PE-4030 Chapter 4

Professor Charlton S. Inao Professor Mechatronics System Design Mechatronics for Armaments Engineering 2012-2013 Defence Engineering College Bishoftu, Ethiopia

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Instructional Objectives
In this lesson, the students shall be able to understand the principle of Pneumatic and Hydraulic System focusing mainly on the following topics: 1. Pneumatic \hydraulic Fundamentals 2. Directional control Valves 3. Pressure Control Valves 4. Flow Control Valves 5. Cylinders and Actuators 6. Rotary Actuators 7. Process Control Valves

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Hydraulic and Pneumatics Fundamentals

Pneumatic Hydraulic

Compressed Air
Light loads,6-8 bars Fast, erratic

Industrial Oil
Heavy loads, unlimited, no OL Slow, stable

Compressor
Compressible Air Receiver/Air Reservoir Exhaust to Atmosphere PU tubes

Pump
Incompressible Tank Liquid back to Tank Hi pressure Wire braided hose

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Hydraulic System

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Hydraulic System

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Hydraulic System

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Hydraulic Reservoir

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Filter Location in hydraulics

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Graphic Symbols

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Circuit symbols for energy transfer (1)

The symbols shown are

used in circuit diagrams for energy transfer and hydraulic-fluid preparation.

In the interests of clarity,

the lines in the circuit diagram should be drawn without cross-overs as far as possible.
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Circuit symbols for energy transfer

The direction of the

arrows in the circuit symbols for the heater and cooler correspond to the direction of heat flow.

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Circuit symbols for energy conversion

Hydraulic pumps are shown

by a circle with a part representation of a drive shaft. Triangles in the circles show the direction of flow. The triangles are shown solid, since pressure fluid is used in hydraulics.
If the pressure medium is

gaseous, as in the case of pneumatics, the triangles are shown in outline.

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Circuit symbols for hydraulic motors

The symbols for

hydraulic motors are distinguished from the symbols for hydraulic pumps by the fact that the arrows showing the direction of flow are the other way round.

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Circuit symbols for single acting cylinders

Single acting cylinders

have one port, i.e. pressure fluid can be applied only to the piston side. With these cylinders, the return stroke is produced either by external force, shown in the symbol by an opening bearing cap, or by a spring is shown within the symbol in this latter case.
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[12] Circuit symbols for double acting cylinders

Double acting cylinders have

two ports to allow pressure fluid to be applied to both cylinder chambers. The symbol for a differential cylinder is distinguished from the symbol for a double acting cylinder by the two lines added to the end of the piston rod. The area ratio is generally 2:1. In the case of cylinders with double- ended piston rods, the symbol shows that the piston areas are of equal size (synchronous cylinders).

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Circuit symbols for directional control valves (1)

Designations for directional control valves always give firstly

the number of ports and then the number of switching positions. Directional control valves always have at least two ports and at least two switching positions. The number of squares shows the number of possible switching positions of a valve. Arrows within the squares show the direction of flow. Lines shown how the ports are interconnected in the various switching positions of the valve. The designations always relate to the normal position of the valve.

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Circuit symbols for directional control valves

This

illustration shows the circuit symbols for 4/2- and 5/2-way valves.

There are two general

methods for the designation of ports, using either the letters P, T, R, A, B and L or consecutively using A, B, C, D etc.; the first method is the preferred one in the relevant standard.
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Circuit symbols for directional control valves (3)

The illustration shows the circuit symbols for 4/3-way valves with various

mid-positions.

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Circuit symbols for manual operation

The switching position of a

directional control valve can be changed by various actuation methods. The symbol for the valve is accordingly supplemented by a symbol indicating the actuation methods shown, such as pushbuttons and pedals, a spring is always necessary for resetting. Resetting can, however, also be achieved by actuating the valve a second time, for example in the case of valves with hand levers and detents.
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Circuit symbols for mechanical actuation

This illustration

shows the symbols for stem or push button, spring and roller stem.

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Circuit symbol for pressure valves

Pressure

valves are represented using squares. The flow direction is indicated by an arrow. The valve ports can be designated as P (supply port) and T (tank return port) or as A and B. The position of the arrow within the square indicates whether the valve is normally open or normally closed. Adjustable pressure valves are indicated by a diagonal arrow through the spring. Pressure valves are divided into pressure relief valves and pressure regulators.

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[19] Circuit symbols for flow control valves

A distinction is made in flow

control valves between types which are affected by viscosity and those which are unaffected. Flow control valves unaffected by viscosity are termed orifices. A 2way flow control valve consists of restrictors, one adjustable restrictor which is unaffected by viscosity (orifice) and a regulating restrictor (pressure compensator). These valves are represented by a rectangle containing the symbol for the adjustable restrictor and an arrow to represent the pressure compensator. The diagonal arrow through the rectangle indicates that the valve is adjustable.

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[20] Circuit symbols for nonreturn valves

The

symbol for nonreturn valves is a ball which is pressed against a seat. Delockable nonreturn valves are shown by a square containing the symbol for a nonreturn valve. The pilot control for unlocking the non- return valve is indicated by a broken line at the pilot port. The pilot port is designated by the letter X.
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Circuit symbols for measuring devices

The

illustration shows the symbols for measuring devices used in hydraulics.

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Pneumatic System

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Component parts of Pneumatic System

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Pneumatic Service Units

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Pneumatic Air Receiver

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Applications of Hydraulics [1] Lathe and Machine Tools

Machine-tool

construction is a typical area of application of hydraulics. With modern CNC machine tools, the tools and workpieces are clamped by hydraulic means. Feed motions and the spindle drive can also be hydraulically powered.

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[2] Press with elevated reservoir

This is an application in which

extremely high forces are required. Due to the suspended cylinder and the tractive load, special measures are required for the activation of the advance stroke. This in turn requires speciallydesigned press drives. A special feature is the elevated reservoir, which utilizes the static pressure in the pressure medium.

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[3] Mobile hydraulics: Excavator

On this hydraulic excavator, not only all working movements (linear drives) but also

the propulsion of the vehicle (rotary drive) are hydraulically powered. The primary drive of the excavator is an internalcombustion engine.
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Structure of a hydraulic system

This simplified block diagram shows the division of hydraulic systems into a signal

control section and a hydraulic power section. This signal control section is used to activate the valves in the power control section.
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Hydraulic power section

The diagram of the hydraulic

power section is complemented in this case by a circuit diagram to allow correlation of the various function groups; the power supply section contains the hydraulic pump and drive motor and the components for the preparation of the hydraulic fluid. The energy control section consists of the various valves used to provide control and regulate the flow rate, pressure and direction of the hydraulic fluid. This drive section consists of cylinders or hydraulic motors, depending on the application in question.

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Interaction of components
The animations show the

sequences in a basic hydraulic circuit in simplified form - the actuation and spring return of the final control element (4/2-way valve), the advance and return of the drive component (double acting cylinder) and the opening and closing of the pressure relief valve.

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Interaction of components (Animation)

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Interaction of components (Animation)

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Interaction of components (Animation)

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[Interaction of components (Animation)

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Interaction of components (Animation)

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Interaction of components (Animation)

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Interaction of components (Animation)

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Interaction of components (Animation)

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Basic Formula
Pressure =Force/Area Power=Work/time Work =Force X distance travelled Flow rate= Area x velocity; Q=AV Power= Pressure x Flow Rate Torque= Force x radius

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Units of Pressure

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Units of Power

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Sample Problems(Seat Work /Assignment)

Chapter 5 \problem #7 Chapter 5 \problem #8

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Hydrostatic pressure
Hydrostatic pressure is the

pressure created above a certain level within a liquid as a result of the weight of the liquid mass. Hydrostatic pressure is not dependent on the shape of the vessel concerned but only on the height and density of the column of liquid.
Hydrostatic pressure can

generally be ignored for the purpose of studying hydraulics

Pressure propagation
If a force F acts on an

area A of an enclosed liquid, a pressure p is produced which acts throughout the liquid (Pascal's Law).
been ignored here. The term pressure propagation is also used to mean the pulse velocity in liquids (approx. 1000 m/s).

Hydrostatic pressure has

Power transmission
If a force F_1 is applied to an

area A_1 of a liquid, a pressure p results. If, as in this case, the pressure acts on a larger surface A_2, then a larger counter-force F_2 must be maintained. If A_2 is three times as large as A1, then F_2 will also be three times as large as F_1.
Hydraulic power transmission

is comparable to the mechanical law of levers.

[25.1] Displacement transmission (1)

If the input piston of the

hydraulic press travels a distance s_1, a volume of fluid will be displaced. This same volume displaces the output piston by the distance s_2. If the area of this piston is larger than that of the input piston, the distance s_2 will be shorter than s_1. Hydraulic displacement transmission is comparable to the mechanical law of levers.

Pascals Law=Force multiplication

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[25.2] Displacement transmission (2)

[26.1] Pressure transfer (1)

The fluid pressure p_1 exerts a force F_1 on the surface A_1 which

is transferred via the piston rod to the small piston. The force F_1 thus acts on the surface A_2 and produces the fluid pressure p2 . Since the piston area A_2 is smaller than the piston area A_1, the pressure p_2 must be larger than the pressure p_1. The pressure-transfer (pressureintensification) effect is put to practical use in pneumatic/hydraulic pressure intensifiers and also in purely hydraulic systems when extremely high pressures are required which a pump cannot deliver.

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Force Display Measurement

Bourdon tube pressure gauge

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Gas laws
Boyles Law => P1V1=P2V2
Charles Law=> P1/T1=P2T2 General Gas Law=> P1V1/T1=P2V2/T2

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{2} Directional Control Valves

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Open and Closed Circuits

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{3} Pressure Control Valves

Pressure Control Valves are very important elements in any Hydraulic Circuit, without these valves we cant achieve correct pressure control in different areas of control, following is a list of different types of Pressure Control Valves

1. Pressure Relief Valve 2. Pressure Reducing Valve 3 . Unloading Valve

4. Sequence Valve
5. Counterbalance

THREE Types of pressure control valves are available from Technology point of view. 1. Spool Types 3. Cartridge Types 60 2. Simple Poppet Types

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{3} Pressure Control Valves

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Pressure Control Valves

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Applications- Pressure Relief Valve

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Applications- Pressure Reducing Valve

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Application of Unloading Valve

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Unloading Valve
A typical example of an unloading valve application is a high-low

system consisting of two pumps, one a high displacement pump and the other a low displacement pump as shown . This system shown above is designed for providing a rapid return on the work cylinder. In this system, the net total displacement of both the pumps is delivered to the work cylinder until the load is contacted. At this point there is an increase in system pressure and this causes the unloading valve to open. This results in the flow from the high displacement pump getting directed back to the tank at a minimal pressure. The low volume pump continues to deliver flow for the higher pressure requirement of the work cycle. For faciUtating rapid return of the cylinder, flow from both the pumps is again utilized

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Application of Sequencing Valve

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Operation of counterbalance valve

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Application of Counterbalance Valve

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Counterbalance Valve Application

When raising the cylinder, an integral check valve opens to allow free flow for retraction of the cylinder. Figure 6.26 is an illustration of how exactly the counterbalance valve operates in a hydraulic circuit. As shown in the figure, the counterbalance valve is placed just after the cylinder in order to avoid any uncontrolled operation. In the event of the counterbalance valve being not provided, there would be an uncontrolled fall of the load, something which the pump flow would find hard to keep pace with. The counterbalance valve is set to a pressure slightly higher than the load-induced pressure. As the cylinder is extended, there must be a slight increase in pressure in order to drive the load down.

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{4} Flow Control Valves

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Meter in circuit

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Meter Out Circuit

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{5} Cylinders and Actuators

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Single acting cylinder

In the case of a single acting

cylinder, only the piston side is pressurized with hydraulic fluid. The cylinder can thus carry out work only in one direction. The fluid which flows into the piston chamber causes a pressure to build up the surface of the piston. The piston travels into its forward end position. The return stroke is effected by a spring, the dead weight of the piston rod or an external load.

Plunger cylinder
In the case of plunger

cylinders, the piston and rod form a single component. Due to the design of the cylinder, the return stroke can only be effected by external forces. The cylinders can therefore generally be installed only vertically.

Double acting cylinder

In the case of double acting

cylinders, both piston surfaces can be pressurized. A working movement can thus be performed in both directions.
With double acting cylinders

with a single-sided piston rod, different forces and speeds are obtained on the advance and return strokes due to the difference in area between the piston surface and annular piston surface.

Double acting cylinder with end position cushioning

Cylinder with end

position cushioning are used to brake high stroke speeds smoothly and prevent hard impacts at the end of the stroke. Shortly before the end position is reached, the cross- section for the outflow of fluid is reduced by the built-in cushioning pistons and then finally closed. The hydraulic fluid is then forced to escape through a flow control valve.

End position cushioning (Animation)

The illustration shows first the

advance of the piston rod from a mid-position to the forward end position, with cushioning at the end of the advance movement. The non-return valve is open during the return stroke.
Animation 101.3a also shows

the opening of the pressure limiter after a certain pressure has been built up on the outlet side by the cushioning piston.

End position cushioning (1)

The piston is a short distance

before its end position; the hydraulic fluid on the pistonrod side must escape via the adjustable flow control valve above the piston rod
This type of end position

cushioning is used for stroke speed between 6 m/min and 20 m/min. At higher speed, additional cushioning or braking devices must be used.

End position cushioning (Animation)

End position cushioning (2)

The piston rod is on its return stroke; in this flow direction, the non-return valve

below the piston rod is opened, thus bypassing the flow control valve. The piston rod retracts at maximum speed.

End position cushioning (Animation)

Double acting cylinder

Actual photograph of a double acting cylinder.

 Single Acting

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Double Acting Cylinder

Double Acting Cylinder

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Rotary Actuators
Pneumatic motors- Torque motors
Hydraulic motors- winch, cement mixer

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Rotary Actuators-Vane Type

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{6} Process Control Valves

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Diaphragm operated control valve

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Formula for Process Control Valves

Change in the flow rate=k(change in stem

displacement)
Q/Qmax=S/Smax Q/Q=k S Q/Qmin=(Qmax/Qmin)(S-Smin)/(Smax-Smin)

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Where k=constant Q=is the flow rate at a valve displacement S Qmax=the maximum flow rate at the maximum displacement Smax Q/Qmax=S/Smax
Therefore the percentage change in the flowrate equals

the percentage change in the stem displacement.

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Sample Problem
An actuator has a stem movement which at full travel

is 40 mm. It is mounted on a process control valve with an equal percentage plug and which has a mimimum flow rate of 0.2 m3/s and a maximum flow rate of 4 m3/s. What will be the flow rate when the stem movement is a) 10 mm b) 20 mm.
Given: Smax=40mm

Smin=0 mm
Qmin=0.2 m3/s Qmax=4m3/s
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 Required: What will be the flow rate when the stem

movement is a) 10 mm b) 20 mm. Solution A: Q/Qmin=(Qmax/Qmin)(S-Smin)/(Smax-Smin)

Q/0.2=(4/0.2) (10/40)
Answer a) 0.423 m3/sec Solution B

Q/0.2=(4/0.2) (20/40)
Answer b) 0.89 m3/sec
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Control Valve Sizing

The choice of valve for a particular application depends on

various factors such as the fluid flow rate, the process temperatures and pressures, and whether the fluid is corrosive or abrasive. An important design consideration for safety is the maximum pressure and temperature of the flowing fluid as this will dictate a safe thickness for the body material and may determine which materials can be used. The capacity of a valve is measured in Cv, Kv or Av and can be determined experimentally for a valve by testing it, for example by measuring the amount of water that flows through it at a certain pressure differential across the valve.
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Flow Coefficients and Valve Sizes

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Control Valve Sizing Formula

Q=Av P/
Where

Av= valve flow coefficient

P = the pressure drop across the valve

=density of the fluid

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Sample problems-Control Valve

Determine the valve size that is required to control the

flow of water when the minimum required flow is 0.012 m3/s and the permissible pressure drop across the valve at this flow rate is 300 kPa. Using the equation:
Q=Av P/
Av=0.0121000kg/m3/300x103 Av=69.3 x10-5 Then using Table 5.1 Flow Coefficients and Valve Sizes, the valve size is 960 mm.
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The End

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