VII Semester B. Tech.

Mechanical Engineering

Automation Laboratory
(Experiments in Pneumatics, Hydraulics, Electro-pneumatics
& Electro-Hydraulics)

Compiled by
Dr. B.M. Rajaprakash
R.Rajashekar

Department of Mechanical Engineering

University of Visvesvaraya College of Engineering
K.R.Circle, Bengaluru 560 001
Introduction
 The basis of fluid power is pressurized fluids. These fluids may be either liquids or gases. The fluids are
incorporated into physical hardware systems that generate, transmit, and control power in a wide variety
of consumer and industrial applications.

 The systems are generally grouped under the two broad classifications of pneumatic and hydraulic.

 Pneumatic systems use gas, usually air, while hydraulic systems use liquids, usually oil. Other fluids are
often used in special applications.

 Fluid power is one of the three types of power transfer systems commonly used today. The other
systems are mechanical and electrical. Each of the systems transfers power from a prime mover (source)
to an actuator that completes the task (work) required of the system.

 Fluid power systems use the prime mover to drive a pump that pressurizes a fluid, which is then
transferred through pipes and hoses to an actuator.

 Mechanical systems transfer power from the prime mover to the point of use by means of shafts, belts,
gears, or other devices.

 Electrical systems transfer power using electrical current flowing through conductors.

 Typical applications in business, industrial, and consumer products and systems use combinations of
fluid, mechanical, and electrical power transfer methods.

Fluid Power Systems

 Fluid power is a highly versatile power transmission system extensively used in manufacturing,
construction, transportation, agriculture, mining, military operations, health, and even recreation.
 The two major divisions of the fluid power field: hydraulics and pneumatics.

System Characteristics
Although hydraulic and pneumatic systems share the characteristics of energy transfer by means of fluid
pressure and flow, differences affect how and where they are applied. These differences include:
■ Accuracy of actuator movement
■ Operating pressure
■ Actuator speed
■ Component weight
■ Cost

Accuracy of movement
 Fluid compressibility is the inherent characteristic that produces the difference between hydraulic and
pneumatic systems.
 A gas is compressible, while a liquid can be compressed only slightly. Hydraulic systems, therefore, can
produce more accurate, easily controlled movement of cylinders and motors than pneumatic systems.
 Compressibility produces a more “spongy” operation in pneumatic systems that is not suitable where
highly accurate movement is required.
Operating pressure
 Hydraulic systems can operate at much higher pressures than pneumatic systems.
 Hydraulic system operating pressure ranges from a few hundred pounds per square inch (psi) to several
thousand psi. Pressures of more than 10,000 psi are used in special situations.
 Pneumatic systems, in contrast, normally operate between 80 to 120 psi. Extremely high–pressure
pneumatic systems normally are not used.

Actuator speed
 Pneumatic systems are commonly used when high-speed movement is required in an application.
Rotation speeds of over 20,000 revolutions per minute (rpm) are possible. Rapid-response cylinder
operation is also possible with pneumatic systems. These designs are generally found in situations
involving lighter loads and lower accuracy requirements.

Component weight
 System operating pressure affects the structure of components. Hydraulic systems operate at higher
pressures, requiring the use of stronger materials and more-massive designs to withstand the pressure.
 Pneumatic systems operate at much lower pressures and, therefore, can be manufactured using
lightweight materials and designs that minimize the amount of material.
 Hydraulic applications tend to involve equipment that handles heavier weights, requiring both higher
system operating pressure and physical strength of machine parts.
 Pneumatic systems tend to involve applications where ease of handling and lightweight are critical for
effective operation of the tool or system.

Cost
 The cost of fluid power systems ranges widely. A variety of situations exist and a number of solutions
are available for each one.
 Understanding system advancements, basic characteristics of hydraulic and pneumatic systems, and
knowing which standard components are available are necessary to produce a system that does the best
job at the lowest cost. The cost of system operation is a factor that must be considered.
 Generally, pneumatic systems are more expensive to operate than hydraulic systems. This cost can be
directly associated with the compression, conditioning, and distribution of air. Careful maintenance to
eliminate leakage can greatly reduce operating cost

Advantages and Disadvantages of Fluid Power Systems

Fluid power systems have several advantages and disadvantages when compared with mechanical and
electrical power transfer systems.
Advantages:
The following list of advantages applies to both hydraulic and pneumatic systems, except as noted.
■ An easy means of multiplying and controlling force and torque.
■ Infinitely variable speed control for both linear and rotary motion.
■ Overloading the system simply stalls the actuator without damage to the components.
■ Provides an easy means of accurately controlling the speed of machines and/or machine parts.
■ Provides the ability to instantly stop and reverse linear and rotary actuators with minimal shock to the system.
■ Systems easily adapt to accommodate a range of machine sizes and designs.Systems readily adapt to external
control methods, including mechanical, pneumatic, electrical, and electronic systems
■ Systems can easily provide component lubrication.
■ Large volumes of compressed air may be easily stored in pneumatic systems to provide energy for
intermittent, heavy system demand.
■ Pneumatic systems provide clean operation with minimal fire hazard.
Disadvantages:
The following list of disadvantages applies to both hydraulic and pneumatic systems, except as noted.
■ Higher safety factors associated with high-pressure oil and compressed air.
■ Susceptibility to dirty environments, which can cause extreme component wear without careful filtration.
■ Fluid leakage and spills cause a slippery, messy work environment around hydraulic equipment.
■ Fire hazard with hydraulic systems using combustible oils.Special handling and disposal procedures for
hydraulic oil required by environmental regulations.
■ High cost of compressing and conditioning air for use in pneumatic systems.
■ Reduced accuracy in actuator speed control in pneumatic systems caused by compressibility of air.
■ Noise level of pneumatic systems when air is directly exhausted to the atmosphere from components.

Pneumatics
 PNEUMA : means “breath” in Greek.
 Pneumatics is the name given to the branch of physics which deals with the properties,
motions and behavior of air.
 In pneumatic transmission, energy in the form of compressed air is transmitted through piping
to a pneumatic actuator(cylinder) where work is to be done.

 In industry pneumatic medium employed for transmitting power is the highly compressible
air.

 The compressed air is then prepared or treated in several stages to remove undesirable
contaminants present in it and stored in a tank called receiver tank.
 The compressed air is used to do work in a controlled manner by allowing it to expand back to
the atmospheric pressure.
 Pneumatic systems have been developed as low-pressure systems in comparisons to hydraulic
power systems.
 The work done in this expansion is transmitted to a load surface such as a piston or a vane,
which will be moved by the expanding air with a force (F = P x A).
 The function of a pneumatic system can be simply summed up as follows: “ Applying a force
to a gaseous fluid like air and transmitting pneumatic pressure all through the fluid, and then
converting the stored energy back into mechanical force before work could be done”
Advantages of Pneumatic system:
1. Air is available everywhere in unlimited quantity.

2. Compressed air can be easily transmitted through pipes over long distances.

3. Huge quantities of compressed air can be easily stored in a receiver tank, and the compressor
need not to be in operation always.

4. Compressed air is a fast working medium ( 1-2m/s)

5. Air is extremely compressible and elastic and is capable of absorbing large amounts of
potential energy, which make possibly to obtain smooth acceleration and deceleration of
actuators and reversal of direction of motions with free from shock.

6. Actuators speeds in a compressed air speed can easily controlled by the simple use of valves.

7. Compressed air tools and working elements can be subjected to loads even at standstills –
overload safe.

8. Components of air systems are usually very compact, light in weight and can be easily
serviced.

9. Air may be exhausted to atmosphere without any harm, so return lines are not required.

10. Entire system can be operated utmost cleanliness.

11. Air equipment is not subjected to sudden failure.

12. Compressed air can be used in hazardous areas where electrical controls cannot be used.

13. Compressed air is relatively insensitive to temperature fluctuations . This ensures reliable
operation, even under extreme conditions.

Disadvantages of Pneumatic system:

1. All compressed air systems are vulnerable to damage by dirt or contamination. Hence,
compressed air requires good preparation to remove dirt and moisture present in it.

2. Compressed air actuators are only economical up to a certain force requirement ( normal
operating pressure 8 to 10 bar, maxi. Force 48KN).

3. It is not possible to achieve uniform and constant piston speeds with compressed air.

4. Compressed air is a relatively expensive energy medium. The high costs of energy are
compensated by inexpensive components and high performance.
 5. Exhaust air is noisy. Problem has been solved with the use of effective silencers.

6. Displacement is not smooth –jerky/ slip stick motion.

Applications of Pneumatic system:

1. Aircraft manufacturers. 2. Cement plants
3. Chemical plants 4. Coal mines
5. Cotton mills 6. Dairies
7. Distilleries 8. Forge shops
9. Foundries 10. Machine tool manufacturers

11.Material conveying 12. Metal forming

13. Oil refineries 14. Paper mills

15. Printing 16. Space exploration

17. Steel mills 18. Automobile industries.

Structure of pneumatic control:

 A Typical Pneumatic system
 A compressor is the most common industrial energy supply unit that converts mechanical
energy into fluid energy.

 It is designed to take in air at atmospheric pressure and deliver the received air to a closed
system with a certain volumetric flow rate, at a higher pressure.

Actuators:
 Pneumatic actuators are output devices that convert energy contained in the compressed air
into motion (linear or rotary) or a force.

 These devices make power and motion available to automated system, machines, and
processes.

 Pneumatic actuators are categorized into two basic types:

1. Linear actuators: They convert pneumatic energy into straight-line mechanical energy.

2. Rotary actuators: They convert pneumatic energy into rotary mechanical energy.
Valves:
 It is device consisting of aluminum or brass body and an internal moving part, like a ball, disc,
spool, etc., which control direction of flow or rate of flow or pressure of the compressed air.

 The valve control a wide range of functions – from the simplest task of switching a signal flow
path „on‟ and „off‟ to the sophisticated proportional control of pressure and flow.
Functional classification of valves:
According to their switching function, pneumatic valves are classified into the following groups:

1. Directional control (DC) valves:

 These control the direction of flow of the compressed air.

 It direct or prevent air flow through selected passages in the valve.

 It is achieved by some moving parts in the valve, such as poppet or slide, controlling the
direction of air flow.

 They are usually used to control pneumatic cylinders and rotary actuators.

 According to construction, DC valves are classified into

a) Poppet valves b) Slide valves (or Spool valves)

2. Non-return valves: These allow the flow of the compressed air in only one direction, blocking the
flow in the other direction.

3. Pressure control valves: These valves regulate or limit the pressure of the compressed air or
generate a control signal when a set pressure is reached.

4. Flow control valves: These valves restrict the compressed air to reduce its flow rate.
Symbol Development:
Port Numbering and Lettering System:

Number Letter

1 P Reserved for Pressure Source.

3, 5 (R)S, R Reserved for exhaust ports.

2, 4 (A)B, A Reserved for working ports.

10 Y Port 1 closed.

12 Y, Z Port 1 connects to port 2.

14 Z Port 1 connects to port 4.

As a general rule Odd numbers are at the bottom and Even

numbers on the top.
Methods of Actuation:
Ex7 Automatic Return motion of double acting cylinder:
A double acting cylinder is to extend and push work pieces on to chute when a push
button is operated. After reaching the forward end position double acting cylinder is
to retract automatically.
Ex8 Pneumatic circuit with Time delay:
A double acting cylinder is used to pressed together glued components. Upon
operation of a push button cylinder is to extend, once fully extended position is
reached cylinder is to remain there for 5 sec and then to retract to initial position
automatically.
Ex9 Pneumatic circuit with pressure sequence valve
A double acting cylinder is used to pressed together glued components. Upon
operation of a push button cylinder is to extend, once fully extended position is
reached cylinder is to remain there until sufficient clamping force is developed and
then to retract to initial position automatically.
Ex10 Continuous cycle of operation of double acting cylinder with counter
A double acting cylinder is to carry out oscillatory motion after a „Start‟ signal is
given. The cylinder should stop automatically after say, 5 cycles of operation.
 Hydraulics

BASIC PRINCIPLES OF HYDRAULICS

Pascal‟s Law:
It is the most fundamental principle in fluid power which deals with hydrostatics, the transmission of
force through a confined fluid under pressure. “ The pressure exerted on a confined fluid is transmitted
undiminished in all directions and acts at right angle to the containing surfaces”
Force (F )
Pressure (p) = -----------
Area (A)

Mechanical Energy OUT

Prime Hydraulic Hydraulic Hydraulic External

Mover Pump Circuit Actuator Load

Mechanical Energy IN
Hydraulic System

Components of a Hydraulic system:

Oil Reservoir, Electric motor, Pump, Pressure relief valve, Piping system ( oil lines with
directional\ flow\ check valves), actuator (double acting cylinder)
 Hydraulics Exercises
1. Actuation of Double acting hydraulics cylinder

Double acting cylinder

4/2 hand lever operated valve

Tank

Pressure Relief valve Fixed Displacement pump

Tank Filter

2. Speed control of double acting cylinder using oneTank

way flow control valves (Metering in)

One way flow control valve

3. Speed control of double acting cylinder using one way flow control valves (Metering
out)

4. Actuation of Double acting cylinders for continuous reciprocating motion using electro
hydraulic circuit
5. Actuation of double acting cylinder using shuttle valve (OR gate) and two pressure
valve (AND gate)

6. Sequencing of double acting cylinder using combined hydraulic and electro hydraulic
circuit.
 Electro-Pneumatics

Solenoid Working Principle

The solenoid simply works on the principle of “electromagnetism”. When the current flow through the coil
magnetic field is generated in it, if you place a metal core inside the coil the magnetic lines of flux is
concentrated on the core which increases the induction of the coil as compared to the air core.

Solenoid valves are control units which, when electrically energized or de-energized, either shut off or allow
fluid flow. The actuator takes the form of an electromagnet. When energized, a magnetic field builds up which
pulls a plunger or pivoted armature against the action of a spring. When de-energized, the plunger or pivoted
armature is returned to its original position by the spring action.

5/2 –way Double Solenoid valve

Electromagnetic relay
Electromagnetic relays are generally composed of iron core, coil, armature, contact reed, etc. When a certain
voltage is added to the two ends of the coil, a certain current will be generated in the coil, which will produce
electromagnetic effect. The armature will overcome the pulling force of the return spring to attract the iron core
under the action of electromagnetic force, and the moving contact and the static contact (normally open contact)
of the armature are closed. When the coil is de-energized, the electromagnetic attraction force disappears, and
the armature returns to its original position by the reaction force of the spring, so that the moving contact and
the original static contact (normally closed contact) are closed. In addition, the "normally open, normally
closed" contacts of the relay can be distinguished as follows: the static contact that is in the off state when the
relay coil is not energized is called "normally open contact (NO contact)"; the static contact that is in the on
state The points are called "normally closed contact (NC contact)".
Push-Buttons
 Exercises in Electro-pneumatics
Ex 1: Memory control by using a double-solenoid valve:

Control task: A double-acting cylinder is to be controlled using a 5/2-way double-solenoid

valve. When push button PBl is pressed, the cylinder is to extend and bas to remain in this
position even when push-button PB2 is released. When push-button PB2 is pressed, the cylinder
is to retract to the home position and has to remain in that position even when push-button PB2
is released.
Ex 2: Speed control of double acting cylinder(Metering In)
Ex 3: Speed control of double acting cylinder(Metering Out)
Ex 4 Cyclic operation of double acting cylinder

Ex 5 Automatic return of double acting cylinder

Ex 6 Control of double-acting cylinder using OR gate, AND gate and Quick exhaust valve

Ex 7 Control of double-acting cylinder using timer

Ex 8 Control of double-acting cylinder using Counter

Ex 9 Control of double-acting cylinder using Pressure switch

Control task: Some components are to be stamped using a stamping device. A double-acting cylinder pushes the
die attached to a fixture when two push-button are pressed simultaneously (TWO HAND SAFETY). The die
is to return to the initial position upon reaching sufficient stamping pressure as sensed by a pressure switch.
Develop an electro-pneumatic control circuit to implement the control task for the stamping operation.