Luke Parry U11 A1

Task 1: Fluid Power devices

a) Electro-Pneumatic component
Electro pneumatic components are components of a pneumatic system which can be altered or
controlled by an electrical current. This typically involves directional control valves or flow control
valves.
For my example of an electro pneumatic component I will be looking at a solenoid valve. Solenoid
valves use a solenoid (electro magnet) to actuate a valve. Different solenoid and different valves are
used depending on the application e.g. high/low pressure. Direct operated valves are the simplest
form. As with many valves or switches, solenoid valves come in Normally Open (NO) and Normally
Closed (NC) configurations. Here we are looking at a normally closed Valve:

www.youtube.com/watch?v=-MLGr1_Fw0c

When current Is passed through the solenoid coil, the plunger will be pulled up into the coil against
the spring, allowing fluid to pass through.
Solenoid valves are incredibly common in both pneumatic/gas and hydraulic/fluid applications since
they allow remote control of fluid or pneumatic flow. The other types of solenoid valve include pilot
valves, 2, 3 and 4 way valves. Pilot valves use a much smaller solenoid valve which in turn opens a
larger valve with higher pressure. These valves tend to operate much slower than direct valves and
have many more components.

b) Electro-hydraulic component
For my example of an electro-hydraulic component I will
be looking at an electro hydraulic actuator. Electro
hydraulic actuators are essentially self-contained
hydraulic actuators which can be used for various
applications. They benefit from the high precision of
hydraulics and a self-contained form factor.
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Compact electro hydraulic actuators typically consist of a pump, reservoir and actuator. The pump
moves hydraulic fluid directly into the double acting cylinder it is mounted to.
Electro hydraulic actuators can either be linear or rotary giving them a broad range of applications.
These actuators are popular for use with either linear or rotary valves for accurate flow control with
remote access. The self-contained nature of these actuators allows for many potential applications.

Task 2: Circuit diagrams

The symbols used here appear to be ISO pneumatics symbols.

1 – this component is a single acting cylinder with a spring return. The cylinder has one input which
requires positive pressure to actuate the piston out against the spring. Then the pressure drops, the
spring pushes/returns the piston to its home position. The zig-zag line indicates a spring and therefor
a spring return.

2 – this component is a one-way flow control valve; it allows air to flow in a single given direction.
The valve allows the flow of air to be restricted manually using a screw.

this represents the flow restriction.

In this case, air can flow upward into the cylinder at a controlled rate. When the air flows
backwards through the component it will not be restricted.

3 – this component is a normally closed (NC) 3 2-way valve. This particular valve is operated by a
push button / manual action and utilises a spring return. When the button is pressed, the valve
moves across and air can travel from inlet 1 to outlet 2. When the button is released, the spring will
return the valve to closed. If the valve is closed, air coming through port 2 will be expelled out of
port 3.

In principle, this circuit would have air supplied to port 1 of the valve, where the valve can be
manually operated to supply air through the flow control valve. The flow control valve has the ability
to be adjusted to restrict airflow into the actuator/cylinder. The cylinder would then extend.

Static / closed
Button pressed
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When the valve button is released, the valve will return to closed and air supply to the cylinder will
stop. Air in the cylinder will be expelled with the returning spring as the piston returns to contracted.

This circuit may be used for operations such as stamping components since it is momentary and
retracts to its original position.

Task 3: Compare Pneumatic and Hydraulic Systems

In this task I will be looking at an air file for my pneumatic example and a bottle jack for my Hydraulic
example. Pneumatic and Hydraulic systems tend to share a lot of similarities with the key difference
being that one expels the fluid after use and the other
www.amazon.in/Docooler-Sander-Compressor-
recirculates it, and that one uses air and the other is Sanding-Pneumatic/dp/B07M639RKM
hydraulic.

Air files or Air belt sanders are tools driven by compressed

air. The air is used to drive a pneumatic motor which
directy rotates the sanding belt. A majority of air powered
sanders follow the same principle, air in > spins motor >
air out. From the breakdown on the right we can see that
the file begins with the air inlet,this inlet would typically
be fitted with a quick connect fitting (with sealing tape) to
suit the other tools in the workshop. These fittings will
seal on the supply line but not on the tool end. Following
the air inlet is the valve switch which allows air to
flowthrough the pneumatic motor and spin the belt. The
air is then expelled through the air outlet into the
atmopshere. The key differences here compared to a

learnchannel-tv.com/pneumatics/pneumatic-motor/
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hydraulic equivalent is that air is vented to atmosphere instead of being recerculated as in a

hydraulic system. Also, with hydraulic quick

connect fittings both fittings will seal as to hold the hydraulic fluid inside. This is so that the system is
constantly primed, this is unnecessary in pneumatic applications.

Air is expelled in pneumatic motors because the airs potentially energy (the compression) is lost
when the energy is used to rotate the motor. Also air isnt harmful for the atmosphere like hydraulic
fluid so there is no need for recerculation.
Air powered tools inherently rely on the supply of compressed air. This compressed air will come
from an adjasent air compressor which uses a motor

Here we can see a very basic diagram for a air motor,

inside the box is an air driven motor with a momentary
3/2 switch and a direct exahsut, essentially an air sander.

Bottle jacks are typically self contained hydrauic systems which use a hydraulic ram to perform lifting
operations such as lifitng cars. A bottle jack is essentially a self contained manually powered
hydraulic ram. Bottle jacks operate using a fairly simple principle.

The hydraulic resevoir is formed

around the central ram. The jack
handle uses a piston to pump
hydraulic fluid using the check valves
princliple of one way flow. This
forces hydraulic fluid into the ram
cyclinder which in turn pushes the
ram upawards. The release valve is
used to bypass fluid past the check
valves and back into the resevoir,
eliminating the need to reverse the check valves to lower the ram.
one of the primary differences between this hydraulic sustem and an equivalent pneumatic system is
that the hydraulic bottle jack recerculates the hydraulic fluid. This recerculation is what allows the
jack to be self contained.

Similarly to air compressors and tools, hydraulic tooling is able to utilise an external hydraulic pump
for the tools function. This is commonly seen with higher power tooling such as ‘the jaws of life’
which use an external high power hydraulic pump. Due to the incompressability of hydraulic fluid,
hydraulics can operate at much higher pressure compared to compressed air.

Over time, both hydraulic and pneumatic systems will begin to deteriorate however air tooling tends
to require less maintenance due to the lower pressure. Air leaks in pneumatic tooling are dangerous
but typically less of a risk whereas leaks in hydraulic tooling can potentially be a minor explosion due
to the pressure.
Air tooling maintenance typically involves lubricating the designated ports around the tool to
lubricate the necessary seals and bearings, doing so stops the sealsdrying out over time and
increases the service life. Air seals failing will lead to gaps in the gaskets and seals and therefore air
leaks leading to a loss of power.
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in a hydraulic system such as a bottle jack, a majoirty of moving components are lubricated by the
hydraulic fluid. However, rubber seals and gaskets will still deteriorate over time therfore the seals
for the ram, piston and check valves may need replacing accordinly. Hydraulic fluid can also
deteriorate overtime depending on the use and age. Just as with pneumatic components, perished
seals compromise the systems ability to hold fuild, leading to dangerous pressure leaks.

To conclude I have condensed key factors into a table, neither positive or negative:

Pneumatic Hydraulic
Exhausts to atmosphere Recerculates air
80-100 PSI 1000-5000+ PSI
Uses readily available air Uses stores of harmful fluid
Rarely tooling is primed Uses primed components

Task 4: current standards

In this task I will be looking at the relevance of current standards such as ISO and CETOP in relation
to the contruction and operation of each device. I will be looking at 4 devices that I have covered
and then discussing the regulations which may apply to them. For simplicity, I will be looking at
regulations relating to the pneumatic or hydraulic aspects of each piece of equipment in order to
stay on topic.

Solenoid Valve: solenoid valves are used for a variety of fluid power systems and therefor the
standards will differe slightly depending on the application.
https://www.smcworld.com/products/en/s.do?ca_id=634#rp

SMC for example creates solenoid valves which conform to the many ISO standards which
standardise the size, interface features etc.

ISO 15407-2:2002 “specifies dimensions and tolerances of the interface features, port identification,
identification of the result of control-mechanism actuation, dimensions, tolerances and
specifications for optional interface electrical connector mateability for a mounting interface and
electrical connector for five-port pneumatic directional control valves, sizes 18 mm and 26 mm, for
use at a maximum rated pressure of 1,6 MPa (16 bar).” https://www.iso.org/standard/27626.html

From what I can deduct from the website, they create products which conform to the various ISO
standards which cover different sizes and ratings.

By looking at the www.iso.org website, I can search for standards relating to solenoid valves, we
have:

- ISO 15218:2003 relating to the dimensions of 3/2 solenoid valves

- ISO 15998-2:2012 relating to machine control systems
- ISO 13849-1:2015 relating to safety related parts of control systems
- ISO 9461:1992 relating to the identification of valve ports and solenoids
- ISO 22153:2020 relating to electrical actuators for industrial valves

Hydraulic actuator - Bottle jack: since hydraulic actuators and hydraulic bottle jacks share many of
the same principles, I have condensed them into a single point. Companies typically state whether
their products abide to the relevant ISO standards.
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ISO 4413:2010 outlines the general rules and safety requirements for hydraulic fluid power. ISO4413
applies to the design, construction and modifation of systems and their components whilst
accounting for “assembly, installation, adjustment, uninterrupted system operation, ease and
economy of maintenance and cleaning, reliable operation in all intended uses, energy efficiency and
environment” https://www.iso.org/standard/44781.html 4413 also identifies the significant hazards
associated with hydraulic systems and the principled to apply to avoid these hazards.

By searching the site for standards relating to “hydraulic piston” I found the results:

- ISO 18387:2019 relating to hydraulic linear actuators in aerospace

- ISO10766:1996 relating to tolerances for hydraulic cylinder piston and rod housings-
amended 2014
- ISO 4395:2009 covers cylinder piston rod end types and dimensions.
- ISO 6020 covers mounting systems and dimensions for single rod cylinders up to 160 BAR

Air File/belt sander:

The primary pneumatic component in an air powered belt sander is the air motor.The different
applications for air motors means that they can be subjected to a variety standards for different
industries, primarily dentistry. Infact, all the search results relating to air motors on the ISO website
related to dentistry, refrigerant and vehicles. A quick search reveals that there are infact ISO
standards relating to pneumantic tooling.

ISO/TC 118 is a classification of standards relating to compressors and pneumatic tools, machines
and equipment. This standards further breaks down into 4 sub categories, the one relating to
pneumatic tools and machines being SC3.

The SC3 class (subcommittee) breaks down into: (most relevant to us)

- ISO 2787:1984 Rotary and percussive pneumatic tools — Performance tests

- ISO 8622:1988 measurement of vibration to the handle
- ISO 11148-8:2011 - Hand Held non electric power tools – safety requirements – sanders and
polishers

SC3 covers everything we may need to consider for the design and use of pneumatic tooling, this is a
very useful set of standards in our application. There are 44 standards set under SC3 not including
the ones under development. The UK is listed as a participating member of this subcommittee. It is
not necessary to list every standard under SC3 here since many relate to other specific pneumatic
tools and not sanders, however the full list is here:
https://www.iso.org/committee/51870/x/catalogue/

Cetop is recognised as the European fluid power committee. “CETOP represents more than 1,000
companies - mainly manufacturers, but also some dealers - with almost 70,000 employees and a
market value of about 13 billion EURO.” https://www.cetop.org/about-cetop/
Cetop aims to share information to better the fluid power industry.

The application / use of these pieces of equipment are typically defined in the standards or by the
manufacturers in operation ratings etc. However the ‘use’ of these equipment by trained persons or
similar is vague since a majority of these components can be bought as consumer products meaning
you don’t need to provide a form of training to buy them.