PAR

SEMESTER : IV SUBJECT : PNEUMATICS &

Chap Sub Categ Questi
Chapter name Topic Name Question
ters Topic ory on No.

PNEUMATIC What is pneumatic system?

1 POWER & A 1
HYDRAULIC
POWER Pneumatic Write down the application of
Power- pneumatics
1.1 Application,
Advantages & A 2
Disadvantages

Write down the advantages and

disadvantages of pneumatic system.

A 3

2.1 What are the applications of Fluid

Power system?
1.2 A 4

Hydraulic Power-
Mechanical
power vs Fluid
power in
transmission,
Application,
Advantages &
Disadvantages
 Write down the advantages and
disadvantages of and hydraulic
system.

Hydraulic Power-
Mechanical
power vs Fluid
power in
transmission,
Application,
Advantages & A 5
Disadvantages

What is low Low Cost Automation

(LCA)?
A 6

What are the benefits of low cost

automation?

A 7

What are the basic Princiole of Low

Cost Automation (LCA)?

A 8

PROPERTIES What is Atmospheric pressure?

OF FLUIDS 2.1 B 1
Common
properties of fluid Define density.
B 2
Define Specific Weight?
B 3
 Define viscosity.
B 4

What is Gauge pressure?

B 5

Explain all the common properties of

fluid.

2 B 6

Differentiate between Working pressure

and Operating pressure.

B 7

What is Absolute Pressure and

Atmospheric Pressure?

B 8

Define Hydrostatics?
2.2 Hydrostatics 9
 What is Hydrostatic Paradox?

A 10

Define Pascal’s Law.

A 11

Determine the pressure at a depth

below the free surface of a liquid.

A 12

What are the applications of Pascal’s

Law?
A 13

Explain Bernoulli’s principle.

2.3 hydro-Dynamics A 14

Define Hydrodynamics ?
15
 What is Orifice Plate?
Application of law 16
2.4
of volume offlow
C

Define Equation of Continuty of Liquid

Flow?
C 17

What is Venturi Effect?

C 18
Explain Boyle’s law and Charles law.

2.5 Gas laws A 19

What is Isothermal Compression?

A 20
A 600 mL sample of Nitrogen is heated
from 270 C to 770 C at constant
pressure. What is
the final volume?

Numerical
2.6 problems applying C 21
Gas laws
Compressed write down the four positive and four
Air Production negative characteristics of Compressed
Air.

characteristics of 1
3.1 A
compressed air

What is Compressor
types of 2
3.2 A
compressor
Briefly Explain the Working Principle of
3 Displacement compressor.
A

Explain the Working Principle of

Dynamic compressor.

A 4
 Write the classification of compressor.
Explain the Sliding Vane compressor
with neat
sketch.

A 5

Explain the working of Single stage

Reciprocating compressor with neat
sketch.

A 6
 Explain the Diapragm compressor with
neat sketch.

A 7

What are the Advantages of sliding

vane rotary compressor?
A 8

Differentiae between Theoretical &

Effective Delivery Volume.
C 9

Drives of what are the Drives of compressor

3.3 B 10
compressor
What is the need of cooling of
compressor? Mention types of cooling.

Cooling of 11
3.4 B
compressor
 What are the different types of
compressor regulation? Explain briefly
Exhaust regulation
with neat sketch.

Regulation of
3.5 C 12
compressor

What is the necessary to regulate the

C 13 compressor?

What are the functions of Air Receiver?

Compressed air
3.6 B 14
receiver

Why Pneumatic system requires Air

Preparation & drying?
Compressed Air .
Distribution of 4.1 A 1
Preparation
compressed air
 Write a short note on routine
maitenance of Compressed Air Filter

B 2

1.1 Draw the symbol of Air Service unit

(FRL).
B 3

What are the methods used for air

drying? Explain Refrigerant drying
method with neat
sketch.

A 4

briefly explain the function of FRL

Unit.

B 5
 What are conditions where
B 6 compressed air by means of mist
lubricators may be necessary?

What are the problems that occur

with excessive lubrication?
B 7

What are the criteria for selecting

pipe diameter in Pneumatics
system?
Distribution of
4.2 C 8
Compressed Air

What are the criteria for selecting

pipe material in Pneumatics
system?
C 9

Pneumatic Pneumatic What is an actuator?

5.1 A 1
Working elements Cylinders
Explain Single Acting Cylinder with
neat Sketch?

A 2

Write down the application of Tandem

cylinder.
B 3
 Differentiate between Single Acting
Cylinder and Double Acting Cylinder.

A 4

Write down the application of Impact

B 5 cylinder.

Briefly explain the Cylinder with end

position cushioning and Hydraulic
Telescopic cylinder.

A 6

Draw neatly the sketch of Impact

cylinder and explain its function.

B 7

What are the applications of

pneumatics Single Acting Cylinder?

A 8
 Explain Diapragm Cylinder with neat
sketch?

A 9

In a Pneumatics System, Operating

pressure is 6 Bar, Diameter of the
piston and Piston Rod of the Double
Acting Cylinder is 21 cm and 7 cm
respectively. Find out the theoretical
output forces generated by the Double
Acting Cylinder during forward &
return stroke.
C 7

2.7 Briefly explain Double acting

cylinder with neat sketch

A 8
 What is Pneumatic Motor. Explain
Gear motor with neat sketch.

5.2 Pneumatic Motors A 9

What are the applications of Air

Motor?

A 10

List down the types of Pneumatic

Motor according to particular industrial
application.
A 11

Write down the Characteristics of

pneumatic motors

C 12
 13 Write a short note on One way
Flow control valve with symbol.

5.3 Pneumatic Valves A 13

Define Valve?
A 14

Define Directional control valve

A 15

What is Non Return Valve?

A 16

Briefly explain the working of Pressure

Sequence Valve with Symbol.

C 17

Briefly explain the Quick Exhaust valve

with neat sketch.

C 18
 Briefly explain the One way Flow
Control valve with Symbol.

A 19

Write down briefly the construction

detail of Time delay valve WITH
Symbol.

C 20

Draw the symbol of OR and AND Gate

valve.
Basic Pneumatic Symbols used in
6.1 C 1
circuits Pneumatics

Draw the symbol of 5 / 2 single Air Pilot

operated DC valve & 4 / 3 Lever
operated DC valve.
C 2

Draw a pneumatic circuit for indirect

actuation of Double Acting Cylinder.

C 3
 Draw a circuit diagram in such a way
that , the advance moment of a DAC is
to be performed by means of two Push
button, and return movement is
effected when the cylinder has
reached the extreme end position and
a certain pressure has build up in the
cylinder. Explain the operation also.

C 4
 Draw a circuit diagram in such a way
that, the piston of a pneumatic double
acting cylinder move out when either
of two pushbutton valves are actuated
simultaneously & a 10 sec delay has to
be achieved in the extended position &
return should be automatic. Explain
the operation also.

C 5
 Write the classification of Hydraulic
Pump. Write down their advantages.

Hydraulic Working
7 Elements 7.1 Hydraulic Pumps A 1

Briefly explain the hydraulic Telescopic

Hydraulic cylinder.
7.2 A 2
Cylinders

Calculate the Theoretical force by the

piston of a hydraulic Double Acting
cylinder during forward stroke, when
A 3 operating pressure is 50 Bar and
Diameter of the Piston is 28 cm.
7.3 Hydraulic Motors A 4

What is the need of Hydraulic Filter in

system? Explain various type of
Hydraulic Filter used in Hydraulic
system.

7.4 Hydraulic Filters B 5

 11. Write the basic function of
Hydraulic Valve.

7.5 Hydraulic Valves A 6

Explain Pressure relief valve with neat

sketch.

A 7

Explin working of One Way Flow

Control Valve with neat Sketch

A 8

Write down the name of elements of

Hydraulic Power pack.
Basic Hydraulic Symbol used in
8.1 C 1
Circuits Hydraulic
 How Pressure relief valve acting as a
safety valve in the Hydraulic circuit?
C 2

What is Hydraulic Accumulator? Name

types of Accumulator
Hydro-Pneumatic Principle of Hydro-
9.1 C 1
System Pneumatic System

What is Hydro-pneumatics?
C 2
What are the needs of Hydro-
Pneumatics?

C 3

What is Hydraulic intensifier?

C 4

Explain functioning of intensifier with

neat sketch.

C 5
 What are the Advantages of
intensifiers?

C 6

What are the advantages of Hydro-

Pneumatics?
C 7

What is Electro-pneumatics?
Electro-Pneumatic
9.2 C 8
System
 PART B
JECT : PNEUMATICS & HYDRAULICS SUBJECT CODE : CP01 04 13
Question
Marks
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SELECT THE MARKS
2 EASY

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 PART B
TICS & HYDRAULICS SUBJECT CODE : CP01 04 13

Answers
SELECT THE MARKS
Fluid power system that used to transmit force, power and energy via a gaseous media is called pneumatic system.

Applications of pneumatics are.

• Packaging
• Medical
• Factory Automation
• Material Handling
• Food & Beverage
• Off- and On-highway Vehicle Systems

The advantages of pneumatic system are follows:-

1. Availability: Air is available everywhere.
2. Transport: Air can be easily transported in pipelines, even over larger distances.
3. Storage: Compressed air can be stored in and removed from a reservoir.
4. Temperature: Compressed air is insensitive to temperature fluctuations.
5. Explosion proof: Compressed air offers no risk of explosion or of fire, hence no expensive protection against explosion is
required.
6. Cleanliness: Compressed air is clean since any air which escapes through leaking pipes or elements does not cause
contamination.
7. Simple components: The operating components are simple in construction.
8. Speed: Compressed air is a very fast working medium.
9. Overload safe: Pneumatic tools and operating components can be loaded to the point of stopping and they are therefore
over load safe.
The disadvantages of pneumatic system are follows:-
1. Preparation: Compressed air requires good preparation.
2. Compressible: Due to compressibility it is not always possible to achieve uniform and constant piston speeds with
compressed air.
3. Force available: Compressed air is economical only up to a certain force requirement.Under the normal working pressure
of 6-7 bar and dependent on the travel and speed, the output limit is between 2000 – 3000 Kgs.
4. Noise level: The exhaust air is loud. This problem has now, however, been largely solved due to silencers.
5. Cost: Compressed air is relatively expensive means of conveying power. The high energy costs are partially
compensated by inexpensive components and higher performance.

Applications of Fluid Power system are as follows:-

• Industrial – material handling and assembly equipment, controllers, welding machines.
• Aerospace – military and commercial aircrafts in flight controls, motor controls, brakes, flight simulators.
• Vehicular – Industries such as agriculture, military, construction, and marine all use fluid power systems in vehicles like
tractors, truck brakes, spreaders, and more.
The advantages of Hydraulic system are follows:-
1. Weight to power ratio is less than electrical mechanical systems
2. The system is self lubricated
3. It provides infinite variable speed and force to a greater accuracy.
4. Simple overload protection and mechanically safe using pressure relief valves.
5. Compact unit
6. Transmission of power is easy to produce power, store, regulate and control.
7. Frictional resistance is much less compare to mechanical movement.
8. Hydraulic element can be located at any place and controlled reversely.
9. Noise and vibration in pump is minimal.
10. Hydraulic system is cheap compare high efficiency of power transmission.
11. Less maintenance and easy.
12. Positive drive- output-linear, rotational or angular .
13. Smooth and uniform easy speed control, generates step less motion
14. Less possibility of damage due to jerks or shocks
15. Drive can be arranged away from machine with connection pipes

The disadvantages of Hydraulic system are follows:-

1. Hydraulic elements have to be machined to a high degree of precision – cost high.
2. Friction of various components increases the temperature of the oil
3. The initial cost is very high
4. There is a leakage problem and chances of slippage
5. Chances of catching fire – petroleum based > limiting upper levels of working temperature

Low Cost Automation (LCA) is defined as the replacement of muscular and mental effort of the human being by the use of
Pneumatic, Hydraulic, Mechanical, Electrical and Electronic components in manufacturing including assembly operations or
otherwise, LCA means any compact, cheap, simple but very effective manufacturing piece of equipment which is designed
and assembled internally by a group of employees.
Benefits of low cost automation are as follows:- 1. Increase
output.
2. Replace manually operated devices by pneumatic actuators.
3. Operators can control several machines when number of machines performs several functions automatically in sequence.
4. Ensures accuracy.
5. Reduces wastage of materials.
6. Reduces human errors.
7. Deploys labour for the best advantage.
8. Reduces physical effort of operators.

FIVE BASIC PRINCIPLES OF LCA

1. Cheap.
2. Simple.
3. Shop floor wisdom.
4. Easy to Assemble & Dismantling.
5. Internally designed & assembled on the Workshop.

The atmospheric pressure may be defined as the air pressure that exerts on every points on earth or close to the earth which
it contacts by atmosphere. 1 atmospheric pressure = 1.033 Kg / cm2 .

Density of a substance defined is its mass per unit volume. ρ = m / V. unit- Kg / m3

Specific weight of a substance defined is its weight per unit volume.

Ws = W / V = m X g / V = Ρ X g.
Viscosity is the quantity that describes a fluid's resistance to flow. Fluids resist the relative motion of immersed objects
through them as well as to the motion of layers with differing velocities within them.
Viscosity (represented by the symbol η "eta") is the ratio of the shearing stress (ƒ/A) to the velocity gradient in a fluid.

The pressure measured over the atmospheric value is called the gauge pressure. A gauge is often used to measure the
pressure difference between a system and the surrounding atmosphere. This pressure is often called the gauge pressure and
can be expressed as pg = pabs - patm
Where
pg = gauge pressure , pabs = absolute pressure
patm = atmospheric pressure

All the common properties of fluid.

Density
Density of a substance defined is its mass per unit volume. ρ = m / V. unit- Kg / m3
Specific volume
It is a reciprocal of density, defined is its volume per unit mass. Vs = V / m = 1 / Ρ.
Specific weight
Specific weight of a substance defined is its weight per unit volume. Ws = W / V = m X g / V = Ρ X g.
Relative density
Relative density of a substance is the ratio of weight of the substance and weight of same volume of water in standard
condition. Viscosity
Viscosity is the measure of the fluid’s resistance to flow; or an inverse measure of fluidity. This is the resistance of a liquid to
flow or the internal friction of the fluid.
Viscosity (represented by the symbol η "eta") is the ratio of the shearing stress (ƒ/A) to the velocity gradient in a fluid.

Ans:- Working pressure is the pressure in the pneumatic system, which is build up by the compressor, stored in the receiver
and available to the user in the pipe line.
Operating pressure is the pressure in the pneumatic system, which is required to actuate the Pneumatic Actuator, after
regulating by the regulator.
Working pressure depends on the compressor efficiency and setting pressure of pressure relief valve.
Operating pressure depends on the regulator adjustment. Normally operating pressure is 06 Bar.

Absolute Pressure
The absolute pressure 'pabs' is measured relative to the absolute zero pressure - the pressure that would occur at absolute
vacuum. All calculation involving
the gas laws requires pressure (and temperature) to be in absolute units. Absolute pressure is zero-referenced against a
perfect vacuum, so it is equal to gauge pressure plus atmospheric pressure.
Gauge pressure
A gauge is often used to measure the pressure difference between a system and the surrounding atmosphere. This pressure
is often called the gauge pressure and can be expressed aspg = pabs - patm
Where
pg = gauge pressure
pabs = absolute pressure
patm = atmospheric pressure
Gauge pressure is zero-referenced against ambient air pressure, so it is equal to absolute pressure minus atmospheric
pressure.

Hydrostatics is the branch of a science, which deals with the characteristics and properties of fluid, when it is in rest
condition.
The hydrostatic pressure, or simply “pressure” as it is known for short, does not depend on the type of vessel used. It is
purely dependent on the height and density of the column of liquid. This is known as hydrostatic paradox.

It states “The intensity of pressure exerted anywhere in a confined incompressible fluid at any point at rest is the same in all
direction”.
OR
“Pascal’s law states that pressure exerted anywhere in a confined incompressible fluid is transmitted equally in all
directions throughout the fluid such that the pressure variations(initial differences) remain the same.”

Ans:- DETERMINATION OF PRESSURE AT A DEPTH BELOW THE FREE SURFACE OF A

LIQUID
Consider a tank with horizontal base containing a liquid of density ‘ρ’ (rho).
The height of the base of the tank to the free surface of the liquid is ‘h’.
Let area of the base of the tank = ‘A’.
Then volume = A X h.
Mass of the liquid = A X h X ρ.(as ρ = m / V )
As gravity act on this mass , producing a force on the area = m X g.
F = A X h X ρ X g.
Pressure acting on the surface of the tank by liquid = F / A = A X h X ρ X g / A.
Pressure ‘P’ = ρ X g X h.
This is the intensity of pressure at a depth ‘h’ below the free surface of a liquid of density ρ
So for a particular liquid density will be constant . “g” also is constant.
So in-case of free surface of a liquid intensity of pressure does not depends on the shape of the container.
It depends on the only height of the liquid.

Applications of Pascal’s law are

1. Bramah’s Hydraulic Press
2. Hydraulic Jack
3. Hydraulic lift
4. Hydraulic brakes

It states “ for a perfectly incompressible liquid flowing in a continuous stream, the total energy remains same, while the
particles moves from one point to another .”
This statement is based on the assumption that there are no losses due to friction in the pipe.
Mathematically:-
Z + p /w +v2 / 2g = Constant
Z = Potential Energy per kg
v2 / 2g= Kinetic Energy per kg
P / w = Pressure Energy per kg
Therefore, if the kinetic energy decreases, it must result in an increased pressure. Likewise, when the cross-sectional area
of the flow path decreases, the kinetic energy (velocity) produces a corresponding decrease in pressure.

Hydrodynamics is the branch of a science, which deals with the characteristics and properties of fluid, when it is in motion.
An orifice plate is a device used for measuring flow rate. Either a volumetric or mass flow rate may be determined,
depending on the calculation associated with the orifice plate.

If an incompressible liquid is continuously flowing through a pipe or channel whose cross sectional area may not be uniform,
the quantity of liquid passing per second is the same at all section. This is known as “EQUATION OF CONTINUTY OF LIQUID
FLOW”.

The Venturi effect is the reduction in fluid pressure that results when a fluid
flows through a constricted section of pipe.
(a) Boyle’s law:-
It is defined as ,at constant temperature, volume of the given mass of a gas is inversely proportional to it’s pressure.
Mathematically,
V α 1/P (at constant temperature)
(b) Charle’s law:-
It is defined as, at constant pressure the volume of the given mass of a gas is directly proportional to the absolute
temperature.
Mathematically,
V α T (P being constant)

The process of compression without change of temperature is known as ISOTHERMAL COMPRESSION.

in the given problem

Ti = initial temperature = 27 °C = 273 + 27 Kelvin (K)
Ti K = 300 K
Tf = final temperature = 77 °C = 273 + 77 K
Tf K = 350 K
Charles' law is expressed as:
Vi/Ti = Vf/Tf where
Vi and Ti is the initial volume and temperature
Vf and Tf is the final volume and temperature
Solve the equation for Vf:
Vf = ViTf/Ti
Enter the known values and solve for Vf.
Vf = (600 mL)(350 K)/(300 K)
Vf = 700 mL
Answer:- The final volume after heating will be 700 mL.
Four positive characteristics of Compressed Air.
1. Availability- in unlimited
2. Transportation- easily transported in pipelines.
3. Explosion proof- no risk of explosion or of fire. No expensive protection.
4. Cleanness- do not cause contamination. This cleanness is necessary, for example, in the food, wood, textile and leather
industry. four
negative characteristics of Compressed
1.Preparation-Needs good preparation. Dirt and humidity may not be present.
2. Compressible- it is not possible to achieve uniform and constant piston speed with compressed air. 3.
Limited output- it is economical only up to a certain force requirement. Output is limited between 20,000 and 30,000 N.

4. Noisy operation- the exhaust air is loud.

Compressor is a device or equipment, which compress the atmospheric air and supplied to the pneumatics system and
equipment at desired working pressure.

This type of group operates on the displacement principle where air is compressed by containing it in a chamber and then
reducing the volume of this chamber. This compressed and pressurized the air.
This type is called piston compressor.

This group operates on the air flow principle by drawing in air on one side and compressing it by mass acceleration. Ex.-
Turbine compressor. It draw
atmospheric air in and compress it by accelerating the air mass.
The pressure is increased by adding kinetic energy to accelerate the mass of air, converting it into pressure energy.
 Flow compressor
1. Radial flow compressor
2. Axial flow compressor
Sliding vane compressor
Sliding vanes are contained in the rotor and form chambers with the cylindrical wall. When rotating, the centrifugal energy
forces the vanes against the wall, and owing to the shape of the housing, the chambers increased or reduced in size. The air
inlet is placed where the volume of the compression chamber is greatest, the outlet where the volume is smallest.
Consequently, as the vanes turn, the space between them is reduced. This reduction in volume compresses the air as it
travels from the inlet to the outlet.
They are smooth in operation but compression is not as high as with multi stage compressor.
Advantages of sliding vane rotary compressor:-
1. Compact dimension,
2. Quiet running,
3. Smooth and steady air delivery.

Single stage Reciprocating piston compressor

Air taken in at atmospheric pressure is compressed to the required pressure in a single stroke. Downward movement of the
piston increase volume to create a lower pressure than that of the atmosphere, causing air to enter the cylinder through the
inlet valve. At the end of the stroke, the piston moves upwards, the inlet valve closes as air is compressed, forcing the outlet
valve to open discharging air into a receiver tank. This type of compressor is generally used in systems requiring air in the 3-
7 bar range.
Diaphragm compressor provides compressed air in the 3-5 bar range totally free of oil and is therefore widely used by food,
pharmaceutical and similar industries. The diaphragm provides a change in chamber volume. This allows air intake in the
down stroke and compression in the up stroke. Smaller types, with an electric motor of 1kW power, make portable
compressors ideal for spray painting.

Advantages of sliding vane rotary compressor:-

1. Compact dimension,
2. Quiet running,
3. Smooth and steady air delivery.

The theoretical delivery volume for reciprocating piston compressor is the product of swept volume times the number of
revolutions
The effective delivery volume depends on the type of compressor and the pressure. It is affected by the volumetric
efficiency
1. Electric Motor,
2. I.C. Engine
Needs : When air is compressed in the compressor, heat is generated and must be removed. To prevent overheating of a
compressor internal motor, some type of cooling method must be employed.
The most suitable type of cooling for the compressor depends on the amount of heat generated.
Types of cooling are:
1. Cooling Fins- Cooling fins on smaller compressors allow the heat to be removed by radiation.
2. Fans - Larger compressors are equipped with an additional fan to remove heat. 3. Water
Cooling - In the case of a compressor plant with a drive power in excess of 30kW, air cooling is no longer sufficient. The
compressors are then equipped with water circulation cooling or fresh water cooling. Frequently, a larger cooling plant with
cooling tower is not installed because of the capital outlay. Good cooling lengthens the life of the compressor, however, and
provides better, cooler air. Sometimes subsequent cooling can be saved or be performed with less power.
There are three types of compressor regulation:-
1.No load regulation
(a) .Exhaust regulation
(b).Shut-off regulation
(c) . Grip arm regulation
2.low speed regulation
(a) .Suction throttle regulation
(b). Speed regulation
3.ON-OFF regulation
Exhaust regulation:-
In this a safety valve is installed in this regulation. Safety valve is preloaded with a certain amount of pressure. When the
receiver is filled up above the predetermined pressure by the compressor, then the safety valve gets operated and exhaust
line gets open. The extra pressure build up by the compressor will exhausted through safety valve into the atmosphere
prevent the receiver from overloaded. When after consumption of compressed air from the receiver, air pressure comes
below the predetermined pressure, then again safety valve gets closed and receiver gets filled up in normal process. A
Check valve is provided in between the compressor and air receiver to prevent the receiver to empty Completely during
exhaust mode.
Sketch:-

In order to maintain the required delivery volume of the compressor to the fluctuating cum consumption, it is necessary to
regulate the compressor.

Its main functions are to store sufficient air to meet temporary heavy demands in excess of compressor capacity
1. It also serves to stabilize the compressed air supply.
2. It smoothen pressure fluctuations in the network when the air is consumed.
3. Storage of compressed air to prevent compressor from running continuously.
4. Heat exchange to assist air cooling and thus produced condensate drop out before the air enters the distribution system..
5. Collection and drop point for dirt and condensate accumulating in the air after compression.

The service life of pneumatic systems is considerably reduced if excessive moisture is carried through the air system to the
components. Therefore it is important to fit the necessary air drying equipment to reduce the moisture content to a level
which suits the application and the components used
The following routine service measures are necessary on a regular Compressed air filter:
The condensate level has to be checked regularly, as the level indicated in the sight glass must not be exceeded. If the level
is exceeded, this can result in the accumulated condensate being drawn into the air supply lines. The excess
condensate can be drained using the drain cock on the sight glass. The filter cartridge must also be checked for
contamination and cleaned or replaced if necessary.

Ans: There are three methods used for air drying

1. Absorption (deliquescent) Dryer
2. Adsorption (desiccant) Drying
3. Refrigerant drying
The cold dry air return pipe passes through air heat exchanger 1 and gains heat from the incoming high temperature air.
This prevents dew forming on the discharge outlet, increases volume and lowers relative humidity.
An output temperature of 2°C is possible by modern methods, although an output air temperature of 5°C is sufficient for
most common applications of compressed air. As a general rule, the cost of drying compressed air may be 10-20% of the
cost of compressing air.

Ans: FRL means Filter, Regulator and Lubricator

Compressed Air Filter
Function of the filter in the pneumatic system to arrest the moisture, air pollutant, compressor oil and pipe scale ( rust).
The selection of the correct filter plays an important role in the determining the quality and performance of the working
system which is to be supplied with compressed air.
Compressed Air Regulators
The compressed air generated by the compressor will fluctuate. Centrally located regulators fitted to the compressed air
network ensure that there is a constant supply pressure(secondary pressure) irrespective of the pressure fluctuations in the
main loop (Primary Pressure).
Air Lubricator
Lubricator is no longer necessity for the majority of modern pneumatic components. They are available pre-lubricated for
life. Certain equipments still requires lubrication. To ensure they are continually lubricated, a certain quantity of oil is added
to the compressed air by means of a lubricator.
compressed air by means of mist lubricators may be necessary in certain cases:
1. Where extremely rapid oscillating motions are required.
2. With cylinders of large diameter, from approximately 125mm upwards.

The problems that occur with excessive lubrication include:

1. Malfunctioning due to excessively lubricated components.
2. Oil mist pollution of the environment.
3. Gumming-up of parts occurs after lengthy plant standstills.
4. Difficulties in adjusting the lubricator correctly.

There are five criteria for selecting pipe diameter in pneumatic system
(a) Working pressure
(b) Flow volume
(c) Number of restriction in pipeline
(d) Network ( length of the pipeline)
(e) Permissible Pressure loss

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.

An actuator is an output device for the conversion of supply energy into useful work.

Single Acting Cylinder permits a thrust in one direction and for this reason is limited in application. The cylinder
can produce work in only one direction. The return movement of the piston is effected by a built-in spring or by the
application of an external force. It may be
used for pressing where it can installed in a vertical position, otherwise auxiliary device must be provided to return the
piston to the starting position

The Tandem cylinder is suitable for such applications where a large force is required but the cylinder diameter is restricted.
Ans:- Differences between Single Acting Cylinder & Double Acting Cylinder are as follows:-
1. In Single-acting cylinders compressed air is applied on only one side of the piston face. The other side is open to
atmosphere.
But in Double Acting Cylinder compressed air is applied on both side of the piston face.
2. In Single-acting cylinders The cylinder can produce work in only one direction. The return movement of the piston is
effected by a built-in spring or by the application of an external force.
In Double-acting cylinders The cylinder can produce work in both direction.
3. In Single Acting Cylinder,The spring force of the built-in spring is designed to return the piston to its start position with a
reasonably high speed under no load conditions
In Double-acting cylinders, The pneumatic force return the piston to its start position with a more speed under load
conditions

impact cylinder is used where high speed is required for actuator ( high Kinetic Energy) to apply impact on the job. The
piston speed of the impact cylinder is between 7.5 m/s and 10 m/s.

Cylinder with end position cushioning

It is very helpful to reduce shock, impact on the cylinder end covers especially when a heavy load is connected to the rod,
or the cylinder is working at very high speed.
Hydraulic Telescopic cylinder
This is a special cylinder with a telescopic piston. In this barrels are working as a piston rod and they are sliding into each
other. The greater cylinder stroke with relatively small installation space can be achieved with this type of cylinder.

The pressure forces of pneumatic cylinders are limited. One cylinder for high kinetic energy is the impact cylinder.
The high kinetic energy is achieved by means of increasing the piston speed. The piston speed of the impact cylinder is
between 7.5 m/s and 10 m/s. However, in the case of large forming distances, the speed is rapidly reduced. The impact
cylinder is therefore not suitable for large forming distances.

Ans:- Applications:
1. Transferring
2. Converging
3. Branching
4. Allocating
5. Clamping
6. Ejecting
With a diaphragm cylinder, a built-in diaphragm made of rubber, plastic or metal performs the task of the piston. The piston
rod is mounted centrally on the diaphragm. There is no sliding seal, but merely friction as a result of the tensile stress of the
diaphragm. They are used in short stroke applications, for clamping, embossing and lifting operations.
They are generally used in food industry

Given:-
Operating pressure( P)=6 Bar=6x105 Pa
Diameter of the piston(D)=21 cm=0.21m
Diameter of the piston rod(d)=7cm=0.07m
During forward stroke:-
Theoretical piston force is Fth =P X A = PX π/4 x D2
Fth={6x105 x 3.14 x (0.21)2 }/4
Fth=20,771 Newton
During Return stroke:-
Theoretical piston force is= P X A = PX π/4 x (D2-d2)
Fth=[6x105 x 3.14 x{ (0.21)2 – (0.07)2}] / 4
= 18,84,000 X 0.039 /4 = 18,369 Newton
Fth=18,369 Newton

Ans:- Double Acting Cylinders (DAC) use the force of air to move in both extend and retract strokes. They have two ports to
allow air in, one for outstroke and one for in stroke. Stroke length for this design is not limited, although buckling and
bending of the extended piston rod must be allowed for. This type of cylinder permits a controlled thrust in both directions
of piston travel and has many application machine tool circuits. This means it is capable of a power stroke either way.
Devices which transform pneumatic energy into mechanical rotary movement with the possibility of continuous motion are
known as pneumatic motors.
Gear motors
In this design, torque is generated by the pressure of the air against the teeth profiles of two meshed gear wheels.
One of the gear wheels is secured to the motor shaft. Gear motors are produced with spur or helical gearing. These gear
motors are used in applications with a very high power rating.
Mostly they are built for higher capacities up to about 45 kW and are usually installed direct in the machinery they are to
drive Coal Mining Equipment.
These motors are used in application with a very high power rating of about 60hp. The direction of rotation is reversible
when spur or helical gearing is used.

Applications of air motor:

Dentist’s Drill
Nut Drivers
Drills
Screw Drivers
Grinders etc.

Types of Air Motors according to particular industrial application

PISTON MOTORS
SLIDING VANE MOTORS
GEAR MOTORS
TURBINES (FLOW MOTORS)
ROOTS MOTORS

Characteristics of pneumatic motors are:

1. Smooth regulation of speed and torque
2. Small size (weight)
3. Overload safe
4. Insensitive to dust, water, heat, cold
5. Explosion proof
6. Large speed selection
7. Maintenance minimal 8.
Direction of rotation easily reversed
The one-way flow control valve allow the air flow is throttled in one direction only. A check valve blocks the flow of air in
the bypass leg and the air can flow only through the regulated cross-section. In the opposite direction, the air can flow
freely through the opened check valve. These valves are used for speed regulation of actuators and if possible, should be
mounted directly on the cylinder.

Valves are devices for controlling or regulating “START”, “STOP” and “DIRECTION”, as well as pressure flow of a pressure
medium conveyed by a hydro pump or stored in a container.

Directional control valve are devices which influences the path taken by an air stream, predominantly start stop direction of
flow.
DC valves are used to start, to stop and to change the directions of the fluid pneumatic system.

Non-return valves are devices which preferentially stop the flow in one direction and permit flow in the opposite direction.

The principle on which this valve acts is the same as for the pressure limiting valve.
If the pressure exceeds that set on the spring, the valve opens. The flow from 1 to 2 is closed. Outlet 2 is opened only if a
preset pressure has built up in pilot line 12.
A pilot spool opens the passage 1 to 2. Pressure sequence valves are installed in pneumatic controls where a specific
pressure is required for a switching operation (pressure dependent controls).

Quick-exhaust valves are used to increase the piston speed of cylinders. This enables lengthy return times to be avoided,
particularly with single acting cylinders. The
principle of operation is to allow the cylinder to retract at its near maximum speed by reducing the resistance to flow of the
exhausting air during motion of the cylinder. To reduce resistance, the air is expelled to atmosphere close to the cylinder via
a large orifice opening.
In the case of the one-way flow control valve, the air flow is throttled in one direction only.
A check valve blocks the flow of air in the by-pass leg and the air can flow only through the regulated cross-section. In the
opposite direction, the air can flow freely through the opened check valve. These valves are used for speed regulation of
actuators and if possible, should be mounted directly on the cylinder

Time Delay valve is combination of one ‘One way flow control valve’, one ‘Receiver and one ‘ 3/2 single air pilot operated
spring return DC valve’. It is having four ports, one pressure, one application, one exhaust and one pilot port.
Operation
When either of two push-button of 3/2 DC valve ( 1.2 or 1.4 ) is pressed, then pressure line and application line get
connected and pneumatic pressure from the compressor reached to the one of the pilot port 12 (Y) of the 5/2 DC valve
(1.1) through OR Gate valve (1.6). In initial position, pressure port of the 5/2 DC valve is connected to the one of the
application port (2), which is connected to the retraction chamber of the double acting cylinder, and DAC get retracted.
When control pressure reached to the pilot port 12 (Y) of the 5/2 DC valve (1.1), then pressure port 1 connected to the
application port 4, and pressure applied to the extension chamber of the double acting cylinder, then piston extended. After
full extension of the piston rod, roller is pressed of 3/2 DC valve (1.3) by the piston rod. When 3/2 DC valve (1.3) get
actuated, it allow to pass the pressure to the pilot port of the Time Delay valve (1.5). Actuation time of the Time Delay valve
depends on the adjustment by the knob of the Time Delay valve. When control pressure is applied to the pilot port of Time
Delay valve, then the time delay valve operated as per the time adjusted by the knob. When 1.5 Time Delay valve get
actuated, pressure and application port of the Time Delay valve get connected and pressure reached to the pilot line 14 (Z)
of the 5/2 DC valve (1.1). then again pressure line get connected with the application port 2 and piston get retracted back
after delaying the time
A double-acting cylinder is used for the pressing and gluing of components. By actuating a pushbutton, the piston rod of the
pressing cylinder slowly advances. When the pressing position is reached, the pressing force should be maintained for a
time of approx. 6 seconds. After expiry of this time, the piston rod automatically retracts into its initial position. A re-start is
possible only when the piston rod is located in its initial position. If a signal is present at both
inputs of the dual pressure valve 1V1, the control element 1V3 switches and the piston rod of cylinder 1A advances.
When actuated, roller lever valve 1S3 sends a signal to the pilot port 12 of the time-delay valve 1V2.
When the preset time has expired, the 3/2-way valve built into Valve 1V2 switches.
The control element 1V3 switches and the piston rod of cylinder 1A retracts. 
Ans: Pump classification
1. Positive or hydrostatic pumps
2. Non-positive or hydrodynamic pumps
Positive displacement pump
 Rotary pump
 Gear Pump
 Vane Pump
 Screw Pump
 Reciprocating pump
 Piston Pump
Advantages-
1. High pressure capability-Small,
2. compact size-High volumetric efficiency-
3. Small change of efficiency throughout the pressure range
4. Greater flexibility of performance-Widely used in hydraulic system
Non-positive displacement pump
 Centrifugal pump
 Axial flow pump
 Radial flow pump
Advantages
1. Fewer moving parts-
2. Low initial cost
3. Minimum maintenance cost-
4. Quieter operation
5. Capable of handling any type of fluid
6. Simplicity of operation
7. High reliability

This is a special cylinder with a telescopic piston. In this barrels are working as a piston rod and they are sliding into each
other. The cylinder stroke with relatively small installation space can be achieved with this type of cylinder.

Operating Pressure 'P'= 50 bar = 50 X 10^5 Pascal = 5 X 10^6 Pascal

Dia of the Piston 'D' = 28 cm = 28 / 100 meter = 0.28 meter.
Area of the piston 'A'= π D^2 / 4 = 22 X(0.28)^2/7X4 = 0.06 Square Meter.
Theoretical Piston force during forward stroke = Fth = P XA = 5 X 10^6 X 0.06 = 3
X 10^5 Newton. Answer Fth = 3 X 10^5 Newton
Types of Hydraulic Motors
Gear Motors
Vane Motors
Piston Motors
Limited Rotation Actuator
External Gear Motor
2 rotating gears, the area of the gear teeth is where the pressure acts to create force. Both gears turn simultaneously, One
gear is connected to the output shaft and the other is an idler.

Needs of the hydraulic filter are as follows.

1. Wear occurs in hydraulic systems if dirt particles are left in suspension. The dirt particles just like a grinding
compound and speed up wear.
2. Filters are a medium in hydraulics system used to arrest the contamination and purify oil thus get rid of unwanted
material.
3. The contamination are mostly in solid form like dust, dirt, worn out metallic parts and other particles. These may also be
in the liquid form like water, a acids, paints etc.
Type of filters
 Air breather filters
 Suction line filter
 Pressure line filter
 Return line filter etc.
Air breather filters
Air breather filters serves two purposes
 As filling filters – When the tank is being filled with fluid, the filter prevents large particle of direct entering the tank and
the system. Filling up should therefore be carried out basically using a filling filter.
 As bleed filter – Where the fluid level varies, for example, due to differential users, the amount of air must change. The
air, flowing into the tank is filtered.
Suction Line Filter
 The suction line filter fitted in the suction of the pump.
 The filter element is fitted with a threaded port.
 The fluid is sucked out of the tank through the filter element, so that only filtered oil reaches system.
 However, a disadvantages is that , it is not easily accessible and maintenance is therefore difficult.
 It is used for application where it is essential to protect the pump.
 It stops large debris and prevent air bubbles from entering the pump inlet.
Pressure Line Filter
The pressure line filter is fitted in the pressure line of the hydraulic circuit. For example at the pressure port of the pump , in
front of the servo calve or in front of a flow control valve, set at very low flow, However, the filter is usually fitted directly in
front of the unit to be protected.
Return Line Filter
 The return line filter is the type of most used.
 The filter is fitted in the return line,.
 This means that fluid coming from the system is filtered and flows back to tank.
 The filter is available for fitting in the oil tank or for direct line mounting.
Hydraulic valves provide the interface between the hydraulic fluid the control signal and the actuators.
They are used to control the
1. Blocking or stopping of flow.
2. Flow Rate
3. The direction of the flow and
4. The pressure of the liquid
5. Other special functions

The functions of a Pressure Relief Valve is to set the maximum pressure in a hydraulic system. It is a
normally closed valve which partially opens permitting flow to the tank port when the pressure at inlet port overcome the
spring force.
The pressure Relief Valve is found in virtually every hydraulic system.
It is a normally closed valve connected between the pressure line(pump output) and the reservoir.
it purpose is to limit pressure in the system to a preset maximum by diverting some or all of the pump’s output to tank
when pressure setting is reached.

The one-way flow control valve is used where the restrictor is only effective in one direction. It is a combination of a
restrictor and a non-return valve.
The restrictor controls the flow rate in a single direction dependent on flow. In the opposite direction, the full cross-
sectional flow is released and the return flow is at full pump delivery.
The hydraulic flow is throttled in the flow direction from A to B. This results in flow division as with the restrictor. Flow to
the power component is reduced, the speed being reduced correspondingly. Flow is not restricted in the opposite direction
(B to A) as the sealing cone of the non-return valve is lifted from its valve seat and the full cross-sectional flow is released.

Elements of Hydraulic Power pack are

a) Oil Reservoir
b) Hydraulic Pump with prime mover.
c) Hydraulic Filter
d) Pressure relief valve with pressure gauge
Hydraulic systems are designed to operate at certain pressures. Relief Valves are built into the system as a protection
device. Normally Pressure relief valve is set at certain pressure and line connected to the tank is closed. when excess
Pressure is build up in the system, then Relief valve get operated and tank line gets open. The excess pressure is again goes
Into the tank and protect the system from damaging.

Hydraulic Accumulator is a device used to store energy in the form of fluid under pressure. The types of accumulator are :-
(a) Dead load accumulator
(b) Spring- loaded accumulator
(c) Gas- loaded accumulator.

This type of combination of hydraulic and pneumatic is termed as hydro-pneumatics. Air-oil reservoir, hydraulic check unit,
and air hydraulic intensifier etc. are very common used in hydro-pneumatic circuits.
Needs of Hydro-Pneumatics for
1. Smooth movement
2. Average speed compared to pneumatics and hydraulics.
3. Less oil leakage compared to hydraulics.
4. . With the help of hydro-pneumatics system a medium amount of pressure and a more accurate control can be achieved.
5. Cost is optimum.

Intensifiers
 An intensifier is a device used to multiply pressure in certain application such as riveters or piercing machines, a small
amount of oil at high pressure may be required for the final portion of the work cylinder travel. An intensifier can develop
pressure several times higher than what can be developed by the pump

Functioning of Intensifiers
An intensifier usually consists of two cylinders with different inner diameters. The piston with the largest diameter is driven
by a low-pressure hydraulic system (normally 5 to 35 MPa). The pressure in the other cylinder is higher due to the difference
in diameter and the ratio of the pressures varies directly as the ratios of cross sectional areas of the two cylinders making up
the intensifier.
These ratios are typically of the order of 1:10 to 1:25. The resulting magnification in pressure results in values up to 400
MPa. To operate in a quasi-continuous mode, two or more intensifiers are used together.
Advantages of intensifiers:- 
1. Heat is not generated while static hydraulic pressure is maintained and little is generated during rapid cycling, small oil
reserves are required.
2. Direction control of intensifier-operated cylinders is through air valves which are usually less expensive than hydraulic
valves, but just as reliable. 3. Since
high hydraulic pressure is easily attained, booster-operated cylinders can be smaller in diameter. intensifier systems are
generally more compact than equivalent pump-and tank units. 4. Since
pressure and direction-control valves are located in the air portion of the air-oil booster circuits, few fittings and usually no
valves are required in the intensifier-to cylinder connection. 5. Air-to-air intensifiers
permit the use of low-cost air cylinders at line pressures greater than those available from normal shop-air compressors.

Advantages of Hydro-Pneumatics are

1. Smooth movement
2. Average speed compared to pneumatics and hydraulics.
3. Less oil leakage compared to hydraulics.

Development of large range of industrial automation has called for integration of pneumatics and electrical technologies.
This integration of pneumatics and electrical technologies for industrial automation is known as electro-pneumatics.
DIFFICUL
T
EASY