A Course Project Report

On
DESIGN AND ANALYSIS OF INDUSTRIAL CIRCUIT
Submitted By
ASHUTOSH RAUT 53
RIYA TEKADE 54
ABHISHEK SALUNKE 55
NIKITA SAPKALE 58
PRANITA SAYAM 59
Under the Guidance of
Prof. S.R. Yewale

Department of Mechanical Engineering

Vishwakarma Institute of Technology Pune.
(An Autonomous Institute Affiliated to SPPU)
YEAR 2019-20.

Prof. S.R. Yewale Prof. M.D. Chaudhari

(Guide) (H.O.D)
 DESIGN AND ANALYSIS OF INDUSTRIAL HYDRAULIC CIRCUIT.

Ashutosh Raut1, Riya Tekade2, Abhishek Salunke3, Nikita Sapkale4, Pranita Sayam5

INTRODUCTION: CALCULATION:
Hydraulic circuit comprises of various Given Data:
components such as electric motor which Fext = Fret = 20 KN
convert electric energy into mechanical Vext = 0.02 m/s
Vret = 0.06 m/s.
energy and the pump converts mechanical
energy into hydraulic energy and the
DESIGN CATALOGUE:
actuator converts back hydraulic energy into
mechanical energy. Control elements like
valves are used which controls the fluid in
the circuit such as direction control valves,
flow control valves & pressure relief valves
etc.
Various energy conversions in hydraulics:

PROBLEM STATEMENT:
To draw, design and simulate a hydraulic
circuit which will operate a hydraulic
cylinder of a weight raising and lowering
machine. The load during forward stroke is
20KN, and same during return stroke. The
forward and return speeds are 0.02 m/s and
0.06 m/s respectively. Total stroke of the
cylinder is 300 mm. Provision is required to
hold the cylinder anywhere in between the
end positions. Select different components
from the design data book.
Selection of different components is based
on pressure and flow rate.
1. Selection of Actuator:
From given data let us randomly select the
actuator having Dpiston=40 mm and Drod=16
mm.
Pressure built in circuit according to selected
actuator:
P = (F/Apiston) = 20000/ ∗ 0.02 = 159 bar.
Above capacity pump is not valid in the
data. So, modifying the actuator size.

Maximum pressure available = 70 bar

Calculating Actuator dimensions:
70* 105 = 20000/ ∗
So, Diameter of Cylinder= 60.31 mm
From table [9], we can select actuator.
Final dimensions of an Actuator:
A4: Dp=75mm, Dr=45mm
Dp= Diameter of piston.
Dr= Diameter of piston rod.
Now by considering above actuator we can
calculate maximum pressure build in the
circuit.
P=(F/Apiston)= 20000/ ∗ 0.03725 = 45.27
bar.
Qext = Ap* V = ∗ 0.03725 * 0.02 = 5.23
LPM.
Qret= ∗ 0.03725 * 0.02 = 15 LPM

Pmax= 45.27 bar. Qmax= 15 LPM.

Depending on these two values we can 6. Pressure Gauge:
select other components from the design
data book.

2. Pump:

7. Directional Control Valve:

3. Reservoir:

8. Flow Control Valve:

4. Filter:

9. Check Valve:

5. Pressure Relief Valve:

Comparison between pneumatics supplied to the circuit and also stores
and hydraulic fluid power: the oil which comes back in return line
as shown in the Fig.

2. Suction filter: It is used in circuit to

filter the dirt and foreign particles
present in the oil. This prevents the
entry of the dirt particles in the circuit.
From the above table the comparison
between the Pneumatics and Hydraulics
system, the hydraulic system has more
advantages than Pneumatics the only
disadvantage it has is the cost but when the
load exceeds the 10 bar it is not possible to
operate the system with pneumatics only the
hydraulic system has to be selected.
3. Pressure relief valve - It is also called
Advantage of hydraulic system over
as safety valve, it maintains the safe
pneumatic system:
operating pressure in the circuit if the
1. In pneumatic system the exhaust air
pressure exceeds in the circuit it
generates noise but noise generation
discharges the excess fluid back to the
is less in hydraulics.
reservoir.
2. Can be used for heavy load
applications and accurate positioning
or stopping at the stations are
possible in the hydraulics system.

HYDRAULIC CIRCUIT DESIGN:

The hydraulic circuit comprises of the
following major components.
1. Atmospheric reservoir: It is used to
store the hydraulic oil which is to be

4. 4/3 Lever operated Spring return
DCV: It is used in the circuit for
actuating the cylinder.
5. Throttling valve: This valve controls
the flow of the fluid enters in to the
cylinder which in turn control the
motion of the piston.
6. Cylinder:
It is used to raise and lower the load by
attaching required arrangement to the
piston rod.
7. One-way flow control valve: This
valve is the combination of check valve
and throttling valve controls the flow of
the fluid enters in to the cylinder for
extension and there is no control over
retraction as during retraction the
bucket will be empty.
Software Used:
FluidSIM Hydraulics 4.5
Using this software we can design, analyse
and simulate hydraulic as well as pneumatic
circuits. We have used this software for
designing and simulating of given problem
statement.
CIRCUIT DIAGRAM: SIMULATION:

POSITION 1:

The arrangement of the different

components is shown in figure. The circuit
diagram is used for the application of raising
and lowering the load. Load is also shown in
the figure. Pressure relief valve is used to
dump the excess pressure of the oil. Filter is
used to avoid unwanted particles going to
the pump. With the help of flow-meter we
can check the flow rate. 4/3 DCV is used to
manually operate the cylinder to different In the figure shown above the 4/3 DCV in
positions. We can also stop the cylinder in its centre position where oil is going to tank
between the end positions of an actuator. directly as the centre position is closed type.
As the pressure in the cylinder is exceeding
set pressure so the pressure relief valve gets
opened and oil goes from pump to tank
through the pressure relief valve.
POSITION 2: that the velocity is 0.02 m/s which we have
designed. We can also observe the pressure
is also the same as that of designed pressure.

POSITION 3:

In the above figure 4/3 DCV is shifted to the

leftmost position in such a way that the
high-pressure oil from the pump is going to
the left portion of the cylinder through one-
way DCV so that we can control the flow
In the figure shown above we can observe
rate of the oil going into the cylinder. The
the third position. 4/3 DCV has been shifted
oil from the front portion of the cylinder is to the rightmost position. In this position the
coming back to the tank through the check oil from the pump is going to the front
portion of the cylinder so that weight is
valve. Check valve is provided to allow the
lowered. The oil from the back portion of
oil flow in single direction only. So, the the cylinder goes to the tank through the
weight will be lifted. We can also observe one-way FCV through the check valve. We
can also observe the velocity and pressure is
same as that of designed velocity and
pressure.

CONCLUSION:
1. In this project we have considered a
problem statement and designed a
suitable hydraulic circuit which can
serve the purpose.
2. By using hydraulic systems and
proper circuits we can automate all
type of movements, speeds, forces.
3. Using FluidSIM software we have
designed the circuit for given
pressure and velocities and using
software we have designed and
simulated the circuit which gave
nearly same results as that of
theoretical design.

REFERENCES:
I. https://www.academia.edu/
II. https://www.hydraulicspneumatics.c
om/
III. “FluidSIM hydraulics 4.5” software.