MATTU UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

COURSE TITLE : HYDRAULICS AND PNEUMATICS

: SEMINAR PROJECT

PROJECT TITLE : DESIGN OF COMMON ELECTRO-HYDRAULIC AND ELECTRO PNEUMATIC

SYSTEM

NAME ID. NUMBER

ANWAR MOHAMMED RU 5293/12
ABDULREHIM AKMEL RU 5721/12

SUBMITTED TO: SUBMISSION DATE:

Mr. LELISO DEC - 5 - 2023
CONTENTS

 DESIGN OF ELECTRO-HYDRAULIC SYSTEM

 DESIGN CONSIDERATION FOR ELECTRO-HYDRAULIC SYSTEM

 COMPONENTS AND PROCESSES OF ELECTRO-HYDRAULIC SYSTEM

 APPLICATIONS OF ELECTRO-HYDRAULIC SYSTEM

 DESIGN OF ELECTRO-PNEUMATIC SYSTEM

DESIGN CONSIDERATION FOR ELECTRO-PNEUMATIC SYSTEM

COMPONENTS AND PROCESSES OF ELECTRO-PNEUMATIC SYSTEM

APPLICATIONS OF ELECTRO-PNEUMATIC SYSTEM

CONCLUSION

REFERENCES
TITLE: DESIGN OF COMMON ELECTRO-HYDRAULIC AND ELECTRO PNEUMATIC SYSTEM

 DESIGN OF ELECTRO-HYDRAULIC SYSTEM

 An electro-hydraulic system is a type of hydraulic system that uses electrical control to operate the hydraulic
components. It typically consists of an electric motor, hydraulic pump, hydraulic valves, and actuators.

 The electric motor powers the hydraulic pump, which generates hydraulic pressure to operate the system.
The hydraulic valves are controlled by electrical signals to regulate the flow of hydraulic fluid and the
movement of the actuators. This type of system is commonly used in industrial and mobile equipment
applications where precise control and automation are required.

 Hydraulic system are used wherever high power concentration, good heat dissipation or extremely high
forces are required.

 Electro-hydraulic systems are made up of hydraulic and electrical components.

 The movement and forces are generated by hydraulic means (e.g. by cylinders).
 Signal input and signal processsing, on the other hand are affected by electrical and electronic components
(e.g. electromechanical switching elements or stored-program controles).

One major advantage of an electrohydraulic system over a conventional hydraulic system is its ability to implement
automatic controls.

 To accomplish automatic control of a hydraulic system, taking a valve-controlled hydraulic cylinder actuating
system as an example without loss of generality, three fundamental actions are required:

(1) Obtaining the cylinder-actuating information;

(2) Comparing the obtained information with the commanded operation to make a decision for further action; &

(3) Performing the action.

Instead of relying on a human operator to observe the actuation to maneuver the system, an automatic control
system could use sensors to obtain the desired information, a controller to compare the actual actuation with the
commanded operations to determine adequate control actions, and an actuator to implement the required control
actions.
 In a hydraulic system, fluid power provides the “muscles” or power to do work,while a control part provides the
“brain” to command system operation. Control of a hydraulic system may range from the simple starting and
stopping of the system to controlling extension and retraction of several cylinders in a completely automated
factory.

The use of electrical and electronics components in the control of hydraulic systems is advantageous for the
following reasons:

 Electrical signals can be transmitted via cables quickly and easily and over great distances. mechanical signal
transmission (linkages, cable-pulls) or hydraulic signal transmission (tubes, pipes) are far more complex. for
example, this is the reason why electro-hydraulic systems are being used increasingly frequently in aeroplanes,

 In the field of automation, signal processing is generally effected by electrical means. this enhances the options
for the use of electro-hydraulic systems in automatic production operations (e.g. in a fully automatic pressing line
for the manufacture of car wings).

 Many machines require complex control procedures (e.g. plastics processing). in such cases, an electrical control
is often less complex and more economical than a mechanical or hydraulic control system.
 DESIGN CONSIDERATION FOR ELECTRO-HYDRAULIC SYSTEM

1) Selection of electric motor: The electric motor should be chosen based on the power requirements of the
hydraulic pump and the specific application needs. Factors such as speed, torque, and efficiency should be
considered in the selection process.

2) Hydraulic pump selection: The hydraulic pump should be chosen based on the flow rate and pressure
requirements of the system. Different types of pumps, such as gear pumps, vane pumps, and piston pumps, may
be used depending on the specific application needs.

3) Hydraulic valve selection: The selection of hydraulic valves is crucial for controlling the flow and direction of
hydraulic fluid. Various types of valves, such as directional control valves, pressure control valves, and flow
control valves, may be used based on the system requirements.
4) Actuator selection: The actuators, such as hydraulic cylinders or hydraulic motors, should be chosen based
on the specific application needs for movement and force requirements.

5) Electrical control system: The electrical control system includes components such as sensors, PLCs
(Programmable Logic Controllers), HMI (Human-Machine Interface), and electrical wiring for controlling the
operation of the hydraulic components.

6) Integration and testing: Once the components are selected, they need to be integrated into a cohesive system
design. Testing is essential to ensure that the system operates as intended and meets the performance
requirements.

7) Safety considerations: Safety features such as pressure relief valves, emergency stop buttons, and safety
interlocks should be incorporated into the design to ensure safe operation of the electro-hydraulic system

overall, the design of an electro-hydraulic system requires a through understanding of both electrical and
pneumatic principles, as well as focus on precision,reliability and safety.
The following schematic diagram shows the two principal sub-assemblies in an electro-hydraulic system:

 signal control section: with signal input, signal processing and control energy supply.

 hydraulic power section: with power supply section, power control section and drive section.

 An electrical signal generated in the signal

control section,where it is processed & then
transmitted to the power section via the
interface.
 In the power section, this electrical energy is
converted first into hydraulic & then to
mechanical energy

Figure 1: Schimatic diagram of electro-hydraulic system

 Electro-hydraulic systems are used to control the flow and pressure of hydraulic fluid using electrical signals.

 COMPONENTS OF ELECTRO-HYDRAULIC SYSTEM

 Signal Processing Control Technology: it is a type of technology that is used to process signals in order to
control hydraulic systems. It is used to control the flow and pressure of hydraulic fluid using electrical signals.

 Continuously Adjustable Valves: it is the collective term for valves such as proportional valves, high response
proportional valves and servo valves, which can be continuously adjusted. Continuously adjustable valve is used
to regulate the flow of a media such as , liquids by opening, closing, or partially obstructing the passageway.

 Proportional Valves: it provides control in applications where output pressure or flow varies or is based on a
dynamic set point. They provide control over water through rapid, highly precise response and help streamline
applications while delivering repeatable control and desired output.

 Setpoints: are a type of data that can be queried in a control panel. They are used to set the desired value for a
parameter, such as temperature, pressure, or flow rate
 Servo Valve: is a type of valve that can be used to control the flow of hydraulic fluid using electrical signals. It is a
high-precision device that is used in a wide range of applications, including aerospace, automotive, and industrial
automation1. Servo valves are used to control the position, velocity, and force of hydraulic actuators.

 Control Amplifiers: Control amplifiers are a type of electronic device used to increase the magnitude of
voltage/current/power of an input signal.

 Electro-hydraulic circuit consists of different components such as electric motor which converts electric energy into
mechanical energy, the pump which converts mechanical energy into hydraulic energy and the actuator convert back
hydraulic energy into mechanical energy. Control elements like valves are used which controls the fluid in the circuit
such as direction control valves, flow control valves, solenoid valves & pressure relief valves, and others

 ELECTRO-HYDRAULIC SYSTEM PROCESSES

1) Input signal: The process begins with an input signal, which can come from a variety of sources such as a sensor,

switch, or control system.

2) Electrical signal: The input signal is converted into an electrical signal by a transducer or sensor. This electrical
signal is then sent to the control unit of the electro-pneumatic system.
3) Control unit: The control unit processes the electrical signal and generates an output signal based on the input. This
output signal is used to control the operation of the pneumatic components in the system.

4) Pneumatic components: The output signal from the control unit is sent to pneumatic components such as solenoid
valves, cylinders, and actuators. These components use compressed air to perform mechanical work, such as moving
a piston or opening a valve.

5) Mechanical work: The pneumatic components perform the required mechanical work based on the output signal
from the control unit. This could include moving a load, controlling the flow of a fluid, or performing a specific task.

6) Feedback: In some systems, feedback sensors are used to monitor the performance of the pneumatic components and
provide information back to the control unit. This allows for real-time adjustments to be made to the system based on
the actual performance of the pneumatic components.

7) Output signal: The control unit may adjust the output signal based on the feedback from the pneumatic components,
ensuring that the system operates as intended and achieves the desired results.

8) End of process: Once the task is completed or the input signal changes, the electro-pneumatic system circuit flow
process comes to an end until a new input signal is received
Figure 2: electro-hydraulic system Circuit
Figure 3: electro-hydraulic system
  APPLICATIONS OF ELECTRO-HYDRAULIC SYSTEM

 Aerospace: One example of electro-hydraulic system application is in the aerospace industry, where these systems are
used in aircraft landing gears and flight control systems. Electro-hydraulic systems’ high precision and responsiveness
ensure the safe and reliable operation of critical components in these applications.

 Construction: In the construction industry, electro-hydraulic systems are used in heavy machinery, such as excavators,
bulldozers, and cranes. These systems provide precise control and enable operators to perform complex tasks efficiently
and safely.

 Manufacturing: The manufacturing industry uses electro-hydraulic systems in automated assembly lines, robotic arms,
and packaging machinery. These systems offer high-speed and high-precision control, increasing productivity and
reducing production costs.

Electro-hydraulic systems offer a reliable and versatile solution for various industries that require precise control and high
performance. With their numerous advantages and applications, these systems continue to play a vital role in the
advancement of modern technology.
 DESIGN OF ELECTRO-PNEUMATIC SYSTEM
 Pneumatic systems use air as the medium which is abundantly available and can be exhausted into the
atmosphere after completion of the assigned task.
 The most used pneumatic actuation systems are electrically controlled systems. These systems are called
electro-pneumatic actuation systems. The automation systems that use electro-pneumatic technology are formed
by mainly three kinds of elements: actuators or motors, sensors or buttons and control elements like valves.
 Electro-pneumatic systems are a type of system that integrates pneumatic and electrical technologies into one
system where the signal/control medium is electrical and the working medium is compressed air.
 In electro-pneumatics, the pneumatic components are controlled by using electrical and electronic circuits.
Electronic and electro magnetic sensors, electrical switches and industrial computers are used to replace the
manual control of a pneumatic system.
 In electro-pneumatic circuits solenoid operated directional control valves, limit switches and pressure switches
are used .On an automation system one can find three families of components, which are sensors,valves and
actuators . A solenoid is used in pneumatic valves to act as the actuating element.
 This type of system is used in many industrial applications, such as in the automation of manufacturing processes.
devices like relays, solenoid valves, and limit switches can be used to interface electrical control with pneumatic
action.

 Electro-pneumatic systems are used in many applications, including:-

• control of pneumatic actuators,

• control of pneumatic valves,

• control of pneumatic cylinders

• control of pneumatic motors,

• control of pneumatic pumps,

• control of pneumatic compressors.

• and in different industries, including the automotive industry, the aerospace industry, and the food and beverage
industry.
 Advantages of Electro-Pneumatic Systems:-
 The system allows easy automation of complex industrial processes.

 The high speed of signal transmitting and processing leads to the significant enhancement of the productivity of the
automation system.

 Electric equipment costs less than pneumatic equipment.

 Significant loads are controlled with a reduced control signal.

 The loading gauge of the control equipment is reduced.

 Electronic programmers and process computers are used for the control of the system

Disadvantages of Electro-Pneumatic Systems:-

 The systems use two supply units (pneumatic and electric).

 Functioning is not allowed in flammable environments, in environments subjected to hazard of explosion or in high
humidity conditions.
 FACTORS FOR DESIGNING ELECTRO-PNEUMATIC SYSTEM

 Compressed air supply: The first step is to ensure that the compressor and feed lines are adequately sized to ensure
proper system operation. Consistent plant air pressure with suitable flow allows pneumatic devices to operate as
designed. Low or varying air pressure can negatively impact the final product and overall machine sequence.

 A filter regulator: should also be installed at the air dump valve to remove dust particles and water that can cause wear
and operation problems for pneumatic system components.

 Air flow control: Once consistent and correct pneumatic system air pressure and flow is established, plant supply air
should be connected to a manual, lockable air dump valve at each use point.

 Cylinder types: The first step in choosing a cylinder is deciding whether to use the single- or double-acting version. As
mentioned previously, single-acting cylinders use compressed air to move the load in one direction and double-acting
cylinders use compressed air for movement in both directions

 System requirements: Determine the specific requirements of the system, including the desired functionality,
operating pressure, and environmental conditions.
 Component selection: Choose appropriate solenoid valves, pressure regulators, air cylinders, sensors, control units,
filters, lubricators, manifolds, hoses, actuators, and electrical connections based on the system requirements and
application.

 Integration: Ensure that all components are compatible and can be seamlessly integrated into the system. Consider
factors such as mounting options, connection types, and electrical compatibility.

 Control strategy: Develop a control strategy that utilizes the capabilities of the electro-pneumatic components to
achieve the desired system performance. This may involve programming the control unit to manage valve actuation,
pressure regulation, and sensor feedback.

 Safety considerations: Incorporate safety features such as pressure relief valves, emergency stop buttons, and
protective enclosures to ensure safe operation of the system.

 Documentation: Create detailed documentation that includes component specifications, wiring diagrams, control
logic, and maintenance procedures to facilitate installation, operation, and maintenance of the system.

By carefully considering these aspects during the design process, an effective and reliable electro-pneumatic system can
be developed to meet the specific needs of the application.
 DESIGN CONSIDERATION FOR ELECTRO-PNEUMATIC SYSTEM
1) Safety: The design of an electro-pneumatic system should prioritize safety, with proper
measures in place to prevent over-pressurization, leaks, and other potential hazards.
2) Reliability: The system should be designed to operate reliably under various conditions,
with durable components and effective maintenance procedures.
3) Efficiency: The design should aim to maximize the efficiency of the system, minimizing
energy consumption and reducing waste.
4) Control: The system should provide precise control over pneumatic components, with the
ability to adjust pressure, flow rates, and other parameters as needed.
5) Integration: The design should consider how the electro-pneumatic system will integrate
with other systems and equipment, ensuring compatibility and smooth operation.
6) Flexibility: The system should be designed to accommodate changes and adaptations,
allowing for easy modifications and expansions as needed.
7) Environmental impact: The design should consider the environmental impact of the
system, with measures in place to minimize air pollution and other negative effects.
8) Cost-effectiveness: The design should balance performance and functionality with cost
considerations, aiming to achieve the most efficient and economical solution.
9) Noise reduction: The design should consider ways to minimize noise generated by the system, with proper insulation and
sound-dampening measures.

10) User interface: The system should provide a user-friendly interface for operators to monitor and control the pneumatic
components, with clear displays and intuitive controls.

 COMPONENTS OF ELECTRO-PNEUMATIC SYSTEM

Some common components of an electro-pneumatic system include:

 Solenoid valves: These valves are used to control the flow of compressed air in the system, typically by using an
electrical signal to actuate the valve.

 Pressure regulators: These components are used to maintain a consistent pressure level in the system, ensuring that
pneumatic components operate as intended.

 Air cylinders: These devices use compressed air to create linear or rotary motion, and are commonly used in
applications such as actuating valves or moving mechanical components.
 Sensors: Various sensors, such as pressure sensors or flow sensors, may be used to monitor the performance of the system
and provide feedback for control purposes.

 Control units: These units may include programmable logic controllers (PLCs) or other electronic control systems that
manage the operation of the electro-pneumatic system.

 Filters and lubricators: These components are used to clean and prepare the compressed air supply, removing
contaminants and adding lubrication to ensure proper function of pneumatic components.

 Manifolds: Manifolds are used to distribute compressed air to different parts of the system, allowing for centralized
control and distribution.

 Hoses and tubing: These components are used to transport compressed air throughout the system, connecting various
pneumatic components together.

 Actuators: Actuators are devices that convert pneumatic energy into mechanical motion, and may include components
such as rotary actuators or grippers.

 Electrical connections: Various electrical components, such as wiring, connectors, and switches, are used to provide
power and control signals to the electro-pneumatic system
• It is essential to consider the overall system performance and reliability. This includes conducting thorough testing and
validation of the system to ensure that it meets the desired functionality and performance requirements.

 ELECTRO-PNEUMATIC SYSTEM PROCESSES

1) Air compressor: Supplies compressed air to the system.

2) Air preparation unit: Filters, regulates, and lubricates the compressed air before it enters the system.

3) Solenoid valves: Control the flow of compressed air to various actuators and components.

4) Actuators: Convert the pneumatic energy into mechanical motion to perform work, such as cylinders and rotary actuators.

5) Pressure regulators: Maintain a consistent pressure level in specific parts of the system.

6) Flow control valves: Regulate the speed and direction of the airflow in the system.

7) Sensors: Detect various parameters, such as pressure, temperature, and position, to provide feedback to the control system.

8) PLC (Programmable Logic Controller): Controls the operation of the electro pneumatic system based on input from
sensors and other components.
9) Control panel: Houses the PLC and other control components, allowing for manual control and monitoring of the
system.

10) Manifolds: Distribute the compressed air to various components and actuators in the system.

11) Pneumatic tubing and fittings: Connect the different components of the system, allowing for the transfer of
compressed air.

12) Lubricator: Adds a small amount of oil to the compressed air to lubricate the moving parts of the system.

13) Pressure gauges: Measure the pressure of the compressed air at various points in the system.

14) Check valves: Allow air to flow in one direction only, preventing backflow and maintaining pressure in specific parts
of the system.

15) Exhaust valves: Release excess or residual air from the system to maintain optimal pressure levels.

The process shows the connections between the different components, the flow of compressed air, and the electrical
signals controlling the system.
• The signal flow diagram of Figure below illustrates the signal flow within an electro-pneumatic system.
1. Signal input: This signal is usually generated from sensor or switch.
2. Signal processing: the signal is processed in the processing station such OR gate, AND gate or time delay
valve.
3. Signal output: the signal forms as a link between the signal control section and the power section
4. Command execution: it takes place at high power level either for : High speed-fast ejection of product.
: Apply high force as in power presses.

Figure 4: Signal flow and components of an electro-pneumatic control system

 FFFFFF

Figure 5: Electro pneumatic system Processes

 APPLICATIONS OF ELECTRO-PNEUMATIC SYSTEM

 Industrial automation: Electro-pneumatic systems are commonly used in industrial automation for tasks such as material handling,
assembly, packaging, and machining. They can be used to control the movement of robotic arms, conveyor belts, and pneumatic
cylinders.

 Manufacturing processes: Electro-pneumatic systems are used in manufacturing processes for tasks such as clamping, lifting, pushing,
pulling, and sorting. They can be found in industries such as automotive, aerospace, food and beverage, and pharmaceuticals.

 Machine tools: Electro-pneumatic systems are used in machine tools such as CNC machines, lathes, milling machines, and grinding
machines for tasks such as tool changing, workpiece clamping, and coolant control.

 Transportation: Electro-pneumatic systems are used in transportation applications for tasks such as braking, door opening/closing,
suspension control, and tire inflation.

 Medical equipment: Electro-pneumatic systems are used in medical equipment for tasks such as patient positioning, fluid control, and
surgical tool operation.

 Packaging and printing: Electro-pneumatic systems are used in packaging and printing machines for tasks such as labeling, sealing,
cutting, and stacking.

 HVAC systems: Electro-pneumatic systems are used in heating, ventilation, and air conditioning (HVAC) systems for tasks such as
 CONCLUSION

• Electro-pneumatic and electro-hydraulic systems are two types of fluid power systems that use electricity to control the
motion of mechanical components. Electro-pneumatic systems use compressed air to generate motion, while electro-
hydraulic systems use hydraulic fluid.

• Electro-pneumatic systems are generally faster than electro-hydraulic systems, but they are less powerful and less
precise. They are also cleaner and more cost-effective than hydraulic systems. Electro-hydraulic systems, on the other
hand, are more powerful and precise than electro-pneumatic systems, but they are also more expensive and require
more maintenance.

• The choice between electro-pneumatic and electro-hydraulic systems depends on the specific application requirements.
For example, electro-pneumatic systems are often used in applications that require fast and precise motion, such as in
the semiconductor industry. Electro-hydraulic systems are often used in applications that require high force and
precision, such as in the aerospace industry.
 REFERENCES

1. Laboratory Manual for Hydraulics & Pneumatics Circuit System Prepared by Aklilu Getachew ; February
2023

2. Hydraulic Systems Volume 2 Electro-Hydraulic Components and System by Dr. Medhat Kamel Bahr Khalil,
Ph.D,

3. Engineering Applications of Pneumatics and Hydraulics, Turner, Ian C. 2020 August 10

4. Design of Electro-Hydraulic Circuits,S.Z. Mafokwane ; December 7/ 2020

5. Pneumatic and hydraulic control systems; M.A.Aizerman, january , 2016

6. "Electro-Pneumatic and Electro-Hydraulic Systems" by Jon Stenerson, published in Pearson.

7. "Electro-Pneumatic Controls" by Frederick C. Jones, published in Goodheart-Willcox Publisher.

8. Stenerson, Jon. "Electro-Pneumatic and Electro-Hydraulic Systems."

THANK YOU!!