FLUID POWER AUTOMATION UNIT-1 Introduction Fluid Power Fluid power is the use of fluids under pressure to generate, control, and transmit power. Fluid power is subdivided into hydraulics using a liquid such as mineral oil or water, and pneumatics using a gas such as air or other gases. Compressed-air and water-pressure systems were once used to transmit power from a central source to industrial users over extended geographic areas. Fluid Power Characteristics Fluid power systems can produce high power and high forces in small volumes, compared with electrically-driven systems. The forces that are exerted can be easily monitored within a system by gauges and meters. In comparison to systems that provide force through electricity or fuel, fluid power systems are known to have long service lives if maintained properly. The working fluid passing through a fluid motor inherently provides cooling of the motor, which must be separately arranged for an electric motor, Fluid motors normally produce no sparks, which are a source of ignition or explosions in hazardous areas containing flammable gases or vapors. Fluid power systems are susceptible to pressure and flow losses within pipes and control devices. Fluid power systems are equipped with filters and other measures to preserve the cleanliness of the working fluid. Any dirt in the system can cause wear of seals and leakage, or can obstruct control valves and cause erratic operation. The hydraulic fluid itself is sensitive to temperature and pressure along with being somewhat compressible. These can cause systems to not run properly. If not run properly, cavitation and aeration can occur. Applications Mobile applications of fluid power are widespread. Nearly every self-propelled wheeled vehicle has either —_hydraulically-operated —_or pneumatically- operated brakes. Earthmoving equipment such as bulldozers, backhoes and others use powerful hydraulic systems for digging and also for propulsion. A very compact fluid power system is the automatic transmission found in many vehicles, which includes a hydraulic torque converter. Fluid power is also used in automated systems, where tools or work pieces are moved or held using fluid power. Variable-flow control valves and position sensors may be included in a servomechanism system for precision machine tools. Below is a more detailed list of applications and categories that fluid power is used for:+ Industrial (also known as fixed) * metalworking «injection molding + controllers + material handling + Aerospace + landing gears + brakes Advantages and Disadvantages of Fluid Power Systems Fluid power systems have several advantages and disadvantages when compared with mechanical and electrical power transfer systems. Several of the important advantages and disadvantages of fluid power systems are presented in the next two sections, Advantages The following list of advantages applies to both hydraulic and pneumatic systems, except as noted. m An easy means of multiplying and controlling force and torque, Infinitely variable speed control for both linear and rotary motion, m Overloading the system simply stalls the actuator without damage to the components. ™ Provides an easy means of accurately controlling the speed af machines and/or machine parts. m Provides the ability to instantly stop and reverse linear and rotary actuators with minimal shock to the system. m Systems easily adapt to accommodate a range of machine sizes and designs. ™ Systems readily adapt to external control methods, including mechanical, pneumatic, electrical, and electronic systems. 1m Systems can easily provide component lubrication. Pneumatics are commonly used where high speeds and lightweight tools are needed. a Large volumes of compressed air may be easily stored in pneumatic systems to provide energy for intermittent, heavy system demand, ™ Pneumatic systems provide clean operation with minimal fire hazardDisadvantages The following list of disadvantages applies to both hydraulic and pneumatic systems, except as-noted. w Higher safety factors associated with high-pressure oil and compressed air. @ Susceptibility to dirty environments, which can cause extreme component wear without careful filtration. = Fluid leakage and spills cause a slippery, messy work environment around hydraulic equipment. @ Fire hazard with hydraulic systems using combustible oils. m Special handling and disposal procedures for hydraulic oil required by environmental regulations. w High cost of compressing and conditioning air for use in pneumatic systems. m Reduced accuracy in actuator speed control in pneumatic systems caused by compressibility of air, ® Noise level of pneumatic systems when air from components. directly exhausted to the atmosphere Need for automation * Reduce Worker Fatigue and Effort or Labor Intensive Operation — Typically, humans dislike banal, repetitive tasks. However, computer systems perform them without complaint. Tasks that lack variability provide a place for automated systems to shine, but this also holds true for systems utilizing advanced sensors and integration. If the task requires conditions not suited to human comfort or focus, consider automation. * Prevent Products or Materials from Being Damaged or Destroyed — Humans make mistakes when they fatigue. This embodies the sentiment of the “human condition.” Mistakes using tools mean damaging raw materials, components, assemblies, and end products, © Prevent Non-conforming Product from Shipping — Computers controlling robots do not forget steps. Neglecting to put in a screw requires 4 human touch, Amachine not doing it yields an error to be addressed. Does the process require doing something in a specific order to improve yield? Automated systems will not violate the instruction set. Moreover, automated systems may employ inspection capabilities. Tune the system and allow the data to roll in without preference or bias. * Increase Efficiency — Improving processes for efficiency makes a company more competitive, but do people always de the same thing, in the same way,every time they do it? No, human variation exists. Automated systems allow for improvements that benefit from consistent execution. Perfect planning and training do not defend against the human touch. * Collect Better Data - Remove the accidental data entry or missed data point from logging. Make the method of collecting sensor and process data regulated. * Improve Metrics —Sending reliatile data directly to a database provides an ongoing resource. Does the process improve with changes? Why do! see more failures now than in the past? Leveraging data can provide these answers beyond a simple list of pass/fail statistics from the past. Correlation of associated process data with pass/fail records provides insight rather than guessing “what is causing this?”. © Devise the Right Process Improvements — Automated systems now collect reliable data. The database provides a searchable forum. What comes next? Equipped with copious amounts of reliable data, engineers make the most of this information. Where problems existed, light shines on the problem, Rather than just changing to seek “continuous improvement,” make changes with better information. * Save Money —Why instrument that test stand? Why log that data? Why spend the money now? Simply, inventing in industrial automation yields cost savings through making processes more regular and collecting data for making confident decision. Intraduction to hydraulic system The controlled movement of parts or a controlled application af force isa common requirement in the industries. These operations are performed mainly by using electrical machines or diesel, petrol and steam engines as.a prime mover. These prime movers can provide various movements to the objects by using some mechanical attachments like screw jack, lever, rack and pinions etc, However, these are not the only prime movers. The enclosed fluids (liquids and gases) can also be used as prime movers to provide controlled motion and force to the objects or substances. The specially designed enclosed fluid systems can provide both linear as well as rotary motion. The high magnitude controlled force can also be applied by using these systems. This kind of enclosed fluid based systems using pressurized incompressibie liquids as transmission media are called as hydraulic systems. The hydraulic system works on the principle of Pascal's law which says that the pressure in an enclosed fluid is uniform in all the directions. The force given by fluid is given by the multiplication of pressure and area of cross section. As the pressure is same in all the direction, the smaller piston feels a smaller force and a large piston feels alarge force. Therefore, a large force can be generated with smaller force input by using hydraulic systems. Basic Hydraulic system The hydraulic systems consists a number of parts for its proper functioning. These include storage tank, filter, hydraulic pump, pressure regulator, control valve, hydraulic cylinder, piston and leak proof fluid flow pipelines. The schematic of a simple hydraulic system is shown in fig, Applications of hydraulic systems The hydraulic systems are mainly used for precise control of larger forces. The main applications of hydraulic system can be classified in five categories: > 2.1 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 ete. » 2.2 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. > 2.3 Automobiles: It is used in the systems like breaks, shock absorbers, steering system, wind shield, lift and cleaning etc. > 2.4 Marine applications: It mostly covers ocean going vessels, fishing boats and navel equipment. } 2.5 Aerospace equipment: There are equipment and systems used for rudder contral, landing gear, breaks, flight control and transmission etc. which are used in airplanes, rockets and spaceships.Advantages and Disadvantages of Hydraulic system Advantages » The hydraulic system uses incompressible fluid which results in higher efficiency. > It delivers consistent power output which is difficult in pneumatic or mechanical drive systems. } Hydraulic systems employ high density incompressible fluid. Possibility of leakage is less in hydraulic system as compared to that in pneumatic system. The maintenance cost is less. ® These systems perform well in hot environment conditions. Disadvantage > The 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. > The structural weight and size of the system is more which makes it unsuitable for the smaller instruments. » The small impurities in the hydraulic fluid can permanently damage the complete system, therefore one should be careful and suitable filter must be installed. » The leakage of hydraulic fluid is also a critical issue and suitable prevention method and seals must be adopted. > The hydraulic fluids, if not disposed properly, can be harmful to the environment, Pneumatic Systems A pneumatic system isa system that uses compressed air to transmit and control energy, Pneumatic systems are used in controlling train doors, automatic production lines, mechanical clamps, etcThe advantages of pneumatic systems Pneumatic control systems are widely used in our society, especially in the industrial sectorsfor the driving of automatic machines. Pneumatic systems have a lot of advantages. (i) High effectiveness Many factories have equipped their production lines with compressed air supplies and movable compressors. There is an unlimited supply of air in our atmosphere to produce compressed air, Moreover, the use of compressed air is not restricted by distance, as it can easily be transported through pipes. After use, compressed air can be released directly into the atmosphere without the need of processing. (ii) High durability and reliability Pneumatic components are extremely durable and can not be damaged easily. Compared to electromotive components, pneumatic components are more durable and reliable. (iii) Simple design The designs of pneumatic components are relatively simple. They are thus more suitable far use in simple automatic control systems. Technological Studies Pneumatic Systems (iv) High adaptability to harsh environment Compared to the elements of other systems, compressed air is less affected by high temperature, dust, corrasion, etc. (v) Safety Pneumatic systems are safer than electromotive systems because they can work in inflammable environment without causing fire or explosion. Apart from that, overloading in pneumatic system will only lead to sliding or cessation of Operation. Unlike electromotive components, pneumatic components do not burn or get overheated when overloaded. (vi) Easy selection of speed and pressureThe speeds of rectilinear and oscillating movement of pneumatic systems are easy to adjust and subject to few limitations. The pressure and the volume of air can easily be adjusted by a pressure regulator. (vil) Environmental friendly The operation of pneumatic systems do not produce pollutants. The air released is also processed in special ways. Therefore, pneumatic systems can work in environments that demand high level of cleanliness. One example is the production lines of integrated circuits. (vili) Economical As pneumatic components are not expensive, the costs of pneumatic systems are quite low. Moreover, as pneumatic systems are very durable, the cost of repair is significantly lower than that of other systems. Limitations of pneumatic systems Although pneumatic systems possess a lot of advantages, they are also subject to many limitations. (i) Relatively low accuracy As pneumatic systems are powered by the force provided by compressed air, their operation is subject to the volume of the compressed air. As the volume of air may change when compressed or heated, the supply of air to the system may not be accurate, causing a decrease in the overall accuracy of the system. (ii) Low loading As the cylinders of pneumatic components are not very large, a pneumatic system cannot drive loads that are too heavy. (iii) Processing required before use Compressed air must be processed before use to ensure the absence of water vapour or dust, Otherwise, the moving parts of the pneumatic components may wear out quickly due to friction. (iv) Uneven moving speedAs air can easily be compressed, the moving speeds of the pistons are relatively uneven. (W) Noise Noise will be produced when compressed air is released from the pneumatic components. n Between Hydraulic And Pneumatic System Comp: popaou am wonmoiqn soy siuouatieue yeiseds Sase® passaxdtos prado) pasn are suossaudwog, ydian ut saya] Aswa ame suonesado aapra, yn wants ay aye 10WL s90p aHrxe>] tarsis uado se. poudisop Single Stage With Lead Sensing Air Bleed Valve for Rell Valve Direct Acting Adusable Relief Valve Pilot Opera Adwaatte ‘With Ven Post 1SO Designation Symbol Picture Representation Oa Conta) Hydraaic Purp Varutie Volume 4 pain! 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This technology has advanced rapidly over the last five to 10 years, with vast improvements in functionality, including more precise moventent and even bui sophisticated contrals, 3. Valve sizing, Correct sizing of components, including piping, valves and actuators, can improve the productive capacity of pneumatic systems. Valve sizing is particularly important. If the flaw capacity is too small, it can have a negative impact on production cycles. If you want to improve production cycle time and quality, then proper sizing is critical. 4. Align pipelines. if pipelines are not aligned properly at the correct angle, as indicated in the installation drawings, there is a great possibility of equipment damage. 5. Choose 3-position valves. Wherever operators will be working near an operation, a 3-position valve is a better choice than a 2-position valve. This is because a 3- position valve will stop the equipment instantly in the event of an emergency. This is in contrast to a 2-position valve, which will first complete the operation before stopping. 6, Check temperatures. Be sure to check the surface temperatures of equipment during preventive maintenance time and make a record. High temperatures could damage the viscosity praperties of the hydraulic oil 7, Built-in flow control. When you are using a pneumatic cylinder in a project, especially In high cycle count projects, use a fitting that has a flow control valve built in to make the cylinder last longer. 8. Use feedback sensors. Don't rely on software interlocks to control pneumatic devices unless you account for the delay caused by physical actuation. 100msec is a Jong time in the computer world. Always back up actuators with electrical feedback sensors, redundant if possible.9, Parallel air, Make sure you have an adequate air supply when using pneumatic technology. Costly leaks are often hard to detect in a noisy plant environment. To avoid failure in the supply of compressed air on a network, it is important to verify that the distribution is closed so that the compressed air comes in parallel and not in series. Inspect tubing, ferrule, connection and joints for leakages. Make sure the air being produced is dry. All air filters should be checked periodically for accumulated water drainage. 10, Choose quality tubing. To prevent leaks, use nylon tubing on machines rather than push-on fittings and PE tubing, The leakage often found with soft tubing is hard to detect in a plant environment. 11. Inlet side flow control. In a pneumatic logic circuit controlling a double-acting cylinder, place the flow controls on the inlet side of your cylinder depending on the direction of travel. Air is compressible and positioning will float if controlled on the outlet. This will also create back pressure. 12. Low fire risk. One of the advantages of pneumatic technology is that it can operate without using electricity. This minimizes the risk of fire or explosions from sparks or arc flash events. This technology is particularly useful in a plant making edible oils or hydrogenating oils or when using flammable gases in the production process. Important questions Part-A question 2 Marks What is fluid power? . What are the limitation of fluid power?( Jan 2018) Define hydraulic system and its elements? . Draw the symbol for a 3 position,4 way closed center solenoid operated direction control valve, (Jan2018) Draw any one type of hydraulic system. What are the advantages of fluid power? . Write the advantages of pneumatic system? Draw any four pneumatic symbols? . What are the benefits of automation? 10, Define pneumatic system and its elements? wre wannuPart- B Questions (S,6,7,8 Mark) 13 marks 1. Explain the needs and benefits of Automation. 2. Draw the fluid power symbols of any four accessories. 3. Describe any four application of fluid power system. 4. Describe the advantages and disadvantages of hydraulic power system. 5. Describe the selection criteria for pneumatic and hydraulic power system, 6. Explain the applications for pneumatic power system. 7. Explain the applications for hydraulic power system. 8. Draw the pneumatic circuit for automatic vehicle door open system. 9. Differentiate between hydraulic system and pneumatic system. Part-C Questions 15 marks 1. Briefly Explain the pneumatic and hydraulic power system and its components. 2. Draw the ISO symbols for pneumatic and hydraulic fluid power elements.