3ME05: CONTROL ENGINEERING

Dr. Ketul Brahmbhatt

Mechanical Engineering Dept’
BVM Engineering College-
V.V.Nagar

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 Course Objective:
To develop know how for implementation of control system
for engineering application

3ME05.pdf

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Hydraulic and Pneumatic Control System

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 Need to create a linear motion
 Need to supply force required
 Force*Displacement = Work required
 Work required per unit time= Power
 Need to supply power - Power can be supplied from a
prime mover, electrical motor and so on
 Power from the electrical motor is to be transmitted to
create linear motion with required force

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A load W to be lifted up to 500 mm at constant speed, v mm/s; shall be returned to
original position
ELETRO-MECHANICAL POWER
TRANSMISSION POWER

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Hydraulic System

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Pneumatic System

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 Fluid Power Transmission
Fluid power is a term which was created to include the
generation, control, and application of smooth, effective
power of pumped or compressed fluids (either liquids or
gases) when this power is used to provide force and motion
to mechanisms.
This force and motion may be in the form of pushing,
pulling, rotating, regulating, or driving.
Fluid power includes hydraulics, which involves liquids,
and pneumatics, which involves gases.
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 Fluid power systems are widely used for materials handling
operations such as clamping, shifting, positioning and
orientating.
 Such operations may be in packaging, feeding and positioning
components in machines into suitable positions for drilling,
milling, etc., sorting and stacking parts, positioning
components for stamping and embossing, and transferring
materials between machines.
 Fluid power systems are also used to sense the position of
components and feed such information to a controller which
can then determine which actuator needs to be actuated.
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Energy generating Source → Power Transmission → Energy-
use area
➢Power can be transmitted through mediums like solids,
liquids and gases
➢Mechanical Power Transmission, Electrical Power
transmission, Fluid Power Transmission
➢Mechanical elements like links, gears, chains, cams, levers

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 Pascal's law
Pascal's law or Pascal’s principle, was discovered over 350 years by a
French mathematician Blaise Pascal.
“the pressure change occurring at any point in a confined fluid will
be transmitted equally in all direction. When you apply pressure on
an enclosed fluid, it will be distributed equally undiminished.”

That is, the pressure of the fluid at the bottom of the container will be
equal to the pressure at top of the container.

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 The relationships
between force,
pressure, flow and
speed

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 FORCE IS CONTROLLED BY PRESSURE
 VELOCITY/RPM IS CONTROLLED BY FLOW
 DIRECTION OF FLUID FLOW HAS TO BE CHANGED FOR RETURN TO SUMP

Energy Hydraulic Pressure flow Hydraulic

Generating pump rotary and direction actuator
Source or linear control motor or
cylinder

Energy use area

(Load)

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 Hydraulic system schematic of a large
airliner
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Power Analogy
Conversion of power from electrical to mechanical to hydraulic to output
mechanical in a hydraulic system ….

Electrical Hydraulic Hydraulic Load

Motor Pump cylinder or P=Fv
P=VI P=Tω motor P=pQ
• P=Power
• V= Voltage • F= Force
• I= Current • V= Velocity
• T= Torque • ω= Angular Velocity
• Q= Flow rate

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Comparison

Movement of pressurized fluid resembles the action of electric

current in an electrical system
 Electrical energy is continually moving when work is being
done.
 The same is true of a fluid power system
 For DC system, speed can be varied by the flow of a current;
for AC phase shifting is used for speed control
 Infinite speed variations in hydraulic systems – through pumps
or flow control valve

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 Crude speed control in pneumatic systems due to springiness of
the gas ,Slight compressibility of hydraulic fluids can be used to
absorb small, erratic machine movements which cause pressure
variations.
 Gravity, springs, and compressed gases provides potential energy
– stored form
 Pressure control valve controls or regulates pressure by restricting
the flow
 Direction control in electrical system is usually obtained by
reversing an electric motor

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 Potential energy is removed when electrical system is switched off
– could be hazardous in hydraulic system
 Use of fuse and grounding in electrical systems to prevent
overloads, which might lead to excessive heating or fire
 Hydraulic and pneumatic systems do not have such comparable
fuses (similar provisions can be made)
 Line leakage, flammability of oil are issue

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Aspect Electrical Hydraulic Pneumatic
Energy Usually from outside Electric motor or Electric motor or diesel
source supplier diesel driven driven
Energy Limited
Limited (batteries) Good (reservoir)
storage (accumulator)
Distribution Excellent, with Limited basically a Good. Can be treated as
system minimal loss local facility a plant wide service
Energy cost Low cost Moderate cost High cost
Short motion via
Linear solenoid. Otherwise Cylinders. Very Cylinders. Medium
actuators via mechanical high force force
conversion

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Aspect Electrical Hydraulic Pneumatic
AC and DC motors.
Low speed. Good Wide spread range.
Rotary Good control on DC
control. Can be Accurate speed
actuators motors. AC motors
stalled control difficult
cheap
Possible with solenoid
Controllable & DC motors Controllable high Controllable mediu
force complicated by need force m force.
for cooling
Leakage dangerous
Dangers from electric
Problems and unsightly. Fire Noisy
shock
hazard
Complexity Simple Moderate Multiple complex
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Aspect Electrical Hydraulic Pneumatic
Peak power High Very high High
Flexibility of motion
control Simple valves User must control capabilities with
electronic controller
Mid-stroke position
Position capability and
Position Very difficult to requires with
velocity control allow
accuracy achieve position additional
for synchronization
components
Speed Very high speed Moderate speed Moderate speed
High load rating
Extremely high
Load rating High load rating depended on the speed
load rating
and position desired.
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Aspect Electrical Hydraulic Pneumatic
Moderate life time – With proper maintained
With proper
Life time easy to replace if long life
maintained long life
needed
Acceleration Very high Very high Moderate
Able to handle the Shock proof , spark
Shock loads
shock load proof
Hydraulic fluid leaks
Environmental High noise level Minimal
& disposal
Efficiency Low Low High
Reliability Excellent Good Good
High amount of High amount of No maintenance
Maintenance
Maintenance Maintenance throughout life
Purchase cost Low High High
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 Summary
Electric power excels for constant-speed rotary power
 Pneumatic power provide resilient power with fast reversal for either linear or
rotary output
 Forces developed in pneumatic system are limited – relatively low gas or air
pressure
 Hydraulic fluid power systems excel for infinitely variable speed, precise
control of applied force, and instant reversibility in linear and rotary
applications
 All three systems considered here are superior to mechanical power
transmission systems because of relative freedom of position of the power
transfer devices

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Fluid power plant symbols

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Fluid power plant symbols

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Components of hydraulic system
Power pack Control valves

Tank / reservoir Direction

Oil Pressure
Filters Flow
Strainers
Prime movers
Pumps
Oil level and Temperature indicators
Heat exchangers

Actuators Accessories
Cylinders Accumulators
Motors Pressure gauges
Temperature gauges

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 1 – pump
2 – oil tank
3 – flow control valve
4 – pressure relief valve
5 – hydraulic cylinder
6 – directional control
valve
7 – throttle valve

A typical hhydraulic system

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Power pack
Elements of Power Pack:
• Tank
• Oil
• Filters & Strainers
• Breathers
• Pump
• Electrical Motor
• Heat Exchangers
• Oil level indicators
• Pressure and Temperature
gauges

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Advantages and Disadvantages of Hydraulic Systems.
There are certain advantages and disadvantages in using hydraulic systems rather than other
systems.
1. Hydraulic fluid acts as a lubricant, in addition to carrying away heat generated in
the system to a convenient heat exchanger.
2. Comparatively small-sized hydraulic actuators can develop large forces or torques.
3. Hydraulic actuators have a higher speed of response with fast starts, stops, and
speed reversals.
4. Hydraulic actuators can be operated under continuous, intermittent, reversing,
and stalled conditions without damage.
5. Availability of both linear and rotary actuators gives flexibility in design.
6. Because of low leakages in hydraulic actuators, speed drop when loads are applied
is small.

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On the other hand, several disadvantages tend to limit their use.

1. Hydraulic power is not readily available compared to electric power.

2. Cost of a hydraulic system may be higher than that of a comparable electrical
system performing a similar function.
3. Fire and explosion hazards exist unless fire-resistant fluids are used.
4. Because it is difficult to maintain a hydraulic system that is free from leaks, the
system tends to be messy.
5. Contaminated oil may cause failure in the proper functioning of a hydraulic
system.
6. As a result of the nonlinear and other complex characteristics involved, the design
of sophisticated hydraulic systems is quite involved.
7. Hydraulic circuits have generally poor damping characteristics. If a hydraulic circuit
is not designed properly, some unstable phenomena may occur or disappear, depending
on the operating condition.

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Hydraulic Servo System

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It is essentially a pilot-valve-controlled hydraulic power amplifier and actuator. The
pilot valve is a balanced valve, in the sense that the pressure forces acting on it are all
balanced. A very large power output can be controlled by a pilot valve, which can be
positioned with very little power.

Similar to the hydraulic servo system, for negligibly small load mass the servomotor
acts as an integrator or an integral controller. Such a servomotor constitutes the basis
of the hydraulic control circuit.

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 Block Diagram:

Dashpots

(a)
(b)

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Dashpots. The dashpot (also called a damper) shown in Figure (a) acts as a
differentiating element.

Suppose that we introduce a step displacement to the piston position then the
displacement z becomes equal to y momentarily. Because of the spring force, however,
the oil will flow through the resistance R and the cylinder will come back to the original
position. The curves y versus t and z versus t are shown in Figure (b).

Let us derive the transfer function between the displacement z and displacement y.
Define the pressures existing on the right and left sides of the piston as and respectively.
Suppose that the inertia force involved is negligible. Then the force acting on the piston
must balance the spring force. Thus

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Since the flow through the restriction during dt seconds must equal the change in the
mass of oil to the left of the piston during the same dt seconds, we obtain

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Hydraulic Proportional Controller

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