RMD SINHGAD SCHOOL OF ENGINEERING, WARJE,

PUNE-58
NAAC accredited with "A" grade

LABORATORY MANUAL
Hydraulics & Pneumatics
(Course Code: 402041)

Final Year of Mechanical Engineering

(2015 Course)

A. Y. 2018-2019
Semester I

DEPARTMENT OF MECHANICAL ENGINEERING

 Sinhgad Technical Educational Society’s

RMD SINHGAD SCHOOL OF ENGINEERING, WARJE,

PUNE-58
NAAC accredited with "A" grade

CERTIFICATE

This is to certify that

Mr./Ms.___________________________________________________________

of Class ________ Roll No. ________ has completed all the practical

work/term work in subject _________________________________________

satisfactorily in the department of Mechanical Engineering as prescribed by

Savitribai Phule Pune University during the academic year

___________________

Staff In-charge Head of Department Principal

Date:
 B. E. (Mechanical) (2015 Course) Semester – I

Teaching Scheme Examination Scheme Credits

Hrs / week Total
Code Subject
In End Marks TW/
Lecture Tut Pract TW PR OR Theory
Sem Sem Pr/OR
Hydraulics
402041 and 3 - 2 30 70 25 - 25 150 3 1
Pneumatics

Pre-requisites:
Fluid Mechanics, Manufacturing Processes and Machines, Mechatronics
Course Objectives:
 To study governing laws used in fluid power systems

 To study fluid power applications

 To study working principles of various components

 To study selection of different components

 To study how to design fluid power systems

 To study low cost automation
Course Outcomes:
On completion of the course, students will be able to -

 Understand working principle of components used in hydraulic & pneumatic

systems

 Identify various applications of hydraulic & pneumatic systems.

 Selection of appropriate components required for hydraulic and pneumatic
systems.

 Analyze hydraulic and pneumatic systems for industrial/mobile applications.

 Design a system according to the requirements.

 Develop and apply knowledge to various applications.
Term Work shall consist of following experiments and assignments
(As per university):
1. Test on Gear/Vane/Piston pump and plotting performance characteristics.
2. Following experiments to be done on hydraulic trainer (any 3)
a. Regenerative circuit
b. Speed control circuit
c. Sequencing circuit
d. Traverse and feed circuit etc.
3. Following experiments to be done on pneumatic trainer (any 3)
a. Automatic reciprocating circuit
b. Speed control circuit
c. Pneumatic circuit involving Shuttle valve/ Quick exhaust valve /
Two pressure valve
d. Electro pneumatic circuits
4. Test on pressure relief valve/flow control valve.
5. Test on linear /rotary actuator.
6. Design of simple hydraulic systems used in practice using manufacturers’
catalogue and analysis using software such as Automation Studio.
7. Design of simple pneumatic systems used in practice using manufacturers’
catalogue and analysis using software such as Automation Studio.
8. Industrial visit to study Hydraulic / Pneumatic based Automation systems.
9. Assignment: Symbols for different components as per standards.
10. Assignment: Trouble shooting procedures.
11. Assignment: Standard specifications of hydraulic/ pneumatic components
using manufacturer’s catalogues.
 INDEX
Sr. Page
Details
No. No.

As per university syllabus

1 Test on Gear/Vane/Piston pump and plotting performance characteristics.
2 Following experiments to be done on hydraulic trainer (any 3)
  Regenerative circuit
  Speed control circuit
  Sequencing circuit
  Traverse and feed circuit etc.
3 Following experiments to be done on pneumatic trainer (any 3)
  Automatic reciprocating circuit
 Speed control circuit

 Pneumatic circuit involving Shuttle valve/ Quick exhaust valve / Two
 pressure valve
  Electro pneumatic circuits
4 Test on pressure relief valve/flow control valve.
5 Test on linear /rotary actuator.
6 Design of simple hydraulic systems used in practice using manufacturers’
catalogue and analysis using software such as Automation Studio.
7 Design of simple pneumatic systems used in practice using manufacturers’
catalogue and analysis using software such as Automation Studio.
8 Industrial visit to study Hydraulic / Pneumatic based Automation systems.
9 Assignment: Symbols for different components as per standards.
10 Assignment: Trouble shooting procedures.

11 Assignment: Standard specifications of hydraulic/ pneumatic components

using manufacturer’s catalogues.
 EXPERIMENT NO.1

TRIAL ON GEAR PUMP AND PLOTTING OF PERFORMANCE

CHARACTERISTICS

Aim: To conduct test on Gear Pump and plot performance characteristics

Apparatus: Gear pump with electric motor, pressure relief valve, control valve, reservoir,
measuring tank with scale, pressure gauge and vacuum gauge

Theory:

External Gear Pump

The operation of an external gear pump, which develops flow by carrying fluid between
the teeth of two meshing gears, is shown in the figure 2.1. One of the gears is connected to a
drive shaft connected to the prime mover. The second gear is driven as it meshes with the driver
gear. Oil chambers are formed between the gear teeth, the pump housing and the side wear
plates. The suction side is where teeth come out of the mesh and it is here that the volume
expands, bringing about a reduction in pressure below atmospheric pressure. Fluid is pushed into
this void by atmospheric pressure because the oil supply tank is vented to the atmosphere. The
discharge side is where teeth go into mesh and it is here that the volume decreases between
mating teeth. Since the pump has a positive internal seal against leakage, the oil is positively
ejected into the outlet port.
Figure 1: External Gear Pump
Figure 2. Hydraulic setup for Gear pump
 Operation procedure:

1. Check the oil level in the sump. Initially the bypass valve must be open.
2. Switch on the main supply. Let the system run for 2-3 min for stabilizing.
3. Adjust the delivery pressure using pressure regulating valve.
4. Adjust the valve near to the Rotameter and oil level will start rising.
5. Note the readings as per observation table.
6. Again adjust the delivery pressure using pressure regulating valve and note down the
readings.
7. Repeat the procedure for different settings of delivery pressure.
8. Switch off the electrical connections.
9. Calculate the results as per calculation procedures.

Observation table
Sr Suction pressure Delivery pressure Energy Power
Flow Q
No. [P1] [P2] consumption Pin
mm of Hg N/m2 kg/cm2 N/m2 lpm m3/s Wh watt
1 -720 40 8.5 14 840
2
3
4
5

Sample Calculations
Suction pressure -720 mm of Hg = 13600 x 9.81 x (-720) x 10 -3 N/m2
Delivery Pressure 40 kg/cm2 = 40 x 9.81 x 10 4 N/m2
Flow 8.5 lpm = 8.5 x 10-3/60 m3/s
Power = 14 x 60 W
Pout = (P2-P1) x Q
Efficiency of Pump = Pout / Pin

={[392.4 x 10 4 N/m2 – (- 9.601 x 10 10 4 N/m2)] x 0.141 x 10 -3 N/m2} /

840 = 67.47 %

Conclusions:

1. From the graph of discharge vs head it can be seen that discharge is constant for
increasing head but after some period it decreases due to increased leakage loss.
2. From the graph of efficiency vs head, efficiency increases for increasing head.
3. From the graph of input power vs head, discharge head increases the input power
required to drive the pump.

Standard graph.
 QUESTION BANK
1 Classify hydraulic fluids. What are the desirable properties of hydraulic fluid?
2 Explain different types of hydraulic fluids.
3 What is the efficiency of vane pump?
4 Differentiate between hydraulic system and Pneumatics system.
5 What are the energy losses in hydraulic system?
6 Classify pumps in hydraulic system. Define various efficiencies of pump.
7 What is the performance characteristic of gear pump?
8 What is the efficiency of piston pump?
9 What is the difference between gear pump and vane pump?
10 What is the efficiency of gear pump?
11 What are various factors are to be considered for selection of pumps for specific applications.
12 Explain the factors that justify the pump selection.
13 State advantages, disadvantages and applications of hydraulic system.
14 Explain the construction and working of Gear pump.
 EXPERIMENT NO.2

Following experiments to be done on hydraulic trainer:

a. Regenerative circuit b. Speed control circuit
c. Sequencing circuit d. Transverse and feed circuit

Aim: To study demonstration of Hydraulic Trainer

Apparatus: a) Hydraulic trainer Kit. b) Supply board

Theory:
It is the need of time to modernize & automate the machines. Most of the
activities are automated with the help of modern state of the art electronics technologies
while doing this same electro mechanical interface is required. The mechanical interface
actually accepts electrical signals & converts them into mechanical action to execute
mechanical action it requires some energy resource. The most commonly used
& readily available source is air & liquid. The atmospheric air is collected, compressed
& stored in a vessel at required pressure same that way liquid is stored in a huge tank
and which is used for generating a pressure. It is used as mechanical driving force.
High-pressure liquid as energy source is used to operate mechanical devices called
hydraulic devices and the control is by electrical excitation. Sometime the automation is
semi automation where only mechanical actuation is used & is activated by Manual
intervention.

The various devices used with certain operation sequence in mind, while automation
of any job, process or machine. These devices along with necessary fitting are called as
hydraulic components & hydraulic fittings. The hydraulic trainer is designed to study &
understand various such component used while automation. The trainer consists of
actuating devices, controlling devices, accessories, gauges, regulating devices & fitting
& hoses. Basic purpose of the trainer is to give student an exposure to various hydraulic
components & its principal of working and operation.
Precautions: Ensure following points for proper functioning of the trainer.
1) Ensure the oil level in oil tank by oil indicator proper level.
2) Ensure the 3-phase supply is given to the trainer.
3) Ensure the proper connection of hoses to P & T manifold.
Procedure : 1) Do the proper connection of P & T port of valves by using hoses.

2) Do the proper connection of A & B port of valves to cylinder (for either single
acting or double acting cylinder).
3) Switch on the main supply. Let the system run for 2-3 min for stabilizing.

4) Release the hydraulic pressure by using pressure relief valve at proper

value And see the system pressure on the pressure gauge.

Shut down procedure: -

1) Reduce the system pressure.
2) Switch off the electrical connections.
3) Leaves the connections of hoses.

Technical specification:
1. LENTH X WIDTH X HEIGHT : 900 X600 X1400 MM
2. WEIGHT : APPRX.150 Kg
3. ELECRIC MOTOR : Foot Mounted, 1/2 HP 230 Volts, 1425 RPM, Single Phase
4. TANK CAPACITY : 25 Liters
5. PUMP : Gear Pump
6. HOSE PIPE : ¼ ” Diameter, Working Pressure Max. 230 Kg /cm2

Powder coated frame, Starter, single acting cylinder, double acting cylinder, 4x3 & 3x2
direction control valve, Unidirectional flow control valve, bi-directional flow control
valve, sequencing valve, pressure relief valve, QRC & fittings, pressure gauge, QRC hose,
3-phase motor, P & T manifolds.

Self-Diagnosis & Trouble Shooting Chart :

Symptoms Action

No system Pressure Pl check motor rotate in clockwise direction

No system Pressure Check open the pressure relief valves

No actuation of devices Check and ensure the proper system pressure

Trip the starter Check proper selection of current rating.

A double acting cylinder is to be actuated such that it has a fast extend speed, intermediate ‘hold’
facility ‘and manual actuation. These requirements can be met using a regenerative circuit. One
of the ports of a 4-ways 3 position valve should be blocked, as seen from the hydraulic circuit
shown in figure above.

WORKING:

Step 1: This is known as regenerative circuit and is used to increase the extended speed of the
double acting hydraulic cylinder. One port of the DC valve (4) is blocked. Connection to the rod
end side of the cylinder is given to the pipe from the pump.

Step 2: The extension of cylinder occurs when the D.C. valve is shifted to left position (a). The
speed of extension is greater than that of a regular double acting cylinder because the flow from
the rod end, regenerates with pump flow to provide total flow rate.
C= double acting cylinder; P = pump; T= Tank; F=Filter; R=Relief Valve; CV= check valve; FCV=
Flow Control Valve; D= 3-position, 4 way, Close Centre, Manually operated, Spring Centre DCV.

2. Meter-in circuit

In this type of speed control, the flow control valve is placed between the pump and the actuator.
Thereby, it controls the amount of fluid going into the actuator. FIG 4.4 shows meter-in circuit.
When the directional control valve is actuated to the 1st position, oil flows through the
flow control valve to extend the cylinder. The extending speed of the cylinder depends on the
setting (percent of full opening position) of the flow control valve. When the directional control
valve is actuated to the second position, the cylinder retracts as oil flows from the cylinder to the
oil tank through the check valve as well as the flow control valve.
2. Meter-out circuit:

In this type of speed control, the flow control valve is placed between the actuator and the tank.
Thereby, it controls the amount of fluid going out of the actuator. Figure 4.5 shows a meter-out
circuit. Meter-in systems are used primarily when the external load opposes the direction of
motion of the hydraulic cylinder. An example of the opposite situation is in the case of a weight
pulling downward on the piston rod of a vertical cylinder. In this case the weight would suddenly
drop by pulling the piston rod down if a meter-in system is used even if the flow control valve is
completely closed. Thus, the meter-out system is generally preferred over the meter-in type.

One drawback of a meter-out system is the possibility of excessive pressure build-up in the rod
end of the cylinder while it is extending. This is due to magnitude of back pressure that being
fully closed as well as the size of the external load and the piston-to-rod area ratio of the
cylinder. In addition of an excessive pressure build-up in the rod end of the cylinder results in a
large pressure drop across the flow control valve. This produce the undesirable effect of high
heat generation rate with a resulting increase in oil temperature.
 Sequencing Circuit

One can find the application of this circuit in manufacturing process circuit. Consider if
two cylinders are used during manufacturing process, then the sequence may be for example, one
of the cylinder the clamping cylinder C1 could extend and clamp a work piece. Then the second
cylinder C2, the punching cylinder extends to punch a hole in the work piece. The right cylinder
then retracts to de-clamp the work piece for removal. Obvious these machining operations must
occur in the proper sequence as established by the sequence valves in the circuit.

A sequence valve causes operations in a hydraulic circuit sequentially. Figure above is an

example where two sequence valves are used to control the sequence of operations of two
double-acting cylinders 11-12.
For central position of DCV (6): Both the cylinders (11) and (12) are stopped in the given
position.

For left position of DCV (6): By actuating the left solenoid, the oil from the pump (1) passes
through the blind end of the cylinder (11), after completion of extension stroke of the cylinder
(11), the pressure in the blind goes on rising which gives a pilot signal to the sequence valve (7)
and valve (7) opens and allows the oil to flow through the rod end of the cylinder (12), getting
retraction of the cylinder (12).

For the left position of DCV (6), first there is extension stroke of cylinder (11), then retraction of
cylinder (12).

For right position of DCV (6): By actuating the right solenoid, the oil from the pump enters
first in the rod end of cylinder (11) and does a complete retraction of the cylinder (11). Then the
pressure goes on building at the rod end side of the cylinder (11) which opens the sequence valve
(9) allowing the oil to end in the blind end of cylinder (12) causing the cylinder (12) to extend.

Thus, for the right position of DCV (6), first retraction of cylinder (11) then extension of cylinder
(12) takes place.
 Transverse and Feed Circuit
For achieving different feeds in systems we can use a circuit as shown in Figure above The
circuit uses a solenoid controlled 4/3 DC valve with spring Centre. The 2 solenoids are
controlled by the limit switches.
When the actuator energizes the first limit switch, the DC valve will be in first
limit switch, the DC valve will be in first position and hence the cylinder will move in the
forward direction. The initial speed of the cylinder is fast and after the 2/2 roller operated de-
accelerated valve is actuated the speed of the actuator is controlled by the flow control valve as
much as required.
When the forward stroke is completed the second limit switch will actuate the 4/3 dc valve for
the reverse stroke of the cylinder. The reverse stroke is fast. The circuit can be automated.
 QUESTION BANK
1 Draw the regenerative circuit.
2 What are the applications of Speed control circuit?
3 Draw the Sequencing circuit.
4 Draw the Speed control circuit.
5 What are the applications of Sequencing circuit?
6 Draw the Transverse and feed circuit.
7 What are the applications of Speed control circuit?
8 What are the applications of Regenerative circuit?
9 What is meter in circuit?
10 Explain the significance of meter out circuit?
11 What is meter out circuit?
12 Explain the significance of meter in circuit?
 EXPERIMENT NO.3

Following experiments to be done on pneumatic trainer:

a. Automatic reciprocating circuit
b. Speed control circuit
c. Pneumatic circuit involving shuttle valve/ quick exhaust Valve
d. Electro pneumatic valves and circuit

Aim: To study demonstration of Pneumatic Trainer

Apparatus: a) Pneumatic trainer Kit.

b) Supply board Theory
It is the need of time to modernize & automate the machines. Most of the activities are automated
with the help of modern state of the art electronics technologies while doing this same electro
mechanical interface is required. The mechanical interface actually accepts electrical signals &
converts them into mechanical action to execute mechanical action it requires some energy
resource. The most commonly used & readily available source is air. The atmospheric air is
collected, compressed & stored in a vessel at required pressure. It is used as mechanical driving
force. High-pressure compressed air as energy source is used to operate mechanical devices
called pneumatic devices and the control is by electrical excitation. Sometime the automation is
semi automation where only mechanical actuation is used & is activated by Manual intervention.

The various devices used with certain operation sequence in mind, while automation of any
job, process or machine. These devices along with necessary fitting are called as pneumatic
components & pneumatic fittings.

The pneumatic trainer is designed to study & understand various such components used
while automation. The trainer consists of actuating devices, controlling devices,
accessories, gauges, regulating devices & fitting & tubing. Basic purpose of the trainer is to
give student an exposure to various pneumatic components & its principal of working and
operation.
Apparatus: a) Electro-pneumatic trainer.
b) Air compressor
Precautions: Ensure following point for proper functioning of the trainer.
1) Ensure the compressor is of proper rating
 2) Ensure the compressor is with safety devices like pressure relief valve,
spring-loaded safety valve, isolation valve etc.
3) Ensure the proper connection of air inlet using proper size tube.
4) Once the supply pressure is set, do not play with the AFR knob.
5) Always Keep the switches off when trainer not in use.
Procedure:
1. Connect air inlet to the pneumatic trainer
2. Connect the PLC Trainer
3. Connect 5X2 & 3X2 solenoid operated valve to the PLC trainer.
4. Connect PLC to the 230v AC main supply, & switch on supply.
5. Stop air supply to trainer
6. Reduce the output air pressure on pneumatic trainer by using air regulator.
7. Disconnect the air connection.
Shut down procedure:-
1) Switch off the compressor.
2) Remove the air supply.
3) Switch off the supply.
4) Remove the all connection
Technical specification: -
1. Length : 1250 mm
2. Width : 650 mm
3. Height : 1900 mm
4. Weight : Approx. 85 Kg.
2
5. Working Pressure : 2.1 to 5 kg/cm
6. Compressor : Single Phase, 230V AC 50Hz, 5-6 Kg/cm2
7.Tank Capacity : 30 Ltr. Compressed Air 5 to 8 kg/cm 2
Powder coated frame, FRL, Single acting cylinder, Double acting cylinder, 5x3 & 3x2
solenoid operated direction control valve, flow control valve, Quick exhaust valve, PU
tubing & fittings, Pressure gauge, Manifolds, Inductive Proximities Sensors, All fittings
¼” BSP (M/F). MS fabricated powder painted enclosure and mounting frame.

Self-Diagnosis & Trouble Shooting Chart:

Symptoms Action

No air supply Check and ensure the compressor air.

No actuation of devices check and ensure the air pressure in compressor between 5-10
Kg/cm2
 1. Automatic reciprocating circuit:
Figure shows automatic continuous operation of double acting cylinder. In the circuit 4/2 double
solenoid DCV is used. There are 2 limit switches to operate this 4/2 DCV. When a limit switch is
pressed, electric current flows to the connected solenoid and hence the spool of 4/2 DCV shift to
other position.

The piston rod while reciprocating actuate this limit switch which in turn actuates 4/2
DCV. Thus automatic reciprocation of RAM is achieved. In first position of 4/2 DCV,
compressed air flow from P to A and B to T hence the cylinder extends. By the end of extension
the cam fitted to Piston rod presses the limit switch LS2. Hence electric current flow to solenoid
S2 and due to this the spool of 4/2 DCV shift to second position. In second position 4/2 DCV
compressed air flow from P to B and A to T hence the cylinder retracts. By the end of retraction
the cam presses the limit switch LS1. Hence electric current flow to solenoid S1 and due to this
the spool of 4/2 DCV shifts to first position and the cycle continues.

Fig: Automatic reciprocating circuit

 2. Speed Control Unit:
Speed control circuit is as shown in figure. In first position of 4/2 DCV compressed air flow
from P to A and B to T. This flow is through flow control valve. The flow is controlled and
hence piston extends slowly. In second position 4/2 DCV compressed air flow from P to B and A
to T. This flow is through check valve. This is free flow, hence the piston retract at higher speed
which is not controlled.

Fig: Speed Control Circuit

 3. Pneumatic Circuit Involving Shuttle Valve \ Quick Exhaust Valve:
Figure shows circuit diagram using quick exhaust valve. In first position of 4/2 DCV compressed
air flow from P to A. Air present in the rod end side of the cylinder is exhausted to atmosphere at
the quick exhaust valve(2). In second position of 4/2 DCV, compressed air flow from P to B. Air
present in the head end side of the cylinder is exhausted to atmosphere through quick exhaust
valve(1).

Fig: Pneumatic Circuit Involving Quick Exhaust Valve

 4. Electro pneumatic valves and circuit
PNEUMATIC CONNECTIONS PROCEDURE:
 Experimental setup for study of Solenoid Valve is as shown in block diagram.

 Connect the air compressor ti the Air Filter Regulator. Give O/P of AFR to one of the
terminal of air manifold.

 Start the compressor and build some air pressure with the help of AFR.

 Give air supply to the I/P of the Solenoid Valve from air manifold and give its O/P to the
Double Acting Cylinder.

 Do the electrical connections as shown in the connection diagram below.

Fig: Circuit diagram for double acting reciprocating cylinder

ELECTRICAL CONNECTION PROCEDURE:

 Connect +24V DC to the +ve terminal of PS1 (red) & C1.


 Connect -24V to the –ve terminal (black) of PS1.

 Connect O/P (Grey) of the PS1 to the NO1 and C2.

 Connect +24V DC to the +ve terminal (red) of PS2.

 Connect -24V to the –ve terminal (black) of PS2.

 Connect NC3 to +ve terminal of left most solenoid and R2+.

 Connect R2- and –ve terminal to leftmost solenoid and R2+.

 Connect NC2 to the R1+ & R3+. Connect R1- & R3- to the -24V DC.

 Connect C3 to the +24V DC.

 Connect NO3 to the +ve terminal of the rightmost solenoid of the 5/2 S.V.

 Connect –ve terminal of 5/2 S.V. to the -24V DC.

 Make the switches on the panel
‘ON’. Working:

As soon as the current flows through Solenoid Valve it starts operating. There is force at
the O/P which is given to the Double Acting Cylinder and because of this the shaft moves
forward. As Supply to solenoid valve is switched OFF, there is no force and the shaft
retracts to its normal position.
 QUESTION BANK
1 Draw automatic reciprocating circuit.
2 Explain the significance of automatic reciprocating circuit
3 Draw speed control circuit.
4 Explain the significance of speed control circuit.
5 What is Electro pneumatic circuit?
6 Explain pneumatic circuit involving Shuttle valve.
7 Explain pneumatic circuit involving Quick exhaust valve.
8 Explain pneumatic circuit involving Two pressure valve.
9 What is the significance of Quick exhaust valve?
10 What is the significance of Shuttle valve?

11 Explain FRL Unit. Draw its symbol.

 Experiment No. 4
Pressure Relief Valve

Aim: To study the working principle of a pressure relief valve.

Apparatus:
1. Power pack
2. Working table
3. P manifold
4. T manifold
5. Relief valve
6. Flexible hose pipe with quick connecting fittings
7. Pressure gauge

Theory:
A Pressure relief valve is an essential element of every hydraulic system. It is normally a
closed valve connected between the pressure line (pump outlet) and the reservoir. Its purpose
is to limit pressure in the system to a preset maximum by diverting some or all the pumps
output to tank when the pressure setting is reached.
Operation:
This relief valve remains closed as long as the pressure at 1 is lower than the
"Cracking Pressure". When the pressure at 1 is greater or equal to the "Cracking Pressure",
the fluid flows from 1 to 2. In this case, port 2 is already connected to its own individual tank.
Port 2 is not accessible.
When the pressure in the system increases above a preset value, the relief valve opens
and lets the fluid flow to the tank. This component acts only in case of an emergency, to
bring down the pressure to its set value to protect components from pressure surges. The
pressure setting can be done when editing the valve or when simulating a diagram.
Procedure:
1. Ensure that connection to electrical board is done.
2. Ensure that hydraulic oil is available in enough quantity.
3. Open the shut off valve used for basic hydraulic components so that oil flows to
P manifold.
4. Close other all shut off valves, except the valve to main pressure gauge.
5. Connect the flexible hose pipe from P manifold to inlet of relief valve & also to
a pressure gauge.
6. Connect outlet of relief valve to T manifold.
7. Switch on the electrical power supply of electrical board mains and motor on - off
switch.
8. Observe the flow through relief valve under study to tank.
9. Adjust the pressure of main relief valve of power pack at 2.5 bar.
10. By adjustable knob change the pressure of main relief valve from 2.5 bar to 6 bar.
11. Adjust the pressure of main relief valve.
12. Note the pressure on pressure gauge 2, which is the pressure of relief valve
under study.
13. Switch off the electrical power supply of motor with on - off switch.
Observation table:

Conclusion:
The above operation of relief valve shows how the operating system pressures of hydraulic
system can be set.
 QUESTION BANK
1 What is pressure relief valve?
2 Draw the symbol of pressure relief valve.
3 What are the applications of pressure relief valve?
4 What is flow control valve?
5 What are the applications of flow control valve
6 What are the advantages of pressure relief valve?
7 What are the types of flow control valve?
8 Which are the other types of valves?
9 Explain the working of pressure relief valve.
10 Explain the working of flow control valve.
 Experiment No. 5
Linear and Rotary Actuators

Aim: To study the working of linear and rotary actuators.

Apparatus:
1. Power supply
2. Working table
3. P manifold
4. T manifold
5. Single and double acting cylinder
6. Gear motor
7. Flexible hose pipe with quick connecting fittings
8. Pressure gauge

Theory:
Pumps add energy to hydraulic fluid for transmission to the point application Pumps receive
mechanical power input from the prime mover and impart hydraulic energy to fluid. The
actuators perform just the opposite role. They convert the hydraulic energy of the fluid into
mechanical power to serve the application.
Linear Actuators: These are essentially cylinder-piston systems which extend and retract
during the operating cycle.
Semi-Rotary Actuators: These actuators are also known as limited rotation motors or
oscillation fluid motors. These actuators produce limited rotation or oscillatory motion
Rotary Actuators: These are also known as hydraulic motors. These actuators can be of
fixed or variable displacement.
Hydrostatic transmission systems have a pump driving a motor The hydrostatic
transmission has several advantages, like stepless variation of speed in-built overload
protection bi-directional rotation, dynamic braking and high power-to-weight ratio. These
systems are extensively used in material handling equipment agricultural equipment earth
moving machinery, machine tools. automobiles, loco-traction etc.

Linear Actuators:
These actuators convert hydraulic energy into linear mechanical force and linear motion. The
linear actuator usually consists of piston and a piston rod, a plunger or a ram moving to and
fro within a cylinder. Following are the types of hydraulic cylinder.
Single Acting Cylinder: In single acting cylinders (Refer Fig. 4.1), oil pressure acts on
only one side of the piston during extension or retraction. When the oil pressure is cut off, the
piston returns to its normal position by a spring or by an external load. The later type of
cylinders are installed vertical to avail the force of gravity.

Fig. 4.1: Single acting spring return cylinder

In a spring return type cylinder, the spring may be inside or outside the cylinder. The spring
index is dependent upon the load operating speed etc. The actuators are suitable for small
stroke lengths only.
Double Acting Cylinder: Double acting cylinders are operated by application of oil pressure
on both sides of the piston. These actuators are extensively used for various applications. Double
acting cylinders (Fig. 4.2) can be single rod ended or double rod end type. For a given oil supply
pressure, a single rod ended cylinder exerts greater force during extension than during retraction.
The double rod ended cylinder exerts equal forces in either direction.
 Fig. 4.2: Double acting cylinder

Rotary Actuators:
These actuators provide rotational motion. Rotary actuators are commonly addressed as
hydraulic motors. The hydraulic motor converts hydraulic energy of the oil into rotary
mechanical energy, to drive the load.
The construction of hydraulic motors is more or less similar to hydraulic pumps. In a pump,
the pump element pushes the oil thereby imparting hydraulic energy whereas in a hydraulic
motor, the hydraulic energy of the oil causes the element to rotate.

Gear Motor:
Gear motors have generally of fixed displacement motors. The construction of gear motors is
similar to that of gear pumps. The gear motor includes pressure loaded side plates for control
of internal leakage and to achieve good volumetric efficiency.
 Fig. 4.3: Gear Motor

Fig. 4.3 illustrates a gear motor. The torque developed is function of the force exerted by oil
pressure on one tooth. The fluctuation of torque generated can be smoothened out by using
large number of teeth. The volumetric displacement however decreases with increase in the
number of teeth, with low output power for a given size.
For gear motors, minimum recommended speed lies between 400 rpm. and 1000 rpm. Lower
speeds can be obtained by coupling a gear motor through a reduction gear. External gear
motors can be uni-directional or bi-directional. Unidirectional gear motor should not be
reversed as it may damage shaft seals and internal seals.
Gear motors are preferred for high speed applications upto 4000 rpm., and low torque
requirement. Their output power is limited to about 10 kW.

Conclusion:
The above working operation of actuators shows how the operating system of hydraulic
actuators are carried out.
 QUESTION BANK
1 What is the difference between linear and rotary actuators?
2 Explain the linear actuators.
3 What are the types of linear actuators?
4 What are the types of rotary actuators?
5 Explain the rotary actuators.
6 What are the applications of linear actuators?
7 What are the functions of rotary actuators?
8 What are the applications of rotary actuators?
9 What are the functions of linear actuators?
10 Explain the construction and working of single acting cylinder.
11 Explain the construction and working of double acting cylinder.
 EXPERIMENT NO. 6
DESIGN OF SIMPLE HYDRAULIC SYSTEM
Aim: To Design simple hydraulic system
Theory:
Hydraulic Shaper:
Circuit Diagram for Hydraulic Shaper:
The following diagram shows circuit representation of Hydraulic Shaper machine .

Fig.1 Circuit of Hydraulic Shaper

The schematic of hydraulic shaping machine is shown in the figure. Its ram is mounted
on a double rod end DAC. The cutting stroke of the ram should be slow and return stroke should
be fast. For this particular application we can choose meter out circuit.

Continuous reciprocation of ram can be obtained either by using solenoid DCV or by

using pilot operated DCV. Limit switches are needed if Solenoid is chosen and limit valves if
pilot operated DCV is used. As shown in the figure solenoid DCV and limit switches are used.
Working:

1. 4/2 double solenoid is used with two limit switches on either end of piston rod. The
piston rod while reciprocating actuates these limit switches which in turn actuates 4/2
DCV. Thus automatic reciprocation is complete.
2. In first position of 4/2 DCV oil flow from P-A. This flow is through check valve. Hence
the piston moves fast. Oil which is present in right side of the piston in the cylinder flows
from B-T.
3. In second position of 4/2 DCV oil flows from P-B and A-T. This flow is through FCV i.e.
it is controlled flow, hence the piston moves slowly.
4. The stroke length and position of stroke can be easily adjusted by adjusting the position
of limit switches the speed of cutting stroke is adjusted by adjusting the FCV opening.

Hydraulic Press:

Theory:

The hydraulic press circuit consists of three hydraulic cylinders; the main cylinder is the
larger cylinder located in the middle while the two other cylinders are referred to be side cylinders
or kicker cylinders. The primary function of the side cylinder is to raise and lower the platen. The
main press cylinder supplies most of the force needed once the platen contacts the
work piece.
Working:

The circuit above works as follows.

1. When the operator shifts the DCV, flow goes to the two side cylinders, and they extend.
Flow does not go to the press cylinder, because the sequence valve remains closed.
2. As the press cylinder descends, the resulting negative pressure in the cap end pulls fluid
from the reservoir into the press cylinder. (Often, the reservoir is above the press so that
gravity helps to fill the large cylinder.)
3. When the platen contacts the work piece, the pressure builds, and the sequence valve
opens. Now system pressure is applied to the press cylinder, and full force (side cylinders
+ press cylinder) is applied to the work piece.
4. When the DCV is shifted for retraction, the line to the sequence valve is connected to the
reservoir. There is no pressure to hold the sequence valve open; consequently, it closes.
5. Flow from the press cylinder cannot go back through the sequence valve; it must go
through the check valve into the reservoir. The key to operation of this circuit is the pilot-
operated check valve.

Conclusion: Thus, we have design the Hydraulic system used in practice and analysis with
the help of software
 QUESTION BANK
1 Explain the simple hydraulic system.
2 How a best hydraulic system is designed?
3 List the different hydraulic systems used in industries.
4 What is hydraulic power pack?
5 What is the difference between hydraulic system and pneumatic system?
6 What are factors to be considered to design a hydraulic system?
7 What are the components of hydraulic system?
8 What is hydraulic system consists of?
9 What are the components of reservoir?
10 Draw the reservoir components.
11 What are the parameters required to design a good hydraulic system?
 Experiment No. 7
Design of air distribution in pneumatic system.
Aim: -To study air distribution in pneumatic system.
Introduction:-
The main function of the air generation and distribution is to provide the system with
compressed air which is dry, clean, and at the required pressure the compressed air supply for a
pneumatic system should be adequately calculated and made available in the appropriate quality.
Air is compressed by the air compressor and delivered to an air distribution system in the
factory. To ensure that the quality of the air is acceptable In order to ensure reliable and trouble-
free air distribution, a number of points must be observed. This includes primarily the correct
sizing of the pipe system, but also the pipe material, flow resistances, pipe layout and
maintenance.
Sizing pipe systems:-
In the case of new installations, allowance should be made in all cases for extension of
the compressed-air network. The main line size determined by current requirements should
therefore be increased to include an appropriate safety margin. Plugs and shut-off valves allow
extension to be carried out easily at a later time.
Losses occur in all pipes due to flow resistances. Flow resistances are represented by
restrictions, bends, branches and fittings. These losses must be made up by the compressor. The
pressure drop in the entire network should be as small as possible.

To be able to calculate the pressure drop the total pipe length must beknown. For fittings,
branches and bends, equivalent pipe lengths are determined. The choice of the correct internal
diameter is also dependent on the operating pressure and delivery of the compressor. Selection is
best made with the aid of a monograph.

Flow resistances:-
Any influence or change of direction within the pipe system means interference with the
air flow and thus an increase of the flow resistance. This leads to a continuous pressure drop
along the pipe system. Since branches, bends, adapters and fittings are required in all
compressed-air networks, this pressure drop cannot be avoided but can be considerably reduced
by routing pipes favorably, choosing suitable materials and assembling the fittings correctly.
Pipe material:-
The choice of suitable pipe material is determined by the requirements placed on a
modern compressed-air network:
 Low pressure losses

 Freedom from leaks

 Resistant to corrosion

 Capability of system expansion.

In selecting a suitable pipe material, consideration must be given notonly to price per

metre run but also to another major factor, the installation costs. These are lowest with plastics.
Plastic pipes can be joined 100% airtight by means of adhesives or fittings and can easily be
extended.
Copper, steel and iron pipes have a lower purchase price but must bebrazed, welded or
joined by means of threaded connectors; if this work is not carried out correctly, swarf, scale,
welding particles or sealing materials may be introduced into the system. This may lead to major
malfunctions. For small and medium diameters, plastic pipes are superior to other materials as
regards price, assembly, maintenance and ease of extension.

Pressure fluctuations in the network make it necessary to ensure that the pipes are
mounted securely in order to avoid leakages at screwedand brazed connections.

Fig. 1 Air supply system

Piping layout:-
 Apart from correct sizing of the piping and the quality of the pipe material, correct pipe
layout is the decisive factor in determining the economic operation of the compressed-air system.
Compressed air is fed into thesystem at intervals by the compressor. It is often the case that
consumption at consuming devices raises for only a short time. This may lead to unfavorable
conditions in the compressed-air network. It is therefore recommended that the compressed-air
network should be produced in the form of a ring main. A ring main ensures largely constant
pressure conditions.

Fig. 2 Ring circuit

For ease of maintenance, repair or extension of the network without interferingwith the
overall air supply, it is advisable to sub-divide the network into individual sections. Branches
with T-pieces and manifolds with plug-in couplings make this possible. It is advisable to fit the
branch lines with standard ball valves or shut off valves.

Fig. 3 Interconnected networks

Despite the best water separation in the pressure generating system,pressure drops and
external cooling may produce condensate in the pipe system. In order to discharge this
condensate, the pipes should be inclined 1-2%; this can also be carried out in stages. The
condensate can then be discharged from the system via water separators at the lowest point.

Conclusion: Thus, we have design the air distribution system used in practice analysis with
the help of software
 QUESTION BANK
1 Explain the simple pneumatic system.
2 How a best pneumatic system is designed?
3 List the different pneumatic systems used in industries.
4 What is the difference between hydraulic system and pneumatic system?
5 What are factors to be considered to design a pneumatic system?
6 What are the components of pneumatic system?
7 What is pneumatic system consists of?
8 What are the parameters required to design a good pneumatic system?
9 What are the air properties?
10 Explain the good fluid required for a good pneumatic system.
 Experiment No. 8
1. Title: Industrial Visit to any Hydraulic or Pneumatic automation Plant.

2. Day and Date of Visit:

3. College Name: RMD Sinhgad School of Engineering, Warje, Pune-411058

4. Name of the Company Visited:

5. Location of the company:

6. Person contacted in the company, his department and designation:

7. Company History:

8. Company Products:

9. Mention various departments/section visited in the company

10. Theory of relevant products seen in the Company

Here actual products which are seen in the company can be discussed in detail

Here in this Specifications of the component should be mentioned

1. Working of the component should be explained

2. Diagram of the component should be drawn
3. Application of the component should be mentioned

Example: Check valve

Working pressures up to 6000 psig (413 bar)

1. Adjustable and fixed cracking pressures
2. Variety of end connections
3. 316 stainless steel and brass materials
Conclusion:
Scanned by CamScanner
 Assignment No. 2
Trouble shooting of Hydraulic Cylinders:

Aim: To study the Trouble shooting of Hydraulic Cylinders

A] Valves:

Trouble Cause Remedy

1 Dirt in system 1. Drain and flush system.
Disassemble and clean.
2 Pilot pressure low 2 Check pilot pressure system.
Response is sluggish
3. Malfunctions of solenoid 3 Check for proper source voltage
and frequency
1. Dirt in system 1 Disassemble, clean, and flash

2. No pilot pressure 2. Check source of pilot pressure

Spool is not moving
3. Solenoids not working 3. Check electrical source and
solenoid fields
1. Improper connections 1. Check installation drawings
Undesired response
2. Improper assembly of 2. Check parts and drawings.
valves

B] Cylinders:

Trouble Cause Remedy

1. Check for dirt or gummy deposit.

1. Valves sticking or binding Check for worn parts. Check for
contamination of oil.
2. Check for dirt or gummy deposit.
2. Cylinder sticking or
Check for worn parts. Check for
binding
misalignment.
Erratic action
3. Control line may be too small or
3. Pilot pressure too low
metering valve not working properly.

4. Internal leakage in 4 Repair or replace worn parts and

cylinder loose packing
C] Fluid Motors:

Trouble Cause Remedy

Running in Wrong 1. Check circuit and correct

1. Incorrect pipe connection
Direction it.

1. Remove dirt under

1. Relief valve is open pressure adjustment ball or
piston
2. DCV may be in open in
2. Free flow back to tank is center position or any other
being allowed in system return line is open. Repair or
Motor Running, but Not replace valve.
Developing Proper Speed
3. Remove motor and check
3. Driven mechanism binding
torque requirement of driven
because of is-alignment
shaft.

4. Pump not delivering 4. Check the pump delivery

sufficient pressure or volume and pressure.

External Leakage of Oil 1. Gaskets leaking. 1. Check and Replace.

D] Pumps :

Trouble Cause Remedy

1 Wrong direction of 1. Observe arrow on pump case.

pump rotation Direction of rotation must correspond.
2. Fill reservoir so that surface of oil is
2 Low oil level well above end of action line during all
Excessive Pump of work cycle.
Noise 3. Reduce speed. Speeds above rating
3. Pump running too fast are harmful and cause early failure of
pumps. Refer to pump ratings.

4 Coupling misalignment 4. Re-align pump and motor accurately.

 5. Ar bubbles intake line 5. Provide reservoir with baffles.

6. Worn or broken parts 6. Replace.

1. Test circuit pressure progressively.

1. Oil bypassing to
Watch for open center valves or other
reservoir
valves open to reservoir.
2. Defective pressure 2. Install pressure gauge known to be
Pump Not Delivering
gauge, gauge line is shut accurate in a line open to pump
Pressure
off. pressure.
3. Check minimum speed
3. Pump speed is less
recommendations.
1. Observe arrow on pump case or
1. Wrong direction of
nameplate. Direction of must
pump rotation
correspond.
Pump not Delivering 2 Oil level low in 2 Maintain oil level in reservoir well
Oil reservoir above bottom of suction line at all times
3. Increase speed. Check minimum
3. Pump running too
speed recommendations to be sure of
slowly
proper priming.

E] System :

Trouble Cause Remedy

1. Pressure is high 1. Reduce pump pressure

2. Oil is becoming hot 2. Idle period may be more, reduce it.

3. Insufficient cooling 3. Install oil cooler. Increase reservoir
facilities capacity.
System Excessively 4. Re-locate the power unit, or baffle
4. High ambient temperature
Hot against radiant heat.
5. Add oil and bring level up to the
5. Low oil in reservoir
recommended point.
6. Excessive friction 6. Internal parts may be too tight.
7. Increase size or install auxiliary
7. Reservoir too small
cooling equipment.
 Assignment No. 3
Standard specifications of hydraulic and pneumatic
components
Aim: To study the Standard specifications of hydraulic and pneumatic components.
1. Pilot Operated Pressure Relief Valves:

Specifications:

Model Number Max. Mass Kg.

Pres. Adj. Max.
Operating
Threaded Sub-plate Range Flow
Pressure 2 BT type BG type
Connection Mounting Kgf/cm L/min.
Kgf/cm 2
- BG-03-_-32 100 - 4.7

BT-06-_-3280 BG-06-_-32 250 * ~ 250 200 5 5.6

- BG-10-_-32 400 - 8.7
2. H type Pressure Control Valves:

Specifications:

Model Number Max. Mass Kg.

Max.
Operating
Threaded Sub-plate Flow
Pressure BT type BG type
Connection Mounting L/min.
Kgf/cm 2
HT-03-__-_-
--- 50 3.7 4
2280
HT-06-__-_- 125 6.2 6.1
--- 210
2280
HT-10-__-_-
HG-10-__-_ 250 12 11
2280 -10
3. Flow Control Valves:
4. Solenoid Operated Directional Valves, DSG-03 Series:

5. Manually Operated Directional Valves:

6. Cam Operated Directional Valves:

Conclusion:
The above various specifications shows the required data for various hydraulic and pneumatic
applications.