CAM and AUTOMATION

MCL 431
CAM AND AUTOMATION

Hydraulic Circuit Design

Dr. Sunil Jha

suniljha@mech.iitd.ac.in
Of ce: Block III/156

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 1

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CAM and AUTOMATION

Circuit Design Considerations

Safety of Operation
Pressure and Temperature Ratings
Interlocks for sequential operations
Emergency Shutdown features
Power Failure locks
Operation Speed
Environment conditions

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

CAM and AUTOMATION

Circuit Design Considerations

Meet Functional Requirements
Meet required performance speci cation
Life expectancy same as machine
Facilitate good maintenance practice
Compatibility with electrical and
mechanical components
Withstand operational hazards

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

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CAM and AUTOMATION

Circuit Design Considerations

Ef ciency of Operation
Keep system Simple, Safe and Functional
Access to parts need repair or adjustment
Design to keep Min operational cost
Design to prevent and remove
contamination.

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

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CAM and AUTOMATION

Q1
Circuit Design Problem
In a Sheet metal forming press. The shape to be
formed is hemispherical cup of radius 15 cm in 2
mm thick mild steel sheet. The force required to
deform sheet is 8 kN. The forming hammer should
approach job from a distance of 30 cm. The
production rate required is 240 components/hr.

Calculate and suggest the following speci cations

of the various hydraulic components used:

Hydraulic Cylinder (bore & length) La

Pump pressure and ow rate
Electric motor HP considering 75% pump ef ciency
Reservoir size
Size of pump inlet and discharge tubing

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

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Circuit Design Approach

What are the speci cations of the job?

Force requirement – 8 kN
Length of work stroke – 15 cm
Production rate – 240 comp/hr

What Size of Cylinder is needed? 8 kN

Force known.
Cylinder Area & Operating Pressure
must be selected. F = PA
Standard bore and rod size cylinders

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

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CAM and AUTOMATION

Circuit Design Approach

What Size of Cylinder is needed?
Large Diameter Cylinder
Small Diameter Cylinder P Q

Cylinder selected = 50 mm bore

Find Pressure and then select suitable pump

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

CAM and AUTOMATION

Circuit Design Approach

What Capacity Pump is needed?
Max Cylinder Speed required
Flow rate = (Cyl Area)x(Stroke)/(time)
Pump selection

What size of Electric Motor needed?

Calculate power required to run Pump
Consider ef ciency of pump
Shaft size, type and electric source

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi

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CAM and AUTOMATION

Circuit Design Approach

What Size reservoir should be used?
2.5-3.0 times the pump capacity (l/min)

Size of pump inlet?

Inlet ow velocity = 60-150 cm/sec

Size of Discharge tubing?

Outlet ow velocity = 200 - 450 cm/sec

Relief valve selection

Pressure range
Valve port size

Direction Control valve

Based on function
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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Control of a Hydraulic Motor

Hydraulic Motor – Rotary Motion

Motor Rotate
Clockwise
Motor Rotate
Antilockwise

Spring Centre Position

Motor hydraulically
locked

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 10

CAM and AUTOMATION

Hydraulic Motor Braking

Hydraulic motor may be driving Machine having a large inertia

Creates Flywheel effect.

Stopping motor, acts as a pump

Circuit is designed to provide uid to

the motor while it is pumping

Provisions should be made for

discharge uid from motor to be
returned to Tank

This would stop motor without damaging

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 11

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Hydraulic Motor Braking

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 12

CAM and AUTOMATION

Hydraulic Motor Braking

RV2
A C

B D

DCV

RV1

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 13

 CAM and AUTOMATION

Q2
Circuit Design Problem
Design a hydraulic circuit for a shaper machine of size 250 mm without using
ow control valve. The ram should perform cutting during extension stroke with
a speed of 1.6 m/min and return at 4 m/min. The maximum cutting force on ram
is 25kN. The cutter should approach and leave the work piece as per Figure
below. Piston Area = 2000 sq. mm. Attempt the following

b a

• Draw the hydraulic circuit for the shaper machine. State the position of
DCV for cutting and return motion
• Piston Rod Area (sq. mm)
• Pump pressure and ow rate
• Electric motor HP considering 72% pump ef ciency
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 14
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Q3
Circuit Design Problem
A hydraulic motor is required to deliver 1.85 kNm
torque at 1800 rpm. The mechanical ef ciency of
hydraulic motor is 68%. Calculate and suggest the
following speci cations of the various hydraulic
components used:

• Pump pressure and ow rate

• Electric motor HP considering 75% pump ef ciency
• Reservoir size
• Size of pump inlet and discharge tubing

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 15

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Q4
Problem
Hydraulic Jack
450 kg

15 cm 5

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 16

CAM and AUTOMATION

Q4
Problem
Hydraulic Jack

a b

A1

A2

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 17

CAM and AUTOMATION

Q4
Problem
An operator makes one complete cycle per second using
the hydraulic jack as sown in Figure. Each complete cycle
consists of two pump cylinder strokes (intake and power). The
pump cylinder has a 25 mm diameter piston and the load
cylinder has a 80 mm diameter piston. If the average hand
force is 10 kg during the power stroke,
a) How much load can be lifted?

b) How many cycles are required to lift the load 25 cm assuming no

oil leakage? The pump piston has a stroke of 5 cm.

c) What is output HP assuming 80% ef ciency of the system?

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 18

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Q5
Problem

A 10 kN weight is to be lowered
by a vertical cylinder as shown in
Fig. The cylinder has a 75 mm
diameter piston and a 50 mm
diameter rod. The weight is to
decelerate from 100 m/min to a
stop in 0.5 s. Determine the
required pressure in the rod end
of the cylinder during the
deceleration motion.

Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 19