FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA.

DEPARTMENT OF MECHATRONICS ENGINEERING.

MCE 416 (MECHATRONIC SYSTEM LABORATORY 2)

PRACTICAL TITLE: ELECTRO-HYDRAULICS

SYSTEM

JOHN GIDEON ONORUOIZA

2021/1/81801ET
02/05/2025

EXPERIMENT 1: Operating a Double Acting Cylinder Using Push Button

OBJECTIVES:

At the end of this practical, the students should be able to:

1. Read and translate electronic circuit into reality

2. Build and operate a simple double acting cylinder electro- hydraulic system operated by push
button

EQUIPMENT REQUIRED:

1. Power unit

2. TPS-3860/B – Hydraulic metal base

3. TPS-3860/E – Hydraulic accessories

4. HYD-386B – Double acting cylinder 50 mm modules

5. HYD-386O – 4/2way spring return solenoid valve module

6. PNL-3810

7. 12V power supply

8. Banana wires

THEORY:

Some systems are electrically connected or operated. A hydraulic system or circuit can be operated by
pressing a pushbutton.

In this experiment, we will learn about some electro-hydraulic and electric components.

The first component we use is a 4/2 solenoid valve

 Figure 1

This is a spring-return valve. The square with the diagonal line (next to the lever) indicates an electric
coil. Current flowing through this coil activates the valve, thus air flows from input P to output A.

Figure 1 describes a circuit that includes a single acting cylinder operated by a 3/2 single solenoid valve.
The electric circuit described in figure 1 operates the valve.

We usually design electro-hydraulic circuits in two stages:

1) Designing the hydraulic system.

2) Designing the electric system. The conventional way of planning an electric circuit in the electro-
hydraulic field is called a Ladder Diagram. This method enables us to plan the circuit in a simple and
organized way

Figure 2 Operating a Double Acting Cylinder with a Solenoid/Spring Valve by push button

In figure 3, you can see a simple ladder diagram. This ladder diagram describes the operation of the
solenoid SV1 by the pushbutton switch PB1. Pressing PB1 closes the circuit and current flows to the coil
in the SV1 valve. The current causes the valve to change its state exactly as in a similar valve operated by
air.
 Figure 3 The Electric Circuit that Operates the Valve

The control circuit is built in the shape of branches which remind us of a ladder. This is why this kind of
electric circuit is called a ladder diagram.

The two perpendicular lines (on both sides of the diagram) indicate the voltage supply lines (the positive
and negative).

The valve's solenoid coil is called SV (Solenoid Valve). In figure 3, one of the coil's terminals is
connected to the positive line of the power supply and the other terminal is connected to the negative line
via a pushbutton switch.

The power supply's negative pole connects to the solenoid's coil and operates the valve when the
pushbutton is pressed.

The voltage supply lines can be replaced without affecting the system's behavior.

ELECTRONIC CIRCUIT BOARD:

PROCEDURE:

Safety rules:
 1. Before connecting or disconnecting components, make sure that the power unit is in the OFF
position and that the pressure gauge indicates no pressure.
2. Always ask your instructor for permission before switching the power unit ON.
3. Be careful while charging the accumulator with gas.
4. Make sure that it is done in accordance with the safety rules.

Step 1: Install the electric component module PNL-3810 on the system's panel.

Step 2: Install the double acting cylinder module on the system's panel.

Step 3: Install the 4/2 single solenoid valve module.

Step 4: Implement the following hydraulic system.

Step 5: Implement the electric system described in figure 7 as follows:

Step 6: Turn ON the power unit and allow oil to flow into the system.

Step 7: Connect the 12V power supply to the power inlet socket on PNL-3810.

Step 8: Press the pushbutton. The piston should pop out.

Step 9: Release the pushbutton. The piston should pop back in.

OBSERVTION(S):

1. Pressing the push button causes the double acting cylinder to extend.
2. Releasing the button retracts the cylinder due to the spring-return solenoid valve.
3. The system responds immediately to button input, confirming correct electrical and hydraulic
integration.
PRECAUTION(S):

1. Ensure the power unit is turned off before making any connections.
2. Verify the pressure gauge reads zero before starting.
3. Only operate the system with instructor permission.
4. Handle all hydraulic components carefully to avoid leaks or damage.

CONCLUSION:

The experiment successfully demonstrated how a push button can control a double acting cylinder using a
4/2 spring-return solenoid valve in an electro-hydraulic setup.
Experiment 2 Operating a Double Acting Cylinder Using Switches

OBJECTIVES:

At the end of this practical, the students should be able to:

1. Read and translate electronic circuit into reality

2. Build and operate a simple double acting cylinder electro- hydraulic system using switch(es)

EQUIPMENT REQUIRED:

1. Power unit

2. TPS-3860/B – Hydraulic metal base

3. TPS-3860/E – Hydraulic accessories

4. HYD-386B – Single acting cylinder 50mm module

5. HYD-386O – 4/2 way spring return solenoid valve module

6. PNL-3810

7. 12V power supply

8. Banana wires

THEORY:

Various consumers with different currents and voltages are needed to operate many electro-hydraulic
systems in the industry.

For example, a solenoid valve needs various voltages according to its size. A regular solenoid valve needs
a current above 2A, while a small solenoid valve need a current of 200mA-1A. This is why we need
components such as relays which can be operated with low currents and in turn can operate a solenoid
valve which is operated with high currents.
 Figure 1

Figure 2

The relay is composed of an electromagnet (a coil with an iron core) and three contacts which create two
switches with a common contact. One switch is Normally Close (N.C.) and the second one is Normally
Open (N.O.). When current flows in the electromagnet coil, the switches change their state.

The symbol of the relay's coil is:

The symbols of the connections are:

a) Normally Open connection:

b) Normally Close connection:

The relay's electric circuit is dismantled into two branches. The first branch includes the relay's coil and
the second branch includes the relay's switch.
The relay's coil R1 is connected (in its own circuit) to the pushbutton switch PB1.

The relay's coil R1 is used as a Normally Open (N.O.) switch which operates the solenoid valve's coil
SV1.

The connection between the two branches is because of the name R1 which appear on the relay's coil and
on the relay's switch. When the coil is operated, the switch is also operated.

ELECTRONIC CIRCUIT BOARD:

PROCEDURE:

Safety rules:

1. Before connecting or disconnecting components, make sure that the power unit is in the OFF
position and that the pressure gauge indicates no pressure.
2. Always ask your instructor for permission before switching the power unit ON.
3. Be careful while charging the accumulator with gas.
4. Make sure that it is done in accordance with the safety rules.

Step 1: Install the electric component module PNL-3810 on the system's panel.
Step 2: Install the single acting cylinder module on the system's panel.

Step 3: Install the 4/2 single solenoid valve module.

Step 4: Implement the following hydraulic system.

Step 5: Implement the electric system described in figure 2 as follows:

Step 6: Turn ON the power unit and allow oil to flow into the system.

Step 7: Connect the 12V power supply to the power inlet socket on PNL-3810.

Step 8: Press the PB1 pushbutton.

The K1 relay should be activated and in turn operates the valve's coil. The valve should flow air into the
piston which pops out.

Step 9: Release the relay. The whole process will be inverted and the piston will pop in.

OBSERVTION(S):

1. Pressing the switch activates the relay, which in turn powers the solenoid valve.
2. The valve allows oil flow, extending the piston.
3. Releasing the switch causes the relay to disengage, retracting the piston.
4. The relay successfully acted as an intermediary control for the valve.

PRECAUTION(S):

1. Confirm that the power is off and the system is depressurized before connecting components.
2. Get instructor approval before turning on the power unit.
3. Use proper safety measures when handling hydraulic or electrical components.
4. Ensure all wiring and hydraulic lines are securely connected.

CONCLUSION:

Using switches and relays allowed controlled activation of the cylinder. The experiment highlights the
importance of relays in handling components with varying current requirements.
Experiment 3 Operating a Double Acting Cylinder Using a Relay

EXPERIMENT REQUIRED:

1. Power unit

2. TPS-3860/B – Hydraulic metal base

3. TPS-3860/E – Hydraulic accessories

4. HYD-386B – Single acting cylinder 50mm module

5. HYD-386O – 4/2 way spring return solenoid valve module

6. PNL-3810

7. 12V power supply

8. Banana wires

OBJECTIVES:

At the end of this practical, the students should be able to:

1. Read and translate electronic circuit into reality

2. Build and operate a simple double acting cylinder electro- hydraulic system using switch

THEORY:

Various consumers with different currents and voltages are needed to operate many electro-hydraulic
systems in the industry.

For example, a solenoid valve needs various voltages according to its size. A regular solenoid valve needs
a current above 2A, while a small solenoid valve need a current of 200mA-1A. This is why we need
components such as relays which can be operated with low currents and in turn can operate a solenoid
valve which is operated with high currents.
 Figure 2-7

Figure 2-8

The relay is composed of an electromagnet (a coil with an iron core) and three contacts which create two
switches with a common contact. One switch is Normally Close (N.C.) and the second one is Normally
Open (N.O.). When current flows in the electromagnet coil, the switches change their state.

The symbol of the relay's coil is:

The symbols of the connections are:

a) Normally Open connection:

b) Normally Close connection:

The relay's electric circuit is dismantled into two branches. The first branch includes the relay's coil and
the second branch includes the relay's switch.

The relay's coil R1 is connected (in its own circuit) to the pushbutton switch PB1.
The relay's coil R1 is used as a Normally Open (N.O.) switch which operates the solenoid valve's coil
SV1.

The connection between the two branches is because of the name R1 which appear on the relay's coil and
on the relay's switch. When the coil is operated, the switch is also operated.

ELECTRONIC CIRCUIT BOARD:

PROCEDURE:

Safety rules:

1. Before connecting or disconnecting components, make sure that the power unit is in the OFF
position and that the pressure gauge indicates no pressure.
2. Always ask your instructor for permission before switching the power unit ON.
3. Be careful while charging the accumulator with gas.
4. Make sure that it is done in accordance with the safety rules.

Step 1: Install the electric component module PNL-3810 on the system's panel.

Step 2: Install the double acting cylinder module on the system's panel.

Step 3: Install the 4/2 double solenoid valve module.

Step 4: Implement the following hydraulic system.

Step 5: Implement the electric system described in figure 2 as follows:

Step 6: Turn ON the power unit and allow oil to flow into the system.

Step 7: Connect the 12V power supply to the power inlet socket on PNL-3810.

Step 8: Press the PB1 pushbutton.

The K1 relay should be activated and in turn operates the valve's coil. The valve should flow air into the
piston which pops out.

Step 9: Release the relay. The whole process will be inverted and the piston will pop in.

OBSERVTION(S):

1. Activating the push button energized the relay coil.

2. The relay then activated the solenoid valve, causing the piston to extend.
3. Upon releasing the button, the relay de-energized, and the piston retracted.
4. The response was smooth and reliable, confirming proper relay function in the circuit.
PRECAUTION(S):

1. Disconnect power before any wiring or hydraulic connection.

2. Make sure the pressure gauge reads zero before adjustments.
3. Only energize the system under supervision.
4. Follow all relevant lab safety protocols during setup and operation.

CONCLUSION

The relay-based control successfully operated the double acting cylinder. The experiment reinforced how
relays isolate low and high voltage/current systems in an industrial control setup.