Hydraulic valves Capacity coefficient Servo valves ure relief precplicl = reas Hydro mechanical seryy wal Poppet vatves C ind pressure relief valves Sliding spool valves a Electrobydraulic servo Rotary spool valves valtes oy Directional control valves Flow control valves amine Ps compensated Single stage servo valves Non-return valves flow control valves ‘Two stage servo valves Position valves flow Jet pipe servo valves ‘Shuttle vaives Pressure compensated ae 22. DC valves control valves Flapper 0 valves ‘32 DC valves Volume control valves Proportional valves 422 DC valves Speed control valves, Proportional pressure reliet 423 DC valves A valves Pressure control valves pibicGina! Pressure limiting valves Butterfly valves we — Pressure reducing valves Plug-type valves ‘Sequence valves Ball-type valves Proportional direction aa balance valves, Needle valves control valves rane switch ee Hydraulic fase Pressure switches On Directional Control Valves 1. What are the control functions of different valves in hydraulic systems? actuator is controlled. [A.U, Nov/Dec 2007] a a # To control the direction of flow by which the direction of 2. Pressure control valves: To control the pressure of th fluid i , Pon the force exerted by actuator is controlled, 1¢ fluid in the circuit by whi 3. Flow control valves: To control the flowrate of fl of the actuator is controlled. luid in the circuit by which the speed | 2. Name the three basic types of control val can 1. Directional control valves, — 2. Pressure control valves, and 3. Flow control (or volume control) valves,ra CO ————— i canponents (Hydraulic Valves) Se 6.47 the three types of cont “ is Ch ig ‘rol valves based on their configuration ? 1 sliding spool valves, and + poary spool valves. what is the function of a DCV ? oa of a directional control valve (DCV) is to control the direction of flow in a ow do you classify directional control valves ? [A.U, Nov/Dec 2005] 4. Based on the construction, the DCVs are classified as: ; (i) Poppet (or seat) valves, (i) Sliding spool valves, and (iii) Rotary spool valves. 3, Based on the number of ports present, the DCVs are classified as: (i) Two way valves, (if) Three way valves, and (iif) Four way valves. . What are the function of check valves ? Check valves are used : (i) toallow free flow in only one direction, and (ii) to prevent any flow in the other direction. . What is the difference between a simple check valve and a pilot check valve ? The simple check valve does not permit any reverse flow. The pilot-check valve can lw luid flow in both directions, but the reversed flow depends upon the pilot actuation. [A.U,, Apr/May 2005] &. What is two-way valve ? y valves are generally used as check and Two-way valve contains two ports. Two-wat htoff valves. ’. What does a 4/3 control valve represent ? A.43 control valve has 4 ways and 3 positions. ! 2 ". What are the different valve actuation methods used ? 2, Mechanical actuation, 4, Fluid actuation. |. Manual actuation, 3. Electrical actuation, andin Migr ot Prey, 4-way, closed-centre solenoid ope, 11. Give the hydraulic symbol for a S-position, 4-4), [AU, Mayline 1! | direction control valve. ) AB “fly Boy 12. Give the symbol for an electro-pneumatic 3 position 4 way DC valve. (AU, May/hine 2099) 13. Draw the graphic symbol for the following DC valves : (a) Push button operated, four way, two position, spring offset DC vaive, and (2) Solenoid actuator, spring return 4/3 DC valve. [A.U,, Nov/Dec 2008] @ ) | AB AB | PT PT | 14, Draw a neat sketch of the graphical symbol for 3 position 4 way solenoid energized pilot operated tandem centre direction control control valve, [A.U, Apr/May 2010; Nov/Dec 2010) 15. Identify Metre elements, represented in Fig.(a) and Fig.(). ) ra May/June 2012] > SSComponents (Hydraulic Valves) ns. (A) Solenoid actuated, spring ret or i tum 4/2 DC valve, 16, What is the purpose of a shuttle valve? Draw ts graphic Symbol ol, IA.U. Apr/May 2018; Nov/Dec 2010, Nov/Dec 2016; Apr/ 7 Shuitle valves are used when control is required from more than Apr/May 2018) more than one power source. id flow from the second and back up source, ive, when the main source becomes inoperat 4 The graphic symbol of shuttle valve: 11. Draw the ANSI symbols for a pilot-operated check valve. [A.U,, Apr/May 2008] On Pressure Control Valves 18 What are pressure control valves ? Mention any two functions. + Pressure control valves are the devices used to control the fluid pressure in a system. ¥ Functions of pressure control valves are : (i) To limit the maximum pressure in various circuit components as a safety measure. (i) To maintain the desired pressure levels in various parts of the circuits. 19. Name various types of pressure control valves. 1. Pressure limiting (or relief) valves, 2, Pressure reducing valves, 3. Sequence valves, 4, Counter balance valves, and 5. Unloading valves. rressure control valve and pressure relief valve. [AU., Now/Dec 2006] rols the fluid pressure in a system whereas pressure relief over and above the design pressure 2, Differentiate between p' Pressure control valve conti i valve protects a system from excessive fluid pressure limit, in pressure control valves. [A.U,, Nov/Dec 2006] lve that opens is called the cracking pressure, The cracking trol valve is not same. Moreover in most cases, the valve 4. Define ‘pressure override" The pressure at which the ¥ ‘2d closing pressure of the com!Mpdraulics and Preimay, 6.80 justed pressure but the valve closes at aj Poppet cracks at a pressure lower than the le een Scan mine Pressure than at which it cracks. This phenomenon i " a Benween pilot operated and direct operated pressure py za li the difference (AU, May valve? Direct operated pressure relief valves are used where the flow rate and the sys, Pressure are reasonably smaller or there is not much variation in system cere S flow rate Whereas for-a larger flow rate and higher pressure, pilot operated pressure relief valves gy, used. The great advantage of pilot valve is that it ean be kept spatially separated from i, main valve wer 23. Distinguish between the pressure reducing valve and pressure relief valve bY giving the graphical symbols. [4.U., Nov/Dec 2005; May/June 2006; Nov/Dec 2009; Nov/Dec 2010; Nov/Dec 2013) Pressure reducing valve maintains a prescribed reduced pressure at its outlet regardless of the valve inlet pressure. But the pressure relief valve limits the maximum pressure tht can be applied to the Part of the system to which it is connected. oe 24. What is twin ‘Pressure valve? Twin pressure valve, like counter restricted flow in the opposite direction, 2, What is the function of a sequence valve ? 1A.U, May/Sune 2009; Nov/Dec 2012] LU, Now 2 _ The sequence valves are used to control the uid flow to ensure 1 = Particular ordet of priority in the system, Several operations i 26, What is the purpose ofa counterbalance valve » The counterbalance valve is used to permit f in the opposite direction. flow in one direction and restricted flow 27. What is the function of an untoading vatye » lAU, The unloading valve allows pressure tof the flow as long as a remote source maintains ¢ Ne Tat? 2009: Nov-Dec 2011; Now/Dee 201) uild up to Gi an adjustable setting, then bypasses ig, then he preset pressure on the pilot port. —— Oe+ jeatconoent (Hydraulic Valves) te ER hat isthe use of a hydraulic fuse ? ie i /A.U., Apr/May 2005, The ‘ae — eae to an electrical fuse, is used é ae ety me pos: fon ig beyond the allowable limit in order t e Senet from damage. 10 protect the system flow Control Valves 3, What are flow control valves ? Why are they referred as speed-control valves ? (01) ‘Why flow control valve is essential in hydraulic circuits? [A.U., Nov/Dec 2016] ¥ Flow control valves, also known as volume. — regulate : : control valves, are used to the rate of fluid flow to different parts of a hydraulic system. = ¢ Since control of flow rate is a means by which the speed of hydraulic machine elements is governed, therefore flow control valves are also referred as speed-control valves. un. List the three ways of applying flow control valves. [A.U, Apr/May 2011] (i Non-pressure compensated flow control valves, (i) Pressure compensated flow control valves, and (iii) Pressure and temperature compensated flow control valves. 41, Name few non-pressure compensated flow control valves. 1. Disk-type globe valve, 2. Plugetype globe valve, 3. Ball-type globe valve, and 4. Needle valve. 2. Draw the graphic symbol for a pressure-compensated flow control valve. [A.U,, Nov/Dec 2006; May/June 2009] ae | B, Draw the ANSI symbol for: (a) Adjustable, temperature and pressure compensated flow control valve, and (b) Counter balance valve. [A.U,, Nov/Dec 2010] (ee () | es I Pressure and temperature Internally piloted counterbalance valve | | compensated flow control valve cog ae Beer Peasated flow con’ aioe ees65s — Hydraulics and Pheumayic, On Servo Valves YAU, Apr/May 2011; Nov/Dec 2016 34. What is a servo system ? i ‘A servo system is one in which a comparatively large ei by small impulses or command signals and any errors are corrected 35. List six elements of a basic closed-loop servo system. 1. Command signal, 2. Servo amplifier, 3. Servo valve, 4, Actuator, 5. Load, and 6. Feedback transducer. 36. What are servo valves ? Write their purpose in fluid power systems. [A.U, Nov/Dec: 2006; Nov/Dec 2008; Nov/Dec 2013) Y Servo valves are nothing but DC valves having infinitely variable Positioning capability. The servo valves are used to control not only the direction of fluid flow, but also the amount of flow. 37. How can you classify servo valves ? 1A.U,, Nov/Dec 2009) 1. Mechanical type servo valve, and 2. Electrohydraulic servo valve, (@ Single-stage servo valve, (ii) Two-stage servo valve, Gif) Jet pipe servo valve, and (iv) Flapper jet servo valve. 38. Define the terms ‘lap’ and ‘null’ with respect to servo valves. _[4.U., Apr/May 2008) Lap is the length relationship between the metering lands to the Spool and the port openings in the sleeve or body. Y Null is the relational condition between the spool and valve port where the valve supplies no control flow at zero load pressure drop. a 39. Mention any four applications of hydromechanical servo valves, Hydromechanical servo valves are employed in stering devices (such as power steering of automobiles), test and training devi a — ae mobile equipment. ues, copying devices (such as machine tools) 40. How does an electrohydraulle servo valve valve ? In electrohydraulic servo valves, electrical Signal is used to But in mechanical servo valves, mechanical linkages are usc iffer from the hydromechanical ser” [4.U., Nov/Dec 2010] Control the hydraulic output for the same purpose.Cai F jana components (Hydraulic Valves ee write few applications of electrohydraulic Servo valves, « ig, Whatis solenoid valve and how does u work 4 solenoid valve isan electromechancaly ope ¥ The valve can use a two-port desi . ign to regulate design to switch flows between ports, nn” OW OF Use & three or more port [A.U, Nov/Dec 2006; Now/Dec 2009] rated valve, (on Proportional Control Valves {, What are proportional control valves ? Similar to servo valves, proportional valves are also infinite variable position valves. They aso use a variable force direct current solenoid to control the output from the main gol. 4, How does a servo valve differ from proportional valve? [A.U, Apr/May 2010; Nov/Dec 2010] Servo valve spools differ from proportional valve spools because they have no overlap in caste condition. Spool overlap makes proportional valves (and the activators they control) respond slowly. With no overlap or underlap, any servovalve spool movement gives immediate flow and actuator response. However, this type is difficult to manufacture, which makes the valve expensive. 48. List the types of proportional control valve. [A.U, Nov/Dec 2010] 1, Proportional pressure relief valve, 2. Proportional pressure reducing valve, and 3. Proportional direction control valve. On Accessories 4 Name any six ancillary equipment commonly used in the hydraulic system. 1. Fluid reservoir, 2. Filters and strainers, 3. Heat exchangers, 4, Pressure and temperature switches, 5. Accumulators, and 6. Intensifiers. i ir? Wh id reservoir ? (or) What are the functions of reservo at is the purpose of a flui ere Fluid reservoirs are basically used to provide a storage facility for the hydraulic fluid ‘ed by the system, In addition, the reservoirs also serve to separate entrained air, remove mtaminants, and dissipate heat from the fluid.Hydraulics and Prema, 6 $4 ? in by systems 48. ‘Whar isthe purpose ofa hea exchanger in ‘ets devices used to dissipate the hey Heat exchangers, also known as hydraulic coolers, generated in a hydraulic system. ie [AU, Apr/May 2008) OIE Se el eae automatically senses a change in temperature A temperature switch is an instrument that ined temperature and opens or closes an electrical switching element when a predetermi Pe Point e ae thee pocssere roi ond Cero [AU, Nov/Dec 2017) Y Pressure switch is used to sense a change in pressure automatically, and opens o, closes an electrical switch when a predetermined pressure is reached. . Y Temperature switch is used to sense a change in temperature automatically, and opens or closes an electrical switch when a predetermined temperature is reached, 51. What is the use of a shock absorber in hydraulic systems 2 A shock absorber is a device that brings a moving load to a gentle rest through the use of metered hydraulic fluid. On Directional Control Valves 1. (@) Explain how poppet type DC valve and a sliding spool type DC valve differ in construction and operation. (©) Which of these two types are mostly used in a hydraulic. system ? Why ? Explain the operational features of the check valve with neat diagram, ; [4.U, Nov/Dec 2006; NowDec 2011) fAns. Refer Section 6.7 How does a pilot-operated direction control valve function? Explain with a diagram a ____ (AU. Nov/Dec 2007; May/Jun 2012] [Ans. Refer Section 6.74] ( Classify the direction control valves in terms of position and explain each with neat circuits, (A.U, Nov/Dec 2016} [Ans, Refer Sections 6.8.7 — 6.10.2 in hydraulic power circuits? Explain the eS ooN = e = g i. § = a & } Nov/Dec 2010} fAns. Refer Section 6.10] o center, and tandem center valves. [AU, Now/Dec 2013) FAns. Refe 0) scribe wit rr Section 6.10) 7. Deseribe withthe help of neat sketch * sxstncion ind option oan On Pressure Control Valves ' Now Dec 2006] (Ans. Refer Section 6.11] 8. Explain the construction of pressure relief valve with neat (4.U, May/June 2012. Apr/Mayke — Hydraulics and Prepay, een Non-return valves : Fluid power symbols devices Graphic symbols Directional control valves Measuring Pamps Pressure valves ew Motors Flow control valves 1 Wilat Rene eee ? Fluid power symbols are used to represent individual components in fluid power cir diagrams, which identify components and their functions uniquely. 2. Draw the graphic symbols for the following pumps : (@) Fixed displacement bidirectional pump, and (0) Variable displacement unidirectional pump. Ans. @ z w® 3. Draw the ANSI symbols for the following motors : (@) Fixed displacement unidirectional motor, and (©) Variable displacement bidirectional motor, 1"rs TR et eR ete am power Symbols 7 J get. , fluid power symbols for the 3/2- and 43-way valve 8. A Prt ais. @ 3/2 - way valve flow cam you indicate the direction of flow (i) for hydraulic fluid, and (i) for _pesmatic fd zs > 5 filled triangle «>. | Indicates the direction of flow for hydraulic fluid (system). F > ‘ ) Unfilled triangle Indicates the direction of flow for pneumatic fluid (system). For the following graphic symbols shown, identify their mode of operation/actuation. oct oA oR @®a Ans, (@) Push button actuation, (c) Lever actuation, and Draw the ANSI symbols for the following hydraulic components (@ Reservoir, (b) Filter, _(c) Cooler, and (d) Accumulator. Ans, @ () a) a @ 0 Le] ea } Cooler ‘Accumulator Filter ing some measuring devices. (b) Pedal actuation, (d) Solenoid actuation. Vented reservoir Pressurised reservoir The following graphic symbols are used for indicat Mentify them. @ 8 (>) ® © © @ Ans, (8 Filling evel indicator, (6) Thermomsee> () Pressure gmige (d) Flow meter. iia Hydraulics and eS ee . meting ! 836 the flow control valve is toca, 3 circuit controls the amoun of fy ontrot circuit, in Y In meter-in-speed (or flow) Thereby this id between the pump and actuator. in Jinder. a Slowing into the cyli al iret, the flow control valve is located of Ps i ni vIn a speed os = reservoir. Thereby this circuit controls th 9, | between the actuator i the actuator. F Slowing out oft circuit, the flow control valve is locates in Y In bleed-off speed (or flow) cooee Thereby this circuit controls the fig , between the pressure line and return line. és bleeding off the excess not needed by the actuator. > i ic circuits are coupled to ger bo icatie lic and pneumatic circuil aes oe 1 Lt eee ee nba and air mediums. This combination circuit is known as cones ‘pneumohydraulic circuits. Example: Air-over-oil circuit Y Hydrostatic transmission is special case of energy transmission system where th, mechanical energy of the input drive shaft is converted into pressure energy in the nearly incompressible working fluid and then reconverted into mechanical energy the output shaft. Y At the end of this chapter, automotive power-steering application of hydro. mechanical servo system and electro-hydraulic servo system are presented. KEY TERMS ONE SHOULD REMEMBER Fluid power circuits Synchronizing circuits Pneumohydraulic circuits Hydraulic circuits Fail-safe circuits Air-over-oil circuit Regerative circuits. Speed control circuits Hydrostatic transmission system Pump-unloading circuit Meter-in circuit Mechanical hydraulic servo system Double-pump hydraulic Meter-out cireuit Electrohydraulic servo system circuit Bleed-off circuit Sequencing circuits Hydropneumatic circuits ANSWERS |. What are the four important factors that should be considered while designing a fi power circuit ? 1. Safety of operation, 2. Performance of desired function, 3. Efficiency of operation, and coe 2. What is the use of a regenerative circuit 2 TAU. Novw/Dec 2019] P the extending speed of the double-stil? cylinder.ial Hydraulic Circuits a phys the load-carrying capaci fs is small ? “pacity of a regenerative cylinder small when the piston rod ___ Regenerative cylinder extending load-carrying capacity fs ee ‘Therefore when piston area (A,) is small, then the load-carryi will also be small, carrying capacity of the regenerative Why & extension stroke faster than retraction stroke in a regenerative circuit ? ___This is because oil flow from the rod end regenerates with the pump flow to provide @ ‘alow rater, which is greater than the pump flow rate to the blank end of the cylinder. ‘& What do you mean by sequencing of cylinders ? (or) What is a sequencing circuit? . [A.U,, Apr/May 2005; Apr/May 2017] “Jn many applications, the operation of two hydraulic cylinders is required to be performed jesequence one after another. This is known as sequencing of cylinders. ‘6, What is the advantage of using sequencing circuit? J [A.U,, Nov/Dec 2013; Nov/Dec 2018] Sequencing circuits automatically move actuators in a predetermined sequence. “1, State the need for synchronization of hydraulic cylinders. _[A.U., Apr/May 2005} "There are many industrial applications which require nearly perfect synchronization of ment of two or more cylinders in order to complete some phase of operation, ‘S§mchronization is required where exact movement is required at both ends of a span, such as rolling equipment, power shears, power brakes, large presses, efc. 4. When synchronizing circuit is required? [A.U, Nov/Dec 2016] Synchronizing circuit is needed to accomplish the identical task from the cylinders at the Sane rate 9. What is the purpose of a fail-safe circuit ? [A.U,, Nov/Dec 2008] Fail safe circuit is designed to safeguard the operator, the machine, and the workpiece. It events any possible injury to the operator or damage to the machine and the workpiece. U0, Where speed control circuits are required? —_[A.U, Nov/Dec 2013; Nov/Dec 2018) Speed control circuits are required to reduce the speed of cylinder from maximum speed based on selected size of final control valve to the nominal speed depending on the plications, IL. Differentiate between meter-in and meter-out circuits with respect to speed control caceta [A.U,, Nov/Dec 2010] ¥ In meter-in circuit, the flow control valve i located in between the pump and the ). Thereby, it controls the amount of fluid flowing actuator (piston side connection into the cylinder. : ; : Y In meter-out circuit, the flow control valve is located in between the actuator (rod side connection) andthe oil reservoir. Thereby, it controls the Auid lowing out ofthe actuator.Bydraulies ard Pres, he Me ae ? [A.U, May/June 2 12, What is “meter-in” circuit? What is its ot flowing into the cylinder, ) ¥ The ‘meter-in’ circuit ae pressure fed to the cylinder due to throting v nts Ue will a a etn system, meter-in circuit; effect of control valve. Hence Se not preferred. 13, What is “meter-out” circuit? What are its limitations? 14.U,, Nov/Dec 2099 ¥ The ‘meter-out” circuit controls the fluid flowing out of the actuator. Y Limitation: Even at no-load, the actuator is subjected to maximum Pressure. Also, a the cylinder is fed with the entire pump pressure, pressure there is possibilty o¢ higher friction loss. 14. What is the function of bleed-off circuit ? LAU, Apr/May 2005; Nov/Dec 2010) Y Bleed-off circuit is used to control the flow of fluid by bleeding off the excess not needed by the actuator. ¥ In bleed-off circuit, the flow control valve is located in between the pressure line and retum line (either before the DC valve or after the DC valve). 15. What are hydropneumatic circuits ? {n some applications, the hydraulic and pneumatic circuits are coupled to get best use of the advantages of both oil and air medi . These combination circuits are known as hydropneumatic or pneumohydraulic circuits, 16. ‘List any four advantages of employing pneumo-hydraulic circuits [A.U,, May/June 2012] 1. Using the combination circuit, the oH ing the « uick action of air and smooth, high pressure action of oil can be blended, 2. The hydropneumatic circuits will a ‘These circuits increase the performance ofthe equipment, 1. Make a circuit sketch for control of a double act, io ee ‘draulic cylinder. (AU, NowDec 2008} [Ans. Refer Section 8:4)yors and Intensifiers LS nd of the chapter, the jane’ Purpose, constructio and. mm, and Onset intensifier circuits have been nae operation of the pressure med. 4 formulae Summary : y,sicing of accumulators : por weight-loaded type accumulators : Capacity = P x4 xp For gas-loaded type accumulators : @ Pi Vy = P2V, = PyV, of the accumulator compressed gas supplied Gi) My = 2 0 ti 1000 Size or total voli Volume of th wi) { aa ume -{ A ‘| { Volume of the liquid } required by the system 2 For pressure intensifiers : fe _ Qn Qout P, Intensifier ratio, P. = KEY TERMS ONE SHOULD REMEMBER, Accumulators Accumulator circuits ‘Weight-loaded type Sizing of accumulators Spring-loaded type Capacity of accumulators Gas-loaded type Intensifiers Non-separator accumulators Pressure boosters Separator accumulators Intensifier ratio Piston-type Diaphragm type Bladder type cireuits Accumulator symbols ___ Intensifier symbols ] TWO MARKS QUESTIONS AND ANSWERS "hat isthe function of an accumulator ? I [AU, Nov/Dec 2005; Nov/Dec 2008; Nov/Dec 2010] : " accumulator is @ pressure storage reservoir in which @ non-compressible hydraulic “Telained under pressure from an external source. a eee ie A—_ >» Hydraulics and Prey, iy 934 ic circuits. ir in hydraulic circui aaccumulato [A.U, Nov/Dec is analogous to that of the flywhee| 2. Highlight the need of using an a A I Y The function of hydraulic Se seats aeat f iprocating engine and a capacitor ctr reciprocating engine Han ae or lift, the liquid under Pressure pee be SUpplig vIn a Sere motion of the load. This energy is supplied from hy e ped Hee Soe the lift is moving downward, no large, external energy i, fei aa Ge that period the energy from the pump is stored in the accumutato, 3. What electrical device is accumulator analogous to ? The function of hydraulic accumulator is analogous to that of a capacitor in an Clectricg circuit. ‘ lic systems. 4. Name the basic types of accumulators used in Aydraul or is [A.U, Apr/May 201) 1. Weight-loaded (or dead-weight) accumulators, 2. Spring-loaded accumulators, and 3. Gas-loaded accumulators. 5. What are the uses/functions of accumulators ? accumulators, (or) List any four applications of [A.U, Apr/May 2010; Nov/Dec 2010] Accumulators are used as : (®) Leakage compensator, (it) Auxiliary power source, (iii) Emergency power source, (iv) Hydraulic shock absorber, (vi) Holding device, erc [A.U,, Apr/May 2005] ‘ator operates at constant pressure. 1g the dead-weight of the accumulator. desirable for mobile equipment? Because of the weight loaded ty [A.U,, Apr/May 2008] Pe accumulator is vey " and do not respond quickly to changes inthe system demany "Y heavy; not portable; an 8. What type of gas is used in mae as-loaded accumulators > Why is oxygen not used for tho ged by changin, 7. Why weight loaded type accumulator js un Bas-loaded accumulator. ‘ol used due to the danger i : of es ig explosion. 2007; a [A.U, Nov/Dec 2007; Nov/Dec 2012: Nov/Dec 2013; Apr/May 2017] Pressure intensifier, also known as pressure booster, is used to compress the liquid in a tydmulic system to a value above the pump discharge pressure. 83, What is gained and what is lost in an intensifier? [A.U., Nov/Dec 2010] In intensifier, pressure is gained and the volume is lost. MM, What electrical device is pressure intensifier analogous to ? Pressure intensifier is analogous to a step-up electrical transformer. 18, List the applications of an intensifier. [A.U., Nov/Dec 2011; Nov/Dec 2012] Intensifiers find most useful applications where the output pressure requirements are uch higher than that are obtainable from a pump. Typical applications include punching ses, riveting machines, spot-welders, and in many high-pressure testing machines such as fubing fixtures for testing bursting pressures and high pressure holding fixtures. 16, What is meant by air-oil intensifier? [A.U., Nov/Dec 2005] Air-over-oil intensifier is used for driving a cylinder over a large distance at a low PeSure and then over a small distance at high pressure (such as in punch press application). '. Define the term intensifier ratio. ’ igh outlet pressure (P,) _ Area of large piston (Ay) = ‘Area of small piston (A,) Intensifier ratio = Low inlet pressure (P) "draw the fluid power symbols for ()) 4 pressure intensifier and (ii) gas-loaded type er @ Gii) Symbol for gas-loaded accumulator accumulator. @ Symbol for pressure intensifierss of Pneumatics e a ey F the basic components required f - for any i 1. Air compressor, re me ee system are = ss Control val 2. Air tank, Ives, 6 3. Prime mover, 5 a neumatic actuators, and ; i 4. Air processing equipment ‘ping. @ Air filters, " (iii) Air lubricator Ms Air pressure regulator, , hells (v)_Pneumatic silencer. Al deye, and eS KEY TERMS ONE SHOULD REMEMBER sumatics = sc acyias nei 7 Decne - Charles’ law Regulator Atmospheric pressure Gas-Lussac’s law Lubricator Sundard air General gas law Air dryer Compressor Silencer Air tank Control valves Prime mover Actuators Piping TWO MARKS QUESTIONS AND ANSWERS 1, Define ‘pneumatics’. The pneumatics may be defined as that branch of engineering-science which deals with the study of the behaviour and application of compressed air. 2. Why is air used as the fluid medium in all pneumatic systems ? The air is popularly used as the fluid-medium in pneumatic systems due to the following reasons : (0 Air is abundantly available. (ii) It is safe to use (as it has the fire-proof characteristics). (iti) It is very cheaper in cost. (iv) Easier maintenance and easily handling. (0) It can be exhausted easily to the atmosphere after use. 3. Pneumatic systems cannot provide precise actuator control’—Why ? Due to the high compressibility of air pneumatic systems cannot provide precise actuator tro 4. Pneumatic systems cannot be applied to high-pressure application Why ? Due to compressor design limitations, pneumatic systems can be applied only to low- Prssure (less than 17 bars) applications.i ae Hydraulics ang Pn 10.12 he, 5. accut vp For what type of application, you would prefer to use pneumatic systems on ‘or what type , hydraulic systems. If the application req rate feed, then pneumatic system can be i f pressure, sires speed, a medium amount of and ony, used. REVIEW QUESTIONS (a) What are the reasons for considering the use of pneumatic systems ins hydraulic systems ? / : (b) What are the major drawbacks of using. pneumatic systems. (c) How can you select a fluid medium for a given application. . With a simple sketch, explain the functions and working of basic component ren, for a pneumatic system. (or) Draw the layout of the complete pneumatic system explain its subsystems. [A.U,, May/June 2006; Nov/Dec 201g (Ans. Refer Section ng nv » - PROBLEMS FOR PRACTICE . The atmospheric air is compressed by an compressor to 1/5" the volume. What is gauge pressure of compressed air, assuming the temperature does not change V; [Hint : v = and P, = 1 bar are given; now use Boyle’s law ] [Ans. 5b - $00 cm? of air at temperature 30°C, contained in a cylinder, is heated at const Pressure to a temperature of 70°C. Calculate the increase in volume of air ? [Ans 66m} . Air is contained in a cylinder at P, = 3 bar gauge, and T, = 25°C. If the air is heated» 80°C without changing its volume, what is the new pressure of the air ? [Ans. 3.74 bar gaust] Gas at SO bars gauge and 60°C is contained in the 0.75 m} cylinder. The gis compressed to the volume of 0.6 m? and the temperature increases to 130°C. What's the final pressure of the gas ? [Ans. 76.15 bars gu! ooo. ee 11.20 ma ‘Air receiver size Compressors cae Jacement compreners = iuld conditio reens Air filters ae ‘Air pressure regulators joss ee ‘Air lubricator vane a Muffler Staging Air dryers Single stage compressors ‘Multi-stage compressors -apacity rating of compressors ‘TWO MARKS QUESTIONS AND ANSWERS On Compressors 1. What is the use of a compressor in a pneumatic system ? In pneumatic systems, compressors are used to compress and supply the reqing quantities of air, 2. How are air compressors classified? [A.U, Nov/Dec 2007; NowDec 2 [Leones Positive displacement types, Dynamic displacement types (Turbo compressors) | 4. Centrifugal | Reciprocating Rotary 2. Axial flow eet ‘ypes 3. Mixed flow | 4. Piston 1, Screw | 2. Labyrinth 2 Vane | 3. Diaphragm | | 3 Lobe | 4, Liquid ring | 5. Gear Bl es 3. What are the types of compressors which are used in the fluid power system? [A.U,, Nov/Dec 2005) Piston type, screw type and vane type compressors are used in the fluid power system 4. What does staging mean ? ‘Staging means dividing the total pressure amon, outlet from one cylinder into the inlet of the next eylin ‘wo or more cylinders by allowing inder and so on,gpCompressors and Fluid Conditioners —_!,_— 1. 4, What is multi-stage compressor? When the compression of air from the init [A.U., Nov/Dec 2009] sore tun one cylinder, then the comp initial pressure to the final pressure is carried out ssor is known as multi-sta , \ge compressor. 6, Why are multi-stage compressors preferred over single-stage When the multistage compressors are use. stages. This effective coolin; (gincreases the effi compressors ? d, the effective cooling can be implemented 8 (i) reduces ii i my of the compres es input power requirements, and 1, What is the purpose of compressor starting unloader control ? ‘The ‘starting unloader control’ is used to start the ‘compressor whenever desired. This mangement releases the pressure in the piping to the atmosphere so that the compressor can tesurted whenever needed. 8, How can you specify an air compressor? (or) How can you rate a compressor? {A.U,, Nov/Dec 2006; Apr/May 2008] Air compressors are generally specified by the following : (i) Outlet pressure of air that can be delivered by the compressor, (ii) Capacity of volume of air that can be delivered by the compressor, and (iii) Compressor configuration and cylinder geometry. (On Fluid Conditioners 9, What is the purpose of fluid conditioners ? The purpose of fluid conditioners is to make the compressed air more acceptable and suitable fluid medium for the pneumatic system components as well as for operating personnel 10. Name any four fluid conditioners used in pneumatic systems. 1. Filters, 2, Regulators, 3. Lubricators, and 4, Mufflers. 11, What is the function of air filters ? {A.U, NowDec 2012] The function of air filters is to remove all foreign matter and allow dry, clean air to flow Without restriction to the regulator and then on to the lubricator. 12, Name the various types of filters used in the pneumatic system [A i id 1. Dry filters (with replaceable cartridges), an ; 2 wa ee (where the incoming air is bubbled through an oil bath then passed through a wire mesh filter) 1, Nov/Dec 2006] 13, What is the purpose/function of an air pressure regulator? [AU, Nov/Dec 2008; Apr/May 2017] regulator is to regulate the pressure of the incoming i ir pressure The function of the air Pri red air pressure at a steady condition. Compressed air so as to achieve the desi4 ee ‘ lir pressure repul 14. Sketch the graphical symbol of pneumatic regulator (07 P regulator) AU, 4m May gy 15, What is the need of lubricator unit in the pneumatic system ? [AU, Nov/Dec 2006; May/une 2009 The function of an air lubricator is to add a controlled amount of oil with air to ensure Proper lubrication of internal moving parts of pneumatic components. 16. What do you mean by FRL unit ? [A.U, NowDec 2611) The combination of filter, regulator, and lubricator is often labelled as FRL unit or service unit, 17. Why are mufflers used in | pneumatic systems ? LA.U, Apr/May 2018) The function of mufflers is to control the noise caused by a rapidly exhausting air-stream flowing into the atmosphere. 18. What is the need for air dryers ? [4.U, Nov/Dec 2012] The air dryers are needed to remove all water vapour/moisture from the air leaving the compressor, 19. Draw the graphic symbol of a FRL unit, (AU, May/June 2006; Nov/Dec 2010) ( filter, and (c) muffler. Bom (®) Filter-strainer . Air is | atmospl m/min ¢ » () Cale syste befor (4) What standar displacement compressor (©) MufflerRS TWO MARKS QUESTIONS AND ANSWE! On Pneumatic Valves 1. What are the functions of air control valves if The main functions of pneumatic valves are = (i) To start and stop pneumatic energy; ie (ii) To control the directional flow of compressed air, (iti) To control the flow rate of the compressed air; and (iv) To control the pressure rating of the compressed air. 2. Mention the applications of a 2 way, 3 way, and 4 way DC valves. ase Generally two way DC valves are used as on-off type valves; three way DC valves used to control single-acting linear actuators; and four way DC valves are used to control double-acting actuators. 3. What is the purpose of a shuttle valve in a pneumatic circuit? [A.U., Nov/Dec 2011) Shuttle valves are used when control is required from more than one power source. They are generally used to shift the fluid flow from the second and back up source, when the main source becomes inoperative. 4. What is the purpose of a quick exhaust valve ? Where is this valve installed? [A.U,, Nov/Dec 2010) The quick (or fast) exhaust valve is used to exhaust the cylinder air to the atmosphere quickly, so as to increase the piston speed of cylinders. This valve is installed between the interface valve and the actuator. 5. ‘Quick exhaust valve is used to increase the piston speed of spring return single-acting pneumatic cylinder’ - Justify. [A.U,, May/June 2012] The higher speed of piston in a cylinder is possible by reducing the resistance to flow of the exhausting air during motion of the cylinder. The resistance can be reduced by expelling the exhausting air to the atmosphere quickly by using the quick exhaust valve. 6. What is the function of an air pressure regulator ? [A.U., Nov/Dec 2016; Nov/Dec 2018] The function of the air pressure regulator is to regulate the pressure of the incoming compressed air so as to achieve the desired air pressure at a steady condition. 7. What is the function of a flow control valve ina Pneumatic circuit ? Flow control valves are used to regulate the volumetric flow of the compressed air 10 different parts of a pneumatic system, 8. State the difference between quick exhaust valve and flow control valve [A.U,, Apr/May 2011] atmosphere quickly, 5° ntrol valves are used t0 ‘a pneumatic system. The quick exhaust valve is used to exhaust the cylinder air to the 8s to increase the piston speed of cylinders. On the other hand, flow co regulate the volumetric flow of the compressed air to different parts ofpeas Valves and Actuators ow pneumatic Actuators 9, What is the function of a pneumatic actuator ? Pneumatic actuators are the devices ust i ‘ seta cal energy to perform useful work, ed for converting the pressure energy of air into ee do pneumatic act if 10, How do pi actuators differ from hydraulic actuators ? [AU, Apr/May 2011] tic actuat i i . * ee ee of lighter Construction and of lesser weight when compared to ‘hat , rs. is is because the pneumatic actuators are used mostly for low or edium pressure applications only, 11. What is the function of a pneumatic cylinder ? * Pneumatic cylinders are the devices used for converting the air pressure into linear mechanical force and motion. 12. What is the function of an air motor ? The function of an air motor is to convert the pressure energy of the compressed air into lary mechanical energy. 13, Name the different types of air motors. [A.U,, Apr/May 2018] 1. Continuous rotary actuator, and (a) Gear motor, (b) Vane motors, and (c) Piston motors. 2. Limited rotation hydraulic motors. (a) Vane type, and (b) Piston type. 14, Mention advantages of air motors over electric motors. [A.U,, May/June 2013] ‘Air motors are well-suited to those applications that require a compact, lightweight source of smooth, vibration-less power. Air motors stop and start almost instantly and rovide extremely variable torque and speed without complicated controls. They can operate in hot, corrosive, and wet environments without damage, and are unaffected by continuous Salling or overload. a REVIEW QUESTIONS On Pneumatic Valves Pe i various typed of [A.U., Apr/May 2011] [Ans. Refer Section 12.2.2] ration of a valve-seat type four-way, two-position ir control valves. 2 Describe the construction and ope' directional control valve- 3. What urn valves? Discuss with a diagram the working of a non-return valve, . What are non-re 2 [A.U, May/June 2009] [Ans. Refer Section 12.4] sumatic check valve. 4. Draw ir functions of pne é . ead explsio [AU, Nov/Dec 2007] [Ans. Refer Section 12.4.2] OOOO