers, fertilizer spreaders, harvesters

Automation Automated transfer lines, robotics

Automobiles Power steering, power brakes, suspension systems,

hydrostatic transmission

Aviation Fluid power equipment such as landing wheels in aircraft.

Helicopters, aircraft trolleys, aircraft test beds, luggage
loading and unloading systems, ailerons, aircraft servicing,
flight simulators

Construction industry/equipment For metering and mixing of concrete rudders, excavators,

lifts, bucket loaders, crawlers, post-hole diggers, road
graders, road cleaners, road maintenance vehicles, tippers
Defense Missile-launching systems, navigation controls
Entertainment Amusement park entertainment rides such as roller coasters

Fabrication industry Hand tools such as pneumatic drills, grinders, borers,

riveting machines, nut runners

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Food and beverage All types of food processing equipment, wrapping, bottling,
Foundry Full and semi-automatic molding machines, tilting of
furnaces, die-casting machines
Glass industry Vacuum suction cups for handling

Hazardous gaseous areas Hydraulic fracturing technologies: It involves pumping large

volumes of water and sand into a well at high pressure to
fracture shale and other tight formations, allowing hazardous
oil and gas to flow into the well. However, hydraulic
fracturing has serious environmental and water pollution relate
dissues.

Instrumentation Used to create/operate complex instruments in space

rockets, gas turbines, nuclear power plants, industrial labs
Jigs and fixtures Work holding devices, clamps, stoppers, indexers

Machine tools Automated machine tools, numerically controlled(NC)

machine tools
Materials handling Jacks, hoists, cranes, forklifts, conveyor systems

Medical Medical equipment such as breathing assistors, heart assist

devices, cardiac compression machines, dental drives and
human patient simulator
Movies Special-effect equipment use fluid power; movies such as
Jurassic park, Jaws, Anaconda, Titanic
Mining Rock drills, excavating equipment, ore conveyors, loaders

Newspapers and periodicals Edge trimming, stapling, pressing, bundle wrapping

Oil industry Off-shore oil rigs

Paper and packaging Process control systems, special-purpose machines for
rolling and packing
Pharmaceuticals Process control systems such as bottle filling, tablet
placement, packaging
Plastic industry Automatic injection molding machines, raw material
feeding, jaw closing, movement of slides of blow molder

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Press tools Heavy duty presses for bulk metal formation such as sheet
metal, forging, bending, punching, etc.
Printing industry For paper feeding, packaging

Robots Fluid power operated robots, pneumatic systems

Ships Stabilizing systems, unloading and loading unit, gyroscopic

instruments, movement of flat forms, lifters, subsea
inspection equipment
Textiles Web tensioning devices, trolleys, process controllers

Transportation Hydraulic elevators, winches, overhead trams

Under sea Submarines, under sea research vehicles, marine drives and
control of ships
Wood working Tree shearers, handling huge logs, feeding clamping and
saw operations

The following are the two types of hydraulic systems:

1. Fluid transport systems: Their sole objective is the delivery of a fluid from one
location to another to accomplish some useful purpose. Examples include pumping
stations for pumping water to homes, cross-country gas lines,etc.
2. Fluid power systems: These are designed to perform work. In fluid power systems,
work is obtained by pressurized fluid acting directly on a fluid cylinder or a fluid
motor. A cylinder produces a force resulting in linear motion, whereas a fluid motor
produces a torque resulting in rotarymotion.

Classification of Fluid Power Systems

The fluid power system can be categorized as follows:
3. Based on the control system
Open-loop system: There is no feedback in the open system and
performance is
basedonthecharacteristicsoftheindividualcomponentsofthesystem.Theop
en-

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 loop system is not accurate and error can be reduced by proper
calibration and control.
Closed-loop system: This system uses feedback. The output of the system is fed
back to a comparator by a measuring element. The comparator compares the
actual output to the desired output and gives an error signal to the control
element. The error is used to change the actual output and bring it closer to the
desired value. A simple closed- loop system uses servo valves and an advanced
system uses digital electronics.

4. Based on the type of control

Fluid logic control: This type of system is controlled by hydraulic oil or
air. The system employs fluid logic devices such as AND, NAND, OR,
NOR, etc. Two types of fluid logic systems are available:
(a) Moving part logic (MPL): These devices are miniature fluid elements using
moving parts such as diaphragms, disks and poppet’s to implement various logic
gates.
(b) Fluidics: Fluid devices contain no moving parts and depend solely on interacting
fluid jets to implement various logic gates.

Electrical control: This type of system is controlled by electrical

devices. Four basic electrical devices are used for controlling the fluid
power systems: switches, relays, timers and solenoids. These devices
help to control the starting, stopping, sequencing, speed, positioning,
timing and reversing of actuating cylinders and fluid motors. Electrical
control and fluid power work well together where remote control is
essential.
Electronic control: This type of system is controlled by microelectronic
devices. The electronic brain is used to control the fluid power muscles
for doing work. This system uses the most advanced type of
electronic hardware including programmable
logic control (PLC) or microprocessor ( P). In the electrical control, a
change in system operation results in a cumbersome process of redoing
hardware connections.
Thedifficultyisovercomebyprogrammableelectroniccontrol.Theprogramca
nbe
modified or a new program can be fed to meet the change of operations.

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 A number of such programs can be stored in these devices, which makes
the systems more flexible.

Advantages of a Fluid PowerSystem

Oil hydraulics stands out as the prime moving force in machinery and
equipment designed to handle medium to heavy loads. In the early stages of
industrial development, mechanical linkages were used along with prime movers
such as electrical motors and engines for handling loads. But the mechanical
efficiency of linkages was very low and the linkages often failed under critical
loading conditions. With the advent of fluid power technology and associated
electronics and control, it is used in every industrynow.

The advantages of a fluid power system are as follows:

1. Fluid power systems are simple, easy to operate and can be controlled

accurately: Fluid power gives flexibility to equipment without requiring a

complex mechanism. Using fluid power, we can start, stop, accelerate,
decelerate, reverse or position large forces/components with great accuracy
using simple levers and push buttons. For example, in Earth-moving
equipment, bucket carrying load can be raised or lowered by an operator
using a lever. The landing gear of an aircraft can be retrieved to home
position by the pushbutton.

2. Multiplication and variation of forces: Linear or rotary force can be

multiplied by a fraction of a kilogram to several hundreds oftons.

3. Multifunction control: A single hydraulic pump or air compressor can
provide power and control for numerous machines using valve manifolds and
distribution systems. The fluid power controls can be placed at a central
station so that the operator has, at all times, a complete control of the entire
production line, whether it be a multiple operation machine or a group of
machines. Such a setup is more or less standard in the steel mill industry.

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4. Low-speed torque: Unlike electric motors, air or hydraulic motors can
produce a large amount of torque while operating at low speeds. Some
hydraulic and pneumatic motors can even maintain torque at a very slow
speed withoutoverheating.
5. Constant force or torque: Fluid power systems can deliver constant torque
or force regardless of speedchanges.

6. Economical: Not only reduction in required manpower but also the

production or elimination of operator fatigue, as a production factor, is an
important element in the use of fluidpower.
7. Low weight to power ratio: The hydraulic system has a low weight to
power ratio compared to electromechanical systems. Fluid power systems
arecompact.

8. Fluid power systems can be used where safety is of vital importance:

Safety is of vital importance in air and space travel, in the production and
operation of motor vehicles, in mining and manufacture of delicate products.
For example, hydraulic systems are responsible for the safety of takeoff,
landing and flight of aeroplanes and space craft. Rapid advances in mining
and tunneling are the results of the application of modern hydraulic and
pneumaticsystems.

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 Basic Components of a Hydraulic System

Hydraulic systems are power-transmitting assemblies employing pressurized

liquid as a fluid for transmitting energy from an energy-generating source to an
energy-using point to accomplish useful work. Figure 1.1 shows a simple
circuit of a hydraulic system with basic components.

Loa
Moto 1 – Off 2 – Forward 3– d
r Return
1
3 2
Pressur
Filte e
r regulato
r

Pum
p
Directio
n
control
valve Actuato
r
Oil
tank

Figure 1.1 Components of a hydraulic

system Functions of the components shown in Fig. 1.1 are

as follows:
1. The hydraulic actuator is a device used to convert the fluid power into mechanical power
to do useful work. The actuator may be of the linear type (e.g., hydraulic cylinder) or
rotary type(e.g., hydraulic motor) to provide linear or rotary motion, respectively.
2. The hydraulic pump is used to force the fluid from the reservoir to rest of the
hydraulic circuit by converting mechanical energy into hydraulicenergy.
3. Valves are used to control the direction, pressure and flow rate of a fluid flowing
through thecircuit.

4. External power supply (motor) is required to drive thepump.

5. Reservoir is used to hold the hydraulic liquid, usually hydraulicoil.
6. Piping system carries the hydraulic oil from one place toanother.
7. Filters are used to remove any foreign particles so as keep the fluid system clean and
efficient, as well as avoid damage to the actuator andvalves.

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 8. Pressure regulator regulates (i.e., maintains) the required level of pressure in the
hydraulicfluid.

The piping shown in Fig. 1.1 is of closed-loop type with fluid transferred from
the storage tank to one side of the piston and returned back from the other side of
the piston to the tank. Fluid is drawn from the tank by a pump that produces fluid
flow at the required level of pressure. If the fluid pressure exceeds the required
level, then the excess fluid returns back to the reservoir and remains there until
the pressure acquires the requiredlevel.

Cylinder movement is controlled by a three-position change over a control valve.

1. When the piston of the valve is changed to upper position, the pipe pressure line is
connected to port A and thus the load is raised.

2. When the position of the valve is changed to lower position, the pipe pressure line is
connected to port B and thus the load is lowered.

3. When the valve is at center position, it locks the fluid into the cylinder (thereby holding it in
position) and dead-ends the fluid line (causing all the pump output fluid to return to tank via
the pressure relief).

In industry, a machine designer conveys the design of hydraulic systems using

a circuit diagram. Figure 1.2 shows the components of the hydraulic system
using symbols. The working fluid, which is the hydraulic oil, is stored in a
reservoir. When the electric motor is switched ON, it runs a positive
displacement pump that draws hydraulic oil through a filter and delivers at
high pressure. The pressurized oil passes through the regulating valve and does
work on actuator. Oil from the other end of the actuator goes back to the tank
via return line. To and fro motion of the cylinder is controlled using directional
controlvalve.

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 Cylind
er Extende
d

Retrac
t

Moto Directional control

r valve

Pum
p
Pressure
regulator
Filte
r

Breathe
r

Reservo
ir

Figure 1.2 Components of a hydraulic system (shown

using symbols).

The hydraulic system discussed above can be broken down into four main
divisions that are analogous to the four main divisions in an electrical system.

1. The power device parallels the electrical generating station.

2. The control valves parallel the switches, resistors, timers, pressure switches, relays, etc.

3. The lines in which the fluid power flows parallel the electrical lines.

4. The fluid power motor (whether it is a rotating or a non rotating cylinder or a fluid power
motor) parallels the solenoids and electrical motors.

Basic Components of a Pneumatic System

A pneumatic system carries power by employing compressed gas, generally

air, as a fluid for transmitting energy from an energy-generating source to an
energy-using point to accomplish useful work. Figure 1.3 shows a simple
circuit of a pneumatic system with basic components.

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 Power Opens when set
supply pressure is
reached Load

1 – Off 2 – Forward 3-
Pressure Return
switch 1
Motor 3 2
Storage
Air reservoir
Air filter cooler

Air compressor

Directio
n
Air from
control
atmospher
valve Air actuator
e

Air to atmosphere

Figure 1.3 Components of a pneumatic

system. The functions of various components shown in Fig

1.3 are as follows:

1. The pneumatic actuator converts the fluid power into mechanical power to perform
useful work.
2. The compressor is used to compress the fresh air drawn from theatmo sphere.
3. The storage reservoir is used to store a given volume of compressed air.
4. The valves are used to control the direction, flow rate and pressure of compressed air.
5. External power supply (motor) is used to drive thecompressor.
6. The piping system carries the pressurized air from one location to another.

Air is drawn from the atmosphere through an air filter and raised to required
pressure by an air compressor. As the pressure rises, the temperature also rises;
hence, an air cooler is provided to cool the air with some preliminary
treatment to remove the moisture. The treated pressurized air then needs to get
stored to maintain the pressure. With the storage reservoir, a pressure switch is
fitted to start and stop the electric motor when pressure falls and reaches the
required level,respectively.

The three-position change over the valve delivering air to the cylinder operates
in a way similar to its hydraulic circuit.

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 Comparison between Hydraulic and Pneumatic Systems
Usually hydraulic and pneumatic systems and equipment do not compete. They are
so dissimilar that there are few problems in selecting any of them that cannot
be readily resolved. Certainly, availability is one of the important factors of
selection but this may be outweighed by other factors. In numerous instances, for
example, air is preferred to meet certain unalterable conditions, that is, in“hot
spots” where there is an open furnace or other potential ignition hazard or in
operations where motion is required at extremely high speeds. It is often found
more efficient to use a combined circuit in which oil is used in one part and air
in another on the same machine or process. Table 1.2 shows a brief comparison of
hydraulic and pneumatic systems.

Table 1.2 Comparison between a hydraulic and a pneumatic system</table>

S. No. Hydraulic System Pneumatic System

It employs a pressurized liquid It employs a compressed gas, usually

1. air, as a fluid
as a fluid

2. An oil hydraulic system operates at A pneumatic system usually operates

pressures up to 700 bar at 5–10 bar
3. Generally designed as closed system Usually designed as open system

The system slows down when leakage Leakage does not affect the system
4.
occurs much

5. Valve operations are difficult Valve operations are easy

6. Heavier in weight Lighter in weight

Pumps are used to provide Compressors are used to provide

7. compressed gases
pressurized liquids

8. The system is unsafe to fire hazards The system is free from fire hazards

Automatic lubrication is provided Special arrangements for lubrication

9.
are needed

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 Objective Type Questions

Fill in the Blanks

1. Fluid power is the technology that deals withthegeneration, and transmission of

forces and movement of mechanical elements orsystems.

2. The main objective of fluid transport systems is to deliver a fluid from one location to
another, whereas fluid power systems are designedtoperform .

3. There are three basic methods of transmitting power: Electrical,mechanicaland .

4. Only are capable of providing constant force or torque regardless of speed

changes.

5. The weight-to-power ratio of a hydraulic systemiscomparatively than that of an

electromechanicalsystem.

State True or False

1. Hydraulic lines can burst and pose seriousproblems.

2. Power losses and leakages are less in pneumaticsystems.

3. Pneumatic system is not free from firehazards.

4. Hydraulic power is especially useful when performing heavywork.

5. Water is a good functional hydraulicfluid.

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 Review Questions
1. Define the term fluidpower.
2. Differentiate between fluid transport and fluid power systems.
3. Differentiate between hydraulics and pneumatics.
4. List the six basic components used in a hydraulic system.
5. List the six basic components used in a pneumatic system.
6. List 10 applications of fluid power in the automotiveindustry.
7. Name 10 hydraulic applications and 10 pneumaticapplications.
8. List five advantages and five disadvantages ofhydraulics.
9. List five advantages and five disadvantages ofpneumatics.
10. List the main components of a fluid power system and theirfunctions.
11. Discuss in detail the future of fluid power industry inIndia.
12. Compare different power systems used inindustries.
13. What is the main difference between an open-loop and a closed-loop fluid power
system?
14. List five major manufactures of fluid powerequipment and systems in India.
15. List five major manufactures of fluid powerequipment and systems in the world.
16. Visit any industry nearby and list the hydraulic/pneumatic parts or systems used and
theirpurposes.
17. Why is the hydraulic power especially useful when performing heavywork?
18. Differentiate between oil hydraulics andpneumatics.
19. List any five applications of fluid power systems.

20 List the main components of a fluid power system and their function

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 Experiment No. 2
Title: Study and Trial on actuators.

Aim: To Study of Linear Actuator for actuating speed at varying pressure.

Objectives: Students will be able to

 Understand and calculate speed of actuation under different loading and
pressure conditions.
 Students will understand difference between speeds of extension and retraction

Theory:
Introduction:

Hydraulic linear actuators, as their name implies, provide motion in a straight line. The
total movement is a finite amount determined by the construction of the unit. They are usually
referred to as cylinders, rams and jacks. All these items are synonymous in general use, although
ram is sometimes intended to mean a single-acting cylinder and jack often refers to a cylinder
used for lifting. The function of hydraulic cylinder is to convert hydraulic power into linear
mechanical force or motion. Hydraulic cylinders extend and retract a piston rod to provide apush
or pull force to drive the external load along a straight-linepath.

Types of Hydraulic Cylinders

Hydraulic cylinders are of the following types:

 Single-acting cylinders.
 Double-acting cylinders.
 Telescopic cylinders.
 Tandem cylinders.

Single-Acting Cylinders

A single-acting cylinder is simplest in design and is shown schematically in Fig.1.1. It

consists of a piston inside a cylindrical housing called barrel. On one end of the piston there is a
rod, which can reciprocate. At the opposite end, there is a port for the entrance and exit of oil.
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Single-acting cylinders produce force in one direction by hydraulic pressure acting on the piston.
(Single-acting cylinders can exert a force in the extending direction only.) The return of the
piston is not done hydraulically. In single-acting cylinders, retraction is done either by gravity or
by a spring.

According to the type of return, single-acting cylinders are classified as follows:

 Gravity-return single-acting cylinder.
 Spring-return single-acting cylinder.

Double-Acting Cylinder

Figure 1.4 shows the operation of a double-acting cylinder with a piston rod on one side.
To extend the cylinder, the pump flow is sent to the blank-end port as in Fig. 1.4(a). The fluid
from the rod-end port returns to the reservoir. To retract the cylinder, the pump flow is sent tothe
rod-end port and the fluid from the blank-end port returns to the tank as inFig.1.4(b).

Telescopic Cylinder

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 A telescopic cylinder (shown in Fig. 1.6) is used when a long stroke length and a short
retracted length are required. The telescopic cylinder extends in stages, each stage consisting of a
sleeve that fits inside the previous stage. One application for this type of cylinder is raising a
dump truck bed. Telescopic cylinders are available in both single-acting and double-acting
models. They are more expensive than standard cylinders due to their more complex
construction.

Tandem Cylinder

A tandem cylinder, shown in Fig. 1.7, is used in applications where a large amount of
force is required from a small-diameter cylinder. Pressure is applied to both pistons, resulting in
increased force because of the larger area. The drawback is that these cylinders must be longer
than a standard cylinder to achieve an equal speed because flow must go to both pistons.

Schematic Diagram:

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Procedure:

1. Make connections as shown indiagram

2. Place weights of 12 kg on the hanger attached to thecylinder
3. Adjust the pressure to 2 kg/cm2 using pressure reliefvalve
4. Move the lever of 4/3 hand lever operated D. C. valve to oneside
5. Observe the motion of cylinder piston in outwarddirection
6. Bring back the leaver to its initial position, there will not be any motion ofcylinder
7. Move the leaver in opposite direction, the cylinder gets retracted & return to itsinitial
position & the weight gets lifted (observe the speed of thecylinder)
8. Repeat the steps 5-7 for higher pressure. (Up to 20kg/cm2)

Conclusion:

In this experiment it can be observed that, the rate of lifting the load increases as we increase the
operating pressure.

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 EXPERIMENT NO.3
Tittle: Study and trial on Gear/ Vane/ Piston pump

Aim: To perform trial on axial piston pump and plotting performance characteristics

Objective: Students should be able to understand nature of pump efficiencies under

different loading conditions so as to select a proper pump for predefined application

Introduction:

The function of a pump is to convert mechanical energy into hydraulic energy. It is the heart of
any hydraulic system because it generates the force necessary to move the load. Mechanical
energy is delivered to the pump using a prime mover such as an electric motor

Pumps are classified into three different ways and must be considered in any discussion of fluid
power equipment.
1. Classification based on displacement:
Non-positive displacement pumps (hydrodynamic pumps).
Positive displacement pumps (hydrostatic pumps).
2. Classification based on delivery:
Constant delivery pumps.
Variable delivery pumps.
3. Classification based onmotion:
Rotary pump.
Reciprocating pump.
Piston pumps are of the following two types:

1. Axial piston pump: These pumps are of two designs:

1) Bent-axis-type piston pump.
2) Swash-plate-type pistonpump.

1) Bent-axis-type piston pump:

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Schematic diagram and detailed cut section of bent axis type piston pump as shown in fig .It
contains a cylinder block rotating with a drive shaft .However, the centre line of the cylinder
block is set at an offset angle relative to the drive shaft. The cylinder block contains a number of
pistons arranged along the circle. The pistons rods are connected to the drive shaft flange by a
ball and socket joints. The pistons are forced in and out of their bores as the distance between the
drive shaft flange and cylinder block changes. A universal link connects the cylinder block to
drive shaft to provide alignment and positive drive.

The volumetric displacement of the pump depends on the offset angle .No flow is
producedwhen the cylinder block is centre line can vary from 0° to a maximum of about 30° .For
a fixed displacement ,units are usually provided with 23° or 30° offset angles.

2) Swash-plate-type piston pump:

Schematic diagram of swash plate type piston pump shown in fig. In this type,the cylinder block
and drive shaft are located on the same centreline .The pistons are connected to a shoe plate that
bears against an angled swash plate .As the cylinder rotates ,the pistons reciprocate because the
piston shoes follow the angled surface of the swash plate . The outlet and inlet ports are located
in the valve plate so that the pistons pass the inlet as they are being pulled out and pass the outlet
as they are being forced back in .This type of pump can also be designed to have a variable
displacement capability .The maximums wash plate angle is limited to 17.5° byconstruction.

3. Comparisons of Hydraulic pumps

The major factor in adopting a pump to a particular system is the system’s overall needs .It
would be wrong to use a pump that must produce at peak continuously just to meet the minimum
requirements of the system is equally wrong .Making either of these mistakes produces a poor
system due to excessive initial pump costs or maintenancecost.

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 Pressure (Bar) Discharge Maximum Overall
(LPM) Speed (RPM) Efficiency
Gear pump 20-175 7-570 1800-7000 75-90
Vane pump 20-175 2-950 2000-4000 75-90
Axial piston 70-350 2-1700 600-6000 85-95
pump
Radial piston 50-250 20-700 600-1800 80-92
pump

3. Pump Performance

The performance of a pump is a function of the precision of its manufacture . An ideal pump is
one having zero clearance should be as small as possible while maintaining proper oil films for
lubrication between rubbing parts .The performance of a pump is determined by the following
efficiencies :

1. Volumetric efficiency (V):

It is the ratio of actual flow rate of the pump to the theoretical flow rate of the pump .This
is expressed as follows:
Actual flow rate of the pump(QA)
Volumetric efficiency (V)=
Theoreticalflowrateofthepump(QT)
For gear pumps ,V = 80% - 90%
For vane pumps ,V =92%
For piston pumps ,V =90%-98% .

2. Mechanical efficiency (m):

It’s the ratio of the pump output power assuming no leakage to actual power delivered to
the pump :
Pumpoutputpowerassumingnoleakages
Mechanicalefficiency(m)=
Actual power delivered to the pump

Mechanical efficiency (m) indicate the amount of energy losses that occur for reasons other
than leakage .This includes friction in bearings and between mating parts .This includes the
energy losses due to fluid turbulence .Mechanical efficiencies are about 90%-95% .We also have
therelation
PQT
m =
TAN
Where P is the pump discharge pressure in Pa or N/m2, QT is the theoretical flow rate of the
pump in m3/s , TA is the actual torque delivered to the pump in Nm and N is the speed of the
pump in rad/s.
It (m) can also be computed in terms of torque as follows:

11
 Theoretical torque required to operate the pump (TT)
Mechanicalefficiency(m)=
Actual torque delivered to the pump(TA)

VD
Where, Theoretical torque =
2

Theoretical torque (TT) required to operate the pump is the torque that would be required if there
is no leakage.
P
Actual torque TA =
w
Where w=2N/60. Here N is the speed in RPM.

Actual powerdelivered by the pump

Overallefficiency(o) =
Actual power delivered to the pump

Overall efficiency (o)= v m

Qa pQt
 o= ×
Qt TaN

DESCRIPTION OF SET UP:

Base Stand: This is made up of M.S. square tubes & sheets. This is painted specially with
powder coating all equipment are mounted on base stand.

Axial Pump: Axial Pump: Axial pump is a positive displacement pump it basically consists of
inlet and outlet ports, piston and valves.

Electric Motor: This is a 3 phase, 415V AC motor having capacity 7.5HP at 1500 RPM the
motor is used to run the pump.

Pressure Gauge: Discharge pressure of oil is measured by pressure gauge having range 0 – 200
bar.

Vacuum Gauge: This is used to check the suction pressure of the pump having range 0 -760 bar

Pressure relief valve: The discharge pressure can be controlled by using pressure relief valve
provided in discharge line of the pump.

Back pressure valve: A control valve is used to apply back pressure on the pump so as to
change delivery pressure.

Float switch and Timer: The time required for the rise in oil level is measured using a digital
wattmeter.

Wattmeter: Power consumed by electric motor is measured using a digital wattmeter.

12
 Sump Tank: Corrosion resistant M.S. tank is used as sump tank. Oil is pumped from the tank
and discharge back to the sump.

Measuring tank: The oil pumped is discharged into measuring tank. By recording the time
required for certain rise in level we can determine discharge flow rate of the pump.

OBSERVATION TABLE:

Sr.No Suction Delivery Rise in the Time for rise Watt meter
pressure pressure level (mm) (sec) reading (W)
(mm of Hg) (mm of Hg)
1
2
3

Conclusion:
It can be concluded as pump efficiency varies upto its designed pressure and there after it starts
reducing.

13
 EXPERIMENT NO.4
Tittle: Study and design of compressed air generation and distribution system,

Aim: To perform trial on axial piston pump.

Objective: To study the fundamentals of pneumatic system.

Pneumatic technology deals with the study of behavior and applications of

compressed air in our daily life in general and manufacturing automation in particular.
Pneumatic systems use air as the medium which is abundantly available and can be
exhausted into the atmosphere after completion of the assignedtask.

1. Basic Components of Pneumatic System:

Fig. 6.1.1 Components of a pneumatic system

Important components of a pneumatic system are shown in fig.6.1.1.

a) Air filters: These are used to filter out the contaminants from theair.
b) Compressor: Compressed air is generated by using air compressors. Air
compressors are either diesel or electrically operated. Based on the
requirement of compressed air, suitable capacity compressors may beused.
c) Air cooler: During compression operation, air temperature increases.
Therefore coolers are used to reduce the temperature of the compressedair.
d) Dryer: The water vapor or moisture in the air is separated from the air by
using adryer.
e) Control Valves: Control valves are used to regulate, control and monitor for
control of direction flow, pressureetc.
 f) Air Actuator: Air cylinders and motors are used to obtain the required
movements of mechanical elements of pneumaticsystem.

g) Electric Motor: Transforms electrical energy into mechanical energy. It is

used to drive thecompressor.
h) Receiver tank: The compressed air coming from the compressor is stored in
the airreceiver.

These components of the pneumatic system are explained in detail on the next pages.

2. Receivertank
The air is compressed slowly in the compressor. But since the pneumatic system
needs continuous supply of air, this compressed air has to be stored. The compressed
air is stored in an air receiver as shown in Figure 6.1.2. The air receiver smoothens the
pulsating flow from the compressor. It also helps the air to cool and condense the
moisture present. The air receiver should be large enough to hold all the air delivered
by the compressor. The pressure in the receiver is held higher than the system
operating pressure to compensate pressure loss in the pipes. Also the large surface
area of the receiver helps in dissipating the heat from the compressed air. Generally
the size of receiver dependson,
 Delivery volume ofcompressor.
 Airconsumption.
 Pipelinenetwork
 Type and nature of on-offregulation
 Permissible pressure difference in thepipelines

Fig.6.1.2 Air receiver

3. Compressor:

It is a mechanical device which converts mechanical energy into fluid energy. The
compressor increases the air pressure by reducing its volume which also increases the
temperature of the compressed air. The compressor is selected based on the pressure it
needs to operate and the delivery volume.
The compressor can be classified into two main types
a. Positive displacement compressors and
b. Dynamic displacement compressor
Positive displacement compressors include piston type, vane type, diaphragm type
and screwtype.

Piston compressors

Fig. 6.1.3 Single acting piston compressor

Piston compressors are commonly used in pneumatic systems. The simplest form is
single cylinder compressor (Fig. 6.1.3). It produces one pulse of air per piston stroke.
As the piston moves down during the inlet stroke the inlet valve opens and air is
drawn into the cylinder. As the piston moves up the inlet valve closes and the exhaust
valve opens which allows the air to be expelled. The valves are spring loaded. The
single cylinder compressor gives significant amount of pressure pulses at the outlet
port. The pressure developed is about 3-40bar.
Air treatment stages
For satisfactory operation of the pneumatic system the compressed air needs to be
cleaned and dried. Atmospheric air is contaminated with dust, smoke and is humid.
These particles can cause wear of the system components and presence of moisture
may cause corrosion. Hence it is essential to treat the air to get rid of these impurities.
The air treatment can be divided into three stages as shown in Figure 6.3.1.

Fig. 6.3.1 Stages of air treatment

In the first stage, the large sized particles are prevented from entering the compressor
by an intake filter. The air leaving the compressor may be humid and may be at high
temperature. The air from the compressor is treated in the second stage. In this stage
temperature of the compressed air is lowered using a cooler and the air is dried using
a dryer. Also an inline filter is provided to remove any contaminant particles present.
This treatment is called primary air treatment. In the third stage which is the
secondary air treatment process, further filtering is carried out. A lubricator introduces
a fine mist of oil into the compressed air. This will help in lubrication of the moving
components of the system to which the compressed air will beapplied.

Filters
To prevent any damage to the compressor, the contaminants present in the air need to
be filtered out. This is done by using inlet filters. These can be dry or wet filters. Dry
filters use disposable cartridges. In the wet filter, the incoming air is passed through
an oil bath and then through a fine wire mesh filter. Dirt particles cling to the oil drops
during bubbling and are removed by wire mesh as they pass through it. In the dry
filter the cartridges are replaced during servicing. The wet filters are cleaned using
detergentsolution.

Cooler
As the air is compressed, the temperature of the air increases. Therefore the air needs
to be cooled. This is done by using a cooler. It is a type of heat exchanger. There are
two types of coolers commonly employed viz. air cooled and water cooled. In the air
cooled type, ambient air is used to cool the high temperature compressed air, whereas
in the water cooled type, water is used as cooling medium. These are counter flow
type coolers where the cooling medium flows in the direction opposite to the
compressed air. During cooling, the water vapor present will condense which can be
drained awaylater.
2. Main line filter
These filters are used to remove the water vapors or solid contaminants present in the
pneumatic systems main lines. These filters are discussed in detail as follows.

Air filter and water trap

Air filter and water trap is used to
 prevent any solid contaminants from entering in thesystem.
 condense and remove water vapor that is present in the compressedair.

Fig. 6.3.2 Air filter and water trap

The filter cartridge is made of sintered brass. The schematic of the filter is shown in
Fig. 6.3.2. The thickness of sintered cartridge provides random zigzag passage for the
air to flow-in which helps in arresting the solid particles. The air entering the filter
swirls around due to the deflector cone. The centrifugal action causes the large
contaminants and water vapor to be flung out, which hit the glass bowl and get
collected at the bottom. A baffle plate is provided to prevent the turbulent air from
splashing the water into the filter cartridge. At the bottom of the filter bowl there is a
drain plug which can be opened manually to drain off the settled water and solid
particles.
Lubricators

Fig. 6.3.6 Air lubricator

The compressed air is first filtered and then passed through a lubricator in order to
form a mist of oil and air to provide lubrication to the mating components. Figure
6.3.6 shows the schematic of a typical lubricator. The principle of working of
venturimeter is followed in the operation of lubricator. The compressed air from the
dryer enters in the lubricator. Its velocity increases due to a pressure differential
between the upper and lower changer (oil reservoir). Due to the low pressure in the
upper chamber the oil is pushed into the upper chamber from the oil reservoir through
a siphon tube with check valve. The main function of the valve is to control the
amount of oil passing through it. The oil drops inside the throttled zone where the
velocity of air is much higher and this high velocity air breaks the oil drops into tiny
particles. Thus a mist of air and oil is generated. The pressure differential across
chambers is adjusted by a needle valve. It is difficult to hold an oil mixed air in the air
receiver as oil may settle down. Thus air is lubricated during secondary air treatment
process. Low viscosity oil forms better mist than high viscosity oil and hence ensures
that oil is always present in the air.

3. Pressure regulation
In pneumatic systems, during high velocity compressed air flow, there is flow-
dependent pressure drop between the receiver and load (application). Therefore the
pressure in the receiver is always kept higher than the system pressure. At the
application site, the pressure is regulated to keep it constant. There are three ways to
control the local pressure, these are shown in Figure 6.3.7.
 Fig. 6.3.7 Types of pressure regulation

 In the first method, load X vents the air into atmosphere continuously. The
pressure regulator restricts the air flow to the load, thus controlling the air
pressure. In this type of pressure regulation, some minimum flow is required
to operate the regulator. If the load is a dead end type which draws no air, the
pressure in the receiver will rise to the manifold pressure. These type of
regulators are called as ‘non-relieving regulators’, since the air must pass
through theload.

 In the second type, load Y is a dead end load. However the regulator vents the
air into atmosphere to reduce the pressure. This type of regulator is called as
‘relievingregulator’.

 The third type of regulator has a very large load Z. Therefore its requirement
of air volume is very high and can’t be fulfilled by using a simple regulator. In
such cases, a control loop comprising of pressure transducer, controller and
vent valve is used. Due to large load the system pressure may rise above its
critical value. It is detected by a transducer. Then the signal will be processed
by the controller which will direct the valve to be opened to vent out the air.
This technique can be also be used when it is difficult to mount the pressure
regulating valve close to the point where pressure regulation isneeded.

4. Service units
During the preparation of compressed air, various processes such as filtration,
regulation and lubrication are carried out by individual components. The individual
components are: separator/filter, pressure regulator and lubricator.

Preparatory functions can be combined into one unit which is called as ‘service unit’.
Figure 6.3.10 shows symbolic representation of various processes involved in air
preparation and the service unit.
 (a)

(b)
Fig. 6.3.10 (a) Service unit components (b) Service unit symbol

Conclusion: We have studied the fundamentals of air generation and distribution system and also its
characteristics.
 Experiment No. 5

Title:- Study of Control valves

Aim: To study different types of control valves and Regenerative circuit, Speed control
circuit, Transverse and feed circuit on hydraulic trainer.

Objectives: Students will be able to

 Understand & classify different flow control valves, Regenerative circuit, Speed control
circuit, Transverse and feed circuit on hydraulic trainer.
 Set flow rate through a flow control valve for specific application.

Theory:

Flow-control valves, as the name suggests, control the rate of flow of a fluid through a
hydraulic circuit. Flow-control valves accurately limit the fluid volume rate from fixed
displacement pump to or from branch circuits. Their function is to provide velocity control of
linear actuators, or speed control of rotary actuators. Typical application include regulating
cutting tool speeds, spindle speeds, surface grinder speeds, and the travel rate of vertically
supported loads moved upward and downward by forklifts, and dump lifts. Flow-control valves
also allow one fixed displacement pump to supply two or more branch circuits fluid at different
flow rates on a priority basis. Typically, fixed displacement pumps are sized to supply maximum
system volume flow rate demands. For industrial applications feeding two or more branch
circuits from one pressurized manifold source, an oversupply of fluid in any circuit operated by
itself is virtually assured. Mobile applications that supply branch circuits, such as the power
steering and front end loader from one pump pose a similar situation. If left unrestricted, branch
circuits receiving an oversupply of fluid would operate at greater than specified velocity,
increasing the likelihood of damage to work, hydraulic system and operator.

Functions of Flow-Control Valves:

Flow-control valves have several functions, some of which are listed below:
1. Regulate the speed of linear and rotary actuators: They control the speed of piston
thatis dependent on the flow rate and area of the piston:

2. Regulate the power available to the sub-circuits by controlling the flow to them:
Power (W) = Flow rate (m3/s) ×Pressure (N/m2)
P = Q×p
3. Proportionally divide or regulate the pump flow to various branches of the circuit:
It transfers the power developed by the main pump to different sectors of the circuit to
manage multiple tasks, if necessary.
Non-pressure-compensated flow-control valves are used when the system pressure is
relatively constant and motoring speeds are not too critical. The operating principle behind these
valves is that the flow through an orifice remains constant if the pressure drop across it remains
the same. In other words, the rate of flow through an orifice depends on the pressure drop across
it.
The disadvantage of these valves is discussed below. The inlet pressure is the pressure
from the pump that remains constant. Therefore, the variation in pressure occurs at the outlet that
is defined by the work load. This implies that the flow rate depends on the work load. Hence, the
speed of the piston cannot be defined accurately using non-pressure-compensated flow-control
valves when the working load varies. This is an extremely important problem to be addressed in
hydraulic circuits where the load and pressure vary constantly.

Observations: Table
% Opening of valve Time requires to fill 300ml

Calculations

Discharge (Q)= Volume/time.

Results: Table
% Opening of valve Discharge (m3/sec)

Conclusion: As the opening of flow control valve is increased, the flow rate through the valve is
increased.

Outcomes: Students Understood function of flow control valve

Students can calculate and adjust flow rate as per required application
 (c, d, e) Testing of different circuits on Hydraulic Trainer Kit

Objective: Students should be able to build and analyze different hydraulic circuits.

Equipment / Tools / Apparatus required:-

Hydraulic Trainer Kit

Brief description of Theory / Practical:-

1. Regenerative Circuit:

Conventional reciprocating circuits use a four-way directional valve connected directly to a

cylinder. In a regenerative reciprocating circuit, oil from the rod end of the cylinder is directed
into the cap end to increase speed, without requiring to increase pump flow.

Fig. Regenerative Circuit

11
5
The circuit components are :

A. Hydraulic Pump
B. Reliefvalve
C. Four-way two position solenoid operated valve
D. Double-acting Single rod Cylinder
2. Speed Control Circuit:
a. Meter-In Circuit

Figure shows a meter in the circuit with control of extend stroke. The inlet flow into the
cylinder is controlled using a flow control valve. In the return stroke, however, the fluid can
bypass the needle valve and flow through the check valve and hence the return speed is not
controlled. This implies that the extending speed of the cylinder is control whereas the retracing
speed is not.

Fig. Meter-In Circuit

11
6
b. Meter-Out Circuit

Figure Shows a meter out circuit for flow control during the extend stroke. When thecylinder
extends, the flow coming from the pump into the cylinder is not controlled directly. However,
the flowout of the cylinder is controlled using the flow control valve ( metering orifice). On the
other hand, when the cylinder retracts, the flow passes through the check valve unopposed,
bypassing the needle valve. Thus, only the speed during the extend stroke iscontrolled.
Both the meter in and meter out circuits mentioned above perform the same operation(
control the speed of extending stroke of the piston), even though the processes are exactly
opposite to oneanother.

Fig: Meter-Out Circuit

3. Traverse and Feed Circuits

A machine intended for high volume production has a high piston velocity. If not controlled, the
high speed platen approaching the job instead of making a smooth contact will bang on the job.
This is not desirable. In all such cases, “rapid traverse and feed circuits” are employed.

11
7
 Fig. Traverse and Feed Circuits

In the circuit shown in figure, pump directly normally passes through FCV(3). During
fast approach, the solenoid-operated DCV(4) is energized. This diverts pump delivery to the cap
end of the cylinder through valve(4). Full flow is thus available for the actuator to advance atthe

11
8
rated speed. A few millimetres before the platen makes contact with the die, solenoid valve (4) is
de-energized forcing the pump delivery to pass through FCV (3). The platen now approaches the
die at a controlled speed because the flow to cylinder (6) is now regulated. Directional vales (4)
and (5), however, must be energized simultaneously for the approach phase to begin.

Valves (4) to (5) are solenoid-controlled pilot-operated valves intended for handling large
flows with minimum pressure drop. While valve (5) requires a 4.5 bar check valve (6) in the
return line to develop the pilot pressure required to move the main spool, no such facility is
required in the case of valve (4) because the back pressure generated by valve (3) would serve as
the pilot pressure for this valve.

CONCLUSION: In this experiment we have studied the different circuits like speed control,
Sequencing, Regenerative circuits and their working.

Oral Questions-

1) What are the advantages of a regenerativecircuit?

2) Explain the regenerative circuit for a drillingmachine.
3) With the help of a neat sketch, explain the pump-unloadingcircuit.
4) With the help of a circuit diagram, explain a double-pump hydraulic system (Hi–Locircuit).
5) Explain the application of a counterbalancevalve.

2
0
 Experiment No. 7

Title: Study of automatic reciprocating circuit, pneumatic circuit involving shuttle valve/quick
exhaust valve, electro pneumatic valves and circuit on pneumatic trainer.

Aim: To study and perform experiments of automatic reciprocating circuit, pneumatic circuit
involving shuttle valve/quick exhaust valve, electro pneumatic valves and circuit

Objectives: To have hands on experience of designing and operating pneumatic

components and circuit for required application
Equipment / Tools / Apparatus required:-
Pneumatic Trainer Kit
Theory / Practical:-

1. Automatic reciprocating circuit:

Fig. Automatic Reciprocation Circuit

21
2. Speed Control Circuit:

Figure shows a meter in the circuit with control of extend stroke. The inlet flow into the
cylinder is controlled using a pneumatic flow control valve. In the return stroke, however, the
fluid can bypass the needle valve and flow through the check valve and hence the return speed is
not controlled. This implies that the extending speed of the cylinder is control whereas the
retracing speed is not.

3. Pneumatic circuit involving shuttle valve:

Consider a simple operation where a double-acting cylinder is used to transfer parts from a
magazine. The cylinder is to be advanced either by operating a push button or by a foot pedal.
Once the cylinder is fully advanced, it is to be retracted to its initial position. A 3/2-way roller
lever valve is to be used to detect the full extension of the cylinder. Design a pneumatic circuit
for the above mentioned application.

Components Used :
The pneumatic components which can be used to implement the mentioned task are as follows :
 Double acting cylinder
 3/2 push button valve
 3/2 roller valve
 Shuttle valve
 3/2 foot pedal actuated valve
 5/3 pneumatic actuated direction control valve
 Compressed air source and connecting piping

22
Diagram:

CONCLUSION: In this Experiment we have studied Automatic reciprocating circuit, pneumatic

circuit involving shuttle valve/quick exhaust valve, electro pneumatic valves and circuit on
pneumatic trainer.

Outcomes: on completion of this experiment students will be able to,

 Design and develop pneumatic circuit
 Understand function of each pneumatic components in the circuit

Oral Questions-
1) Name five characteristics of pneumaticsystems
2) List twenty applications ofpneumatics
3) Differentiate between Free air and standardair
4) Differentiate between Absolute pressure and atmospherepressure
5) Discuss various pressure ranges used in pneumaticapplications

23
 Experiment No. 8
Title: Design of simple hydraulic systems used in practice using manufacturer’s catalogue and
analysis using software such as Automation Studio.

Aim:
Design of simple hydraulic systems used in practice using Automation Studio.

Objective:
To have hands on experience on hydraulic simulation software

Design of Hydraulic Lift

Most of us probably have a general idea of what a forklift is, but there are a number of
different classifications, power sources, sizes, uses and new technologies that make up these
useful machines. Some are used on rugged construction sites and lift heavy materials and
equipment while other forklifts drive themselves inside modernized warehouses. Whether
indoors or out, forklifts are a necessary tool in most warehouses and an integral part of our
industries.
Forklifts might seem more industrial than inventive, but consider that they're typically the
size of a small car yet they can lift loads that are thousands of pounds, often several stories into
the air, all without tipping over. These machines work long hours each day lifting and moving
heavy loads to keep our manufacturing, automotive, aerospace and other industries humming
along.

3
0
Experiment:
In this experiment, we have to study two different circuits. One is Hydraulic Lift circuit using
Pressure Intensifier to lift the Material or Load. Second Circuit is Hydraulic TILT Circuit which
is used for releasing the Material or Load and Un-Load to the particular space. In this circuit we
are using Flow Divider Component which divides Fluid flow in equal proportion.
Hydraulic Lift Circuit is nothing but a Pressure Intensifier Circuit. You can follow the Expt.
No. 6 procedure for creating the Hydraulic Lift Circuit. But we will change the Directional Valve
to a Joystick operated Proportional valve. In Expt.6 we have used two cylinders. But in "Lift
Circuit" of Forklift, One Cylinder is sufficient to lift the Load. So we will use only one Cylinder
for Forklift.

We have to make some changes incircuit. To operate the Lift Circuit we will use Joystick
and a Proportional Valve instead of a Push Button OperatedValve.
Click on Proportional Hydraulic Library. Drag 4/3 way electrically controlled valve and
Joystick from Library. Connect them as shownbelow.

Now this is the Hydraulic Lift Circuit. To operate it with Joystick we have to Link the
Joystick to the ProportionalValve.
Double click on Cylinder. Click on Builder tab. On the Right hand side Adaptor Option id
there. You can select any type of Adaptor for Rod. Select and click onapply.

31
Now we have to load the piston. Provide following data to Cylinder by using Technical data
property.
Piston Diameter = 50 mm
Rod Diameter = 20 mm
Stroke = 500 mm
Inclination = 90 degree
External Load = 6000Kg

Double Click on Joystick. Its property window gets open. Click on Configuration.
Set minimum signal to -10 and maximum to 10. Click on apply and close it.
32
Now double click on Proportional valve. Its property window willopen.

Click on the Left hand side valve operator (solenoid) of the valve symbol which is located at
the top left of the window. Under basic data set Minimum signal as -10 and maximum signal
as10.
Set Minimum force to -12 daN and Maximum force to 12 daN. Click on Apply. Don’t close
the window.

33
Now we have to link the Proportional valve to the Joystick. Click on variable assignment.

This window shows Component variables and Internal links. You can link the Component
variable to the other component variables like Joystick X or Y signal, Linear position of
cylinderetc.

Select "Input Signal" i.e. the second line from component variable and click on "JY_X"
signal which is the Joystick X i.e. Horizontal signal (-10 to +10). Click on apply and Close
the window. You can observe that question mark on the left hand side of the valve isreplaced
with JY_Xsignal.

34
 Now double Click on Pressure Intensifier. Click on "Technical Data". And feed the values as
shown in belowscreen.

This is a 3:1 pressure intensifier. Piston sode volume is 5449.42 cm3 which is three times
greater than Rear side volume, which iss 1815.84 cm3. Intensifier has to produce up to
three times higher pressure than input pressure.

Set Cracking pressure of Pressure relief valve to 150 bar. Lift Cylinder is having 6000 Kg of
Load. To carry this load Pressure Intensifier is required.
Start the Simulation. Click on Joystick. Move the Joystick Pointer in horozaontal +X
direction using mouse.

35
In simulation you can observe that Intensifier has produced 450 bar pressure to handle the
6000Kg of load with low input system pressure of 150 bar. Save the Circuit.

Tilt Circuit:

By using Lift Circuit you can lift the given Load/Material, then you can carry that load to the
target location. At that location you have to release that Load or Material. For this a TILT Circuit
is essential.

In Hydraylic Tilt Circuit we have to use two Cylinders because its easy to release the material by
two cylinders than a single cylinder.

Now During the tilt operation, load may be different on both cylinders. Hence it is essential to
use a flow divider component which can divide the flow in same proportioan.

ForTiltCircuitdragtherequiredComponentsandbuildacircuitasshowninfollowingfig.
Don’t use any component from Lift circuit.

Note: We need both circuits on same page. On one side you have Lift Circuit. Now create Tilt
circuit in other side.

36
 d=50mm d=50mm
D=100mm D=100mm
Load=3000Kg Load=3000Kg

0bar 0bar

? ? ? ?

0bar 0bar
0L/min 0 L/min

100 cm3/rev 100 cm3/rev

Operate using
Joystick

Flow Divider:
From Hydraulic Library click on "Flow Valves" library. Select Flow divider and drag the “2
way ratio Rotary Flow Divider” onto working space.

Double click on it. In technical data it shows you two displacement options.

37
We can connect Joystick to both the proportional valve. Follow similar process for both the
valves which is used for Lift Circuit and then link the Joystick to Both thevalves.

Now simulate the circuit. Operate the Joystick.

38
 In simulation you can observe that, Flow divider is producing same flow of 80.34 L/min on both
the sides which is important task for Tilt Operation. Due to this, both the Cylinders are having
same Linear position while operation.

Now let us see simulation of both the Circuits.

Conclusion: This experiment can be concluded that simulation of real application in software
like Automation Studio provides more realistic data so as one can have better decisionpower.

Outcomes: After completion of this experiment students will be able to,

 Analyse and formulate real life application in AutomationStudio

 Understand different simulation tools and their role in simulationprocess.

39
 Experiment No. 9

Report of Industry visit to Jyoti Solutions Works Private Limited

Students Benefited: T.E. (Div. ) Mechanical Engineering Date of Visit-

Name of Student:

The subject associated with industrial Visit: Fluid Power & Control Laboratory

Name and address of Visit: Jyoti Solutions Works Private Limited, Pune, Maharashtra

 Outcomes of the Visit:

 Awareness and understanding of the course by virtue of industrial visit was
achieved.
 Students were made aware regarding atomization and mechanization processes in
industry.
 Learning of different manufacturing processes carried out in an industry.
 Students were made familiar with technology and machines used for the
preparation of mineral water.
 Students got information about production capacitance of the concerned
manufacturing unit.

 Course objectives:

1. UNDERSTAND working principles of control devices and accessories.

2. SELECT different components from manufactures’ catalogues.

3. DEMONSTRATE the capabilities to simulate and design fluid power systems.

4. UNDERTAKE digitalization of fluid power system.

Introduction:

The Jyoti SolutionsWorks Pvt Ltd (Formally known as Jyoti Toolings and Press
Components Pvt Ltd.) came into its inception in 1987 with the sole purpose to deliver the
most managed and professional facilities that are proficient to tackle all sorts of
challenges in terms of design, manufacturing, and testing of any kind of sheet metal tools.
JYOTI Toolings is one of the largest and most sophisticated tool rooms in India. We
believe in partnering closely with our customers to ensure that our projects have
successful outcomes.

We have a proficient and dynamic team of engineers that take care of End to End
activities making a TOTAL SOLUTION PARTNER for sheet metal. We have adequate
workforce in the tool room to streamline the processes and deal with inconsistency in the
operational process. We follow stringent quality control measures at every stage of the
production process and we have expert team available who are completely fit to confront
global requirements.

Subject Teacher and Students At Jyoti SolutionsWorks Private Limited, Pune

 PRESS TOOLS ( SHEET METAL DIES)
Jyoti Toolings is engaged in the manufacturing of Sheet Metal Dies with vast experience
of more than 30+ years. Over the time we have built a team of our expert engineers to
meet the diverse requirements of our clients from various industries. We have a vision to
offer high-quality Dies & sheet metal components, We have now chiseled a niche for
ourselves in the market. Right from conceptualization of the idea to the final delivery,
each stage is stringently put under the system approach to ensure optimum quality.

SHEET METAL CUTTING AND TRIM TOOLS

Metal production includes operations that are designed to change the shape of metals to
conform to the needs of a product. One of the essential parts of these metal forming
methods is cutting, which is far more complex than simply slicing a piece of metal to a
specific size. Jyoti Toolings is a leading firm, engaged in offering accurate and precise
Sheet Metal Cutting Services. With the help of advanced tools and machinery, our
service professionals can precisely cut the metals. The machines used in the cutting
process include hydraulic machines, shearing machines and so on.

STAMPING

Metal stamping is a metal forming process. In this process, stamping presses economically,
rapidly, precisely and in large volumes, shape flat stock sheet metal or metal coils into metal
parts. Metal stamping equipment can produce both two-dimensional and three-dimensional parts,
while simultaneously or continuously stamping, pressing, cutting and forming more. Metal
stamping is popular with manufacturers for its ability to produce uniform parts at high volumes,
all while keeping the costs low.Metal stamping has endless industrial applications, like plumbing,
household appliances, automotive parts and medical stampings. Among the industries in which it
is most popular are: automotive manufacturing, aerospace, healthcare, research and development,
military and defence and electronics.

 Conclusions:
1. To understand the working of manufacturing of sheet metal tools, stamping solutions,
dies, fixtures, and many more.
2. To understand the sheet metal components are being used by various industries like
Automobiles, Consumer durables, Public Sectors.
3. To understand the manufacturing of sheet metal dies & components has put us apart from
the competition by delivering end-to-end services vigilantly
 Experiment No. 10
Aim - Study of Circuit with cam operated pilot valves operating a pilot operated 4way
direction control valve or proximity/ limit switches, solenoid operated 4way direction control
valve for Auto reversing circuit.

Procedure
1] Switch on the three phase connection given to Induction motor
2] Rotate pressure relief valve anticlockwise direction for two minutes
3] By observing the pressure gauge of pressure line adjust pressure between 12 to 15kgf/cm²
4] Check oil level in tank to be full shown by indicator

Theory:

Electro pneumatics is now commonly used in many areas of Industrial low cost automation.
They are also used extensively in production, assembly, pharmaceutical, chemical and packaging
systems. There is a significant change in controls systems. Relays have increasingly been
replaced by the programmable logic controllers in order to meet the growing demand for more
flexible automation

Electro-pneumatic control consists of electrical control systems operating pneumatic power

systems. In this solenoid valves are used as interface between the electrical and pneumatic
systems. Devices like limit switches and proximity sensors are used as feedback elements.

Electro Pneumatic control integrates pneumatic and electrical technologies, is more widely used
for large applications. In Electro Pneumatics, the signal medium is the electrical signal either AC
or DC source is used. Working medium is compressed air. Operating voltages from around 12 V
to 220 Volts are often used. The final control valve is activated by solenoid actuation

In Electro pneumatic controls, mainly three important steps are involved:

Signal input devices -Signal generation such as switches and contactor, Various types of
contact and proximity sensors

Signal Processing – Use of combination of Contactors of Relay or using Programmable

Logic Controllers
 Signal Out puts – Out puts obtained after processing are used for activation of solenoids,

SEVEN BASICELECTRICALDEVICES

Seven basic electrical devices commonly used in the control of fluid power systems are
1. Manually actuated push button switches
2. switches

3. Pressure switches

4. Solenoids

5. Relays

6. Timers

7. Temperature switches

Other devices used in electro pneumatics are

1. Proximity sensors

2. Electric counters

2 Limit switches
Any switch that is actuated due to the position of a fluid power component (usually a piston rod
or hydraulic motor shaft or the position of load is termed as limit switch. The actuation of a limit
switch provides an electrical signal that causes an appropriate system response.
 Fig Shows contact type limit switches

Limit switches perform the same function as push button switches. Push buttons are manually
actuated whereas limit switches are mechanically actuated

Fig- Working of Solenoid valve

Application - This hydraulic circuit can be used in a production operation clamping, locating
such as drilling. Cylinder A is used as a clamp cylinder and cylinder B as a drill cylinder.
 Experiment No. 6

Title - Study of accessory used in hydraulic systems

Aim: To study fundamentals and accessories used in hydraulic system.

Objectives:
 To study the fundamentals of hydraulic systems and understand their role in the industrial
automation.

Introduction

The accompanying material on Hydraulic Systems (HS)

is intended to cover the syllabus of the V Unit of the
subject ‘Hydraulic Machines & Systems” for BE III
(Mech.) of OU.

It also helps to introduce the area to beginners.

Hydraulic systems find extensive applications

in industry. As such the evolution has seen a
great variety of pumps, valves and circuits
including very complex ones. The notes provides a brief coverage of the
working principles of major components and circuits used in hydraulic
systems, and deals with:

i. What and why of hydraulic systems

ii. Pumps used in HS
iii. Accessories – Filters, Accumulators, Heat exchangers
iv. Commonly used Directional and Pressure control valves
v. Important hydraulic circuits.
vi. Hydraulic Servo Systems
 Hydraulic systems are used for transmission of power through the medium of
hydraulic oil. The hydraulic system works on the principle of Pascal’s law which says
that “the pressure in a fluid at rest is transmitted uniformly in all directions” .

The fluid medium used is hydraulic oil, which may be mineral oil or water or
combinations. This area is also known as oil hydraulics.

The power transferred is

Power = Pressure x flow rate in the tubes or hoses.

The schematic of a simple hydraulic system is shown in the figure below. It

consists of:

 a movable piston connected to the output shaft in an enclosed cylinder

 storage tank containing hydraulic fluid
 filter which is in suction line of pump inside the tank or on tank inlet line.
 Electric motor / Diesel or petrol engine which is the primary source of power
 Hydraulic pump driven by motor or engine
 Pressure control valve
 Leak proof closed loop piping.
 Direction control valve which controls the direction of fluid flow so as to
change the direction of motion of a linear or rotary actuator
 Actuator – A cylinder for linear movement or a hydraulic motor for rotary
actuation of load
 Applications of Hydraulic Systems
The chief advantage that hydraulic systems derive is from the high pressures that
can be applied leading to high force or toque by the actuating piston or motor.

Pressures normally used in Industry are 140 bar (140 kgf/ cm2 ≈14 MPA ≈ 2000
psi). But in some specific applications in machine tools and aerospace, 350 bar
(35 MPa or 5000 psi) is also common.

Example: Consider an actuator with a 10 cms diameter piston. If the pressure

applied on the piston is 140 bar, Force that the piston rod delivers

= F = Pressure x Area = 140 * π/4* 102 = 10,996 Kgf = 108 KN.

ie nearly 10 Tons of load can be applied using a 10 cms dia cylinder. If the
pressure is 350 bar, load will be 25 Tons.

Similarly high torques can be applied with a small sized motor compared to an
electric motor. The high Power / Weight ratio of the hydraulic actuators is the
prime reason for use of hydraulics.

Application areas:
Hydraulic systems are generally used for precise control of larger forces. The
main applications of hydraulic system can be classified in five categories:
Industrial: Plastic processing machineries, steel making and primary
metal extraction applications, automated production lines, machine tool
industries, paper industries, loaders, crushes, textile machineries, R & D
equipment and robotic systems etc.
Mobile hydraulics: Tractors, irrigation system, earthmoving equipment,
material handling equipment, commercial vehicles, tunnel boring
equipment, rail equipment, building and construction machineries and
drilling rigs etc.
Automobiles: brakes, shock absorbers, steering system, wind shield, lift
and cleaning etc.
Marine applications: Controls in ocean going vessels, fishing boats and navel
equipment.
Aerospace equipment: R udder control, landing gear, breaks, flight control
and transmission, rocket motor movement
 Advantages and Disadvantages of Hydraulic systems
Advantages of Hydraulic systems

 High power to weight ratio compared to electrical systems

 Allows easy control of speed and position, and direction
 Facilitates stepless power control
 Allows combination with electric controls
 Delivers consistent power output which is difficult in pneumatic or
mechanical drive systems
 Performs well in hot environment conditions

Compared to Pneumatics:
 Much stiffer (or rigid) due to incompressible fluid
 Better speed of response
 Better lubricity (less friction) and rust resistance
 Low maintenance cost.

Disadvantages

• Material of storage tank, piping, cylinder and piston can be corroded

with the hydraulic fluid. Therefore one must be careful while selecting
materials and hydraulic fluid.
• Structural weight and size of the system is more which makes it unsuitable
for the smaller instruments.
• Small impurities in the hydraulic fluid can permanently damage the
complete system. Therefore suitable filter must be installed.
• Leakage of hydraulic fluid is also a critical issue and suitable
prevention method and seals must be adopted.
• Hydraulic fluids, if not disposed properly, can be harmful to the environment.
 Relative advantages of different power transmission systems:
Each type of power transmission and control system has specifically suitable application
areas. However, we can make some general comparisons between them.

Fluid power and Electrical are good at transmitting power over long distances, and also better
controllable compared to mechanical devices. Electrical devices are the cheapest. Hydraulic
systems have better power/weight ratio. In terms of cost, electrical would be the cheapest.

Following table gives a relative comparison of Hydraulic, pneumatic and Mech / EM systems .

H – Hydraulic; P – Pneumatic M – Mechanical/Electromechanical; E – Electrical

Property Best Good Fair

Torque/Inertia H P M

Power /weight H,P - M

Rigidity H M P

Dirt vulnerability E,M - H,P

Speed of response E H M. P

Compactness E H M,P

Ability to work in - P,M,H E

adverse conditions

Relative cost M,E H,P -

Hydraulic fluids:
The general requirements of fluids in power transmission are :

1. Low cost
2. Non-corrosive
3. Have infinite stiffness
4. Good lubrication properties
5. Store well without degradation
6. Non-toxic
7. Non-inflammable
8. Properties remain stable over wide range of temperatures.
 Many types of fluids are used ranging from water, mineral oils, vegetable oils, synthetic
and organic liquids. Water was the first liquid used and is very cheap. But its
disadvantages are – freezes easily, rusts metal parts, boils and relatively poor lubricant.
Mineral oils are far superior in these properties. Its success also lies in – the ease with
which their properties can be changed with additives.

Additives used are - various chemicals like phenols and amines, chlorine and lead
compounds, esters, organo-metallic compounds, for change in properties such as:
1. Antioxidants
2. Corrosion inhibitor
3. Rust inhibitor
4. Anti-foam
5. Lubrication improver
6. Pour point depressant
7. Viscosity index improver.

FILTERS
When hydraulic fluids are contaminated, hydraulic systems may get damaged and malfunction
due to clogging and internal wear . They require filtration to remove contaminants.

Filters are classified as

i. Reservoir filters:
ii. Line filters
iii. Off-line filters
iv. Other cleaning equipment
1. Reservoir filters: These may be installed in the reservoir at the pump suction port
or in the return line cleaning the liquid returning to the port.
Suction type filter consists of a core rolled up with a filter paper and submerged in
working fluid. Typically they use 100 micron filter papers.
Return filters or either mounted on the reservoir or in the lines.
Filtration ratings in return lines vary from 10 micron to 35 micron, lower micron
rating being used for higher pressures.
2. Line filters: These are installed when high filtration is required and are used to
avoid high suction at the reservoir filters. These are used with a separate line
connection. Filter selection depends upon pressure, flow rate and filtration rating.
3. Off-line filters: These filters clean fluids in a reservoir using a dedicated pump
and filter separate from the line. These are used when higher cleaning level is
required.
4. Other equipment include air breather (filtering out dust in the air), oil filling port
or magnetic separator to absorb iron powders in reservoir.
 ACCUMULATORS:
These are used to supply additional fluid when main line fluid pump is inadequate
to perform the actuation. Usually gas filled bladders at high pressure act on the
reservoir of fluid in the accumulator to make up for the required line flow.
Accumulators are used
i. to accommodate large flow rates or to compensate leakages.
ii. Absorb pulsations and reducing noise
iii. To absorb shocks.

Types:

i. Bladder type: Separates gas from oil by a rubber bladder

ii. Diaphragm type: Sometimes used as a small accumulator
iii. Piston type: Shaped as a cylinder without a rod
iv. Spring type, weight loaded type.

HEAT EXCHANGERS:
Energy generated by prime movers transforms to thermal energy which increases the temperature
of the working fluid. High temperatures deteriorate the fluid properties and result in shorter fluid
life. Hence it is required to cool the oil to certain level for smooth operation.

Typical heat exchangers used are:

i. Tubular heat exchangers: This delivers cooling fluid through copper tubes to
accomplish heat exchange between fluid and cooling water.
ii. Plate heat exchanger: This consists of many thin cooling plates which exchange heat
with cooling water.
iii. Air cooing radiator: Forced air flows through tubes and cools the fluid
iv. Refrigerant exchanger: This is like a domestic refrigerator and dissipates heat from
fluid. It consists of a hydraulic pump, a motor and thermos stat . It is used when
accurate temperature control is needed.

Heaters: In cold regions, viscosity becomes high causing high pressure loss in the system. Hence
electronic heater or steam heaters are used for heating the oil to the desired temperature