Prpc27 Mechatronics and Industrial AUTOMATION (Theory & Lab)

PRPC27 MECHATRONICS AND INDUSTRIAL
AUTOMATION (Theory & Lab)

Experiment Number: 3(a) Date: 15/02/2021
Aim: To study the meter-in and meter-out control of hydraulic actuators by simulating it in FESTO
Fluid-Sim.
Components Required:
1. Tanks (6 numbers)
2. Fixed Displacement Pump (2 numbers)
3. Direction Control Valves (DCV) – [4/n Way Valve (2 numbers.)]
4. Pressure Relief Valve (PRV)
5. Manometer
6. Hydraulic Motor
7. One Way Flow Control Valve (Meter-In, Meter-Out)
Circuit Description:
 Pump: They are used to transfer the hydraulic oil from the tank into the system with the aid of
seals or valves.
 Tank: It is used to store the hydraulic oil which is to be supplied to the circuit and stores the
oil which comes back in return line.
 Flow Control Valve (FCV): The presence of the flow control valve enables restriction in the fluid
flow to the cylinder. In the event of the flow direction being reversed, the check valve ensures that
the return flow bypasses the flow control valve. A Meter-In FCV is placed in the direction of fluid
flowing to the actuator and Meter-Out FCV is placed at the exit of the fluid from the actuator.
 Direction Control Valves (DCV): A directional control valve is the extend and retract control for
your hydraulic cylinders. It provides a flow path from the pump to the cylinders and a return path
from the cylinders to the fluid reservoir. Directional control valves perform only three functions:
stop fluid flow; allow fluid flow and change direction of fluid flow.
 Pressure Relief Valve (PRV): A relief valve or pressure relief valve (PRV) is a type of safety
valve used to control or limit the pressure in a system; pressure might otherwise build up and
create a process upset, instrument or equipment failure, or fire. The pressure is relieved by
allowing the pressurized fluid to flow from an auxiliary passage out of the system.
 Manometer: A manometer is an instrument used to measure and indicate pressure.
 Hydraulic Motor: A hydraulic motor is a mechanical actuator that converts hydraulic pressure and
flow into torque and angular displacement (rotation). The hydraulic motor is the rotary counterpart
of the hydraulic cylinder as a linear actuator.
Working of the Circuits:

1. In the initial phase, when the Direction Control Valve (DCV) is not used, the hydraulic oil flows through
the hydraulic motor after the pump is turned on.
2. The Meter-In FCV restricts the fluid flow, and thus controls the speed of the hydraulic motor.
3. The readings of the speed is noted for the corresponding opening levels of the FCV. When the DCV is
reversed, the motor runs in full speed as there is no fluid flow restriction.
4. A similar observation is done for the Meter-out circuit. The difference would be the placement in the
hydraulic circuit. Despite wherever it is placed, the main goal of controlling the speed of the hydraulic
motor is achieved in all times.
5. The pump is turned off.
Simulate circuit with State Diagram using FluidSIM-H:
Graph:
180
160
Opening Level of Meter-In Flow Control Valve vs RPM of Hydraulic
Motor
RPM of 140
Hydraulic 120
Motor
100
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10
Opening Level of Meter-In Flow Control Valve (in %)

Opening Level of Meter-Out Flow Control Valve vs RPM of

180
Hydraulic Motor
160
RPM of 140
Hydraulic 120
Motor
100
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10
Opening Level of Meter-Out Flow Control Valve (in %)
Inferences: The opening levels of the fluid control valve maintains approximately a linear relationship
with the speed at which the pump pushes the fluid into the hydraulic circuit.
Results: The hydraulic system's working is successfully studied with the help of constructed design
through simulations in FESTO Fluid-Sim.
Experiment Number: 3(b) Date: 15/02/2021
Aim: To study the sequence valve using a double acting cylinder.
1. Tanks (4 numbers.)
2. Fixed Displacement Pump (1 numbers)
3. Direction Control Valves (DCV) – [3/2 – Way Hand Lever, 4/3 – Way Hand Lever Bypass position]
4. Pressure Relief Valve (PRV – 3 numbers)
5. Check Valve (2 numbers)
6. Double Acting Cylinder (In and Out Piston Rod)
 Pump: They are used to transfer the hydraulic oil from the tank into the system with the aid of seals
or valves.
 Flow Control Valve (FCV): The presence of the flow control valve enables restriction in the fluid
flow to the cylinder. In the event of the flow direction being reversed, the check valve ensures that
the return flow bypasses the flow control valve. A Meter-In FCV is placed in the direction of fluid
flowing to the actuator and Meter-Out FCV is placed at the exit of the fluid from the actuator.
 Direction Control Valves (DCV): A directional control valve is the extend and retract control for
your hydraulic cylinders. It provides a flow path from the pump to the cylinders and a return path
from the cylinders to the fluid reservoir. Directional control valves perform only three functions:
stop fluid flow; allow fluid flow and change direction of fluid flow.
 Pressure Relief Valve (PRV): A relief valve or pressure relief valve (PRV) is a type of safety
valve used to control or limit the pressure in a system; pressure might otherwise build up and create
a process upset, instrument or equipment failure, or fire. The pressure is relieved by allowing the
pressurized fluid to flow from an auxiliary passage out of the system.
 Actuator: A hydraulic motor is a mechanical hydraulic actuator that converts hydraulic energy or
hydraulic pressure into torque and angular displacement/rotation. They have a port at each end and
move the piston forward and back by transfer of the hydraulic oil, necessary when a load must be
moved in both directions such as opening and closing doors. The force exertion in a Single acting
cylinder would only be in one direction and would be in dual directions in a Double acting cylinder.
Because of the difference in the area present in a double acting cylinder, there would be more force
in extension than retraction.
 Check Valve: Check valves are generally installed in pipelines to prevent backflow. A check
valve is basically a one-way valve, in which the flow can run freely one way, but if the flow turns
the valve will close to protect the piping, other valves, pumps etc.
1. DCV–1 acts as the Run/End Valve. After it is switched ON, the pump is connected DCV–2. DCV–2
is a part of automated control in the hydraulic circuit along with PRV and the Check Valves.
2. The Check Valve is placed in such a way that it restricts the fluid to pass through the FCV–1 in the
initial pumping stage.
3. The hydraulic fluid is pumped into the DAC through DCV–1, DCV–2 and FCV–1. The fluid on the
other side of the piston travels to the tank through FCV–2.
4. Once the piston moves to the extreme right, the PRV–3 allows the fluid to pass through as the pressure
built up exceeds the limit of PRV–3. It in turn actuates the solenoid of DCV–2 switching the direction
of flow in the DAC. Figure 3 and Figure 4 demonstrates the hydraulic circuit before and after the
switching taking place in DCV–2.
5. A similar function takes place. This time the fluid flows through the FCV–2 and the fluid on the other
side flows through FCV–1 returning to the tank.
6. The velocity at which the piston rod moves is observed along with the opening levels of the meter-in
and meter-out flow control valves.
7. The pump is turned off once the required study is conducted.
Figure 1:
Figure 2:
Figure 3:
Figure 4:
Figure 5:
Graphs:
Speed of Double Acting Cylinder

vs
Opening Level of Meter-In, Meter-Out Flow Control Valve
0.35
0.29 0.29 0.29 0.29 0.29

Speed of Double Acting Cylinder (m/s)
0.3
0.25
0.2
0.15
0.1
0.05
0
40, 40 50, 50 60,60 70,70 80,80
Opening Level of Meter-In, Meter-Out Flow Control Valve (in %)
Inferences: The velocity of the piston rod remains constant irrespective of the opening level in the flow
control valves.
Results: The hydraulic system's working is successfully studied with the help of constructed design
through simulations.
Experiment Number: 3(c) Date: 15/02/2021
Aim: To study the operation of shutoff valve and PRV using high-low pump circuit.
1. Tanks (4 numbers)
2. Pump – [Fixed Displacement Pump (1 numbers), Variable Displacement Pump (1 number)]
3. Direction Control Valves (DCV) – [4/N Way]
4. Pressure Relief Valve (PRV – 1 number)
5. Check Valve (2 numbers)
6. Double Acting Cylinder (DAC)
8. Shut Off Valve
 Pump: They are used to transfer the hydraulic oil from the tank into the system with the aid of seals or
valves.
 Flow Control Valve (FCV): The presence of the flow control valve enables restriction in the fluid flow to the
cylinder. In the event of the flow direction being reversed, the check valve ensures that the return flow
bypasses the flow control valve. A Meter-In FCV is placed in the direction of fluid flowing to the actuator
and Meter-Out FCV is placed at the exit of the fluid from the actuator.
 Direction Control Valves (DCV): A directional control valve is the extend and retract control for your
hydraulic cylinders. It provides a flow path from the pump to the cylinders and a return path from the
cylinders to the fluid reservoir. Directional control valves perform only three functions: stop fluid flow;
allow fluid flow and change direction of fluid flow.
 Pressure Relief Valve (PRV): A relief valve or pressure relief valve (PRV) is a type of safety valve used to
control or limit the pressure in a system; pressure might otherwise build up and create a process upset,
instrument or equipment failure, or fire. The pressure is relieved by allowing the pressurized fluid to flow
from an auxiliary passage out of the system.
 Actuator: A hydraulic motor is a mechanical hydraulic actuator that converts hydraulic energy or hydraulic
pressure into torque and angular displacement/rotation. They have a port at each end and move the piston
forward and back by transfer of the hydraulic oil, necessary when a load must be moved in both directions
such as opening and closing doors. The force exertion in a Single acting cylinder would only be in one
direction and would be in dual directions in a Double acting cylinder; because of the difference in the area
present in a double acting cylinder, there would be more force in extension than retraction.
 Check Valve: Check valves are generally installed in pipelines to prevent backflow. A check valve is
basically a one-way valve, in which the flow can run freely one way, but if the flow turns the valve will
close to protect the piping, other valves, pumps etc.
 Shut Off Valve: Shut off valves are designed to safely stop or continue the flow of hazardous fluids in the
hydraulic circuit.
1. When the DCV is switched on, the pump is connected to the DAC through FCV–1.
2. The Check valves are placed before the pumps restricting the backflow of the fluid.
3. The fluid on the other side of the piston travels to the tank through FCV–2.
4. Once the piston moves to the extreme right, the pressure built up triggers the shut off valve halting the
working of the hydraulic system.
5. A similar function takes place when DCV is reversed. This time the fluid flows through the FCV – 2 and the
fluid on the other side flows through FCV – 1 returning to the tank.
6. The pump is turned off once the required study is conducted.
Results: The hydraulic system's working is successfully studied with the help of constructed design through
simulations.

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PRPC27 MECHATRONICS AND INDUSTRIAL

AUTOMATION (Theory & Lab)

Working of the Circuits:

Opening Level of Meter-In Flow Control Valve (in %)

Opening Level of Meter-Out Flow Control Valve vs RPM of

Opening Level of Meter-Out Flow Control Valve (in %)

Speed of Double Acting Cylinder

0.29 0.29 0.29 0.29 0.29

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