1. HYDRAULIC SYSTEM ‘A hydraulic system is a drive technology where a fluid is used to move the energy from e.g. an» electric motor to an actuator, such as a hydraulic cylinder. BASIC ELEMENTS OF A HYDRAULIC SYSTEM toad 1-0ff 2=Forward 3-Return 1 29 ot Pressure — regulator mi =o Motor ‘Actuator oil tank Components ofa hyurauli system In a hydraulic-power system six basic components required are as follows: 1. A tank (reservoir) to hold the hydraulic oil. 2..A pump to force the oil through the system. 3. An electric motor or other power source to drive the pump 4, Valves to control oil direction, pressure, and flow rate 5. An actuator to convert the pressure ofthe oil into mechanical force or torque to do useful ‘work. Actuators can either be a cylinder to provide linear motion, or a motor (hydraulic) to provide rotary motion . which caries the oil from one location to anotherOil reservoir The function of the oil reservoir is to store the oil which acts as the working medium for oil power hydraulic system. Oil is drawn from this reservoir to different parts of the machine and after performing its function during a cycle, the oil returns back tothe oil reservoir. The oil reservoir is usually installed atthe bottom of the hydraulic system so that oil may flow back to the reservoir by gravity. Oil pump ‘The function of the pump is to suck oil from the oil reservoir and to deliver this oil under pressure tothe rest of the hydraulic circuit. In doing soit raises oil pressure to the required level. This enable the oil to flow through the system uninterrupted. Hydraulic pumps are generally driven at constant speed by a three phase AC induction motor. Often pump and motor are supplied as one combined unit. There are various types of oil pumps used in oil powered hydraulic system such as positive displacement pump, gear pump, vane pump, screw pump, lobe pump ete. Filter Hydraulic fluid needs to be very clean, hence a filter is needed to remove dirt particles before the fluid passes from the tank to the pump. Control valves Valves are necessary to control the pressure, flow rate and direction of the fluid. Hydraulic, valves are made with high standard quality and uses strong mater (eg, steel) and robustness. Different types of valves are used for different purposes. In general the different functions of valves are as follows. 4. To regulate the flow of oil through a pipe line. This valve permit the oil to flow through the pipe and stops the flow whenever itis required. The gate valve and plug valve serve these purpose. 2, Torelease pressure of ol inthe system when the pressure of oil inthe system exceeds the ‘maximum allowable limit. This valve is called relief valve. 3 To prevent the back flow of oil into the oil reservoir when the pump is not in operation. This valve is called check valve or non-return valve.\ 4. To route the fluid to the desired direction. This valve is called as directional control valve (cv). 5, 5:To reduce the existing pressure of reducing valve. il supplied by the pump. This is called pressure2.PNEUMATIC SYSTEM ‘A pneumatic system isa collection of interconnected components using compressed air to do ‘work for automated equipment. The compressed air or pressurized gas is usually filtered and ried to protect the cylinders, actuators, tools and bladders performing the work. Main Components of a Pneumatic System Actuator Control valve ltake Compressor Cooler Receiver filter Separator Secondary alr weatment Pressure switch Motor control center Components of pneumatic systems ‘A basic pneumatic system consists of the following two main sections. ‘+ Compressed air production, transportation, and distribution system + Compressed air consuming system ‘The main components of the compressed air production, transportation, and distribution system consist of 1. Air compressor ‘Air compressor converts the mechanical energy of an electric or combustion motor into the potential energy of compressed air. 2. Electric motor and motor control centre Electric motor transforms electrical energy into mechanical energy. Itis used to drive the air compressor.4. Storage tank. The compressed air coming from the compressor is stored inthe air receiver. The purpose of ait receiver is to smooth the pulsating flow from the compressor, It also helps the air to ‘cool and condense the moisture present, The air receiver is fo be large enough to hold all the air delivered by the compressor . 4. Pressure gauge To measure pressure in the pneumatic system S. Auto drain, air dryer, filters For satisfactory operation of the pneumatic system the compressed air needs to be cleaned and dried, Atmospheric air is contaminated with dust, smoke and is humid. These particles can cause wear of the system components and presence of moisture may cause corrosion. Hence it is essential to treat the air to get rd of these impurities. Further during compression operation, air temperature increases, Therefore cooler is used to reduce the temperature of the compressed air. The water vapour or moisture in the air is separated from the air by using a separator or air dryer. 6. Air lubricator Lubrication of moving parts of eylinder and valves is very essential in pneumatie system, For this purpose compressed air lubrcators are used ahead of pneumatic equipment. 7. Control valves. Control valves are used to regulate, control and monitor for control of direction flow, pressure ete. The main components of air consuming system consist of 8. Directional valve 9. Actuators Actuators are output devices which convert energy from compressed air into the required type of action or motion. 10. Speed controllers, PNEUMATIC CONTROLS To contol the to and fro motion of a pneumatic cylinder, the air energy has to be regulated, controlled, and reversed with a predetermined sequence in a pneumatic system. Broadly valves are used to (1) start and stop pneumatic energy, (i) control the direction of flow of compressed air, (ii) control the flow rate of the compressed air and (iv) control the pressure rating of the compressed air.at There are various types of valves available in the far mily of compressed air system but according to their main function, they may be divided into four broad groups: * Direction control valves The directional control valves can be used to start, stop, hydraulic system, Directional control valves are classifi {ike inlet control element structure, number of ports or ways, number of postion, method of actuation, and center position flow pattem. Directional control valves ean be actuated in many ways. Actuation is the process of moving the valve element from one position to another. So in a directional control valve, there are four methods of actuation they are ‘manual, mechanical, solenoid-operated, and pilot-operated. and to change the fluid flow in a ied according to certain factors Direction control check valves or non-return valves Annon-retur valve allows a medium to flow in only one direction and is fitted to ensure {hat the medium flows through a pipe inthe right direction, where pressure conditions may otherwise cause reversed flow. * Flow control valves One of the most common uses of a flow control valve is to regulate the speed of motors or cylinders within the system. * Pressure control valves, ‘The valves enable the regulation of system pressure to adjust the force on a hydraulic piston rod or the torque on a hydraulic motor shaft.Hydraulic systems The working fluid is hydraulic oil. As oil is incompressible, oil can be Pneumatic systems Working fluid is compressed air. Air is compressible; hence air can be pressurized to very high pressure. (500 pressurized to lesser pressure. (Only bar or even more) Since pressure is high, the force Up to 10 bar approx.) Since pressure is very less, the force developed is also very high (thousands developed is very less (up to | ton) of tones). Since pressure is high, components Components of the pneumatic system are very strong, made of steel, and are _are lighter in weight, are made of heavy. aluminum. As oil has more viscosity, it cannot flow Air has very less viscosity, it can flow fast. Hence hydraulic systems are slower in operation. Due to continuous recirculation, the “temperature of oil increases. Hydraulic oils are pétroleum-based oils; they are inflammable and there is every chance of fire hazard if neglected. Leakage of oil results in dirty and slippery Surroundings that may lead to accidents. The pump used is a positive displacement pump, So a pressure relief valve is necessary There is no need for a separable lubrication System, because, hydraulic oil itself is a lubricant. Applications: CNC. Machine tools, earth-moving machines, automobiles. fast. Hence pneumatic systems are quicker in operation. The harder it runs, the cooler it works. Free expansion of air in cylinders and motors causes a chilling effect. No chance of fire hazard. Hence pneumatic tools are preferably used inside mines, where flammable gasses may present. The very clean and dry surrounding is maintained. No need for a pressure relief valve. Alubricator is necessary. Oil is mixed with the compressed air in the lubricator and then supplied to the system. Applications: Material handling systems, hand tools mining worksa CIRCUIT DIAGRAMS AND SYMBOLS FLUID POWER SYMBOLS a) Energy Conversion Elements Elements Description Symbol Hydraulic Fined eee ie | Pumps a) With one Conversion of directional flow Mcch.energy to hyd. energy. b) With two directional flow Hydraulic Motor Conversion of | a) With one hyd. energy to directional flow Mech. energy. b) With two directional flow ¢) Limited rotation motor Components Pump/ which can Motor operate both as Pump and Motor 5/6 6/6. Be] RRSee FLUID POWER SYMBOLS 4) Energy Conversion Elements Elements. Description Symbol Compressors Conversion of Mech, enemy to pressure energy. Displacement Fixed Variable Alr Motors Conversion of pressure cnensy Mech. energy. 1) With one directional flow b) With wo directional flow Drives Provide mechanical energy to system Electric Motor Internat Combustion Engine é © a2 @A % @ oF © OFLUID POWER SYMBOLS b) Hydraulic cylinders Elements Description Symbol Cylinders | Conversion of pressure energy into Mechanical energy. ay ——— 1 a) Single acti Fluid exerts pressure ) Single acting | on one side only. t by Single acting with Spring retum Return action caused by Spring. ¢) Double cylinder single piston rod. ting ‘Two different piston areas 4d) Double acting| cylinder with double piston rod. ‘Two identical piston areas cc) Cylinder with a end cushioning 1 Adjustable x cushion at both i ends a g) Telescopic Cylinder =FLUID POWER SYMBOLS c) Energy Transmitting Elements d) Fluid Storage Elements Elements Description Symbol Main working line —— Conduct an 5; aed lot (control) —_ Drain line Flexible connection lines |_——7— Line Dot at eross point Sametton : t+ Crossed No dot at cross Line with no| — point + connection Pressure Line Sed with plug Quick actin; Note that in connected | position both check valves} —C >+-L Pneumatically actuated P41 Pilot Operated - " Directional control valve . with spring centering | eea FLUID POWER SYMBOLS e) Flow Control Valves Elements Description Symbol 8) Orifice Valve Short throttle segment ~~ po b) Throttle valve Fixed Flow depends on thepressure Variable difference c) Throttle and ta check valve in : one consturction = a =~ Pressure Compensated d) Flow control Valve Pressure & temperature Compensated Pressure & temperature flow control valve with by pass check valve, Divides flow into two ¢) Flow divider |. equal parts. Flow divider with two coupled motors.FLUID POWER SYMBOLS 4 Directional Control Valves Elements Description Parts of Valves are named with letters P- Pump, Pressrue T = Tank, Return A,B- Load, Consumer X.Y,Z - Pilot Ports L. Leakage Oil Port R- Return line Designation 4/3. directional control valve L. Number of switching position] Number of Ports Switching Positions shown by blocks Internal connections shown by arrows and lines 2/2 directional control valve 3/2 directional control valve 4/2 directional control valve 4/3directional control valve 5/2 directional control valve 5/3 directional control valve A SN 4 i ff 6/3 directional control valveFLUID POWER SYMBOLS g) Check Valves Elements [ Description Symbol a) Non-return | With Avithout closing valves spring b) Pilot Operated] Opens in One direction only check valve |when set pressure is reached] at pilot line iu ©) Solenoid | Position a) allows flow in operated chee both direction coll valve b) allows flow a in only one direction b h) Fluid Conditioning elements a) Filter b) Cooler | Outside arrows indicates heat flowing out of system ¢)Heater | Inside arrow indicates heat flowing into the system. ° ? Heater with liquid heating ? medium a a <> <> Heater with gaseous heating medium 4) Separator | Separator with a manual [removing | drain water from air]! Separator with automatic drainFLUID POWER SYMBOLS i) Pressure Control Valve symbol Elements Description a) Directly operated | Normally closed pressure relief | (Open on netuation) valve. b) Pilot operated pressure relief valve. ¢) Directly operated | Normally open ressure reducing | (Closes on actuation) |} valve. Sce difference in iS / symbol. 4) Pilot operated pressure reducing valve. ©) Pilot operated | ‘The valve switches & sequence valve | opens flow when set with extemal signal] value of pressure is input reached. f) Pressure switchsFLUID POWER SYMBOLS j) Accessories Elements Description a) Accumulators. Weight loaded Spring loaded by Intensifier [Pressure booster] ©) Flow meter d) Pressure gauge} ¢) Temperature gauge.