Fundamental of Mechanical

Engineering and
Mechatronics
Unit – 5
Mechatronics
Dr. Ajay Singh Verma, ME Dept.
 MECHATRONICS
• Term Mechatronics was first introduced by
Tetsuro Mori, senior Engineer of a Japanese
Company in 1969 to denote the combination
of technologies which go together to
produce Industrial robots.

• The word Mechatronics refers to a

combination of “Mecha” from mechanism
and “tronics” from electronics.

• In other words, technologies and developed

products will be incorporating electronics
more and more into mechanisms.
 Definitions of Mechatronics
According to Mechatronics forum, UK

The synergistic integration of Mechanics and Mechanical Engineering,

Electronics, Computer Technology and IT to produce or enhance products
or systems.

Concluded Definition:

“Mechatronics is synergistic Integration of Mechanical Engineering,

Electronics and Intelligent computer control in design and manufacturing
of products and process.”
Graphical Representation of Mechatronics showing
Integrated and Inter-disciplinary approach of nature
 Evolution OR Development of Mechatronics
Development of Mechatronics has gone through 3 stages:
1. Stage 1 (1970’s)
2. Stage 2 (1980’s)
3. Stage 3 (1990’s)

Stage 1 (1970’s)
• Technologies developed rather independently and individually.
• Main focus was on servo technology.
• Simple implementation aided technologies related to control
methods.
Example: Automatic door openers and Auto focus Cameras.
 Stage 2 (1980’s)
• Synergistic Integration of different technologies takes
place.
• Concept of Hardware Software Co-design started.
• Main focus was on Information Technology.
• Microprocessors were embedded into mechanical
systems to improve performance.
Example: Optoelectronics (Integration of Optics and
Electronics)
Optoelectronics
Stage 3 (1990’s)
• Centered on communication technologies to connect
products into large networks.
• Production of the computational Intelligent systems,
technologies and products.
• Miniaturization of components in the form of micro
actuators and micro sensors.
Example: Micro Mechatronics(manufacture of mechatronics
products with dimensions in the range of 1 micrometer to 1 mm.)
Micro Mechatronics
1996: First Journal (IEEE) on Mechatronics was released.

After 2000: Application in

Aerospace,

Defense engineering,

Bio-Mechanics,

Automotive Electronics,

Banking (ATM) etc.

Scope of Mechatronics
• Mechatronics combine the various discipline to create a smart
product which is better than the sum of its parts depending
upon the market demand.
• Dynamic market conditions

• Producing next generation products

• Integration of modern technologies in product

• Variety in product ranges

• Batch production

• Change in design perspective

• Product quality and consistency

• Ease of reconfiguration of the process

• Demand for increased flexibility

• Better design of products.

• Better process planning.

• Reliable and quality oriented manufacturing.

• Intelligent process control.

• Intelligent product development

Application Areas of Mechatronics
•Smart consumer products: home security, camera, microwave oven, toaster, dish
washer, laundry washer-dryer, climate control units, Automatic Digital Cemera etc.

•Computer disk VCR/DVD drives, ATM, etc

• Medical: implant-devices, assisted surgery, haptic, etc.

• Defense: unmanned air, ground, and underwater vehicles, smart weapons, jet engines,
etc.

• Manufacturing: NC & CNC machine tools, Rapid Prototyping, robotics, etc.

•Automotive: climate control, antilock brake, active suspension, cruise control, air
bags, engine management, safety, etc.

•Network-centric, distributed systems: distributed robotics, telerobotics, intelligent

highways, etc.
Application Areas of Mechatronics contd..

• Medical Mechatronics and medical imaging system

• Structural dynamic system

• Transportation and vehicular systems

• Diagnostic and reliability techniques

• Computer integrated manufacturing (CIM) systems

• Micro/ Nano mechatronics

• Mechatronics in energy systems

• Human machine interface

• Mechatronics application in cyber-physical system

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Elements of Mechatronics Systems
ACTUATORS AND SENSORS

SIGNALS AND CONDITIONING

DIGITAL LOGIC SYSTEMS

SOFTWARE AND DATA

ACQUISTION SYSTEMS

COMPUTERS AND DISPLAY

DEVICES
 Advantages and Disadvantages of Mechatronics
Advantages:
• It is cost effective and can produce high quality products.
• Production of parts and products of International standard gives better reputation and
return.
• It serves effectively for high dimensional accuracy requirements.
• It provides high degree of flexibility to modify or redesign the products.
• It provides excellent performance characteristics.
• It results automation in production, assembly and quality control.
• Mechatronics systems provide the increased productivity in manufacturing organization.
• Reconfiguration feature by pre supplied programs facilitate the low volume production.
• It provides the facility of remote controlling as well as centralized monitoring and control.
• It has greater extend of machine utilization
• Higher life is expected by proper maintenance and timely diagnosis of the faults.
Disadvantages:

• Initial cost is high

• Maintenance and repair may workout costly

• Multi-disciplinary engineering background is required to design and

implementation.

• It needs highly trained workers to operate.

• Techno-economic estimation has to be done carefully in the selection of

mechatronic system.

• It has complexity in identification and correction of problems in the systems.

 Elements of a Mechatronics system
• Actuators and Sensors
Actuators produce motion or cause some action.
Sensors detect the state of the system parameters, inputs and
outputs.
• Signals and conditioning
Input conditioning devices: Discrete circuits, Amplifiers, A/D
convertor, D/D convertor
Output conditioning devices: D/A convertor, D/D convertor,
power transistors, power OP-amplifiers.
• Digital Logic systems
Logic circuits, microcontrollers, PLC, Sequencing and timing
control, control algorithms
• Software and data acquisition systems
Software is used to control the acquisition of data through DAC
board
Data loggers, computer with plug-in boards.
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Signals & Conditioning
•Mechatronic system deals with two types of signals and conditioning , i.e. Input & Output
• Input devices receive input signals from the mechatronics system via interfacing devices an
sensors.
•From sensors the signal is send to the control circuits for conditioning or processing.
•Various input signal conditioning devices are amplifiers, A2D, D2D converters .
•Output signals from the system are send to the output/display devices through interfacing devices
•Various output signal conditioning devices are D2A, display decoders, power transistors, op-amps.

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 Digital Thermometer

•The thermocouple is a transducer that converts temperature to a small voltage;

•The amplifier increases the magnitude of the voltage;
•The A/D (analog-to-digital) converter is a device that changes the analog signal to a
coded digital signal; and
•The LEDs (light emitting diodes) display the value of the temperature.
 Digital Logic System
•It will control overall system operation
•Various digital logic systems are logic circuits, microcontrollers, PLC, sequencing & timing
controls

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Programmable Logic Controllers (PLCs)
• The PLC takes inputs, performs logic on the inputs in the CPU and then turns on or off
outputs based on that logic.

• Programmable Logic Controllers (PLCs) are small industrial computers with modular
components designed to automate customized control processes.

• PLCs are often used in factories and industrial plants to control motors, pumps, lights, fans,
circuit breakers and other machinery.

• In 1968 the first programmable logic controller came along to replace complicated relay
circuitry in industrial plants.

• The PLC was designed to be easily programmable by plant engineers and technicians that
were already familiar with relay logic and control schematics.
 Software & Data Acquisition Systems

•Data acquisition system acquires the output signals from sensors in

the form of voltage, frequency, resistance etc. an inputting into the
microprocessor or computer.

•Software is used to control the acquisition of data through DAC board.

•Data acquisition system consists of multiplexer, amplifier, register and
control circuits.

•Software Examples: Ladder Logic, Visual C++, Visual Basic, Lab VIEW,
MATLAB, Lab Chart

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 Computers and display devices
•Computers are use to store large amount of data and process further through software.

•Display devices are used to give visual feedback to the user. Display devices are LED, CRT,

LCD, Digital displays etc.

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Water Level Controller
Washing machine control
 Autotronics
• Autotronics is an innovative approach in Automotive Mechatronics.

• Modern cars are as much electronic as they are mechanical, thus creating a new

AUTOTRONIC area (AUTOmobile + elecTRONIC).

• Modern car has several control modules, which monitor and manage most of the major
systems in the vehicle.

Control in Automotive: Engine and drive line control, cruise control, suspension control,
anti-lock braking and airbag control, climate control, GPS-based navigation system, stability
management system, instrumentation, infotaiment, etc.

Systems such as 'by-wire' braking and steering systems, collision warning, voice recognition,
Internet access, night vision enhancement and collision avoidance systems all start to be
introduced.
Bionics
Bionics or biologically inspired engineering is the
application of biological methods and systems found
in nature to the study and design of engineering
systems and modern technology.

Bionics Biology + Electronics

 In robotics, bionics and biomimetic
are used to apply the way animals
move to the design of robots. Bionic
Kangaroo was based on the
movements and physiology of
kangaroos.

In medicine, bionics means the

replacement or enhancement
of organs or other body parts by
mechanical versions. Bionic implants
differ from mere prostheses by
mimicking the original function very
closely, or even surpassing it.
in computer science, cybernetics is the
scientific study of communication and
control, in which, for example, human
and animal brains are compared with
machines and electronic devices.
Avionics
•Avionics are the electronic systems
used on aircraft, artificial satellites,
and spacecraft.
•Avionic systems include
communications, navigation, the display
and management of multiple systems,
and the hundreds of systems that are
fitted to aircraft to perform individual
functions.
•The cockpit of an aircraft is a typical
location for avionic equipment, including
control, monitoring, communication,
navigation, weather, and anti-collision
systems.
•The majority of aircraft power their
avionics using 14- or 28-volt DC electrical
systems.
Sensor or Transducer:
Sensor or Transducer is a device which converts a physical quantity, property or
condition into output.

Physical Quantity
or Property or Voltage or Resistance
Condition SENSOR/TRANSDUCER or Capacitance
(INPUT) (OUTPUT)

Example: A thermocouple is a sensor which converts changes in temperature

into a voltage.
Signal Processor: Signal processor or conditioner receives the output signal
from the sensor or transducer and manipulates or processes it into a suitable input
signal to control system.
• Signal processor performs filtering and amplification functions.
Example: A/D Convertor
 Sensor Definition:
A Sensor is defined as a device which
measures a physical quality (light, sound,
space) and converts them into an easily
readable format.

If calibrated correctly, sensors are highly

accurate devices. Not all transducers are
sensors, but most sensors are transducers.
For example, a thermistor is a type of sensor; it
will respond to the change in temperature but
does not convert the energy into a different
format to what it was originally sensed in.
 Different Types of Analog and Digital Sensors

Light Sensor
Temperature
Color Sensor
& Thermocouple Sensors
Touch Sensor
Proximity Sensor
Tilt Sensor
Ultrasonic sensor
Infrared Sensor(IR Sensor)
Accelerometers & Gyroscope
PIR Motion Detector & Vibration Sensor
Sensor
Metal detector, Water Flow & Heartbeat Sensor
Pressure Sensor
Flow and Level Sensor
Hall Effect Sensor
Smoke, Fog, Gas, Ethanol & Alcohol Sensor
Load cell
Humidity, Soil Moisture & Rain Sensor
 Classification of sensors
Active and Passive Sensors
Analog and Digital Sensors
Passive sensors
A Passive Sensor requires an external
source of power to operate while an Active
Sensor does not.
Example: Thermocouple, which generates
a voltage value corresponding to the heat,
applied. It does not require any external
power supply.
Active sensors
A Thermocouple is an Active Sensor as it
does not require any external power supply
to operate.
Therefore, it is also called as Self enerating
Sensors.
Examples: LVDT and strain gauge.
•Transducer:
•An electrical transducer is a device which is capable of converting physical quantities into a
proportional electrical quantity such as voltage or electric current.
•Hence it converts any quantity to be measured into a usable electrical signal.
•This physical quantity which is to be measured can be pressure, level, temperature, displacement
etc.
•The output which is obtained from the transducer is in the electrical form and is equivalent to the
measured quantity.
•For example, a temperature transducer will convert temperature to an equivalent electrical
potential. This output signal can be used to control the physical quantity or display it.
Types of Transducer
•Temperature transducers (e.g. a thermocouple)
•Pressure transducers (e.g. a diaphragm)
•Displacement transducers (e.g. LVDT)
•Oscillator transducer
•Flow transducers
•Inductive Transducer
•Photovoltaic (e.g. a solar cell)
•Piezoelectric transducer
•Chemical
•Mutual induction
•Electromagnetic
•Hall effect
•Photoconductors
Static and Dynamic Characteristics of sensor and Transducer:
Static Characteristics relate to the performance of a transducer when the measured quantity
is essentially constant,
Dynamic Characteristics relate to dynamic inputs, which means that they are dependent on
its own parameters as well as the nature of the input signal.
Static Characteristics:
The following are the static characteristics.
Static Error
Accuracy
Precision
Sensitivity
Reproducibility
Hysteresis
Drift
Dead zone
 Static Characteristics

Desirable Undesirable

• Hysteresis
• Static Error • Drift
• Accuracy • Dead zone
• Precision • Dynamic Error
• Sensitivity
• Reproducibility
• Resolution
Static Error:
The difference between the true value of the measuring quantity to the value shown
by the measuring instrument under not varying process conditions.
Static error = True value of a measured variable – Instrument reading.
+ Ve Static error means Instrument reads high,
– Ve Static error means Instrument reading low
Accuracy: may be defined as the degree of closeness with which the instrument
reading approaching the true value of the quantity to be measured.
The measured quantity may be different from the true value due to the effects of
temperature, humidity, etc.,
Accuracy is expressed in the “ percentage of full-scale reading”. In the case of
instruments having a uniform scale, the accuracy can be expressed as “
Percentage of Full-scale reading.
The best way to develop the ideas of accuracy is to specify it in terms of the
percentage of the true value of a quantity being measured.
•Precision: is the degree of exactness for which the instrument is
designed.
It composed of two characteristics: conformity and significant figures.
More significant figures, estimated precision is more.

For example two resistors for values of 1792 ohms and 1710 ohms.
A person even repeated measurement it indicates 1.7 K ohms.
The reader can not read the true value from the scale.
He estimates from the scale reading consistently yield a value of 1.5 M ohms.
This is as close to the true scale as he can read the scale by estimation
although there are no deviations from the observed value, the error created
by the limitation of the error is called precision error.
This example indicates that the conformity is necessary but not enough
condition, because of the lack of significant figures obtained.
Sensitivity:
•Sensitivity can also be derived as for the smallest changes in the measured variable for
which the instrument responds.
•Sensitivity can be defined as the ratio of a change in output to change in input which causes
it, in steady-state conditions.
•The usage of this term is generally limited to linear devices, where the plot of output to input
magnitude is straight.

Sensitivity = Change in output / Change in input

Sensitivity can also be derived as for smallest changes in the measured variable instrument
responds.
The term sensitivity is sometimes used to describe the maximum change in an input signal
that will not initiate on the output.
Note: The sensitivity of the instrument should be high.
Reproducibility: Under the different measurement conditions, if the successive measurements of the
same variable produce agreed results are called Reproducibility.
Resolution: It is the smallest quantity being measured which can be detected with certainty by an
instrument.
If a non-zero input quantity is slowly increased, the output reading won’t increase until some minimum
change in the input takes place. The minimum change which causes the change in output is termed
resolution.
Dead Zone: for the largest range of values of a measured variable, to which the instrument does not
respond.
•The dead zone occurs more often due to static friction in indicating an instrument.
•A practical example is: Due to static friction, a Control valve does not open even for a large opening
signals from the controller.
Hysteresis: Hysteresis: Hysteresis is a phenomenon that illustrates the different output effects
when loading and unloading.
Many times, for the increasing values of input an instrument, may indicate one set of output
values. For the decreasing values of the input, the same instrument may indicate its different
set of output values. When output values are plotted against input the following kind of graph is
obtained.

From the above figure, it can be seen that for increasing inputs and decreasing inputs the
maximum variation is seen at 50% of the full scale.
Drift is an undesired change in the output of a measured variable over a period that is
unrelated to the changes in output, operating conditions, load.
Drift may be caused by environmental factors mechanical vibrations, changes in temperatures, stray
electric fields, stray magnetic fields, thermal EMFs.

A drift in the calibration of the instrument occurs due to the aging of component parts. Drift occurs
in flow measurement due to wear and tear of primary sensing elements such as orifice plates.
Drift occurs in temperature measurement due to scale formation on thermowell.
Drift occurs in Thermocouple or RTD elements due to the change of metallic properties.
Drift for a measuring device can be systematic or random or both sometimes. Due to wear and
tear in the edge of an orifice plate the flow drift occurs systematic way.
Drift is further classified as :
•Zero Drift
•Span Drift
•Zonal Drift
Zero Drift: The zero drift is defined as the deviation in the measured variable starts right from
zero in the output with time.
The whole instrument calibration may gradually shift by the same amount as shown in the above
figure.
The mechanical bathroom weighing scale is a common example. It is quite casual to find that
there is a reading perhaps 1kg with no one stood on the scale. If someone of known weight weighs
70 kgs were to get on the scale, the reading would be 71 kgs. If someone with a known weight of
100 kg the reading would be 101 kgs.
The Zero shift is normally removable by calibration.
Span Drift:: If there is a proportionate change in its indication right along the upward scale the drift
is termed span drift or sensitivity drift.
Zonal Drift: In case if the drift occurs only a certain portion of the span of an instrument. It is
called zonal drift.
Dynamic Characteristics:
The Following are the dynamic characteristics
• Dynamic Error
• Speed of Response.
• Fidelity
• Lag.
Dynamic Error: The difference between the true value of the measured quantity to the value
shown by the measuring instrument under varying conditions.
Speed of response: It is defined as the rapidity of the measurement system that responds to the
changes in the measuring variable.
It indicates how active and fast the system is.
Fidelity: It is defined as the degree to which a measuring instrument is capable of faithfully
reproducing the changes in input, without any dynamic error.
Lag: Every system takes at least some time to respond, whatever time it may be to the changes in
the measured variable.

For Example Lag occurs in temperature measurement by temperature sensors such as

Thermocouple or RTD or dial thermometer due to scale formation on thermowell due to process
liquid.

Retardation lag: the response of the measurement begins immediately after the change in
measured quantity has occurred.

Time delay lag: in this case after the application of input, the response of the measurement system
begins with some dead times.
 Sensor Transducer
Senses the physical
Senses a physical
measurement and converts
measurement and makes it
it from one form to another
Working principle readable for the user but
- e.g.: Non- electrical to
keeps it in the same format
electrical
Microphones, pressure
Thermistor, motion sensor,
transducer, linear
Examples pressure switch
transducer.
Patient monitoring, infrared HVAC monitoring, engine
toilet flushes, liquid controls, steering systems,
Uses / applications dispensing in drinks ramp and bridge lifting
machines. systems.
Kinematic Link
A kinematic link is defined as a resistant body
having two or more pairing elements which
connect it to other bodies for the purpose of
transmitting force or relative motion.
e.g. Piston, cylinder, crank & connecting rod in IC
Engines
Kinematic Pair
The two kinematic links or elements of a
machine, when in contact with each other to
perform the constrained relative motion
between them , are said to form a
kinematic pair.
For example, the connecting rod with the
crank forms a kinematic pair, the piston with
the cylinder forms a fourth pair..etc.
Kinematic Chain
A kinematic chain is an assembly of rigid bodies connected by joints to provide
constrained (or desired) relative motion.
Types of Kinematic Chains
The most important kinematic chains are those which consist of four lower pairs, each
pair being a sliding pair or a turning pair. The following three types of kinematic chains
with four lower pairs are important from the subject point of view :

1. Four bar chain or quadric cyclic chain 2. Single slider crank chain, 3. Double slider crank chain.
cam
•A cam is a uniformly rotating machine element
which gives reciprocating or oscillating motion to
another element known as follower.
•The cam and the follower have a line contact and
constitute a higher pair.
•The cams are usually rotated at uniform speed by a
shaft, but the follower motion is predetermined and
will be according to the shape of the cam.
•The cam and follower is one of the simplest as well
as one of the most important mechanisms found in
modern machinery today.
•The cams are widely used for operating the inlet
and exhaust valves of internal combustion engines,
automatic attachment of machineries, paper cutting
machines, spinning and weaving textile machineries,
feed mechanism of automatic lathes etc.
Gear
•Gears are toothed wheels that transmit
motion from one shaft to another and
determine the speed, torque, and direction of
rotation of machine elements.
•Gears mesh their teeth with the teeth of
another corresponding gear or toothed
component which prevents slippage during
the transmission process.
•The gear that provides the initial rotational
input, called driving gear (i.e.,) rotates along
with its shaft component, whereas the gear
or toothed component which is impacted by
the driving gear and exhibits the final output
is called as the driven gear
Train Ratchet Mechanism
•A ratchet is a mechanical device that allows
continuous linear or rotary motion in only one
direction while preventing motion in the opposite
direction.
•A ratchet is composed of three main parts: a round
gear, a pawl, and a base.
•The geometry of the gear or rack is usually
designed with a ramp feature on one side of the
tooth leading to a sharp drop off which restricts
motion of the pawl when the linear or rotational
direction is reversed.
Ex.1: Turnstile
The one-way flow of human traffic in places like the
subway.
Ex.2: Zip Tie
The design of the ratchet mechanism allows for the
zip tie to be tightened, but locks when a force is
applied in an attempt to loosen the tie. Turnstile Zip Tie
 Belts
•Belt drive, in machinery, a pair of pulleys attached to
usually parallel shafts and connected by an encircling
flexible belt (band) that can serve to transmit and modify
rotary motion from one shaft to the other.
•Most belt drives consist of flat leather, rubber, or fabric
belts running on cylindrical pulleys or of belts with a V-
shaped cross section running on grooved pulleys.
•To create an effective frictional grip on the pulleys,
belts must be installed with a substantial tension.
•Because of the wedging action of the belts in the
grooves, V belts require less tension than do flat belts
and are particularly suitable for connecting shafts that
are close together.
•Flat and V belts slip when overloaded, and in some
applications this condition may be more desirable than
a rigid drive because it limits the transmitted torque and
may prevent breakage of parts.
Bearing
•A bearing is a machine element that constrains
relative motion to only the desired motion, and
reduces friction between moving parts.
•Machines that use bearings include automobiles,
airplanes, electric generators and so on.
•They are even used in household appliances that we
all use every day, such as refrigerators, vacuum
cleaners and air-conditioners.
•Bearings support the rotating shafts of the wheels,
gears, turbines, rotors, etc. in those machines, allowing
them to rotate more smoothly.
•They fulfill the following two major functions.
•1: Reduce friction and make rotation more smooth
•2: Protect the part that supports the rotation, and
maintain the correct position for the rotating shaft
Types of Bearings:
1. Deep-Groove Ball Bearings.
2. Angular Contact Ball Bearings.
3. Self-Aligning Ball Bearings.
4. Thrust Ball Bearings.
5. Spherical Roller Bearings.
6. Cylindrical Roller Bearings.
7. Tapered Roller Bearings.
8. Needle Roller Bearings.
 What is Hydraulics?
OLD DEFINITION:
Anything which is in affiliation with water is called hydraulics.

NEW ERA DEFINITION:

Transmission & control of forces & movements by means of fluids is called
hydraulics.
 Hydraulic System – Introduction
•Hydraulic systems are power-transmitting assemblies employing pressurized liquid
as a fluid for transmitting energy from an energy-generating source to an energy-
using point to accomplish useful work.
•The figure shows a simple circuit of a hydraulic system with basic components.
•Hydraulic systems are used for transmission of power through the medium of
hydraulic oil.
•The hydraulic system works on the principle of Pascal’s law which says that “ the
pressure in a fluid at rest is transmitted uniformly in all directions”.
•The fluid medium used is hydraulic oil, which may be mineral oil or water or
combinations. This area is also known as oil hydraulics.
Basic components of a hydraulic system

A basic system consists of:

•A hydraulic pump,
•Reservoir for hydraulic fluid,
•Directional valve,
•Check valve,
•Pressure relieve valve,
•Selector valve,
•Actuator, and
•Filter.
 VALVES
• Valve are defined as devices to control or regulate the commencement,
termination and direction and also the pressure or rate of flow of a fluid under
pressure which is delivered by a compressor or vacuum pump or is stored in a
vessel.

1. Pressure control valves

2. Non return valves

3. Flow control valves

4. Direction control valve

Pressure-Control Valves
•In order to avoid hydraulic system damage, power wastage and overheating
of the hydraulic fluid, circuit designers use a variety of cleverly designed
systems to control maximum system pressure and pump flow during non-
action periods.

•Pressure-control valves are found in virtually every hydraulic system, and

they assist in a variety of functions, from keeping system pressures safely
below a desired upper limit to maintaining a set pressure in part of a circuit.

• Pressure-control valves are used in hydraulic systems to control actuator

force (force = pressure × area)and to determine and select pressure levels at
which certain machine operations must occurs.

•ACTUATOR FORCE = Pressure(P)* Area(A).

Classification of Pressure Control Valves

• Pressure-relief valve.

• Pressure-reducing valve.

• Unloading valve.

• Counterbalance valve.

• Pressure-sequence valve.

• Brake valve.
 Pressure-Relief Valves
•Most fluid power systems are designed to
operate within a preset pressure range.

•This range is a function of the forces the

actuators in the system must generate to do the
required work.

•Without controlling or limiting these forces, the

fluid power components (and expensive
equipment) could be damaged.

•Relief valves avoid this hazard. They are the

safeguards which limit maximum pressure in a
system by diverting excess oil when pressures
get too high.
Pressure-Reducing Valves
•The most practical components for maintaining
secondary, lower pressure in a hydraulic system
are pressure-reducing valves.
•Pressure-reducing valves are normally open, 2-way
valves that close when subjected to sufficient
downstream pressure.
•There are two types: direct acting and pilot Direct-acting valves
operated.
•Direct-acting valves are pressure-reducing valves that
limit the maximum pressure available in the secondary
circuit regardless of pressure changes in the main
circuit.
•A small pilot relief valve, usually built into the main
valve body, relieves fluid to tank when reduced
pressure reaches the pilot valve’s spring setting.
Pilot Relief Valve
 Sequence Valves
•In circuits with more than one actuator, it is often necessary
to drive the actuators, such as cylinders, in a definite order
or sequence.
•One way to do this is with limit switches, timers, or other
electrical control devices.
•Sequence valves are normally closed, 2-way valves.
•They regulate the sequence in which various functions in a
circuit occur.
•Sequence valves sometimes have check valves, which
permit reverse flow from the secondary to the primary
circuit.
Direction Control Valves
• Pneumatic systems like hydraulic system also
require control valves to direct and regulate
the flow of fluid from the compressor to the
various devices like air actuators and air
motors.
• Directional control valves perform only three
functions:
• Stop fluid flow
• Allow fluid flow, and
• Change direction of fluid flow.
Hydraulic Cylinder
•A hydraulic cylinder enables a hydraulic
system to do useful work by converting the
energy of the hydraulic fluid into a linear
force.
•Pressurized hydraulic fluid acts on the piston
of the cylinder causing it to move in a linear
motion.

In turn, this causes the rod, which is connected to the load, to move. That is how the
energy in the fluid is converted into a power which can be controlled to do useful work.
The key components of a hydraulic cylinder include:
•A barrel, base and head which form the main body of the cylinder.
•A piston which creates two chambers in the cylinder.
•A rod which is mounted on one side of the piston and connects to the machine
component that does the mechanical work.
•Seal gland and seals to stop the hydraulic fluid from leaking.
 Types of Hydraulic Cylinders

Single acting cylinder

• These cylinders produce work in one

direction of motion hence they are

named as single acting cylinders.

• A spring or an external load is used

to return the cylinder top to its original

position i.e. when pressure of the

fluid is cut off.

Double acting cylinder
In the double acting cylinders, the
pressure from the fluid is applied in
both the directions.
Piston separates the chamber and as
the oil pressure effects the piston, the
piston moves the rod – the oil effects
to the piston’s front or back– when the
cylinder rod moves to both directions.
 Pneumatic system

Pneumatic systems use air as

the medium which is
abundantly available and can
be exhausted into the
atmosphere after completion
of the assigned task.
Basic Components of Pneumatic System
Important components of a pneumatic system

a. Air filters: These are used to filter out the contaminants from the air.
b. Compressor: Compressed air is generated by using air compressors. Air
compressors are either diesel or electrically operated. Based on the requirement of
compressed air, suitable capacity compressors may be used.
c. Air cooler: During compression operation, air temperature increases. Therefore
coolers are used to reduce the temperature of the compressed air.
d. Dryer: The water vapor or moisture in the air is separated from the air by using a
dryer.
e. Control Valves: Control valves are used to regulate, control and monitor for control
of direction flow, pressure etc.
f. Air Actuator: Air cylinders and motors are used to obtain the required movements
of mechanical elements of pneumatic system.
g. Electric Motor: Transforms electrical energy into mechanical energy. It is used to
drive the compressor.
h. Receiver tank: The compressed air coming from the compressor is stored in the air
receiver.
Actuators
• Actuators are output devices which convert energy from pressurized
hydraulic oil or compressed air into the required type of action or motion.
• Actuators can be classified into three types.

• 1. Linear actuators: These devices convert hydraulic/pneumatic

energy into linear motion.
• 2. Rotary actuators: These devices convert hydraulic/pneumatic
energy into rotary motion.
• 3. Actuators to operate flow control valves: these are used to control
the flow and pressure of fluids such as gases, steam or liquid.

• Typical pressure of hydraulic cylinders is about 100 bar and of

pneumatic system is around 10 bar.
 Pneumatic Rotary Actuator
• A pneumatic rotary actuator uses compressed air to
generate its operating energy.
• A pneumatic rotary actuator consists of one or more
air chambers with a piston or a bellows diaphragm.
• Depending on the design, the air pressure forces the
piston or the diaphragm to move creating linear or
rotary motion.
• If the created motion is linear, it then internally
converts the linear motion to rotational motion.
• Pneumatic rotary actuators are durable, offer high
force relative to their size and can be used in
hazardous environments.
Gear motor: A Rotary Actuator
Accumulators
• A hydraulic accumulator is a pressure storage reservoir in which
an incompressible hydraulic fluid is held under pressure that is
applied by an external source of mechanical energy.
• The external source can be an engine, a spring, a raised weight, or
a compressed gas.
• Accumulators usually are installed in hydraulic systems to store
energy and to smooth out pulsations.
• Typically, a hydraulic system with an accumulator can use a smaller
pump because the accumulator stores energy from the pump during
periods of low demand.
• This energy is available for instantaneous use, released upon
demand at a rate many times greater than what could be supplied
by the pump alone.
• Accumulators can increase efficiency, provide smoother, more
reliable operation, and store emergency power in case of electrical
failure.
Pneumatic/Hydraulic Amplifiers
• Air amplifiers or air boosters are ideal for increasing or boosting existing plant air
pressures.
• Each pressure amplifier comprises a spool valve that acts as a 4-way directional control
valve. Plant air is supplied to this spool valve, which automatically cycles back and forth.
• The plant air fed into the spool valve is alternately directed, as the spool cycles to the
main air drive piston in the air drive cylinder.
• This causes the piston to cycle back and forth in the pressure multiplier.
• The air intensifier also consists of a high pressure section where the air to be pressurized
is supplied.
• The air flows into the booster’s pressure chamber, through the inlet check valves, on the
suction stroke.
• It is then compressed out of the chamber on the discharge stroke through the outlet check
valve.
• The reciprocating movement of the air drive section, connected directly to the high
pressure section, creates a positive displacement of air through the inlet and outlet check
valves.