2020

MSBTE

TYDiploma

Strictly as per new revised T' Scheme

w.e.f. academic year 2019-2020

INDUSTRIAL HYDRAULICS
AND PNEUMATICS (Code : 22655)

SemesterVI-Mechanical Enginering Group (ME)

D.V. Lohar
Includes:
Model Question Papers as per Bloom's Revised Taxonomy
Solved Latest Ms8E Question
Papers upto Sum o Knouledge
Tech
Publications
 Industrial Hydraulics and
Pneumatics
(Code: 22655)

THIRD YEAR DIPLOMA

Maliaráshtra State. Board of Technical Educafion (MSBTE

Semester VI - Mechanical Engineering Group (ME)

Strictly as per newrevised T Scheme vw.e.f. academic year 2019-2020

Prof. Dinesh V. Lohar

M.E. (Mechanical)
Head of Department
(Department of Mechanical Engineering
Shri. H.HJ.B Polytecinic,
Chandwad, Nashik

MDE67A Price? 185/

Tech Knowledge
Public ationS

3ook Code:MDE67A)
 Sum-VI) Tablo of Contents
Incdustrinl Hydraulics & Pnoumatice(MSBTE

UNTX 1.5.2 Safoty Procaulons ..

1.6 Comparlson of Hydraullc and Pnournauc Syotom .... 1-26

Chnptor 1: Introductlon to Hydraullc and Pneumatlc

Systom 1-1 to 1-28

Syllnbus:
1.1 Gonornl layout ol oll hydrauillcs and pnoumatc syston
1.2 Appllcatlons, merits limitatlons of oll hydraulle and
pnoumatlcs systom.
1.3 Proportlos of flulds, ISO and SAE grados ol ol
1.4 ISO symbols usod in hydraulle and pnoumatic systom.
1.5 Hazads and salaty In Industrial hydraulle and Pnoumatics:
1.1 Introduction of Fluld Powor. *****'"**

-1
1.1.1 Fluid Powor systom. ***************

1.1.2 Typos of Fluld Powor Systom. **********************************.1-1

1.1.3 Oll Hydraulic Systom. ************* .1-2

1.1.3.1 Gonoml layout of all hydraulic systom

.. *****************"
1-2

.
1.1.3.2 Cornponents ofl Hydraullc System********* .14

1.1.4 Pnounatic Systom 5

1.1.4.1 Goneral layout of Pnoumatic systom. ****************1

.1-6

1.1.5 Comparison ol Oll and Alr Fluld System..

1.2 Applicaiions, Advantogos and Disadvantago3 of Oil

Hydraulic and Pnoumatic System. ****s***s*************

1:2.1 Applications ol Oil Hydraulc Systom 8

1.2.2 Applications ol Pneumotic Systom. ************************* .1-9

1.2.3 Morlls (Advantages) of Oll Hydtaulic Syetem.-10

1.2.4 Limitations/Domorits of lil hydraulia systom. 111
1.2.5

1.2.6

1.3
Morits (Advantngos) ol Pnoumatic

LImitations of Pneunatic System

SAE and IS0 Gradas of Hydraulic

. Systom.

Ol.
-12
112

1-13

..1-13
1.3.1 Important Propordos ol Hydraullc ol. *****************"

1.3.2 SAE and 1SO grndos . 14

1.4 ISO symbols usod in Hydraulics and

Pnoumatice Systom.. ****

16

1.4.1 Graphle Syrnbols lor Hydraulic Cormporients ....1-15

1.4.2 Pnoumallc Systom Symbols.. ****** ****** 20
1.4.3 Gonaral layoul of oll hydraulico using symbolo
24
(Symbollc Layout).

1.4.4 Gonoral layout ol pnoumatlo syolom ustng oymbols

(Symbolle Layout). ***** ****"*********** 1-24

1.5 Hazard and Saloty in Induatrial Hydraulcs and

PnoumalcS. ... *** *sneas*e*essnspns
26

15.1 Hazards In Pnoumatic Systei.. 26

****
 GH
Introduction to Hydraulic and
Pneumatic Systems
UNIT
Syllabus:
1.1 General layout of oil hydraulics and pneumatic system.
12 Aplications, merits limitations of oil hydraulic and pneumatics system:
1.3 Properties of fluids, IS0 and SAE grades of oil.

14 ISO symbols used in hydraulic and pneumatic system.

1.5 Hazards and safety in Industrial hydraulic and Pneumatics.

1.1 Introduction of Fluid Power Block diagram of fluid power system

After learning fluid mechanics and machinery in the Energy o High TO operata
ydrauile o various To d
fourth semester, students of mechanical engineering are Pressure machines and
USetud
pressëd 'air low work
able to know the use of fluids for power generation PDerts
using turbines like pelton wheel, Francis, Kaplan
Flg.1.1.1:8lock dlagram of Fluld power system
turbines,ctc
. It means fluid possesses energy and we can utilize the DXefinison otiuid power system
energies of fuids for various applications. terhnology in uhieh weitruinsmi ar
In this course, fluid power can be used to operate
toforres and velocities b trursmiting and
CuTtaoLins PrESUre and lou offiuids
various industrial machines and equipments, which is
terimed as "Industrial hydraulics and pneumatics." Applications

After various technical developments, from 1920 oil It has wide range of applications in various fields like
bydraulic emerged to operate industrial machines tools, automotive, agricultural uses, aircraft manufacturing,
material handling cquipments, mining equipments, etc. etc.

In indastrial sector, the various machines, equipments 1.1.2 Types of Fluld Power System:
were operated by using the power source of mechanical
transmission, clectrical transmission, fluid transmissipn According to the nature or type of fluid used,
it is
systems. divided into two categories.

eg. screw jack is mechanical operated device to lift the Types of fluld power
load Electrical motor is used to operate various System
machines using electrical power.

1.1.1 Fluld Power System Use of

Incompressible
Use ot
compressible
It is the technology which deals with the transmission air(gas)
energy by means of enclosed pressurized fuids
This technology is highly versatile power transmission OU Hydraulic
Pneumatic
system which utilize the energy of fuid (Oil, air, gas) system System
to perform the required workor task.
Fig.1.1.2:Block diagram of types of fluld power
eg Liting of very huge vehicles by using bydraulic system
crane, hydraulic press machine, etc.

Scanned witn camScanner

 1-2 Introduction to Hydraulic and Pneumatic System
Syr
Industrial Hydraulics & Pneumatics (MSBTE Sem-VI)_

1) Oil hydraulic system: Draw.generaf.ayout ot hydraulic system and en

eplan
ts Working
When the branch of fluid power system which uses W1
incompressible oil for energy transmission to do useful work 0Drawand explain wOrking o ivdraulic syster
stem

it is known as oil hydraulic system. rrs genera layout

eg. 1) Lifting of tractor trolley using hydraulic system. Drawgeneral layout of hydrauic SYstem.represent
Senuro
2 2
2) JCB machine arm movement.
Pump
s
Definition: l defined as luid power system
S1
Pipe line
whieh hydralic oilis used as 0OFRUNg meda
Prossurised oil
wthreguired gi pressure Znstit
orce totionjor usefuwork

Actuator Load e.g. Hydraulic crane system

Oil hydraulic system uses pressurized oil which ji

Fig.1.1.3(a):Oil hydraulic' system
circulated through various components of the hydrauli:
2) Pneumatic system:
system to perform the given task/application.
When the branch of fluid power system, which uses When we observe any oil hydraulic system, it consiss
compressed air for energy transmission to do useful work,
it of various components which are aranged in a
is known as pneumatic system.
systematic manner to transmit energy. It mainly
i

e.g. 1) Pneumatic handtools like pneumatic drill divided into three main elements as given in the block
2) Pneumatic clamping system. diagram.
Compressor Hydrauic
Pipe lIine
Control ACiatng
Abosphern Comprossod air vaves

Lump and Motor ressure Conto

Crinders
Actuator Flter and Reservoit rection ccnio
Load Fow Control

Fig.1.1.3(b):Pneumatic system Fig.1.1.4(a):Hydraulic system

Meaning of General
The two branches are quite different layout:
in behavior and
performance and thertfore The hydraulic system consists
separately treated with their of various compone
names. which are mounted
or placed in a logical sequenc
1.1.3 Oil Hydraulic System per their function
and connected with the belp
pipelines and fittings.
1.1.3.1 General Layout It is known as general layouto
of Oil Hydraulic hydraulic system.
System
MSBTE:W-14:S-15, W-16,W-17.S-18.S-19 The layout may vary licaton
or changes as per the appu
or task to be performed.
QDrawactualhydralic.systemand
explainits working
The Fig. 1.1.46) shows draulhe
W-14 general layout of oilbyar
WH6 system showing various
Draw components
a
ketchof simple oil hydrauliccireuit
IS15
Scanned witn camScanner
Industrial Hydraulics &Pneumatics (MSBTE
Sem-VI)
1-3 Introduction to Hydraulic and Pneumatic
Systems
Sketch of General layout of ol hydraulic system

Actuator

Pressure control
valve

Prossure A Force
gauge
C
Shut off
valve
Motor
Pipe line

Direction
Prime Flow
control
mover Pump control
valve
valve

Filter
-Ol.

Heservolr

Fig.1.1.4(b): Actual General layout of hydraulic system

Actuator

Force
Pressure optro
gauge

Shutoft
valve
Pipe line

im
Direction Flow
Control
control
valve valve

Flg.1.14o):Blockdiagram of general layout of hydraullc system

Scanned with Camscanner

 Pneumatio Syster
Introduction to Hydraulic and
Industrial Hydraulics& Pneumatics (MSBTE Sem-V) 14
mover like electric motor, Io
with the help of prime
1.1.3.2 Components of Hydraulic System: engine etc.
vane pump
use gear pump,
MSBTE S-15 Hydraulic system may
pump, etc.
tunction oreacn Screw pump, piston
Q Wite down the name and workingoilhydraulic.clrcuit able to work without pump hence i
The system will not
the components used in a simple any hydraulic system.
is heart of
S15
4) Control Valves:
It is mainly consists of
are provided to controj
As name indicates, valves
Components of Hydraulic System flow of oil and flow of oi.
pressure of oil, Direction of
position as pe
Control valves are Ic-ated at particular
system.
1) Reservoir/Tank their function in the hydravlic
types of contro
Filler According to function, there are three
2) valves.
to
3)Hydraulic Pump Pressure control valve :t is provided control

pressure of oil in the hydraulic system.

4) Control Valves
e.g. Pressure relief valve.
5) Actuator
b Direction control valve :It is provided to change or
alter the direction of oil to operate hydraulic actuators.
6)Pipelines and fitings c.g. 3/2 D.C. valve used for single acting
hydraulic

actuator.
7)Accessories
e)Flow control valve :It is provided to control flow of oil
Fig. C1.1:Components of Hydraulle System supplied to the actuator to achieve slow/fast movemeat

1) Reservoir/Tank: e.g. Needle type flow control valve.

It is used to store adequate quantity of bydrau]ic oil 5) Actuator:

required for the system.
It is the device which utilises the cncrgy of oil and
It is either circular or rectangular in shape with capacity
in liters.
convert it in mechanical energy in the form of
motion/force.
g. 20 lit, 50 lit.
It is provided with oil level indicator to observe oil It has two types as per mechanical energy produced:
level in the tank. a) Linear actuator:
The oil is circulated through various elements with the
help of pipelines and retums back to the tank. It gives linear motion in horizontal/vertical inclination
using bydraulic cylinders.
It is provided with oil beaters and coolers for operating
under low temperature or high temperature g.Single acting cylinder, Double acting cylinder.
applications. In JCB arm Double acting cylinder is used ior

2) Filter: movement

. It is the device which removes or separate outD) Kotary actuator : It gives rotary motion in
contaminants or impurities from the oil. clockwiselcounter clockwise direction where rota
motion is needed to perform the task/application.
.It will help to supply clean and pure oil to the system.
e.g. Hydraulic motor to rotate heavy mixers.
3) Hydraullc Pump
6) Plpelines and fittings:
It is the device which increases pressure of oil to the

required value. It will supply oil with pressure in They are known as fruid conducting elements. The o
required flow rate to the hydraulic system. It is driven with pressure is circulated to various components SS
pipelines and connections using pipe fittings.

Tedh Lasd

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE
Sem-V) 1-5 Introduction to Hydraulic
and Pneumatic Systems
Rigid pipes, hose pipes and various fittings
like Pneumatic system is désigned to handle
connectors, couplings, reducers etc are needed compressed
for air/gas through various components and is
plumbing layout of oil hydraulic system. used for
performing certain designated task.
7 Accessories: As medium used is compressed air, it will differ from
They are required to improve performance hydraulic system.
of hydraulic
system by smooth functioning of various
components Applications:
of the system.
The various accessories are: Pneumatic system finds applications in various fields
whicharelisted below:
a) Pressure gauges :To measure
pressure of oil at
various points in the hydraulic system
e-g. After 1. Spray painting of automobile body in paint shop.
discharge of the pump,.
2: Pneumatic grinders are used for grinding outer
b) Seals and Gaskets: They are provided layer of casting components.
for leak
proof joints. It prevents leakage of oil.
3. Dentist uses portable pneumatic motor with tooth
c)Accumulator : It stores hydraulic .energy cleaning tools for dental work Pneumatic
pressurised
of
oil. It is energy storage device. handtools also used duringg assembly work.
d) Heat Exchanger: They are provided for heating
of
oil in extreme cold condition and cooling
of oil in
hot working condition.
e) Flow meter: It is provided to measure flow
or
discharge of oil in the hydraulic system.
D Intenstfier or Pressure booster: It is provided to
intensify or boost the pressure of oil whenever
required.
Fig.1.1.6.:Pneumatic nut runner
Temperature sensor/gauge : II will measure
temperature of hydraulic oil. Characteristics of Compressed Alr

1.1.4 Pneumatic System: MSBTE

S 1G Air is freely available anytime from the atmosphere.
There is no need to store as a input medium.
eaures 3) Easy transported using pipelines, hoses and air vessels.

IS10 Air is a safe medium as it is fire proof.

Definitio ft is defined as fluid pODer Systezh 5) No need to recirculation, No returm lines required for
whteh copressed at or gas is Use 1SNO
compressed air.
nediunfor transission and controlO motion
Gria torces It is safe and can be directly exhausted to atmosphere
safcly without any pollution.
e-g. Paeumatic clamping system, Pneumatic hand grinder,
etc. It can be easily stored ia air receiver ät high pressure.
Easy for control of parameters like pressure, flow, etc.
SerMce ur
,Compimsnd a8)
Air from
Imporlant Features of Pneumatic system:
Rrcever
Atmosphere Actuator
1) It has less operating pressure in the range of 10 bar.
Compressor
Foice
There is no need of retum lines (piping) as air is
directly exhausted to atmósphere.
Punch
Workpiecs
3) It has high speed of response or movement of actuator
is faster compared to hydraulic system.
mmir
4) High speed of rotation about 2000 RPM is possible.
Fig.1.1.5 :Pneumatic system

Tedad
Pabllcatloss

Scanned with Camscanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VD 1-6
Introduction to Hydraulic and Pneumatic Sysle
slems

precision/highly accurate movements.

5) As air/gas is compressible in nature, hence it is not suitable for
system.
6) Simple in construction and casy to operate comparcd to hydraulic/electrical
required to reduce noise
7) t produces heavy noise during its operation hence noise reducer/silencers/muflers are
1.1.4.1 General layout of Pneumatic system
MSBTEW15:S-16/S17W18.S39
W-15
rawa general layout and symbolic representation of pneumatic system:
urawa general layout of pneumatic system and state the function of each
components S16,W-18
are
Name anyfour.components of pneumatc systemWhat the factors
considered. while selecing themt 1s7
Draw and ekplain general layout of pneumatic system. S19
arranged in a logical manner. The
When we observe any pneumatic system, it consists of various components
bloct

diagram shows main elements of poeumatic system

Control Actuat
cuatrng
Power valves DevicesS
Source

Regulator
Compressor cylinder
2Air recever DIecton Contro
Control
3)Flow
Ar
2Air Motors
Unt
FHL 4Special valves

Fig.1.1.7(a):8lock diagram of Pneumatic system

Pressure gauge
Cooler Service unit
---*wmm-**Lubicator (Air out)
ON/OFF
Pipe line exhaust

Control
Ar in MoistureiFlter regulator valves
soporator
Compresser K
Receiver

Actuator
Fig.1.1.7(b):Pneumaticsystem
Pressure gauge

ON/OFF
Compressor valve
Pipe line Muffer
LUnit
Air in
Air dryer
Air receiver DC Vae

Motionforce

Actuator
Fig.1.1.8 :General Layout of pneumatic system

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE
Sem-VI)
1-7 Introduction to Hydraulic and Pneumatic Systems
Components of Pneumatic system The water particles may cause
corrosion of metallic
components and therefore
moisture is separated by
1) Compressor mechanical or chemical type moisture
seperators.
5) FRL unit:
2) Aircooler
It is also known as service unit.
3) Air Receiver It consists of three
components arranged in a series combination.

4) Moisture separator a) Filter : It will help to remove impurities/dust

particles from compressed air.
5) FRL unit
b) Regulator lt will help to regulate pressure of

6) Control valves compressed air.

c)Lubricator :It will help to add or mix Lubricating
7 Air actuators oil particles, in compressed air for lubrication
of
moving parts of valves and actuators.
8) Pipeline and fittings
This combined unit is available in market with
required
specifications.
9 Accessories
6) Control valves
Fig. C1.2:Components of Pneumatic
system
They are, provided for controlling direction
1) Compressor: of flow of
compressed air, controlling flow of compressed
air for
It is the main element of pneumatic system. controlling/changing speed of actuators.
It s

from atmosphere and compress it to the desired

They are known as D.C. valves and flow control valves
pressure by suitable mechanism.
as per their use.
It will supply compressed air needed, for pneumatic
system. It includes reciprocating compressor, Special valves are also used like twin pressure
valve,
Screw
Compressor, vane compressor, lobe type compressor, shuttle valve, Time delay valve,
etc for special
etc. applications.
Centralised compressor unit is provided with high) Air actuators :They are output elements
converts air
capacity to store compressed air to operate number of energy into mechanical motion It may be linear
or
pneurmatic machines. rotary, actuátors depending upon
their type. c.g.
It is driven by using prime mover like clectric motor, pneumatic single acting cylinder, Air mofor used in
diesel/petrol engines, gas turbines, etc.
pneumatic hand grinder.
2) Air cooler
It is provided to cool the compressed air 8) Pipeline and fittings:
which was get heated during compression.

3)
It is also knownas air conducting elements through
Alr Receiver. which compressed air is allowed to flow. at pressure
It is cylindrical vessel to store compressed air supplied throughvarious components.
by compressor. It is provided with pressure gaugeto
Rigid pipes, hoses are used with minimum pressure
check the air pressure.
drop to supply compressed air to the application points.
It has capacity in cm and horizontally/vertically
Pipe fitings are used for joining and making
mounted.
connections in pipe layout of pieumatic system
.The air from air receiver is utilised to supply
compressed air to the pneumatic system. 9) Accessories:

4) Moisture separator: They are provided for improving performance and

smooth working of the system.
The compressed, air may contain moisture (water
particles) and it is necessary to separate out moisture It includes coolers, Air dryers, noise reducer (muffler)

with the help of moisture seperator. pressure gauges, seals and Gaskets, etc.

edlasaleda

Scanned with Camscanner

 Introduction to Hydraulic and Pneumatic Syste
Industrial Hydraulics &Pneumatics (MSBTE Sem-VI)1-8 ystems

Factors considered for selection of components 1.2 Applications, Advantages and

1) Compressor:
Disadvantages of Oil Hydraulic an
Pneumatic System
a) Requirement of Pressure for pneumatic system
b) Volume of Air 1.2.1 Applications of Oil Hydraulic System
MSBTE S13:SH16.W-16,Wa17.W-18
e)configuration of Compressor
2) Actuators: Enllstany applications ot olhydraulic system.
a) Maximum pressure S13:S16 W16, V17 W1a
Sate any.four field applicalions af fuid pover
b) Type of motion/application-Lincar/Rotary
c) Shape and size of actuator

3) Oil hydraulic system can able to operate at higher

Air Receiver:
pressure ranges and suitable for various applications in te
a) Air Storage capacity
wide areas of industrial fields.
b) Material of the tank Agricultural
Equipments
4) FRL unit:

a)According to working environment Material

EarthmovingG
(coldhot/Moist) quipmentsU Systen
APplicatlons
b) According to pressure required at handtools
ot
COL Hydraulic
5) DCV: System
a) According to maximum pressure of system. Mining 3 Machine
Tools

b) According to actuator configuration

c)According to application- One hand /Two hand
Defensel Consturction
d) According to actuation method suitable for Aerospace Equipments
application.
Fig. 1.2.1:Applications of oil hydraulic system
1.1.5 Comparison of Oil and Air Fluid
1) Agricultural Equipments:
System
Modern farm equipments uses hydraulic system for
MSETERWHe
aise and lowers equipments with hydraulie
mechanism.
Compare o and air as.aimedium in fud system
Hydraulic operated "tractors, harvesting equipmeas
(W16)
spreaders, special planting, etc.
*

Density It has high It has Low density.

density.
Compressibility Itis It is compressible.
incompressible.
Use Used in Used in pneumatic
hydraulic system system
Suitable for High Low forces/loads
1orces/loads
Fire It can catch fire It is non-explosive.
Fig. 12.2: Iting tractor trolley hydraulialy
characteristics easily

Ted La

Scanned with Camscanner

 Industrial Hydraulics & Pmeumatics (MSBTE Sem-VI) Introduction to Hydraulic and Pneumatic Systems
1-9
Material Handiling system :lt includes bydrauli lits, | 5) Defense/Aerospace : Hydraulie control system in
cranes jacks for movement of heavy and large objects acroplanes, use of JCB, shovels, power steering of land
from one location to other. vebicles, rocket launchers, landing gear mechanism of
e.g. forklift trucks, cranes, etc. aeroplanes, wing control system, etc.
Mining :They are used in open pit and underground
operations. Mine drilling, crushing and material
handling devices are hydraulically operated.

7 Earthmoving equipments:
The large size hydraulic equipments used at mega
projects like bridges, towers, road construction, Metro
railway projects, etc. are known as earthmoving
equipments.
It includes buldozers, excavator, back shoe loaders,
heavy cranes, tractors, cawelers, etc

Fig.1.2.3:Fork lift truck

3) Machine Tools :It includes hydranulic press machines,

bydraulic grinder, bydraulic shaper, Hydraulic power
hacksaw, hydraulic shearing machine, pressure die
casting machines, etc.
Hydraulic press

Fig.1.2.6 Earth moving equipment

8) Other applications :t may include ship. building.
.Adventure rides, roboties, injection moulding, ete

1.2.2 Applications of Pneumatic System

MSBTEKS15
0 Staie any fOur appl mai
Flg.1.24: Hydraulie press
It operated at low pressure range upto 10 bar and
4) Construction Equipments : It includes väious
suitable for various applications given below.
machines at construction sites. like JCB, Hydraulic Driling borewells
shovel, dumper, excavator, caterpillers, hydraulic lif,
mixers, crushers etc.
Pneumatic press
machine
hdusttal
automation
APplice ohs
of
eumac
Ystem Automobil
Materfal
handling
6 field

Construction
3
Equlpments
Portable hand
tools Foundry shcp
Flg.1.2.5: Hydraulic excavator
Fig.1.27: Applications of Pneumatics

Pabicata

Scanned with Camscanner

 Pneumatic Sve
stems
Introduction to Hydraulic and
Industrial Hydraulics & Pneumatics (MSBTE Sem-V) 10
the manual
1) Industrial automation: It helps to roduce
jobs/workpicces by
automation for
handling of
sequence of
loading/unloading. It can be used to obtain
rate by climinating
movement of workpieces at faster
pneumatic bending machine,
human involvement. e,g.
pneumatic embossing
pneumatic automatic packaging,
machinc.

2) Automobile field

Pneumatic system is useful for air brake system for

Fig.1.2.9:Pneumatics Press machine tool
buses/tnucks ie. heavy automobiles.
Vehicle tyres are filled with compressed air. Spray| 6) Borewell drilling:
painting of automobile panels and body parts can be
Underground borewells are possible with the help o
done by using pneuíatic system.
pneumatic drilling of borewells.
3) Construction equipments:
) Packaging :lt includes food, pharmaceutical industies
Pneumatic vibrators, rock drilling during construction agricultural goods packaging, etc.
work can be done using pneumatic system.
8) Other applications Textiles automatic looms
Poeumatic hammers, concrete mixers, paeumatic pistol
pneumatic conveyors, pneumatic dental instruments
drills are also used at construction work.
etc.
4) Foundry shop :Pneumatic system can be used for
operating jolting machines, cleaning 1.2.3 Merits (Advantages) of Oil Hydraulic
of moulds and
castings with the help of pneumatic
power tools like System
hand grinders, etc.
MSBTESS11S-14.S-15W-15
5) Handtools
Q White themerits
Various portable handtools
of oilhydraülicsystem:
are most popular
applications of pneumatic
system. (S11,S14, S-15, W-15)
State any four
Pneumatic handtools meris ofolhydraulicsystem.
includes pneumatic
pneumatic screwdrivers, pneumatic drills, When oil hydraulic
(6
riveters, etc. system was compared wilh
Pneumatic grinders mechanical, clectrical
are commonly used and pneumatic system, has
for finishing of many advantages it
welded joints, casted
components etc. and disadvantages which
Assembly lines, discussed below. at
service stations
equipped with handtools. of automobiles are
The various merits
of oil hydraulic system are
Pneumatic press
machines are used
and as given below. istv
operations like punching, for sheet metal
Easy power distrbution
blanking, cte
Smooth working
No need of lubrication

Widerange
Advantages
of applications
of Weight-power rao
Hydraulilc
system comparatively les
is

Fig. 1.2.8:Pneumatics Highhydraulic

grinder handtool
advantage ACCuracy of moüon
Fig.1.2.10
:Merits
of oil hydraulic system

Kneal
Tech

Scanned witn camScanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 1-11 Introduction to Hydraulic and Pneumatic Systemss

1) No need of lubrication :As hydraulic oil is working 1.2.4 Limitations/Demerits of oil hydraulic
medium. It is 'self lubricated system' and there is no system
nced of any additional lubrication system. MSBTE:S1SH14S15.W15
2) Less weight to power ratio :Compared to clectro-
mechanical system, hydraulic system has less weight
a. Writethe limitations öf hydraulic System
-11S-15,
W15)
required to transmit same power. It is nearly 1/10" of
clectromechanical system.
a. List any three demerits
reasoning
of hydraulic systems with
(S-19
3) Accuracy in motion :It provides highly accurate and
0 Sata the lmtations of hyiraulic syslemGMarke
precise motions, hence suitable for movement of tools After discussion of advantages, there are some demerits
in CNCVMC machines, servo controlled mechanisms, of oil hydraulic system.
ctc. High maintenance cost
oileakages problm

Large Precdison umitatons o

force F
IA omp ents raukc Sysem
-Dity environment

Small
effort
Initial high6
Ivestment
Danger of fire hazards

Disposal protblem
of used od
Fig.-1.2.11:High force gain using hydraulic system
Fig. 12.12:Limitations of hydraulic system
4) High hydraulic advantages :lt generates high output 1) Oil leakage problem:0il leakage may ocur at joints
force with use of small input effort, thus provides high if seals are broken, wormout. It will reduce the pressure
advantage to generate more output forces. of oil and efficiency of the hydraulic system.
e.g. lifting of heavy vehicle at service station 2) Dirty work environiment 0il leakage causes
collection of dirt and causes slippery, messy work
5) Versatile systém : (Wide range of applications)
.
environment around hydraulic equipment.
This system is suitable for various ields ige
3) Fire hazards :As oil is flammable and may cause fire
construction, machine tools, material handling
hazards if lash/fire point occurs due to high operating
cquipments, Aerospace, etc
temperature of the system.
6) Smooth working :When compared to mechanical and
4) Oil disposal issue The oil after use requires special
pneumatic system, it is smooth working with minimum
handling and disposal procedures to avoid pollutionas
noise, friction, vibration during its operation/working. per strict rules of environmental control
Easy power distribution :Using pipe lines and fittings,
We cannot drain/throw away the oil to the soil, water,
it is easy to distribute power to the various subsystems
etc.
easily..
5) Initial high investment :lt requires high investment to
8) High pressure operating range purchase. hydraulic "equipments considering initial
Hydraulic system can able to operate at higher range of investment.
oil pressure upto 700 bar.
Precision components Hydraulic system components
Heavy earth moving equipments arè operated only by are machined to high degrec of accuracy for perfect
hydraulic šystem to handle heavy and massive assembly hence cost of manufacturing is very high.
workloads. 7) High maintenance cost :The cost of maintenance of
There is no any other system can able to work to handde hydraulic components high compared to
such heavy loads efficiently. mechanical/pneumatic system.

*biteathis

Scanned with Camscanner

 Introduction to Hydraulic and Pneumatic Systems
Industrial Hydraulics& Pneumatics (MSBTE Sem-V) 1-12
Merits (Advantages) of Pneumatic 1.2.6 Limitations of Pneumatic System:
1.2.5
System
MSBTE
:
MSBTE W-15.S-16.W16.W-17.W-18:S-18.SHS
S-16,S-17W-17,W-18.S-19aWhat are the limitations ot pneimatic system?
W15,S16, W 16 W17 W18,S 19)
Wat tie advantages.of pneumatic system ove
are

raulcgyrlensS16 17 W17 W 1 S19 O State any four limitationsof pneumato system

aytour meits or pneumatic,s5ystem (4 Mark) S18
Pneumatic system has following advantages explained Paeumatic system has some demerits which are listod
below. below.
Easydistriburion Frooly avalablo alr Adlitional cost
of
lubrication 6 igh
compression

nfta
Simplfed Low pressure
maintenano pneumato Clean system
applications. (6
Of
pneumaticy
SYstem
Roduced
accuarcy

Fre proof

No need of
retum Ines High Noisy
Simple and operation
opeating cost
easy system
Fig.1.2.14:Demerits of Pneumatic system
Fig.1.2.13:Merits of Pneumatic system
1) High cost of compression: The cost of compressing
1) Freely available air The working medium
is and conditioning of air is high in pneumatic system.
atmospheric air whiclt is freely available 24 hours
in
2) Less accuracy : Because of compressible nature of air,
unlimited large quantity naturally.
it may causes errors due to change in pressure and
2) Clean system :It will not create dirty climate or nearby
reduces acCuracy of movement.
work area which is major problem of oil hydraulic
Therefore it is not suitable for precise and accurate
system control of movements.
This system is neat, clean do not create any dirt. 3) Noisy operation: Air when flows through pipes, smal
3) Fire proof :Air is having fire proof characteristics. openings of valves, actuators, will produce noise.
It
can be used in high temperature zones easily. The level of noise is high at exhaust and silencers or
noise reducers (mufflcrs) are provided to reduce this
4) Simple and easy system :lt is easy
to make problem.
connections and operate pneumatic system.
4) High operating cost: Though air is free from
5) No need of return lines :The
air after üse is exhausted atmosphere, cost of compression, distribution,
directly to the atmosphere and conditioning of air is more. Therefore it increases cost
no need to
store/recirculate. Hence of operating the system.
no need to provide return lines.
It will reduce the cost of retum 5) Low pressure applications: It is suitable to worki
pipelines.
6) Simplified maintenance The maintenance the range of 10 bar pressure of compressed air. This
compressor, FRL unit, of low pressure can able to perform applications
lxe
valves and actuators is punching press, etc.
easy
compared to bydraulic
system.
It cannot able to handle heavy
T) Easy distribution loads compared to
:Compressed air is easily stored hydraulic system.
distributed by using and
pipelines. Centralised compressor 6) Additional lubrication
can be used to needed : Pneumatic syste
operate multiple machines. requires additional lubricator
to mix oil particles in
compressed air.
It will help to reduce the nent
friction or smooth moven
of actuators, slidingcomponents,
etc.

Y at
Scanned with Camscanner
Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 1-13 Introduction to Hydraulic and Pneumatic Systems
1.3 SAE and ISo Grades of Hydraulic It is used mainly for calculating pressure drop in the
Oil pipes of hoses. The unit of kinematic viscosity is
ceptistokes.
The primary function of a hydraulic fluid is to convey
The other measure is dynamic viscosity and used for
power to the desired point of application.
calculating the lubricating film thickness in bearings
The efficient running of hydraulic system depends upon
and other sliding parts. .
use of the corect grade of hydraulic oil and
maintaining the oil in good conditions. Dynamic viscosity = Kinematic viscosity x density

2) Stable viscosity index:

1.3.1 Important Properties of Hydraulic oll
It is calculated number which describes the change in
MSBTE S5.W-15.S-16.W-17,5-18.S-19
viscosity with respect to temperaturé.
essentialproperies o ols usedn ol A high viscosity index means a small viscosity change
grauCCreuisiS15 W15S16 W
7 S18 when the temperaure changes.
teany tour properies afgood hyoraulic ol A low viscosity index means a large viscosity change
when the temperature changes.
S19 Most hydraulic oils have viscosity index (V.) of 90 to
The following properties are required for selectionn of
110. Hydraulic oils VI larger than 110 are not as
hydraulic oil.
. sensitive to temperature change.

Properties of Hydraulic Oil High viscosity index reduces damage and machine
breakdown, lowers the operating cost and increases life

1.Viscosity of components.
m Various standards are used to indicate the gades of oil.
Stable Viscosity Index
2 a)SAE-Society of Automotive Engineers
3 Demulsibilty b) ISOnternational organisation for
standardisation.
4 Neutrlizations Number
3) Demulsiblity:
5LoW Foaming Tendency It is the ability of hydraulic oil to separate out easily
when it will get mixed with water.
6. Oxidation Resistance
Demulsibility means seperation of water, or resistance
7. Lubricity (Wear Resistance to mix with water,

8.Corrosion Resistance Water may cause colection of dirt, dust, grit and
reduces operational efficiency of oil bydraulic system.
9. Good HeatDissipationAbily 4) Neutralisation Number This characteristies is related
to acidic nature of oil. II is the amount of KOH
10 FlashPlntand FiraPoit
(potassium hydroxide) required in miligrams to
11. PourPointFreezing Point neutralisel gram of hydraulic oil for a specifiedd
quantity under test.
12 Non Toxic
5) Low foaming tendency
Flg.C1.3: Properties of Hydraulic oll
When oil come in contact with air, it may cause.
1) Viscosity: formation of bubbles (foam) and it is not desired.
It is the resistance to flow and shear. It has effect on A good bydraulic oil will not absorb air easily and will
wear rate and fuel efficiency. The most common unit of release it quickly without causing foam.
measure of viscosity is kinematic viscosity which 15
Itis the ability to produce minimm foam when oil get
usually shown in data sheets at 40° and 100.
circulated between various components.
Teculed
hlcatl*

Scanned with Camscanner

 Sye.
Introduction to Hydraulic and PneumaticSystema
Sem-VI)_ 1-14
Industrial Hydraulics & Pmeumatics (MSBTE
Monograde mean
1) Monograde hydraulic oils: eans Amge
Oxidation resistance one number (10, 20, 20
6) grade oil designated by 30, 41
thicken and produces
Oxidation of oil causes it to make etc.)
yamishes which stain the components. The number indicates a level of the
oil viscósity
y
hence chemical additives temperature. Higher the grade
It decreases useful life of oil particular umber,
resistance of hydraulic higher the oil viscosity.
are added to improve oxidation
oil. without the letter "»
a) Designation with
7)Lubricity: number only
friction, wear between e.g. SABI0, SAE20, SAE30, etc for ig
It is the ability of oil to reduce
sliding or moving components by
formation of layer temperature applications. II indicates viscosity at
the temperature of 212°F(100
°C)
between mating surfaces.

It will reduce friction and smooth

functioning of system b) Designation with number and letter 'W
by
is possible also improves life of components eg. SAE1OW, SAE20W
reducing heat generation.
The letter "W stands for winter and these grads
8) Corrosion resistance :Corrosion resistance is are suitable for low temperature applications.
important to improve life of components and oil should
The viscosity was specified at the temperature et
have high corosion resistance for improving
0°F(-18°C)
performance of the system.

9) Good heat dissipation ability :When oil get heated 2) Multigrade hydraulic oil
during actual operation of equipments, It should carry It means oils with polymeric additives to improe

out the heat generated and dissipate to the surrounding viscosity index.
atmosphere casily at faster rate.
It can be suitable for both high and low temperatue
10) Rlash point and fire point: applications. They are known as multigrades becanse
"W.
They are important for high teimperature application. they are designated by two number and the letter
Flash point is the temperalure at which vapour of oil
eg. SAE 5W30, SAB 10W20, ete.
given off when in contact with the flame.
First number specifies the oil viscosity at co
Fire point is the temperature at which oil starts burning
temperature while second pumber specifies the
continuously.
viscosity at high temperature
11) Pour point/ Freezing point :lt is important for cold viscosiy
operating conditions where temperature is extremely g SAEIOW20 oil has low temperature
similar to that SAEIO and it has high temperau
less. The oil should have low pour point/freezing point
temperature characteristics. viscosity similar to that SAE20.
use. It They are suitable for wide range of temperau
12) Non toxic :0il should be nontoxic and safe for
should not produce poisonous gases or reactions which applications.
may harm to the human being and living things. List of Manufacturers of Hydraulic Oil

1.3.2 SAE and IS0 grades: 1. HPCL

Mono Grade e.g SAE 10

BPCL

Castrol
SAE Grades
Oil
of Veedol
Mult Grade e.g SAE 10W20
5. Gulfoil

Fig.1.3.1:0il grades 6. Mobil

Scanned wIn amScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI)
1-15 Introduction to Hydraulic and Pneumatic Systems

ISO Designation of hydraulic oils Water can be used as a medium in hydraulic system
As per this system, hydraulic oils are designated by glve Justification
letter ISO followed by a number equal to oil viscosity If we use water as a medium following problem may arises
measured in centistokes at 40°C (104°F)
1. It has low viscosity which may cause jerky motion.
eg.IS046, 1So68, ISO100, etc
sometimes VG viscosity grades (VG) is also written 2. It will cause corosion of metallic components.

while designating grades of oils 3. Lubrication property is less hence wear will
eg. ISÓVG32, ISOVG46, cte. increases.

Equivalent charts are also available to refer common 4. Hence water cannot be used directly but it will
charts for both SAE and ISO grades. needed additives to improve performance of
It will easy to sclect the corect grade of oil from the system.
above charts.

1.4 ISO Symbols usedinHydraulics andPneumatics System

.ISO symbols are universally accepted and standardisation of symbols is necessary for uniformity for easy understanding
for the benefit of everyone.
ISO is an intermational level standard and as per guidelines provided by ISO 1219-1 (2006) fuid power systems and
components are representéd by graphic symbols and to draw standardised circnit diagrams using standard symbóls.

1.4.1 Graphic Symbols for Hydraulic Components

MSBTE:S-15,W-15,SW16.W-17,W-18

aW.symboIS of
Unidirectiona hydraulic pump S-15) 2:Pilofoperated check iave S15
3Heater (S154 Temperature and pressure compensaler W15
operat pressure reliefvalve (Wa5 S15) Pedal operated 4/3 DCvave W
15
6
43direction.contrölvalve S168 Sequence valve s16
15 W8 10 Smple chec S16)
9Uncadingvave
1Oilrosevoir IWELG) 2
0 fiter
W Unidirectionalfixed displacament pump
Heat W16 8 14 10
2x W16) 10 ed ype fow.comtro.valve W16
Dead we
17 Pressured reliefvav WE6)18
andem.cGylnder W18
w15)
CDrawSymbokofrany three-fypes otdtauic rmotors
Drawsymbolotunloading valve and'sequence vave, W17
Name of component

Oil filled in the tank

1)a) Oil Reservoir

Empty tank
b) Oil Reservoir

Trchasled
Pabitatleis

Scanned wIn amScanner

 Systems
Introduction to Hydraulic and Pneumatic
Hydraulics & Pneumatics (MSBTE Sem-VI) 116
Industrial
Remar

Oil filter to remove impurities

2) Filter

3) Pump

One triangle only, No arrow

a) Unidirectional fixed displacement

One triangle, arrow

b) Unidirectional variable displacement

Two triangles, No arroww

c) Bi-directional fixed displacement

Two triangles, arrow

a) Bi-directional variable displacement

4) Pressure Control Valves

a) Simple Check valve

Flow
= No Flow
Flow of oil in one direction

External oil supply to actuate

b) Pilot check valve
Check valve

Relief pressure if exceeds

c) Direct operated pressure relief valve

Externally oil supply to

4) Pilot operated pressure relief valve
actuate valve

Scanned with Camscanner

 Industrial Hydraulics& Pneumatics (MSBTE Sem-VI) 1-17 Introduction to Hydraulic and Pneumatic Systems

bol

e) Pressure reducing valve Reduce pressure to the sub

system

Unloading valve Unload the pump

g Sequence valve
|Sequencing operations

b) Counterbalance valve Counterbalance for

Over running loads

Counterbalanca

5) D.Cvalves
a) Shutoff valve. ON/OFF valve

b) 2/2 D.C. valve 2 ports, 2 positions

c) 3/2 D.C. valve 3 ports, 2 positions

d) 4/2 D.C.valve
X
4 ports, 2 positions

e) 4/3 D.C. valve (centre closed) 4 ports, 3 positions

Middle- closed centre

Ted lel

Scanned witn camScanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 1-18 Introductionto Hydraulic and Pneumatic Systems

Nameof component Symböl Remark

5/2 D.C. valve 5 ports, 2positions

ELIX
6/2 D.C. valve 6 ports, 2 positions

EIX
6) Flow control valves
AT
a) Fixed/Throttle valves No arrow for variation (fixed)

b) Variable flow control valve Arrow for variation

c)Flow control with check valve Combined flow control check

valve

d) Pressure compensated Pressure recovered after

throttling

e) Pressure and temperature compensated Pressure and temperature,

7) Actuators
4 compensated

a) Single acting cylinder with spring

|Spring returnm one inlet/outlet

b) Single acting cylinder gravity return

Gravity return one inlet/outlet

c) Double acting cylinder

Two inlet/outlet

d) Double acting through rod

Piston rod on both side

eaasale

Scanned witn camScanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI)
1-19 Introduction to Hydraulic and Pneumatic Systems

me of component
Rem

e) Tandem cylinder
CEEE Cylinder in series

0 Telescopic cylinder
Cylinder in compact type

8Unidirectional hydraulic motor

Single triangle opposite to
pump

h) Bi-directional hydraulic motor Two triangle opposite to

pump

i) Limited Rotary actuator Less than 360° rotation

8) Accumulators

a) Dead weight type Wing dead weight

b) Spring loaded |Spring symbol

c)Gas charged Using gas

d) Unloaded empty

9 Heat Exchanger
a) Oil cooler Cools the oil (arrow
outwards)

lad
Tech
PICalisis

Scanned with Camscanner

 Introduction to Hydraulic and PneumaticSystems
s
Hydraulics&Pneumatics (MSBTE Sem-
1-20
Industrial
Remark
Name orComponen

Heat the oil (arrow inwards)

b) Oil heater

10) Flowmcter
To measure flow of oil

11) 01 ines
a) working line Main line

b) Flexible Pipe Hoses

c) Drain line/Pilot line Auxiliary line

1.4.2 Pneumatic System Symbols

MSBTE W16W-18
Draw symbols.of

1MuffierSlencer
pressure valve
W16 W18B
2Vin
RL W18)
(W-18
Shutte valv9

Pneumatic symbols are differ for some components

because medium is compressed air.
Name of Componen
Symbol Remark
1) |
Compressor

a) Unidirectionalfixed displacement
One triangle empty

b) Unidirectional variable displacement

One triangle empty with
arrow
c) Bi-directional fixed delivery

Two triangles empty

Taeled
Tech
Phlicatiess

Scanned with Camscanner

Industrial Hydraulics & Pneumatics (MSBTE
Sem-V)
1-21 Introduction to Hydraulic and Pneumatic Systems

Symbol Remark

d) Bi-directional variable delivery

Two triangles empty with
arTow

2) Air receiver
Receiver with pressure
gauge

3) Moisture separator
a) Water trap (manual drain)
Manual drain of water

b) Water trap (Automatic drain)

Automatic water drain

c)Filler with water trap and drain

Filter + water trap

d) Desiccator (Chemical air dryer)

Dryer using chemical
substance

FRL unit

a) Separate symbol

) Filter
Filter a

i) Regulator.
Regulates air pressure

ii) Lubricator To add oil in air

b) Combined symbol F Combined unit (compact)

Scanned witn camScanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 1-22 Introductionto Hydraulic and Pneumatic
maticSystems
Svet.

Name
Remark

5) D.C.valves (Refer Hydraulic) symbol

6) Flow control valves (Refer hydraulic
symbols)

7) Special valves

a) Shuttle valve
ORgate valve

b) Twinpressure valve
AND gate valve

c) Time delay valve

1) FCV and check valve

2) Air receiver

3)3/2 DC valve

|8) Actuators
1) CylinderReferhydraulic)
symbols

a) D.A. cylinder with adjustable

cushioning Reduce impact of piston

b) Diaphragm cylinder
Flexible diagram

c)Rollingdiaphragmcylinder
Rolling flexible
diaphragm

Scanned with Camscanner

Industrial Hydraulics& Pneumatics (MSBTE Sem-V) 1-23 Introduction to Hydraulic and Pneumatic Systems

Name of Component Symbol Remar

d) Tum cylinder Linear+Turning

9 Air motors

One direction
a) Unidirectional fixed displacement
Speed constant
(speed)

One direction
b) Unidirectional variable
Speed changes
displacement(speed)

Two directions
Speed constant
c)Bi-directional fixed displacement

Two directions
d) Bi-directional varíable displacement Speed changes

Less than one rotation

e) Limited rotary air motor.

10) Other elements

a) Pressure Booster (Intensifier) To boost pressure

b) Muffler Noise reducer/silencer

11) D.C. valve actuation methods

a) Push button Button pressed by hand

b) Roller Manual control

c)Lever Manual control

Tecaled
catiass

Scanned witn camScanner

 1-24 Introduction to Hydraulic and Pneumatic System
FIndustrial Hydraulics &Pneumatics (MSBTE Sem-VI) stems

Nameprcompenent mbole

d) Peddle Foot operated

) Solenoid Electrically controlled

Pilot control Air signal

1.4.3 General layout of ol hydraulics using symbols(Symbolic

Layout)

Actuator
Load
FCV

D.C valve

R Reservoir,
F-Filter, PPump
M Motor, PRV PressureRelief Valve
SShutoff valve, G Pressure gauge
DCV D.c.Valve FCVFlow Control Valve
DAC Double acting cylinder

Fig.14.1:Symbolic layout of oil

hydraullc system
144 General layout of pneumatic
system using symbols (Symbolic
Layout)
CD
DraWYmbols o
Aolcooler 2 Reservolt

Ka
Ted

Scanned witn camScanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 1-25 Introduction to Hydraulic and Pneumatic Systems
Pressure
gauge Service unit
Cooler ONOFF Pipeline
Air out
vave
(mufler)

Air in
Compressor Receiver Moisture
seperator FRL) Control
valve

Actuator
Force

Fig.14.2:Symbolic layout of Pneumatic system_

1.5 Hazard and Safety in Industrial 13) Malfunctioning of safcty devices like relief valve
Hydraulics and Pneumatics may cause hazards.

Safety General precautions

safety during
Hazards :Hydraulic equipments and. systems may be use/maintenance of hydraulic system are
subjected to hazards from high pressure liquids and
1) Never begin work on hydraulic system until fully
large mechanical forces
trained.
Hydraulic systems store and operate fluids under high
2) Never begin work on bydraulic system without
pressure. The operators are exposed to following using a risk assessment.
hazards:
3) Carefally ieview the instroctional mamual of
1) Burns from hot, high pressure oil equipments before beginning of work.
2) Injection of fluid in to the skin
4) Use all required safety equipments during
.

3) Fire hazards when high tenmperature exceeds use/maintenance work.

4) Bruises, cuts ór abrasions from hydraulic lines 5) Never try to repair components without imprpper
5) Injury of people due to unexpected movement of knowledge.
equipment. 6) Depressurise the system before start of work. Shut
and their down/local isolation may be taken if required
6) During maintenance/repair of equipment
. parts. 7) Do not use base hands to check the hydraulic
leakage. Any fluid leakage through pin hole can
7) Injury due to sudden release of residual
pressurised oil. injected into the skin. Use card board/wooden
piece to check leakage.
8) Slippage due to oily surface/floor area.
from electrical motors/AC. 8) Hot work like gas cutting, welding should be
9) Electric shock
avoided near hydranlic pipeline or near tank.
solenoids.
without 9) Always lower the hydraulic working units to the
10) Removing or adjusting components
ground before leaving the machine.
releasing the oil pressurec.
10) Never service, the hydraulic system while the
11) Pinhole leak injuries causes oil injection to the
machine engine is running unless it is essential.
skin in the fom of bypodernmic syringe.
11) Before disconnecting oil lines, relieve all
12) Improper coupling of low and high pressure
hydraulic components. Do not connect a high hydraulic pressure and discharge the accumulator.

pressure pump to a low pressure system.

TechKaotadgi
Pelitoti

Scanned witn camScanner

Industrial Hydraulics &Pneumatics (MSBTE Sem-VI)_ 1-26 Introduction to Hydraulic and PneumaticS
Systems

12) Ensure that all line connections are tight and lines 8) High pressure air can result into air embolism.
eptured,
renh
are not damaged, oil leakage may cause fire ear drums or organs.
hazards and cause personal injury.
1.5.2 Safety Precautions
13) Use proper material handling systems like chain,
hoist, floor jacks when pump/valves are heavy to 1) Wear appropriate personal protective equipments
(PPE)
handle. like safety glasses, hearing protection devices, gloves,
14) When cleaning/washing parts, use a non volatile eye shicld, shoes, etc.
solvents for cleaning. Ensure all connection are tight and secure and hold the
2
open end of hose firmly to avoid uncontrolled whipping
1.5.1 Hazards in Pneumatic System
of the rose.
aList any four haza hat may cccur n olhydraule3) Never use compressed air to transfer flammable liquids
system. 4 Marks) 4) Use suitable safety devices, instructional manual while
1) Attachments to the handtools may not
be secured doing maintenance and repair.
properly and flyoff the tool cause injury to the user.
5) Suitable trained workman should operate the pneumatic
2) Hoses are accidently disconnected from the system
tools and
canses flogging hazard to workers.
6) Paeumatic lines must be routed and connected
3) Hoses failure can whip around widely correctly. The quality of fittings, hoses, pipes should be
after
disconnection and creates hazards. comply with technical requirements.
4) Tools are accidently activated from connections which 7) The condition of hoses/pipe lines must be checked at
may blockedtrip suddenly. regular intervals and replace defective or damaged
5) Excess noise created beyond permissible level may immediately.
cause hazards to the hearing ability. 8) Release pressure of system before disconnecting any
6) Pneumatic tools may create lying objects hazards line or removing any connections.
hence protection devices must be used. 9) After repair, ensure tightening
of all fittings and
) Flying particles/debris may cause injury to eye, other connection before use.
body parts.

1.6 Comparison of Hydraulic and Pneumatic System:

Q Compare hydrauli Sem.ang
PenauGSyS1EN EE Mario)
Hydraulic Pneni

1. |Medium used Oil Air

2. Storage of medium Required
Not required
3. Storage device Reservoir
Air receiver
4. Reuse Recirculated
Not necessary
5. |Cost of medium Costly
Freely available
6. Power device Pump
Compressor
7. Returaines Required
Not required

edaul
Scanned with Camscanner
 Industrial Hydraulics & Pneumatics (MSBTE Sem-V) 1-27 Introduction to Hydraulic and Pneumatic Systems

Hydraulic
No

8. Lubrication Self lubricated

Separate lubricator needed
9. Drain In the tank To the atmosphere
10. Rigidity Good
Poor
11. Operation Smooth Noisy
12. Accuracy High Less
13. High specd Limited Possible

14. Operating pressure 300 bar Limited to 10 bar

15. Overall cost Moderate/high Low

16. Application
Heavy equipments cranes, lifts, farmHandtools, press machines, foundry machines
equipments, JCB bulldozer, etc small cranes, etc

estons a.8 State the meaning of SAE1OW.(Section 1.3.2)

2 Marks Questions a.9 Draw symbols of 1) 32 D.C. valve 2) Check valve
(Section 1.4.1)
Q.1 Define

a. 10 Draw symbols of 1) compressor 2) Air motor

a) Ol hydraulic system(Sectilon 1.13)
(Section 1.4.)
b) Pneumatic system(Sectlon 1.1.4)
Q.11 List any two safety precautions in oil hydraufic
Q.2 State the function of
system.(Section 1.5.2)
1) Reservoir (Section 1.1.3.2)
a.12 List any two hazards in pneumatic systems.
2) Filler in oil hydraulics.(Section 1.1.3.2)
(Section 1.5.1)
a.3 List any two practical applications of oil hydraulic 4 Marks Questions
system.(Section 1.2.1)
Q.1 Draw general layout of ol hydraulic system.
Q.4 State any two advantages of pneumatic (Section 1.1.31)
system.(Section 1.2.5)
Q.2 Draw. and explain general layout of pneumatic
Q.5 State any two demerits of oil hydraulic system. system.(Section 1.1.4.1)

(Section 1.24) Q.3 Explain any two components of hydraulic

system.(Section 1.1.3.1)
Q.6 Define: a) Demulsibility b) Lubricity

Q.4 State four applications of Pmeumatic systen.

(Section 1.3.1(3),13.107)
(Section 1.2.2)
a.7 Give two ISO grades of hydraulic oil. (Sectlon 1.3.2)

atless

Scanned with Camscanner

Industrial Hydraulics&Pneumalics (MSBTE Sem-V) Introductionto Hydraulic and Pneumatic Syste
1-28 Sems
Q.5 State four properties of hydraulic oil.(Section 1.3.1) 0.9 Slate four hazards and safety precautions in hydrau
system(Sections 1.5.1 and 1.5.2)
Q.6 Write two advantages and imitations of ol hydrauic

system.(Section 1.2.3) Q.10 State any four safety precautions to be followed

n
pneumatic and hydraulic system.(Section 1.5.2
a.7 Water can be used asa medium in hydraulic system'
give your opinion with justfication,(Section 1.3.1) Q.11 Compare oil hydraulic system with
pneumatic

Q.8 State any two ISO and SAE grades of system4Section 1.6)
oil used in
hydraulics(Section 1.3.2)

Scanned with Camscanner

 UNTT 11

Chapter 2: Pumps and Actuators 2-1 to 2-45

Syllabue:
2.1 Classificatilon of pumps.
2.2 Constructlon and working of Goar, Vane, Screw, plston
pumps (axlal and radlal).
2.3 Perfommance characterietics and Seloction of Pumps,
2.4 Classillcation of Hydraulc and Pneumatic actuators.
2.5 Construction and working of Linear and rotary actuators
(Motors).
2.1 Introduction to Pump ***********************************************

2.1.1 Deflinition of Pump. 2-1

**************" *******
** E

2.1.2 Function of the Pump. 1

2.2 Classification of Hydraulic Pumps. ***************************nCG 2-2

2.2.1 Positlivo Displacement Pump.************************************* .2-2

2.2.1.1 Important Features of Positive Displacement Pump..,2-2

2.2.1.2 Avantages of Positive Displacemont Purnps. 2-2

2.2.1.3 Characteristics of Positive Displacement Pump..2-2

2.2.1.4 Classification of Positive Displacement Punps 2-3

2.2.2 Non-positiva Displacement Pumps

(Rolodynamic Pumps).

2.2.2.1Imporlant Features of Non-positive

Displacement Pumps. ***** ******** .2-4

2.2.2.2 Advantagos of Non-positive Displacement Pumps.25

2.2.2.3 Characterislics of Non-positive Displacement Purmp...2.-5

2.2.2.4 Classilication of Non-positive Displacement Pump..25

2.2.3 Diference belween Posiltive Displacement Pump

and Rolodynamlc Pump. * ********************* 2-0

2.2.4 Symbols ol Pumpa .. ********

2.3 Goar Pumps.. *********************t ******* O

2.3.1 Typos of Goar Pump9 **********************************tasC"o

2.3.2 Advantages and disadvanlagos of goar pump 29

2.4 Vano Punp. ********************** * 2-100
2.4.1 Imporlant Foaluros of Vane Pump. ******************ssG -10

2.4.2 Typos of Vano Pumps.. 2-10

2.4.3 Comparison botween Gear Pump and Vane Pump ..2-14

2.4,4 Advantagos and Dlsadvantages of Vane Pump ..2-14

2.5 Screw Pump..***************s************************************** 15
 Tablo oklCcolees
Industrial Hydraulics & Pneumatics(MSBTE Sem-V 2
2.10 noumatic/Air molors (Rolary acualore)
2.5.1 Advantages and Disadvantages of Scrow Pump..2-16
2-16 2.10.1 Typos ot Alr Motors..
2.6 Piston Pumps. *****************************************
***********°lb 210.2 Symbols of Air Motors.
26.1 Types of Piston Pumps. ***************

210.3 Specification of Alr Motor. *********"ti n

2.6.2 Advantages and Disadvantages of Piston Pumps ...2-21
2.10.4 Appllcations of Alr Motors...
2.6.3 Comparison between Gear Pump
2.10.5 Difforonce botwoon Alr Motor, Eloctrlo Motor
and Piston Pump.. 21

and Hydraulic 1Otor**seesgeeenee************sgEsI

27 Performance characteristics and Selection
of Pumps ***** ..2-21

27.1 Performance characteristics of pumps.*****************ann2-21

C°0

272 Selection of Hydraulic Pump.. ***************************** .i2-22

2.8 Hydrautic and Pneumatic actuators. .2-23
2.8.1 Need of the Actuators. *********** .2-24
2.8.2 Classification of Hydraulic /Pneumatic Actuators.2-25

2.8.2.1 Rotary Actuators.. 2-26

2.8.22 Linear Actuators (Hydraulic/Pneumatic Oylinders)..2-26

282.3 Single Acting Oyfinders *************************************** ..2-26

2.8.24 Double Acting Oyinder. **************n********************. .2-27

28.2.5 Cushioning of Double Acting Cyinders. * ********* .2-28

28.2.6 Double Rod Double Acting Cylinder.. ******************6 .2-29

2.8.2.7 Tandem Cylinder 2-29

282.8 Telescopic Cyinder. ***************** ***************** .2-30

2829 Ram Cylinder (Plunger Oylinder).. ..2-31

***************************

2.8.210 Specifications of Hydraulic Oyindor.. .2-31

2.8.3 cylinder Mountings.. ******************************************* ..2-32

2.8.3.1 Types of Cyinder Mountings

29 Rotary Actuators (Hydraulic Motors).. ******************* .2-34

29.1 Difference between Hydraulic Pumnp

and Hydraulic Motor ************************************************ .2-34

29.2 Types of Hydraulic Motors.. ..2-34

29.2.1 Gear Motors.. ***** ***********************************ut**** .2-35

2.9.2.2 Vane Motors.. **** .2-35

2.9.2.3 Piston Motors. 2-36

2.9.24 Rack and Pinion Type Motor. ********************************* ...2-38

2.9.2.5 Semi rotary (Limited Rolary) Actuators. "************ 2-38

2.9.3 Symbols of Rotary Actuators (Hydro motors). 238

2.9.4 Diference between Linear Actuators
and Rotary Actuators .. .2-39
Selection of Hydro-notors.
29.5 ************mesnenune
2-39
2.9.6 Advantages of Hydro Molors over Electrical Motor...2-39
 CHA

Pumps and Actuators

UNIT II
Syllabus:
2.1 Classification of pumps.

2.2 Construction and working of Gear, Vane, Screw, piston pumps (axial and radial).
2.3 Perfomance characteristics and Selection of Pumps.
2.4 Classification of Hydraulic and Pneumatic actuators.

2.5 Construction and working of Linear and Rotary actuators (Motors).

2.1 Introduction to Pump

Inlet of the det
As discussed in Chapter 1, in the layout of hydraulic pUump of the pump
To the contd
vaves
system, basic hydraulic system consists of the reservoir, Hgh press

pump and prime mover, pressure relief valve, control

valves and cylinder or hydro imotor. Couping

H453voi MODpr
In this unit, we are going to discuss the hydraulic

pumps and actuators (hydraulic/pneumatic) which are

Fig. 2.1.1:Function of pump
important elements of hydraulic system and pneumatic
systems. The main purpose or function of the pump is to create
the flow of oil with desired pressure and it helps to
The first important component of any hydraulic system transfer of power and motion by using pressurised oil
is pump; it plays a specific and unique position in the The pump is coupled to and driven by the prime mover

hydraulic system. ofthe system which is most often an clectric motor.

The inlet side of the pump is connected to the oil
2.1.1 Definition of Pump reservoir while the outlet is connected to the control
valve and rest of the hydraulic cireuit.
The pump consists of mechanism to increase pressure

Hdralie punp 9 seehrtoade of oil and deliver it in desired volume required for
conversimechanicakenergy aëAyirglin hydraulic system.

OR
mechankcaevce uh
UhE ksärgulic syaten
2MeSSrE O7
t0
2.1.2 Function of the Pump

Stat 14 funcion and tocatono pump inydrauic

MarksSN
4

Flg. 2.1.2 Actual Gear Pump used in hydraulic system

Scanned with Camscanner

 Pumpsand Actuators
Industrial
Hydraulics&Pneumatics (MSBTE Sem-VI) 22
vol
The pumping action is caused by changing the blume
2.2
Classification of HydraulicPumps
of the fluid in a pumping chamber.

Q Classity hydraulic pump.In delail (4 Marks) Initially volume of fluid increases in the pumping

pumps on thie basis of chamber and then decreases to deliver at increase

a Classity hydraulic
pressure.
mechanism used C
dischar
a.Prncipleb Since the volume per cycle is fixed, the volume of the
d pressure developed
4Marks) fluid pumped for a given pump size is dependent on te
are various types of hydraulic pumps considering murmber of cycles made by the putmp per unit time,
There
the mechanism used to increase pressure of oil, volume Gear, vane, screw, piston pumps are some examples of
of oil to be handled by the pump, space available for positive displacement pumps.
mounting of the pump and other factors.
The flow enters and leaves at the same velocity, hence
Basically pumps
can be classifed in followving
manner: practically no change in kinetic energy takes place.
According to method of displacement of oil : They are also known as hydrostatic power
)Positive displacement generators.

6) Non positive displacement 2.2.1.2 Advantages of Positive Displacement

2.2.1 Positive Displacement Pump Pumps
OWidely used
MSBTERWS12

a Whatis meantby PDE W.12)

No intemal
leakage
. high
Generates
pressure
a Define postive displacement pump
Positive
2
displacement pumps are those whose pumping
volume changes from maximum to minimum during
Marks)
High
fexbity - Advantages
of positve
demnent
PuInps
power to
Hghwelght ratio
each pumping cycle. Small in Hgh vokumetric
size efficiency
.It means that, the pumping element expands from a
small to a large volame and is then contracted to small Fig.221: Advantages of positive dis placement pumps
volume again.
1. They are widely used in hydraulic system.
2.2.1.1 Important Features of Positive They can generate high pressure.
Displacement Pump
3. They are small in size.

Give one exarmple of posilive displacement pump They have high power to weight ratio.

ney have relatively high volumetric efficiency.

12 Marks
They have greater flexibility
They 'are ušed where pressure is the primary of performance under
consideration. varying speed and pressure requirements.

In these pumps, the high and low pressure areas for 7. There is no internal slippage ideally.
suction and delivery are separated so that the
fluid8. There is minimum change in efficiency throughout the
cannot leak back to the low pressure source. pressure range.

2.2.1.3 Characteristics of Positive Displacement

Pump
Commonly used positive displacement pump is the cylinder
and piston operated pump, it
is known as piston pump
The Fig 2.2.2 shows characteristic of piston pump (pressure vs. flow rate of oil).

Koeulg
Ted

Scanned with Camscanner

 Industrial Hydraulics &Pneumatics (MSBTE_Sem-V)
2-3
Pumps and Actuators

ldeal

Leakage
Actual

Out
Pressure
Fig. 2.2.2: Piston pump and its
characteristic
Practically the mating components
are not a perfect fit and small leak
ideal discharge. occurs hence, the actual discharge is less than

2.2.1.4 Classification of Positive

Displacement Pumps

MSBTE:S-14. W-14

E cassication of rotary pumps

Give theclassiicaton posiliVe
(s19
oi dispacement pump
lassiy positive disp ge them in descending order on the basis of pi
W-14
ated by these
PUmps
4 Marks)
ositve dISplacement pump
osiive
O As per mechanism/ motion used
per discharge
Rary As edprocating pump
Fixed Varnable

As per costrution per pston arrangemert

As
eai EVane
gump Pistor

ExtemalLtemal PEae Bert

gear geas
oos
Satilonary Haatng
lnder blodKider bock
Balanoed Urbalanced
vane puime ana pume

Fig. 22.3:Classification of positive displacement pump

Positive displacement pumps are classified as follows: (b) Reciprocating pump: It uses reciprocating
1) According to mechanism / motion used: motion of piston with cylinder to increase pressure

(a) Rotary pump :It uses rotary motion of elements ofoil.

to increase pressure of oil. Rotary pumps are further classified as:

Tech Kauelgi
Pebllatlass

Scanned with Camscanner

 Pumps and Actuators
Industrial Hydraulics & Pneumatics (MSBTE Sem-V) 24
(2) According to the constructional element: pesofpunp ressuretbarlowTate lit/min
(a) Gear pump :lt consists of pair of meshing gcars Fixed vane pump 125-175 200
meshing internally or extemally.
Variable vane pump 75-125 150
b) Vane pump :lt consists of sliding vanes with cam
ring along with eccentric rotor. Screw pump 60-175 7500
()Screw pump :lt consists of pair of meshingVariable axial piston 700 1000
Screws.
Bent axis piston 700 800
Gear pumps are further clasified as

(3) According to arrangement of pair Radial piston 1000 2000

of gear:
(a)External gear pump : Gear pair is meshing 2.2.2 Non-positive Displacement Pumps
cxtemally.
(Rotodynamic Pumps)
b) Internal gear pump : Gear pair
is meshing
internally. MSBTE:S-13
Gerotor pump: Gears of special shaped ge-rotor
are used.
a Whatrdayoumea
-13)
Vane pumps are further classified Defirie Rotody on positives
as:
(4) According to balance
of pressure on suetion/delivery 2Mars
side They are roto dynamic pumps
in which the fluid can be
displaced and transferred
a) Unbalanced vane pump: Pressure using the inertia of the fluid
is unbalanced in motion.
at suction and delivery side of pump.
In this pump, the continuous
(6) Balanced vane flow is produced due
pump: Pressure is balanced rotodynamic principle. to
suction and delivery at
side of pump.
Reciprocating pumps 2.2.2.1 Imporiant
are further classified
as: Features of Non-positive
5) According to arrangement Displacement Pumps
of pistons:
(a)Axial piston: "The axis one Exanmple
of piston is parallel to todynai
axis of the driving
shaft of the pump.
the
Cer
amice o postiv
(b) Radial piston:
along the axis of
The pistons are
aranged radially They are usually
used for low pressure
2arks
the pump. high volume systems. up to 40 bar and
Pumps are also classified
withreferenceto: They have fewer
() According to the number of moving
discharge or delivery Cost is less and operates parts.
of the pump:
(a) Fixed delivery pump with less maintenance.
: The discharge flow These pumps
constant and rate is make use of
have no control
of rate of flow. to move the fluid Newton's first law
against system of motion
b) Variable dellvery pump: resistance
pump is variable The flow rate of the Centrifugal
pump uses
and adjusted rotational inertia
the system up to certain as per demand pumps use while propeller
of translational
range. inertia for pumping
Pressure range The volume of fluid.
of positive displacement of the fluid
pumps: specd of pumped dependent on he
es ofpump the rotating is
ressure mustovercome. member and
(bar) FlowTate resistance the pump
litümin !
External gear pump 100-300 Some examples
Internal gear pump
400 propeller of such pumps
350-400 pump. are centrifugal
450

Tedowl
Scanned witn camScanner
 Industrial Hydraulics& Pneumatics (MSBTE
Sem-VI)
25 Purmps and Actuators
2.2.2.2 Advantages of Non-positive
2.2.2.3 Characteristics of Non-positive
Displacement Pumps
Displacement Pump
0Low Intal cost

High roiabilty0, moving

FeW
parts

Sultable vanageg
for alltype@
of fuds
dnon-positve
Opagement
- Minlmum
maintenance cost

Qulet in
poration
Simplicty h operation
Centrifugal pump Flow rate
Fig. 2.24:Advantages of non-positive displacement
pumps Fig.22.5:Centrifugal pump and its characteristics
There is no positive seal between the inlet and outlet,
1. There is a low initial cost.
when the pressure rises at outlet, flow may slip back
2. They have few moving parts, hence from the outlet to the inlet and the output flow rate is
simplicity in
operation. reduced.
3. There is a minimum maintenance cost. Because of internal slippage, the relationship shows
4. They can be operated quietly. that with increased flow rate, the pressure decreases.
5. They are capable of handling all types 2.2.2.4 Classification of Non-positive
of fluids e.g.
sludge and sluries.
Displacement Pump:
6. High reliability.
Non-positive displacemet pump
(Rotodynamicpump)

Centritugal
pump Axialfow Radlal How

2.2.3 Difference between Positive Displacement Pump end Rotodynamic

Pump
ASBTES-17.S-18

.
QDifferentiate between positiy piaceent pumpsangopdynarn mp
ORDsUnush bewee poSiive dispacomantpump withrorpOsitive dis placement pumy
The above two types of pumps can be compared on the basis of principle,
constructional features and other related
points..

Rotdyamie pumpf
disp3cemeni
1. Principle Change in volume. from maximum to Rotational inertia is used for pumping
minimum during each cycle
Volume It delivers fixed volume of fluid
I's delivery is continuous
Suction/ delivery Depends on each other Continuously and simultaneously
Discharge Depends only on speed Depends on resisting pressure
Work done on fluid No change in kinetic energy (hydro-static) Using kinetic energy (hydro-kinetic)
. Pressure regions Low pressure and high pressure regions are They are merged with each other
separated
7. Examples Gear, vane, piston pump Centrifugal, axial flow pump

Tecael
Pbllcatieis

Scanned with Camscanner

Industrial Hydraulics &Pneumatics (MSBTE Sem-VI) 266 Pumpsaand Actuators

2.2.4 Symbols of Pumps | Delivery

Q. Draw standard symbols of

Oil carried out
by
Unidirectional variable discharge pumps
meshing tooth

2 BPlirectional Txed.delivery punmp: 12Marks)

For easy identification and representation, the purmps

are shown by using following symbols in the hydraulic
circuits.

The basic symbol is a circle with black

a triangular
arrow head showing direction of oil flow.

Table2.2.1:Symbols of pump Suction

Tyneof pump Symbol Fig. 2.3.1: Principle of gear pump

2.3.1 Types of Gear Pumps

1. Unidirectional fixed delivery
pump. 0Listtypes of gearE Pun (2Marks)
2. Unidirectional variable delivery There are three types of gear pump:
pump.
Types of Gear Pumps
3. Bi-directional fixed delivery
pump.
a) Extemal gear pump
Bi-directional variable delivery
pump. (6) Intemal gear pump

2.3 Gear Pumps ) Gerotor pump

Fig.C2.1:Types of Gear Pumps

EHISBEPS5WE15.517
(a) External gear pump:
Epan with neaf sketchthe constnuction and working
gear piump
of S16,W-16,S1n|| MSETESi3
efine gear pump (2Mar
Q
olatn working
ot Exdemal Gea ump 13
Satepinciple.otgear pur
(2.Marks) 0Drawsbeled skelciofExtemal gear pump
BeimitionWen (2Mars
a pau o meshing gears ane
0 State construction and working
LLsed to increase ppre e of Exlernal gearpum
of o
pump itanour as gean
Principle of gear pump
4Hars
When driver gear mesh
with driven gear externally 3
It works on the principle used for increasing
of increasing
the pressure of pressure of oil, it is known
oil by using meshing external gear pump.
of gear teeth one after
another by
Squeczing oil between
meshing teeth and
forcing oil in Important features
forward direction. ofexternal gear puip:
(1), It uses spur/helical
gears.
(2) t can operate for maximum
pressure of 300 bar.
(3) It can give discharge
of 300 litmin.
(4) It has volumetric
efficiency about 65-85%

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE
Sem-V) 2-7 Pumps and Actuators
(5) Ithas low contamination sensitivity.
Atmospheric pressure in the tank forces
(6) It has low weight, low cost the oil into the
tooth space from the port (suction
port) located at that
Construction: point.
-Hasing This tooth space full of oil is
caried around the
periphery of the gear until the teeth again mesh
and the
oil is forced out of the space by the meshing
tooth and
flows out of the delivery port located that
Sucion Discharg at side of the
port port
mesh point.

The meshing of the teth prevents the oil flowing back

from the pressure to the suction side of the pump.

Gearpalr The pressure is developed tooth by tooth from the

Fig. 2.3.2:Construction of external gear suction side to the delivery side linearly.
pump
The basic gear pump consists of : The pressure at the pressure side is determined by the
(a) Gear pair resistance in the system. The most important resistance
is the load on the hydraulic cylinder or hydraulic motor.
Two meshed gears usually spur gears or helical gears
In order to avoid cavitation, the suction pressure of the
areused. pump should not below 0.1 to 02 bar, below
Each gear is mounted on a shaft which is supported atmospheric pressure.
on
bearings in the end covers. Gear Pair

One of these shafts, the drive shaft is coupled to the

prime mover (electric motor)

(b) Housing:

It consists of two cover plates that enclosed the ends of

the gears. The gear pair is mounted in bearings and
mounted precisely with minimum clearance in the
housing."

(Suction and delivery port:

For suction of oil in the punmp, suction or inlet port is Fig 2.3.3:Cut section of gear pump

provided while delivery port is provided to discharge Multi gear pumps:

high pressure oil.
Definition When there are Or 4gears ge
These two ports are located on opposite sides of the mp t is known as
mounted iu dcastng
gear case and it is essential that these ports should open gear pum
72Li
directly on opposite sides of the mesh point of the
Constructión and working:
gears.
It consists of 3 or 4 gears placed in one casing. The
Worklng:
centre gear is connected to the motor shaft
When motor rotates, it will rotate the diver gear and The two outside gears are driven and hence rotate in the
then driven gear. As the meshed gears start rotating one direction opposite to each other.
tooth space after another is evacuated and in the The advantage of this pump is that it has two
resulting space a vaccum is created. independent outputs and they may be connected
together as one.

Teched

Scanned witn camScanner

 (MSBTE_Sem-V)28
Pneumatics
Industrial Hydraulics &

Fig. 2.3.4:Three gear

pump Fig. 2.3.6:Actual construction
short sealing range of the
The main disadvantage the of following main parts:
is
It consists
centre gear thus limiting the system
pressure.
(1) Internal tooth gear: The internal spur gear
(b) Internal gear pump:
connected to the motor shaft
MSBTE :S-15,W-17
(2) External tooth gear: It is mounted eccentrically wit
respect to internal tooth gear. It is driven by
plaim construcions eang working pncple of Inemal intem
A
Gear punD tooth gear.

0. Draw labeled skefcr of internal gear pump (3) Crescent shaped separator: Between the above tio
arisluction and vorking of intemalkg gears, on one side there is a crescent shaped spacr
i
provided. It is stationary
part of the housing arvuai

which oil is caried.

Principle:
4) Inlet and outlet ports: The inlet
When internal meshing gear and outet ports
pair is used along located in the casing
Crescent shaped separator with for suction and delivery of oi
to increase pressure
of oil,| Working:
it is known as internal gear pump
it utilizes the same
principle of external
gear pump. When motor shaft
rotates, it will rotate the intemal
Construction: and it drives the
external gear.
It affects a fluid
Casing fight seal at the meshing poimt
teeth. The teeth which
are un-meshing at thens
I Intemalgeoar CTeates partial
vacuum and suction
of oil occus
Crpsa Oil is get
trapped between
teeth and both ternal and extem
inte
Inlet side of the crescent shapedsps
port
Meshing bd
Outlet of gear teeth
port pressure reduces the volu in the
cavity near
the outlet port and
pressure
oil from the outlet i
port
The internal pnd
Extemalgear gear pumps
ICss noise. Ient and
are very eifiac
The volumetric cncy is about
95%
overall efficiency efficiency
Fig. 2.3.5:Construction
of intemal gear 85-90%.
pump L can produce 3150-*
high pressure ngeof
bars. in the range

Scanned witn camScanner

 Industrial Hydraulics &Pneumatics (MSBTE_Sem-VI)
2-9
Pumps and Actuators
(c)Ge-rotorpump:
(2) Outer gerotor: Outer gerotor is idler and it has
MSBTE :W:13.W 14. S-15.W-15 always one tooth more than inner gerotor.
S:16:W-17.S-18.S19
(3) Inner gerotor: The inner gerotor,
is the driver.
The number of teeth of the outer and inner gerotor
varies. The axis of inner gerotor offset from
W13 815) is the
axis of the outer gerotor.
EXplain geratOtpump with néátsketch W14)
Skotch
4) Suction and discharge port: The suction and
neat sketch: explain sthe prncpe and working
discharge ports are provided to suck and deliver
o gerotoO
W15, S6 S18 E19 oil respectively.
walabeled sketch ot Gerotor pump
W17)Working
te constructional dilference
Neen ntemargear When inner gerotor rotates with the help of motor, it
4 Marko creates partial vacuum near the suction port when mesh
with the outer gerotor. The oil enters through the
Principle:
Suction port.
It works on the principle of internal gear pump If the numbers of teeth for the inner and outer gerotor
by using8
gear shaped rotor elements meshing are 4 and 5 respectively, then while the inner gerotor
internally. The' word
gerotor is derived from "Generated rotof" makes one revolution, the outer one makes only 4/5 or

Construction: 0.8 rvolution.

Due to offset movement between inner and outer
Casing Inner gerotor, the volume near the delivery port decreases
gerokor
and oil is forced out through delivery pot
The care should be taken as gerotors are to be
manufactured with high precision otherwise internal
OUtet leakage becomes excessive.
port They are more compact than extrnal gear pumps.
.
Inlet
port It can operate at the pressure of 125 bar, maximum
speed of 2000-3600 rpm with maximum discharge of
200 lit/min.
Outer gerotor
(a) Advantages of gerotor pump:
High speed

Constant and even discharge

Operates well in either direction

Quiet operation.

2.3.2 Advantages and disadvantages of

gear pump

(6) Advantages of gear pump:

Fig. 2.3.7:Gerotor pump (1) Few moving parts :Gear pump has only two moving
paris hence minimum wear and maintenance.
I's construction is similar to internal gear pump but
separator or crescent is not provided. (2) Simple design and construction :The construction is
II consists of following parts : simple and design is easy.

(1) Outer (3) Less cost :The gear pumps are cheaper than serew
ring: The outer ring is a casing in which
purmp, vane pump.
gerotor pair is mounted.

edali
Puatltis

Scanned with Camscanner

 (MSBTE Sem-VI 2-10 PumpsandActuaton
Industrial Hydraulics& Pneumatics
Gear pumps are simple for repair
2.4.2 Types of Vane Pumps
(4) Easy maintenance
:

and maintenance. Vane pump

OListtpes.of (2 Marks
amount of impurities.
(5) It can allow oil with small
Vane pumps are classified as
Disadvantages:
Types of Vane Pumps
noise during its
(1) Noisy operation :Gear pumps make
operation.
a) Fxed displacememt,
unbalanced vane pump
(2) Leakage of oil :Intermal oil leakage occur in some type
of gear pumps e.g. gerotor pump. b) Fxed displacement,
balanced vane pump
3) Low pressure :lt is used for applications where low
Variable displacemen
pressure in the range of 300 to 350 bar is required. C)
unbalanced vane pumP

2.4 Vane Pump () Variable displacement

pressure compensated vane pump
Marka)
ODEtineVana pump State is pinopi
Fig. C2.2: Types of Vane Pumps
Definition Wher slidinganes ureused fo
bane punp Unbalanced vane pump (fixed displacement):
CTease presszure.okozis kroun as ()
HSBTE AWHEE
Principle of vane pump:

Airg
OEplain vanie type pump witn na Ketehe
Siding vane
(movesout abelled sketchofunbalenced vane
due to centritugal -offset fiting of rotor
forco)
ww 2Marks
0 Drawand esplain working of tunbalanced aneDuTP
mnn2 4 Metis

Principle:
Fig. 2.4.1:Principle of vane pump It works on the principle of sliding vanes allowed to
track along a ring called as cam ring.
It is working on principle of:
The pressure at inlet is partial vacuum (low pressure)
(Changing volume of oil continuously with the help of
while at the outlet, pressure is high, hence it is called as
sliding movement of vanes along with the inner contour
unbalanced vane purmp.
of the ring
Construction
(b) Change in volume occurs due to occentric positioning
This type of vane pump consists of following essential
of the rotor with respect to circular ring.
parts:
2.4.1 Important Features of Vane Pump: (1) Driven rotor with slots

It can work with a maximum pressure of 200 bar. Rotor is a circular disc which has rectangular slots cu
evenly from the centre to the outer face.
It gives pulse free delivery. accommodates the vanes in the slots.
It has low level of noise. The rotor is mounted eccentrically with respect
stationary circular ring.
It can handle moderate viscosity liquids.
(2) Sliding vanes:
It uses sliding vanes of various types.
slots of
The sliding vanes are mounted in rectangular
.It has 85-90% volumetric efficiency.
the rotor and slides due to centrifugal force.
TedKi

Scanned witn camScanner

 OUstnau ryarauics & Pneumatcs (MSBTE Sem-VI) 2-11 Pumps and Actuators

.The vanes has various types which includes:

(0 Dual vane : It consists of two vanes in each slot
of the rotor. This vanc is balanced with positive
sealing.

(ii) Pin vanes: It has pin shape and pressure is

directed underside the pin.

(ii) Intra vane: It consists of smaller vane with in a

larger vane with a bevclled edge.
(iv) Spring loaded vane : In this type of vane,
spring is used to force a vane.

()Angled vane: The vanes are located at an angle Fig. 24.4:Cross section of vane pump
in the rotor.
Working:
(3) Stationary circular ring (cam ring):
When the rotor shaft is diven by the motor, it will
Stationary circular ring is provided which helps to cause the rotation of the slotted rotor.
create number of chambes with vanes and rotor.
The vanes which are free to slide in their slots, moved
The vanes are allowed to track inside surface of the outward due to centrifugal force.
circular ring during rotation of rotor. The vane makes contact with the cireular ring and
(4) Inlet and outlet ports creates low pressure at the inlet port. At the suction side
the chamber volume increases and it is filled with oil
The inlet port is provided to suck the oil and outlet port from the suction side.
is provided opposite to the inlet port where area is As the vanes moves forward, the oil is also carried
reducedto discharge oil.
between the moving vanes in the forward direction. At
(5) Housing: the pressure side near the outlet port. The chamber
It is the outer casing whichi accommodates all above volume decreases and oil is forced in to the outlet
:
pressure port.
parts.
"The amount of eccentricity. between rotor axis and
circular ring axis determines the displacement of the
pump.

(b) Balanced Vane Pump:

Fig.2.4.2:7ypes of vanes (Dual, Pin, Intra, Spring MSETE W
loaded, Angular)
Casing
Q Drawläbe sketch offb

Vanes

the mearlng ofBalanced a

working ot balanced Vane purnp.
Inlet ACam ing W18
port
IOuet port
Principle:

It works on the principle of sliding vanes in which

pressure at inlet and outlet is balanced with the help of the
Rolor with slots
two pressure quadrants opposes each other.

Fig. 24.3:Construction of unbalanced vane pump

Techlled
Publicatisss

Scanned witn camScanner

 Pumps nd Actuators
(MSBTESem-VI)
2-12
Hydraulics&
Pneumatics
Industrial
Oudet Rotaticn
Construction:
vane slots are
cincular rotor with
consists of a an elliptical
It concentrically positioned
with the axis of

cam ring
inlet and two
helps to create two
Elliptical cam ring
pressure quadrants
such that the two
oudet chambers chambers are
oppose each other
and the two inlet
another.
directly opposite to one
balanced, rlet
The pressure at
inlet and outet of the puanp is

therefore the forces

acting on the shaft are fully
shaft is eliminated
balanced and side loading of the
completely.

Working
pump. Due to
Working is similar to unbalanced vane
elliptical cam ring, the radius of vanes is
not constant
Opposing prossure port
and changes volume accordingly. Cnoel side loads on shat

vanes are forced

During rotation of rotor with slots, the
contact with the
Fig. 24.6: Balanced vane
Pump(opposte quadrants)
out due to centrifugal force and in
inner surface of the elliptical cam ring.
(c)Variable Displacement Vane Pump
chamber is less than
The pressure at the inlet
oil to the MSBTE:W-13. S-17
atmospheric pressure which helps to suck the
inlet suction ports of the pump.
ofvanable
forward direction
The oil from inlet port is moved to
with rotating vanes and caried to the
outlet port where displecamenty
its volume decreáses. Whenlorute OETNe
Denmiton
bo emp ean
These types of pumps are constant volume or nxedcnged according
to the requirement of the
displacement pumps. ydrauio System scalted oariahle
They are displacement purp
They can work up to 175 bar pressure.
relatively quiet and having simple construction. In variable displacement vane pump, eccentricity
the
between rotor and cam ring can be changed to vary

Cam ring
Hotatonn flow rate of the pump.
Vane Principle
the
The delivery of vane pump is proportional to
eccentricity between axis of rotor and cam ring.
relaive
By changing the geometric position of the ring
volume 3
Oudet to the rotor centre will change the delivery
per need of the system.
Oudet

Rolor

Inlet
Drive shaft

Fig. 24.5: Balanced vane Pump(Ellptical cam ring type)

Ted

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE
Sem-VI) 2-13 Purmps and Actuators

Caming

Rotor

Positve eccentricity Zero eccentricity Negative eccentricity

( maximum) (Q=0) (Q-ve,ilow reversed)
Fig. 2.4.7:Vane pump with flow rate adjustment

Symbol: If the screw is adjusted slightly so that eccentricity of

the rotor to the cam ring is not enough, the flow rate
will be less.
When eccentricity is increased, then delivery volume
will be increased with the cam ring completely
(Arrow indicates variable
concentric with the rotor axis, eccentricity is zero and
displacement)
these will be no flow rate as volume remains constant
Construction: during rotation of vanes.
Vanes Variable vane pumps are used for pressure range of
-Caming
75-125 bar with 85-90% efficiency."
Screw
adjustment ()PressureCompensated Vane Pump:
Rotor Deinition A
oredelermined system pressune
t desied tia uhen ti
1redched, the
Thrust baaring pup shola stop punpug futhercol to the
Fig.24.8: Construction of variable displacement vane pump stemas
ressune
ypeof vore punpsiS calld as
cor pensated vanie unp
It consists of various components as shown in
Fig. 24.8. The main parts are:
Principle

(1) Cam ring: It is circular ring whose axis is adjusted by It works on the principle of variable displacement vane
using screw adjustment to vary eccentricity with the| pump in which spring is provided to offset
the cam ring to
rotor. the zero eccentricity position when pressure the
of system is
(2) Rotor : It is same for vane, pump with slots to reached to set value.
accommodate rectangular vanes.
Construction and working
3) Vanes: Sliding vanes moves in the slots of the rotor
with respect to cam ring. The pressure compensated variable purmp vane consists
(4) Screw adjustment: II is important component which of an additional spring which is adjusted to offset the
consists of screw and nut mechanism. camring as shown in Fig. 2.4.9.
Screw moves forward to change the cccentricity As the pressure acting on the inner contour of the ring
between axis of cam ring and rotor. is more than the pressure exerted by the spring, the cam
Working ring becomes concentric to the rotor.

The rotor containing the vanes is positioned eccentric

with respect to cam ring by means of screw adjustment.
When rotor is rotated, there is increasing and
decreasing volume similar to vane pump discussed
earlier.

Scanned witn camScanner

 Pumps and Actuators
Sem-VI) 2-14
& Pneumatics (MSBTE
Industrial Hydraulics to zero eccentricity.
Now the pumping action stops due
the system.
No flow is permitted to
to
In such a pump the pumping mecnanism has act very
inside the housing
fast and any build of fluid
is

generally hot.
undesirable. The leakage is
external drain called a
The leakage is drained through
case drain.

Fig. 24.9:Pressure
compensated vane pump
MSBTE: W-18
Vane Pump:
2.4.3 Comparison between Gear Pump and
18}
a Comgaire gear pump and
Yane pump
Gear pump
Sr No Point Sliding vanes
Mechanical element Gear pair
increase Increasing and decreasing volume using
Principle Meshing gears are used to
2. sliding vanes
pressure of oil
(a) Unbalanced vane pump
(a) Extenal gear pump
Types
(b) Internal gear pump b) Balanced vane pump
(c) Pressure compensated vane pump
(c) Gerotor
Less noisy due to sliding vanes.
Operation More noisy due to meshing gears
Expensiye
Complex in construction hence
Simple in construction therefore
5. Cost
Cheaper
Complicated (More number of components)
Construction Simple(Less number of components)
125-175 bar
Pressure range 300-350 bar
of 4) High eficiency:
2.4.4 Advantages and Disadvantages high efficiency about 85
As leakage is less, it has
Vane Pump:
90%.
Advantages of vane pump: Disadvantages
(1) Low internal leakage pressure
reduced by using spring (1) Low pressure: It can efficiently work up to
The leakage of oil can be compared to
gear
loaded vanes fitted in the rotor. range of 125 - 175 bar which is low

(2) Compact design: and piston pump.

force
hence can be : Due to centrifugal
The pump, is compact in size and shape, (2) Low operating speed vanes
excessive wear of
used where space limitation is important. vanes, high speed may create
higher speed.
(3) Low noise: hence cannot be used for

These pumps are comparatively quiet in

operation and
gives smooth flow. Ted Kl

Scanned with Camscanner

 Pumps and ActuatorsS
Industrial Hydraulics& Pneumatics (MSBTE Sem-VI) 2-15
Tirning gears Driven shaft

2.5 Screw Pump

MSBTE
S19
a with neat Sketc
Expaln orking otscraw.pumP

19
Definitions When yair.gmestingSCrews is used Driven shaft
as sorew (b) Plan cut away view
ncretse pressure o ol t is knoun
Fig. 2.5.1

Principle: Working:
mover, the driving
When pump is started by prime
It utilizes the movement of screw which displace the oil other screw and creates
scTew rotates and drives the
axially and meshing of thread flanks forces the oil in the
suction of oi.
space between rotor ànd housing wall and gradually is carried out
The oil entered through inlet suction ports
increases pressure of oil. between screw
linearly (axially) due to helical récesses
linearly.
Construction: pair. The oil does not rotate but moves
thread flanks
Similar to gear pump, the meshing of the
The screw pumps are available in design with one, two :
rotor and
forces oil to flow in the space between the
screws and three screws. The Fig. 2.5.1 shows two
housing wall
screw gear pump.
uniformly with
The volume of the oil moves forward
It consists of following main parts: pressure is
the rotation of screw along the axis and oil
(a) Screw pair: The meshing pair of screws is gradually increased. .

mounted with the help of spindle mounted in The oil from both the ends comes towards the centre of
screw is connected to the
bearing. One of the the pump where discharge port is located
driving shaft. The screws are either left hand or Now the oil is discharged through discharge port to the
right hand. hydraulic system. The flow rate of the oil can be varied
(b) Timing gears: Timing gears are provided to by varying the drive motor speed.
maintain a running clearánce between two
Three Spindle Screw Pump:
meshing screws.
: Inlet suction port In this design, the drive motor is connected to the
C) Suction and discharge poris
and discharge port is middlé screw and on its both sides two idler screws are
is provided for suction of oil
pressure oil. provided
provided to deliver high
which The idler screws are driven by the pressure of the liquid
)Housing: It is body of the pump and therefore no timing gears are required.
gears and
accommodates screw pair, timing
The manufacturing of a three spindle screw pump is
suction and discharge ports.
Diving gear costly and therefore it is used for special applications
where,
Discharge
(a) Low flow rate is required.

NA (b) Nopresure pulsation.

)Maximum noise elimination.

They are used for hydraulic systems of lifts, elevator,

hydraulic press, ship winch, crane, wood working
machine, machine tools, ete.
They work in the pressure range of 250 bar or as high
Suction pumps as 400 bar.
(a) Two element rotary screw

Iatisis

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 2-16 PumpsandActuaton
=
Pump housing
Tnlot

nsert for screw

2.6 Piston Pumps
MSBTE
S
QExplain the pincIple or worMngroF
piston pump
w
sketch
Q State types of piston pumps: 2 Marke

Definition Vhen punping of iydraulic ol is

car ied out with the helpofreciprogcating piston
a yinder called as piston punsp
its
Principle
Drtving apinde Drtver spinde It works on the principle of reciprocating movement of
bore.
Outlet piston or plunger inside finely machined cylinder
Fig. 2.5.2: Spindle screw pump from the
The piston while moving outside sucks the oil
when
tank and pushes it from the cylinder bore
moving
2.5.1 Advantages and Disadvantages of
increased
Screw Pump inside. In this manner oil is supplied with
pressure through the outlet.
MSBTE W:17 1Outlet
antages andmitations of Serew Pump: Reciprooating motion

Piston
W-17E||
Advantages
(1) Reliable performance :Screw pumps are most
reliable
hydraulic pump. Inlet
Cylinder

(2) Operate at very high speeds: They can operate at

very high speed up to 3500 rpm and sometimes even.
Suction
Delivery
higher speeds.

(3) Continuous discharge: The oil supply is pulsation

Fig. 2.6.1: Principle of piston pump
free and continuous.
(4) Silent operation: These pumps are very quiet because 2.6.1 Types of Piston Pumps
of rolling action of the spirndle rotor. This eliminates
pulsation and vibration, noise,ete. Typesof Piston Pumps
(5) Better hydranlic control: There is no oil churning
pump turbulence, etc. In-line crank shaft driven pumpP
a)
Disadvantages:
(6) Axial piston pump
(1) Screw manufacturing difficnlt: Because of specific
pump
profile of scnrew, its manufacturing is difficult when ) In-line axial piston
close tolerance is considered. pump
Fla) Swash plate axal piston
pump
(2) Unsuitable for high viscosity oil: Pumping of higher (b) Wobble plate axial piston
viscosity oil may derate the pump characteristics. pumps
Pressure rating of the screw is viscosity dependant. (U) Bent axis piston
3) Low efficiency: Oveall volumetric and mechanical (c) Radial piston pump
efficiency is elatively low.
Piston Pumps
4) Decrease in efficiency with increase Fig. C2.3:Types of
in viscosity of oil.
d

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI)
2-17 Pumps and Actuators
(a) In-LIne Crank Shaft Drlven Pump:
DeinitionWhencnankshiaft Driving Piston and ayflinder

pumping
is sed for shaft
actionoffuid1stng pistontandcylinder
nechanism, ü is
called in line us crank shaf
drioen puTLp
Swash plate

Fig. 2.6.3:Princlple of axlal piston pump

Pston an
yinders Types of axlal piston pump:
Axial piston puimps are classified according to:

Crank shat Axis of pump:

() In-line axial piston pump

Fig. 2.6.2 In-line crank shaft driven pump
()Bent axis piston pumps
Construction and Working:
In-line axial piston pump:
.It consists of crank shaft with parallel arangement of
In-line axial piston pumps has the pistons are arranged
cylinders along with pistons. It requires more space.
inside the piston block parallel to each other ie. in-line
When crank shaft rotates it will cause reciprocating hence they are called as in-liné axial piston pumps.
movement of pistons in the respective cylinders and
In-line axial piston pumps are classified as :
causes suction and delivery of hydraulic oil, alternately.
(a) Swash plate axial piston pump
The pump are suitable for applications where one or
(b) Wobble plate axial piston pump.
two cylinder piston pumps are used.
It is used in mobile applications like small fork-lifters, (a) Swash plate axial piston pump:
simpleloaders, etc. MSBTE
SN6 W1B
.With 24 cylinders (12 cylinders in two opposite rows)
crank driven can generate very high pressure up to 400 ti swash
plate ts Use2What il
to 450 bar with flow rate of 40 Litermin, happen ve change he Swash pae
Eplain with skatch
(b). Axial Plston Pump: W16)
QNExpai a piston pump
MSBTEW14'S-17

latn woringotaial piston pump With neatisketei Eplain the function o swashpaler sW
(WT4 XalPIston pump

QExplainyaniab nent axial piston purup yit DeimiionWhen Suast plate or

W17 sed to obtun to and

ine axarpstonpUmp and is sypes larksE

idlpistonpunpe
Defimition When pistors.ok pugurekaralEe
Swash plate
ially porllel to tie drwing shaf ofthe pup with
Seroron piston pun
usial angular fac

Principle:
tworks on the principle of reciprocating motion of
pistons with the help of swash plate or wobble plate for
increasing pressure of oil to be supplied to the hydraulic Flg. 2.6.4:Swash plate
system.

Tecaealel
atias
Scanned with Camscanner
 Pumps and Actuators
Sem-VI) 2-18
Industrial Hydraulics & Pneumatics (MSBTE
Since the swash plate has angular surface, the pistone
Principle: reciprocates within the cylinder bore and thus oil i
swash plate helps to produce
The angular surface of sucked during one half of the circle of rotation and
with the piston rods
reciprocating motion when rotates along during other half of rotation, the oil is forced to the
pressure of oil.
of the pistons and increases outlet port:
Construction In another design of swash plate axial piston pump, the
Pisdon Shoeplato location of stationary swash plate and the cylinder
block are reversed and piston arrangement remains
same.

For fixed capacity axial piston pumps, the angle of

swash plate is mostly 30°. The flow rate of pump
Drve Fired depends upon the number of cylinders (n), speed of the
shaft
Swash plate
pump (N), the bore diameter and stroke length of piston
oyfinder block
Shoe () and angle of the swash plate ().
Fig. 2.6.5:Swash plate axial piston pump The theoretical volume (g) is given by the relation-
It consists of following main plates:
9 n-N A
a) Drive shaft with eylinder block: It is rotating element
ofthe pump in which cylinder block is mounted with (AArea of piston bore)
shaft. Function of swash plate:
b) Pistons: Pistons are mounted in the cylinder Swash plate is an angular surface plate used
block in swash
with piston rods. plate axial piston pump. It is provided to
obtain to and
)Shoe and shoe plate : The piston rod ends are covered fro motion of the pistons in the bore cylinders.
of
with shoe and fitted on the shoe The stroke length of a piston is determined
plate as shownin by the
Fig 2.6.5. swash plate angle. With a large swash
plate angle, the
pistons have a larger stroke where
d) Swash plate: 'The cam plate or swash plate as smaller swash
being kept plate angle gives shorter stroke
lengih.
fixed and positioned at an angle
a with the axis of the When the angle of swash
cylinder block. The shoe plate is plate becomes zero, no
attached to the angular displacement of pistons takes
surface of the swash plate. place.
The angle of swash plate can
e)Suction and discharge ports: They are provided be changed to get variable
for piston displacement
and volume flow
suction and delivery of oil. rate. The
maximum angle is
Working: generaly limited to
17 from
various design considerations.
As the drive shaft
rotates, it will cause
By varying the angle,
rotary pump output and flow
movement of cylinder barrel. can be changed from
The piston shoes follows maximum. zero to
the surface of the swash plate.

d maximum
a minimum
Fig.2.6.6:Effect a=0
ofa

TedKnuledgt
EPD t(e

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI)
2-19 Pumps and ActuatorsS

(b)Wobble plate axial piston pump: Principle

Driving shaft
Definition
yinderbar
i When the

1l2ept
wash plate rotateswhile
fedfo obtuuning Bent
reciprocatinE action
LDobble plate.axial pistonDum
Pistons s called as axis3o1
block.

Fig. 2.6.8:Principle of bent axis axlal plston pump

Construction and working:
When cylinder block is inclined at angle a with respect
In this pump, the swash plate rotates with the drive
to drive shaft,it will produce to and fro motion required for
shaft while the cylinder block is fixed. The shoe plate pumping of oil. The cylinder block angle can be charged to
and other components are similar to swash plate piston vary the stroke and flow rate of the pump.
pump.
Construction and working
The swash plate rotates on the surface of the shoe plate Bent axis pump consists of a cylinder block, pistons,
to' produce a motion on it and causes to and fro universal link which keys block to drive shaft, shaft
movement of pistons. bearings and dive shaft.
The cylinder block is mounted at an angle a with the
This movement helps for pumping of oil to the required
drive shaft with inlet and outet ports.
pressure.
The drive shaft is connected to the electric motor with
Wobble plata the help of coupling (QNot shown in Fig 2.6.9).
Shoe As the drive shaft rotates it causes rotation of the
cylinder block. Thus pistons inside the box also getto
Diving and fro motion.
shaft
The rotating cylinder block bores are open to inlet and
outlet slots of the valve plate which is fixed.
Z
During rotation of oylinder block, the pistois are pulled
Shoe plate
to suck thic oil through inlet and get pushed during next

Fig. 2.6.7:Wobble plate axial piston pump rotation for pumping of oil through discharge port.
The angle of cylinder block may be fixed or variable. It
Bent axis piston pumps: is maintained with the help of yoke and actuating

0 Epan Bent adspiston pump wit neats control mechanism. The maximum angle is generally
Marks kept upto 30°.

In bent axis piston pump, the axis of cylinder blockk is Shaft béaring9 Universal
ink
made to form an angle () with the axis of the drive shaft for
Pistons
making reciprocating movement of pistons. Valve plate
Dive
shait
.

Bent axis axial piston pump:

ifiitit
Out
Outet
Definition 1 tha ais Of the Ginuerblpces Inlet
Rade to orn ur angl (oth the ofthe drive
ais Cylinder block

Shaji to obtain recuorocating mOvementtofDIS

for pumpig of ol 1tis called asbent aris
Distor pumD
Fig. 2.6.9:Bent axls axlal piston pump

edKledgi
PobIatinis

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 2-20 Pumps and Actuators

To reduce function betwen cylinder block and valve )Radial pistons: The radial pistons are mounted in the
plate, an oil film is needed. slots or bores of cylinder block usually 4 to 6. They are
provided with the spring to maintain contact with the
Bent axis pump can generate pressure upto 700 bar
with flow rate maximum upto 800 liters/min. cam ring.

(c)Cam ring: It is the outer ring which is positioned

(c) Radial Piston Pump:
eccentricaly with the cylinder block axis. It belps to
O Explain Radal piston pump with neat skoldhi obtain to and fro movement of pistóns. The eccentricity

4 marks) can be varied by using adjusting screw.

efinitionWhen psto are cranged alonE d) Inlet and outlet ports: The inlet and outlet ports ae
provided at the centre of the block and separated with
ratkaus of the olinder ioek suniar to uanes nthe
the help of pintle.
Bane punp KtuledaS adial piston pimp
Working:.
Principle: When driving shaft is rotated, it will cause rotation of
the cylinder block (rotor). During rotation of block, the
Cylinder block
pistons are thrown out by centrifugal force and pusbed
back due to eccentricity between cam ring and cylinder
block
Pump.
housing When movement of rotor is observed step by step it
shows that during movement of rotor from piston (1) to
the piston (2), the radius of rotation increases and
piston is forced out towards cam ring. The piston is
pulled out and causes suction of oil.

During next part of rotation, the piston moves from

Fig. 2.6.10: Principle of radial piston pump point (2) to point (3). The radius of piston movement is
Dischago port
almost same and oil is carried out by the slots of the
Cam ring rotor.
When rotor moves from (3) to (4), the radius of rotation
Radial piston gradualy decreases and piston moves towardsthe
Pintde
centre of the pump. As piston get pushes towards
Adjustng centre, it will cause pumping of oil to the discharge

w screw
port

Sucion port
Oylinder blodk(Rotor)

Fig. 2.6.11:Construction ofradial

piston pump
The reciprocating motion
of the pistons mounted
radially is obtained with the
help of rotating cylinder block
mounted eccentrically with
the pump housing.
Constructlon:

Îtconsists of:
a) Cylinder block: The pistons
are aranged radially (4
pistons) in a slots
of cylinder block. They move
perpendicular to Fig. 2.6.12:5 piston radial pump
theshaftcentreline.
Ted
Scanned with Camscanner
 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 2-21
Pumps and Actuators
From point (4) to (1), as pintle wall is in contact
withS Point
the piston no suction and delivery occurs.
20
These pumps are quite robust and work at a high rpm 1. Mechanical Gear pair Piston and
with very high flow rate about 2000 litmin.
element used cylinder
It can generate pressure in the range of 450-500 bar.
Principle Meshing of To and fro
2.6.2 Advantages and Disadvantages of gears (Rotary motion of
Piston Pumps motion) piston

Advantages Function Low pressure High pressure

range range
1. High range of pressure:
4. Construction Simple, Complex
Piston pumps are able to produce high pressure in the
compact, low requires moe
range of 450 500 bar. Maximum pressure is about
space required space
1000bar.
Types External, Axial piston,
2. High volumetric efficiency:
intemal, gerotor radial piston
It has high volumetric efficiency greater than 95%. pump

3. Variable delivery: Operation Noisy Less noisy

By changing eccentricity between cam ring and rotor 700 bar
Pressure rangge 300-350 bar
flowrate can be varied. Delivery

.
8. Continuous Intermittent
4. Viscosity range high: (pulsating)
It can handle oils of wide range of viscosity. Maintenance
9. Simple Difficult

5. Noiseless operation: 10. Cost Cheap Expensive

It has low level of noise hence sileat operation.

Disadvantages
2.7 Performance characteristics and
Selection of Pumps
1. Cost is high:
2.7.1 Performance characteristics of pumps
Due to complicated construction, it is costly than other
pumps like gear pumip.

2 Cleaning dificult:
.
Characteristics of Gear pumps:

The performance of the gear pump can be studied with

the help of characteristics of gear pump.
It is difficult to clean closely fitted paris located inside
the pump. The characteristics of volumetric efficiency of gear
pumps (pressure vs. discharge voume) are shown in
2.6.3 Comparison between Gear Pump and
Fig. 2.7.1.
Piston Pump
Desired characteristitos
MSBTE: S-09. S-11. W-15
I 10to 12 %

- Undesired characteristics
he
and HOS11W15)
The following table gives the difference between above
[wO pumps.
Pressure (bar)
Fig. 2.7.1:Characteristics of gear pump

Scanned with Camscanner

 Pumps and Actuators
Sem-V) 2-22 Noise
Industrial Hydraulics &Pneumatics (MSBTE
in ne Size Pressure generated
is trappcd
oome volume of oil (10-12%)
meshing gears,
hence thee is a
Carance spaces of the
as given in the
discharge volume
rop of 10 to 12% in Selection ol Flow rate of oil
hydrauic
graph. Lte pump
type pump at
haracteristlcs curve of vane expected
MSBTE S10
constant speed
charactenistio curve of vanetype pumpa Efficiency
Draw Oil compablity
Constant speed and explan
SJ0
Fig. 2.7.3
90
Pressure of oil generated:
80 any pump may be
In general for pressure up to 100 bar,
70+ n(etficiency) suitable for high pressure applications, piston pumps
50
are more suitable.
Efficienay50
power 50 For moderate pressure system internal gear pumps are
40 used while low pressure applications screw and vane
pumps are used.

20
Power
The table gives quick reference for pressure range of
particular pump.
0

ressure Application
10 20 30 40 50 60 70 80 90 100 ngetpar)
Pressure Gear pump 300-350 Moderate pressures
Fig. 2.7.2
Vane pump 125-175 Low pressure
From this curve; it shows that as pressure increases the
power increases the power increases linearly. Screw pump 200-250 LOw presSure
The efficiency increases at middle values
of pressure Piston pump Up to 700 High pressure
and further increase in pressure may drop bar
the
efficiency.
2 Flow rate of oil:
2.7.2 Selection of Hydraulic Pump The flow capacity of any pump depends on
geometric size of its pumping
MSBTE: W:15,S7S:18:S-19 chamber an ts
rotational speed.

2Wnal are the selection criteria fodiydrauic pumps Flow rate is indicated by
the delivery of pump
Litres/min.

0 List outtany four critena tor se

W5 S17S19 The table gives maximum flow
rate of various pu
pumps:
2
Epanin Bret
hydrauic

Q.2.State the factors

S18) lowrate liters/min
Hydraulic pumps
tbe consldered tor selection.of Gear pumpP 400-450

As discussed earlier, there

4 Marks
Vane pump 200
are various hydraulic
hence selection of proper pumps,
respect to the pump is important Screw pump
function with 7500
maintainability of bydraulic ability, reliability
system. d Axial piston
pump 800-1000
The various factors considered
are for selection Radial pistón
of pump pump 2000

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI) 2-23
Pumps and Actuators

3. Efficiency of the pump: This ratio is important for aviation and mobile
Efficiency is the factor which gives frictional and other applications.

losses of the pump. Volumetric efficicncy and overall 7. Cost of the pump:
efficiency is calculated and used as a sclection
The cconomic factor is the cost of the pump. The gear
criterion.
pump is least expensive while piston pumps are most
In general piston purmps have higher overall cfficiency costly than other pumps.
than gear and vane pumps. Rotary pumps are economically good compared to
Gears pumps have low volumetric efficiency about 65 piston pumps for low pressure application.
- 85% while overall efficiency about 60
70%, vane Internal gear pumps are more costly than vane pump
and screw pumps has overall efficiency of 75-85%. while screw pumps are generally more costly than both.

4. Oil Compatibility: Nolse:

Pump has to handle oils of various grades of viscosity, II is desired that the pump should have smooth
lubricity and oils should be suitable for the given pump operation with minimum noise. Gear pumps and piston
to give good performance with high efficiency. pumps are the noisiest while screw pumps are very
It
means compatible oil will give efficient and smooth quiet.
running of pump. Vane and internal gear punps are in between. Noisy
Some ules for oil compatible are given below in the pump generates noise above 90 dB while level of 60 dB

table. while level of 60 dB or less is considered for silent

Tunning
Types of pum Oil viscösity range
2.8 Hydraulic and Pneumatic actuators
Gear pumpP 30 to 70 cst

.
SCrew pumnp 20 to 70 cst Introduction
(all types of oils are acceptable) |
Darnftion drantie ele
Vane pumps 30 to 50 cst
eehancae
4.Piston pumps 60 to 70 cst

cst-Centistoke which is unit of kinemati viscosity In oil hydraulic system/Pneumatic system, the oilair is
allowed to fow through various elements and actuator
5. Life expected:
is the last clement in which oil enters and Ieaves from it
.Modem internal gear pumps run silentlý at moderate
to drain to the reservoir for recirculation.
pressures and have life expectancy to 20000, working
The actuator is the component which utlises the oillair
hours.
energy to produce output motion which may be linear
Radial piston pumps have a very long lifé expectancy , or rotary
and are suitable for high pressure application.
The movement of the actuator (linear/rotary) is used for
The life expectancy of axial pisto pumps may be as performing the required application.
high as 40,000 working hours when used at 200-250 Work plece
Actuator Push
bar.
6. Size of the pump:
Size of the pump is indicated with the help of weight-
to-power ratio. The ratio depends upon the type of the
out
pump añd the materials used for pump and its parts.
ail in Oil
7nmii7
Machine table
Vane pumps have the best weight to powet ratio around
0.2kg/kW. For piston pump 0.3 to 0.6 ky/kW while FIg. 2.8.1:Clamping of work plece using actuator
gear pumps has 0.5 to 0.75 kg/kW.
TecTaete
Platioes

Scanned with Camscanner

 Pumps and Actuators
Industril Hydraulics & Pneumatics (MSBTE_Sem-VI) 2-24
Actuators.
Need of the
The Fig. 2.8.1 shows the linear actuator which Z.0.
MSBTE S16
produces push force using oil energy and it is used for
clamping of work piece on the machine table.
the fúnction
ot Actuators.
The heavy load can be lifted with the help of actuator
movement as shown in Fig. 2.8.2. Hence it is an oulput
State or pull force:
member of hydraulic system. a) To produce push Pull
Push
Rod side
Actuators arc the devices which converts fluid power Face of piston
into mechanical power. side of
piston

-Trolley

(a) Push force (b) Pull force

Fig. 2.8.5

The fluid pushes against the face of the piston and

linder
(Actuatoiy
Ollin produces push force. The force produced is given by
the formula:

F PA
where F Force in Newton
Fig.2.8.2: LIifting of trolley/dumper
P Pressure of oil (N/m)
A = Areaof piston (m)
When pressurised fluid enters
from the rod side of
piston, it produces pull force.
The force produced is
given by the formula

F = P.(A-a)
Where
Area of piston rod (m)
Push/pull force
can be used for various applications
like clamping, lifting,
material handling, etc.
6) To produce rotary
motion (torque) :
Fig. 2.8.3:Actual Single acting Dil
cylinder
n

Shaft

Rotary motion

Out

Fig. 2.8.6:Rotary
motion actuator
The oil encrgy
can beutilised
Fig. 2.8.4:ActualDouble
It is useful to producerotarymotion.
acting cyllnder for feed movement
winding/rewinding,
nent of machine table,
etc.

Ted
Scanned witn camScanner
 Industrial Hydraulics& Pneumatics (MSBTE Sem-VI) 2-25
Pumps and Actuators
2.8.2 Classification of Hydraulic /Pneumatic Actuators: MSBTE S-09.W15.W18
Q Classity hydraulicPneumatic acuators uised in fiuid power system.
S 09 W-15)
QClessity Poeumatic actuators.
Actuatbra

According to motion produoed

Linear (ytnders) Rotary (motors)

According to direcion
According to ol feed

Unidirectiona Bkdfirecional

Sngle Double
acting acting
Double rod Tandem According to construcdon

Ram Telescopic
Sping Gravity Gear Vane Piston SCew
reum

Axdal Radial
piston pston

Fig. 2.8.7:Classification of actuators

The chart shows clasification of hydraulic/pneumatic (b) Gravity/external load return single acting
actuators on the basis of: cylinder When single acting.cylinderis
(e) According to type of mation produced : mounted vertically, the return movement is
carried out through the force of gravity.
0 Linear actuators: This type of actuator produce
linear motion (to and fro motion). It is known as
() Double acting cylinders:. When cylinders are
operated by fecding the ol to the cylinder in both
hydraulic cylinder.
directions ie. face and rod side it is known as
(). Rotary actuators: This type of actuator produces double acting cylinder
rotary motion (angular motion). It is known as
They are further classifñied as;
hydraulic motors.
a) Double rod type : When piston rod is extended
Linear actuators are further clasified on the basis of
through piston on both side of the piston, it is
(b) According to oll feed direction: called as double rod type doutble acting cylinder.

Single acting cylinder: When oil is feed only (b) Tandem type : When two cylinders are mounted
from face side of the piston: It is called as single in line (series) with common piston rod, it is called
acting cylinder. Single acting cylinder has two as tandem double acting cylinder.
types, type : When piston and piston od of almost
Ram
Spring return single acting cylinder When : sáme size, the cylinder is known as ram cylinder.
return movement of the actuator is performed
d) Telescopic : When number of cylinders are
by using spring force, it is called as spring
mounted in a
short retracted envelope like a
retum single acting cylinder.
telescope lenses, it is known as telescopic
cylinder.

PDIICis

Scanned witn camScanner

 Actuators
Pumps and
Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 2:25
cylinders
(ii) Cable
2.8.2.1 Rotary Actuators:
Giv) Diaphragm cylinders
MSBTE : W16.W-17 cylinders
(v) Bcllows
cylinder
(vi) Tandem
OWhat is the meaning of Uni-directional motory an cylinder
(W-16)|| (vii) Duplex
direGianal moto
cylinders, etc.
o (vii) Rotary
RSTany four applications of pneumatic
W-17) Actuators
actuators 2.8.2.2 Linear
(Hydraulic/Pneumatic Cylinders):
Rotary actuators are classified as;
cylinder is
(a) As per direction of rolation: Definition Hydraulicllneuniatie
pover into linear
Uni-directional motors: When oilair
enters and a device uuhich converts la
(0
direction (only one mechanical forceor motion to perform the task
rotates the motor in either
clockwise) it is known effective in conversion of oil lair
cither clockwise or counter is most useful and
It output force in a linear direction
as uni-directional motor. energy to produce
oil/air is feed which may be
horizontal, vertical or at an angle.
(i) Bi-directional motor : When
altermately from inlets of motor
to produce
is suitable for
performing work such as pulling or
it is known as
It moving equipments
clockwise and counterwise motion, pushing in machine tools, earth
bi-directional motor. cranes,construction equipments and space application.

.In oil hydraulic system, they are used at high pressure

(b) As per construction: forces and precise
up to 700 bars and produce large
gear pair is used, it is known
) Gear motors: When movement
as gear motor. handle and
n pneumatics, actuators are designed to
(t) Vane motors: When sliding vanes are
used, it is operate at low pressure up to 10 Bar. Their strength is
known as vane motor. less as compared to hydraulic actuators.
i) Piston motor: When piston and cylinder are used,

it is known as piston motor.

2.8.2.3 Single Acting Cylinders
Ithas two types: O Draw labelled diagran of any one atuator used n
(A) Axial piston (B) Radial piston
ydrauig Syste S stnichonad
Other criterions for classification of actuators are: Working 4Marks)
(a) According to construction style :
iioWen pressurised o conmpressed a
) Tie rod cylinders : It consists of tie rods which eTS Ony
fo
fuce sude of the piston relum
ad
are capable of taking impact loads.
s
troke conipleted by sprtng leterral loadk t t
(i) Mill type cylinders : It is suitable for steel mills
and metal processing industries where
kToitoir,
s Ge acting cyinder
exiraConstruction:
ruggedness is required.
Piston
(i) One piece welded construction : The body is End cover
Cylinder bore
casted or the ends are welded to the
tube. They are Compresslon spfing
simple and inexpensive.
Piston rod
(iv) Threaded head
cylinders: The ends are screwed AA
to the tube by threading
outside or inside.
AWAAW
Bush
6) According to special applications ANZDIZZIIIZIZZ
) Plungerram cylinders
oil inlet O-ring
) Telescopic cylinders
Fig. 2.8.8:Construction of single acting oyind e
eda
Scanned with tamscanner
 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 2-27
Pumps and Actuators
It consists of:
Applications:
o Cylinder bore (tube): It is hollow cylinder seamless
1. It is used when push force is required e.g clamping of
tube chrome plated for corrosion and scratch resistance. work picce.
(b) End corers : The end covers are joined with the tube 2 It is used when work is to be completed in forward
by serew fastcncrs, or welded. direction only.

)Piston: The piston is a sliding element closely fited Advantages:

with the help of O-rings.
1. Simple in construction
()Piston rod: Piston rod is'attached to the piston at the 2. Quick return due to spring action
centre and transmits movement of piston.
Limitations:
() Compression spring: I is provided to exert force
during retracting of piston. Itis applicable for handling load in one direction only.

( Bush: It helps for smooth movement of the piston rod 2. Spring selection is critical to handle load and speed of,
actuator.
in cylinder bore.
3. It cannot be used for longer stroke lengths due to
Working: problem related with spring

The pressurised olcompressed air enters through inlet 2.8.2.4 Double Acting Cylinder
of the cylinder and exerts a force on the face of the
MSBTE S-15.W-15, S16.S-17. S-19
piston.
When suficient oil force eatsketchdesenbe consfucton and ording
is developed to overcome
spring force, it pushes the piston in the extended S15
direction and completes the forward movement. Eplan wifaneat sketch, working of double acing ar
When the oil supply is stopped / out off, the oil W15,S16,S19
pressure drops at the face side and spring forces the oil Draw a dube.ac
through inlet (at this position -outled and brings the
cylinder to the normal posiion. Defimition PRessurtsed ol compressed a
ien
When it is mounted vertically with extemäl load, there- on
hote siderof pision on fuce Stde for te
no need to provide spring, the cylinder retracts due to oruard moverngrt piston tod side or rediurn
is
force of gravity. Eg. lifting of vehicle in aitomobile 7201ernent
d
knoonis double actng cylinder
service station.
Construction:
Rear end cover
-Vehicle platform Pson seals
Piston beang Piston Bushing
Gravity Ram Front
end oover

Ql out
Mountng
munm
end Pston od
Rod bearthgs
Fig.2.8.9:Vertical single acting cylinder Oylinder bore

Fig. 2.8.10:Construction of double acting cylinder

Symbol
It consists of :

LH
Single acing cylinder with Single acting cylinder
a) Cylinder body: It is seamless tube of Al alloy or steel
with chrome plated to provide better corrosion and

spnng retum without spring Scratch resistance, stainless steel, cast iron also used for
body.

edenle
P atisas

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-V) 2-28
Pumps and
Acuatt
(b) Piston and piston rod: The pistons are made of Limitations:
aluminium alloy castings. They are fitted precisely in1, Costly compared to S.A Cylinder
the cylinder bore with the help of piston seals. Piston
2. Movement depends upon two inlets/outlets
od is attached to the piston and made of steel bar.
() End covers: The end covers are provided at the frontAPplications:
end as well as at rear end. They can be joined with
help of screwed fastencrs, welded or tie wd.
the. When work is to be completed in
both the drecions.
can be used for push and pull forces.
h
(d) Piston seals: It is provided for leak proof assembly 2 It is used in machine tools like
shaper machine
between cylinder bore and piston. movement of milling and grinding
machine,
(e) Bushing: Bush are provided for smooth movemcnt press machines, etc. hyaralie
of
piston od and for reducing leakage of oil. They 3. It is used in material handing equipments,
are
made of brass, bronze, Babbitt metal or split nylon and cquipments, etc. constnct
press fitted to the cap end.
2.8.2.5 Cushioning of Double
Working: Acting
Cylinders
MSBTE
S18B
O Descnbe the tem cushioning
of cylinders. Era
neat sketch
S-187
Cushioning of cylinders means
gradual deceleration
of
the piston near the end of its stroke.
It means slowig
A Inlet Outlet down the speed of the piston near
A Outet B Inlet the end of cylinder
body.

Fig. 2.8.11: Outline sketch of D.A. cylinder It is very helpfuül to reduce shock
or impact ofloadon
the cylinder end covers specially
whena heavy load is
When pressurised oilcompressed air enters "through connected to the rod or the cylinder
and is working at
inlet A from face side of piston, it pushes the piston very high speed.
to
the right hand side to complete forward stroke while The cushion assembly is around 25
the mm long fara
oil on the rod side is delivered through the outet to the standard cylinder. It consists
of a
small passage to
tank through the outlet B. allow entrapped oil to the
port with a cushion needle
with a check valve to allow free flow
When pressurised oillcompressed air enters through during of oil
reverse flow of oil during reverse start of piston travel
inlet B from piston rod side. It moves the piston
to the Needle valv
left hand side and completes the return stroke
(retraction). The oil from the face side is drained
out Symbd
through outlet A to the tank.
Oudet
It gives to and fro (reciprocation) movement of piston. OOSS Boss

Symbol

Fig. 2.8.12:Cushioning of cylinder

The end of the cushion nose is tapered in order to cn

more easily into the cushion chamber.
Advantages: The fluid is normally leaves through the outlet p
recss
1. The force is thus applied in both directions directly, but when cushioning boss enters
the fluid around the piston is trapped.
2. The structure of this hydraulic cylinder is very simple
Ted n
Pai"
Scanned with Camscanner
 Sem-VI) 2-29
BIndustrial Hydraulics & Pneumatics (MSBTE Purmps and Actuators

the fluid can cscape is through the Symbol:

The only way
restricted by necedle valve.
secondary path which is
valve is adjusted so that the piston is
slowed
The needle
pressure build up
last part of its stroke by
a
up over the A,
B
past the necdle valve.
in the fluid escaping Advantages:
2.8.2.6 Double Rod Double Acting Cylinder: The force is equal in both directions

Deinition n ating cylinder uhen,

double The velocity is same in both strokes.
giston,
prouded on bothsiue of the it
DESton rod
5 acting Limitations :
as douole 21ton rog double
cled 1. Cosly compared to conventional D.A Cylinder
lnder Piston rod area decreases the oil fow area in cylinder
2
Construction:
Piston seal Applications:
Oylinder body
Piton od It is used when equal force and speed is needed in both
Piston rod ( uIIAR 1.

the directions.
2. It is useful in robotic mechanisms where the rod is
clamped at both ends and the body moves.
machine.
Piston 3. It is used in table movement of grinding

Fig. 2.8.13: Double rod

cylinder 28.2.7 Tandem Cylinder:
body with end covers; the piston
It consists of cylinder MSBTE:S:15.S-18
is fitted with piston seals.
provided on both side of cyliride? What is isbeneficia
The piston rod is extended and
the piston. Hence area
on both side gf the piston' is property ?xplain win sketch ddraw
its Symbolk
previous double acting
same (which is different in (S15
cylinder).
Wsketchand exolan working .ofandem.cyinder
Working

When pressurised oil/compressed. air enters through

a
inlet port A, it pushes the pistoin to complete forward ion Whentuo doüble uctng ders to-a
stroke by draining thie oil from the other port B. pistons conected
7ouned line uth the
When pressurised oilcompressed air enters through Comion Dston rod
inlet port B, it moves the piston to complete return
stroke by draining the oil from the other port A.

As the area on both side

Construction
of piston is same, it produces joined with
acting cylinders
equal forces in both directions. t consists of two doubleshown in Fig. 2.8.14.
The area on both the common partition as
side is, piston rod. The
connected to a common
The pistons are ports of
provided which includes two
D-' (same) four ports are
each double acting cylinder. simple
F Diameter linear dimension compared to
ofcylinderbore t has more more linear
Hence occupy
d'= Diameter of double acting cylinder.
piston rod
The. maximum space.
force of this cylinder duplex cylinder.
cylinder
size is smaller for a given Modification tandem cylinder is the
of
than the single
rod type.

Tedhed
PBca

Scanned with Camscanner

Industial Hydraulics &Pneumatics (MSBTE Sem-VI) 2 Pumps and Actuators

Piston 1

Cylindar 1 Oylinder 2
a Explairnworking of telescopic ylinder

O Wnh a heal sket Working

o 1elesconie
Common CYlinder Draw its symbo S18,819
piston rod

Defnition Wher numbersaOFCylinders ar

Out In Plston 2 Out arranged.in a compactenvelope sumilur to teles
enses, 1s kiont as tülescOpie ty.
Fig. 2.8.14 : Tandem cylinder
it
Construction:
Working
-Pson
When pressurised oil/compressed air enters in the
cylinder 1, it produces force F, and when enters in the Total stroke length{)

cylinder 2 at the same time produces F2 Cyindorl

oyinder
oyinder
Hence at the piston rod, we can get double force Cyinder
2
F+FE) during movement of pistons.
Similarly for the return movement of the piston, we
can
get double force. Oil in Oyfinder

Beneficial Property:

It will produce double force of two cylinders during

movement.
Less axial dimensions due to common wall between A
two cylinders.
(a) Principle (b) Before actuation (c) After
They are designed for applications where high actuation
force Fig. 2.8.1
must be generated within a narrow/less radial
space
where axial length is easily available. .It consists of number of cylinders, with decreasing
in
size. The main cylinder accommodates
Symbol: the number of
cylinders arranged one inside the other.
Q Draw symbols of Tandemo
2Marks The inlet is provided far main cylinder
to enter th

LHH pressurised oil. The corresponding inlets are aso

provided to the each cylinder.

The cylinders are arranged in short envelope hence

a
Applications: space required is less.

1. They are widely used in various applications Working:

which
have two or more independent systems
like power When pressurised oil enters in the main cylinder
operaled flight control system in naval
air craft. will push the cylinder 2 in the upward direction whed
Work holder devices and lathe equipments. sufficient oil pressure is generated.
3. Large press cylinders. Now the cylinder 2 is completely lifted and oil wu

enter into the inlet of cylinder 2.

2.8.2.8 Telescopic Cylinder
The oil will flow in the cylinder 2 and push the psu
MSBTER S-1AVE15:S18,S19 n upward direction. It will raise the piston for so
length of cylinder 2.
a. Drawand explainthe workingoftelescope cylinder
| In this manner, the total length of stroke through wD
S11) the load is lifted is (L+L)

Scanned with Camscanner

 Pneumatics(MSBTE_Serm-VI) 2-31
Industrial Hydraulics & Pumps and Actuators
The platform is provided
Symbol: at the top of the ram
placing the heavy loads for
conveniently.
The single inlet is provided in
the cylinder for oil feed.
The ram is always mounted vertically.
It is single
acting type.

Load

Platon

ApplicationsS:
Ram/Plunger
mounting
1. Itis suitable where les space is available for - Oyfinder
of actuator.
Used in equipments like tilting of truck dump bodies,
2.
cranes.
fork lift trucks, hydraulic
platforms, lifting platforms and other Ol in
3. Tipping
Out ZZZL
commercial vehicle applications.
Fig. 2.8.17:Ram cylinder

Working:
When pressurised oil enters through inlet, it will lifñs
Stroke the ram in the upward direction. The load is lifted to the
required height

When oil supply is cut off to lower the load, the ram
D comes downward due to gravity force and oil is drained
Dump
to the tank through the outlet port.
angle
***
Symbol

'.:
Fig. 2.8.16
.
B cylnder base pin to body hinge pin

2.8.2.9 Ram Cylinder (Plunger Cylinder)

einitionWien.
egumo Applications
Ytiler 1. Commonly used as a lift in automobile service stations.
Construction
2. Material handling equipments
t consists
of cylinder in which ram Calculation of Cylinder speed and force:
or plunger is
mounted. The plunger
is a large size piston with =
d ,
(ddiameter of piston and
length of piston rod).
1. Cylinderspeed
Hence piston piston from one end of
and piston
od are same as It is the movement of the
element a single of cylinder)
the cylinder to another cnd (stroke
with respect to time.

Tec
le

Scanned with Camscanner

 Pumps and Actuaton
Industrial Hydraulics & Pneumatics (MSBTE Sem-V) 232
As the piston reciprocates in the form of linear . Push force = Pressure of oil x Area of cylinder bore

motion, the speed of cylinder is expressed as

distance travelled by the piston per unit time.
PXA Newtons.
Mathematically, it can be calculated as Pull force is produced during
movement of the piston
dh.
of the cylinder during
tTime required for from right to the left end
the piston.
travel of piston retraction (retum) movement of

k-L
(Stroke length) Pull force
Fig. 28.18
Tolin
=
Length of stroke of cylinder (meter)
Let,
L Fig, 28.20
t Time required for travel of piston (sec) Pull force can be calculated as:
(V)-Lengthofstroke
Speed or velocity of piston required A Arta of cylinder bore (m)= n4 (D
a >Area of piston rod (m)= #4 (d?
P Pressure of oil (N/m)
The unit of speed of piston is m/sec
Cylinder speed can be varied by changing the following Pull force = Pressure of oil x(Arca of cylinder box
parameters: - Area of piston rod)

(a) Length of stroke (L) : From the above cquation,

speed of piston is direcdly proportional to the AaNewtons.
stroke length, hence if time is constant, the speed 2.8.2.10 Specifications of hydraulic cylinder :
increases with length of stroke
Hydraulic cylinders are specified by:
(b) Pressure of oil (P): Where oil pressure is more, it
will more the piston at faster rate. (a) Pressure rating in Pascal.

(c)Flow rate of oil(Q): When flow rate is reducedb)

it
Length of stroke in meters.
lowers the speed of piston and vice versa. (c)Diameter of the cylinder bore.
2. Cylinder force () Diameter of piston rod.
The pressurised oil exerts on the piston
face or rod 2.8.3 Cylinder Mountings
side and produces push or pull
force.
The hydraulic cylinders
Push force is produced during
movement ofthe
are used for variety o
applications and it is required
piston from left to the right to mount or install the
end of the cylinder
during forward movement cylinder conveniently
of the piston. considering function and
maintenance activity.
Push foroe
Mountings may be necessary
at one end or both enus
and it may not be same
at both ends.
Oil
Mounting styles affects
the design life and frequency o
Fig. 2.8.19 maintenance of
Push forcecan the hydranlic installation.
be calculated as
2.8.3.1 Types
Let P Pressure of
of Cylinder Mountings
oil (N/m)
D Diameter W37
of cylinder bore
(m)
MSBTES30
A Area of cylinder
bore(m
QLst different types ofcylindermour and
)=n/4 (DÝ ountings. Sketch
abel any one
S10

Scanned with tamscanner

 Industrial Hydraulics & Pmeumatics (MSBTE Sem-VI) 2-33 Pumps and Actuators

of.cylinder (W-17) () Pivot mountings:

Xplain. any two mountng melhods
categorised as: In pivot mounting, the cylinder can be able to rotate
Cylinder mountings can basically
freely while it reciprocates.
Types of Cylinder Mountings The pivot centre line normally intersects the cylinder
centre line.
a) Centre line mounting There are two methods of pivot mounting:

Foot mounting
(a)Clevismounting
(b) Trunnion mounting
(C) Pivot mounting
This mounting gives rofational freedom in one plane. If
freedom is required in all planes, universal joints
0 Clevis mounting
should be used.
0 Trunnion mounting
Clevis mounting:

Flg. C24:Types of Cylinder Mountings O State the meaningot clevis mounting 7 Explan with
jeat sketcha 4Marks)
(a) Centre line mounting:
Forca
The best way to support a cylinder is along its centre
line. It uses rectangular flange or square flange
connected to cap end or head end.
Flange Flange

Center lugs
Links
Pivoted Oylinder
.cap end

Fig. 2.8.21:Centre mounti

The Fig. 2.8.21 shows centre line mounting in which Fig. 2.8.23:Clevis mounting
lugs are attached to the sides of both ends of the
The clevis is a part of cap end and can be either fixed or
cylinder centre line. The flanges are attached at both
universal.
theends.
The Fig. 2.8.23 shows clevis mounting in which the cap
Tie rod mountings are also used but they are less end is pivoted so that it can rotate the cylinder end
strongerthan the flange mountings. during to and fro movement of the cylinder.
(b Foot mounting: While the rod end is attached to the links with the help

Foot mounting consists of mounting of pin joint. One link is pivoted and other link can slide
the cylinder with
to apply the force.
the help of side end lugs side
or covers:
These mountings are used where
cylinders are to be
(ü) Trunnion mounting:
mounted onto surfaces
parallel to the axis of cylinder. Trunnion mounting has three types
Slde cover Oylinder
Side cover (a) Trunnion mounting at head end.

6) Trunnion mounting at cap end.

(c) Trunnion mounting at intermediate.
MS H Base Trunnion is a type of rotary slider which allows rotary
Fig. 2.8.22: Foot movement. The Fig. 2.8.24 shows intermediate
mounting
trunnion mounting.

Tec edan

Scanned with Camscanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 2-34 Pumps aand Actuators
Trunnion
2.9.1. Difference between Hydraulic Pump
-oylinder and Hydraulic Motor

Q Differentiate .between hydrau and.hydraulic

motor 4Marke
Fig. 2.8.24:Trunnion mounting
vdraulic1AEvdraulic m
NaPofnt
2.9 Rotary Actuators (HydraulicMotors) Fump
| It is device Tt is a device which
1. Definition
Desinition The lydruulie rator is a fiid poue which converts fluid
eree hichcowers fld energ into mechaniotl converts energy into
Lereo un thernecotue.noton of tie shat mechanical mechanical energy.
cnergy into
The oil pressure is converted into torque and flow rate
fluid energy.
is converted into speed.

The hydraulic motors are coupled to the resisting object Electrical Oil under pressure.
Energy
for doing the work. It may be used for applications input motor/LC.

where rotary movement is required. Eg. winding and engine

rewinding of cable.
3. Function To supply To produce rotary
Fluid out
highpressure motion and torque.
oil
Rotation
output 4. Types Gear pump, | Gear motor, vane
vane pump, | motor, piston motor,
SCTew pump, | etc.
piston pump.

5. Efficiency More Less

Fluid in
compared to
motor.
Fig. 2.9.1
6. Symbol
Coupling Oil in

Winding
reel
7. Applications Cranes, Windingfrewinding
Shaft machine conveyors, feed
Cable Out tools, earth drives of machine
Hydraulic motor
moving tool etc.
Fig. 2.9.2: Application of hydraulic motor equipments,
farm
Hydraulic motors are similar in construction
and size machineries,
that of hydraulic pumps. The only difference
is that etc
instead of pushing the fluid as
in case of pump, the
rotating clements like gears,
vanes, piston, etc. are 9.2
2.9.2 Types of Hydraulic Motors
pushed by the oil to enable
the motor shaft to rotate.
MSBTE WA
a With sketchexplain
working of anyone yp
hydraulicmotor W
dlv
Scanned with Camscanner
 Hydraulics & PneumaticS (MSBTE Sem-V1) 2-35 Pumps and Actuators
Industrial

Types of Hydraulic Motors a Gear pair: Two meshing gears are mounted with one
gear on the driving shaft while meshing gear is
mounted on driven shaft.
Motors
1.Gear
(b) Casing : It is the outer body of the motor which
2 Vane Motors encloses gear pair and passages for inlet and outlet
ports
Piston Motors
3. (c) Inlet and outlet ports: The oil is allowed to enter
through inlet port and drain out through the outlet port.
HwAxlal piston motor
Swash plate type
Working:
F)
LGi) Bent axdis ype
When pressurised oil enters through the inlet port it
6) Radial piston motor cxerts oil pressure on the gear teeths.
As the casing inside surface and geár pair are closely
4Rack and Pinion Typa Motor
fitted, the oil pressure acts on the one side of one tooth
on the gear located near the inlet port.
5. Semi rotary (LimitedRotary) Actuators
This will cause hydraulic imbalance and it push the
Fig.C2.5: Types of Hydraullc Motors
gear tooth to develop torque. The laiger thie gear tooth
2.9.2.1 Gear Motors or higher the pessure, more is the torque developed.
This action continued to produce rotary motion of the
TnifionWhersn gen pa ised to obtan
shaft. The oil used has low pressure and of no use
hence drained through the outlet port
GSgearmoto
2.9.2.2 Vane Motors
Princlple:
II works on the principle of imbalance of oil pressureto Beinition When siding bane5.u12Used
to.obiun
acton the gear tooth and push the tooth for development of ota moton ti tiieHdp of pressurised oil, s
torque.
eroun usDane moton

Construction: Principle

Gear motors construction is similar to gear pump. It works on the principle of hydrauic imbalance is
It
mainly consists of: caused by the difference in vane area subjected hydraulic
to
Casing energy of oil due to eccentric mounting
-Drive gear of rotor to the
housing.
Construction
Cam ring
(housing)

Shaft
Inet Outlet

Inlet Qutlet

Vanes

:Driven gear
' Rotor
Fig, 2.9.3:Construction of gear motor
Flg. 2.9.4:Construction of vane motor

Trd Kaeelehi
PDatueis
Scanned with tamscanner
 Pumps ana ACuaiorS
Industrial Hydraulics & Pneumatics (MSBTE Sem-) 2-36
Fig. 2.95. Similar
balanced vane motor is shown n
It, mainly A rotor containing
Its construction is similar to vane pump. pump, here also the
to balanced vane
consisis of following components. placed with the cam ring.
vanes is concentrically
(a) Cam ring (housing) is a circular ring which is
:t two outlet ports
oPposite to each
The two inlet and
stationary and it has inlet and out-ports
provided as or pressure on
maintains the balance
other and thus
shown in Fig 2.94.
right side and left side
of the motor.
width
(b) Rotor: The rotor is circular disc with adequate
accommodate 2.9.2.3 Piston
Motors
and provided with number of slots to
respect to the
vanes. It is mounted eccentrically with
Definition WhenreciprocaEmovenient bof
cam ring axis. piston ts utilised fop obfaining
rotary motton
mounted motor
(C) Sliding vanes: Vanes are rectangular, blades pressurised oik iis anoiun as pston
with the help of spring.
provided for entry of Principle:
(d) Inlet and outtet ports : They are conversion of reciprocatine
respectively. It works on the principle of
pressurised oil and drain out used oil using swash plate
or
motion into rotary motion by
Working connecting rod mechanism.
the vane motor, it will
When pressuriscd oil enters in Types of piston motors:
strikes on the
enter in the cam ring and rotor surface. It
(A) Axial piston motor
vancs.
the unequal area of (B) Radial piston motor
Duc to eccentric mounting of rotor,
vanes occurs. The oil passing through unequal area (A) Axial piston motor
pushes the vanes in the forward direction. It results
in

development of torque in the motor shaft. Deinition WherpIston n0tes pardlet to the
The oil strikes the vanes successively and develops ca of the shute to produeearotan motion, t is
rotary motion. Higher the oil pressures, more is the Caled as asia pistor rotor
torque developed.

This motor is unbalanced due to two different pressures

It has two types:
the inlct pressure of oil is much greater than the outlet )Swash plate type
low pressure. Hence it may cause side loading in the i) Bent axis type
motor shaft

To overcome above limitation, a balanced vane motor Swash plate axial piston motor:
is developed which is modification of unbalanced vane
motor.
G Eroain with he hep of sketch. working of sts
Cam ring plate Axalpiston motota

Principle:
Inlet Outlet from
It uses swash plate to obtain rotary motion
Rotor reciprocating movement of axial pistons.

Construction:
Outlet It consist of
Inlet
(a) Swash plate: It is positioned at an angle anu

side of the p
2s a surface on which the shoe
travel. ontains
Fig. 2.9.5:Balanced vane
motor (6) Cylinder barrel : Cylinder barrel couthre
pistons. Minimu
umber of axially placcd
pistons are necessary.
Ted
Poil

Scanned with Camscanner

 Industrial Hydraulics& Pneumatics (MSBTE_Sem-VI) 237 Pumps and Actuators
Oylinder barrel
Swash plate In
Construction and working:
Oll
Shoe It consists of cylinder block in which number pistons
haft of
plate are mounted in number of bores, respectively.
The cylinder block is making an angle with
the shaft
mounted with the help of drive shaft flange.

When pressurised oil enters in the cylinder, it causes

ZA2ZAIIIZIIZAA linear movement -of the piston. This motion is
Piston shoess Piston Toiin transmitted to the drive shaft flange.

2.9.6:Swash plate axial piston motor As there is a angle between cylinder block and flange it
Flg.
The pistons are develops twisting movement of the flange. Further it
(c)Piston and piston shoes: devclops rotation
provided to move in the cylinder bore
provided in of the flange and hence the drive
provided at shaft.
the cylinder barrel. Piston shoes are
the end of piston rods and held
in contact with the These motors are used for machine tools like table

Swash plate by the shoe plate.

movement of die sinking machine.
Pistons
() Shaft : The otating shaft is connected to the
cylinder barrel.
Shaft

Working:
When pressurised oil enters, in the cylinder, it
pushes

the piston out of the cylinder barrel and slides over the
swash plate.
surface, piston
As the swash' plate has angular Out
Dive shaft
Mange
movement causés the twisting movement'of the barrel Oylindor block

and rotation of the shaft is created.

Fig. 2.9.7: Bent axis piston motor
The single piston develops only % rotation of the full
circle of rotation of the cylinder barrel. The number of (B) Radial piston motor :
pistons should be 5 to 7.
1ASBTESO9
The amount of torque produced depends upon the angle
of slide caused by the swash plate and the oil pressure neat labeled otking ot
in the systemL Adia pistoVpebydrauicmotos
For uniform rotation without much fluctuation the
number of pistons should be above seven. Demitionher pistonis are arrnged along the
called as radinl
dius gtheicurcul casin
Duc to inclination of the swash plate, when one piston
reaches its end, it starts with drawing and
PSOr notor
the next takes
is posion producing a movement, hence a torque is Principle:
Created. reciprocating motion of
I utilises the conversion of
They are used for in to rotary motion
medium to high pressures and high pistons produced due to oil pressure
power ranges. connectingg rod
using common crank and
by
() Bent axis
plston motor: mechanism.
Connecting od
In this type
of motor, the axis of the cylinderblock
is inclined at an
angle to the axis of the
shaft

motor
Fig. 2.9.8: Principle of radial piston
Tecaalelgi
YPDatlss

Scanned with Camscanner

 Pumps and Actuaton

Industrial Hydraulics& Pneumatics (MSBTE Sem-VI) 238 Rack

Construction

AA
Connocting od

oylindar and plston Double acting

oylinder
o Prin

motor
Fig. 29.10:
Rack and pinion

it will oduce
moves towards right,
When piston
while towards left will rotate in
clockwise rotation
counterclockwise direction.
Common rotations of the shaft.
crank Itwill give limited

rotary (Limited Rotary)

2.9.2.5 Semi
motor Actuators
of radial piston
Fig. 2.9.9: Construction
Out
motor consists of
:
The radial piston
casing. The
Pistons arranged
radially along the Moving
() pistons. Fxed vane
Fig. 2.9.9 shows four vane
piston rod
is connected to cach
(6) Connecting rod
connecting rod are connected to
and other ends of
crank disc.
which drive
is circular disc on
(c) Crank : Crank a
shaft is mounted.

Working: Fig. 2.9.11:Semi rotary actustor

When oil enters in the cylinder O, it will push the
movement is given to about 300
piston out of the cylinder. This This type of motor produces rotation of
moving vanes
the connecting rod. angle. The oil enters between fixed and
transmits the movement to the to rotate the
The connecting od The oil pressure makes the moving vane
is mounted
crank. As the end of connecting rod shafts.
eccentrically with the centre of the crank, it creates
When two sets of moving fixed vanes are used cn
it
rotary motion.

The motion is produced continuously with other give rotation less than 180.
pistons.
2.9.3 Symbols of Rotary Actuators (Hydro
This type of molors is suitable for low speed high motors)
torque applications. They are used in marine winches,
rudders, construction equipments, high power industial
machines, etc.
1. Uni-directional fixed
displacement
2.9.2.4 Rack and Pinion Type Motor
This motor consists of double acting cylinder, rack and
2 Uni-directional
pinion mechanism as shown in Fig. 29.10.
variable displacement
The reciprocating movement is given to the rack and
converted into rotary motion by using the pinion.
3. Bi-directional fixed
displacement

Ted
Pl

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI) 2-39
Pumps and Actuators
Economical0
OTorguo requirod
Bi-directional
4.

variable displacement
eecto
Hydro moto
-@stompressu
5. Limited rotary

actuator Type of application

OSpoed of rotation
Fig. 2.9.12
2.9.4 Difference between LinearActuators
MSBTE: W1 1. Torque required
and Rotary Actuators
The torque required to move
the work and
and rotaryactiators W-1 calculated as starting torque and it is
AComp running torque. Initial
starting or breakaway torque is higher
than the running
inear act torque.
2. System pressure:
(a)Definition Fluid energy is Fluid energy is
As per guidlines by manufactures in the instruction
converted into converted into manual system pressure is selected
to produce the
reciprocating rotary motion. required torque. Radial pistons motor can work
at very
(linear)motion. high pressures upto 450 bar.

6)Construction It uses piston and It uses gears, 3. Speed of rotation:

cylinder vanes, pistons,
For low speed application, radial piston motors ane
mechanism. SCrews, etc.
suitable and for high speed, vane motors are suitable.

c)Ontput Linear speed. in Rotary speed The high speed motors are provided with cross over
m/sec in RPM reliefvalve.

()Space More lincar space Compact with 4. Type of application:

required isneeded. less space Torque needed with direction reversiblity, space
needed. available for installation, precision machine tools,
Tequires minimum speed fluctuations, etc.

)Types Single acting, Gear, vane, 5 Economical:

double acting. piston motors, The motor is selected on the basis of cost and service
double rod, etc. life expected. It should be easily available of cheaper
tandem,
rate.
telescopic, ctc.
9 Applications Cranes, Grinders, 2.9.6 Advantages of Hydro Motors over
construction mixers, Electrical Motor
equipments, farm conveyors
machineries, etc. crushers, etc. 1. Easy, smooth and instant reversing of motor's shaft
(Symbol without any shock.
**

(double
2 Easy controlling of torque throughout the operating
acting type)
speed
2.9.5 Selection of Hydro-motors 3. Possibility of breaking action easily without any shock.
4. Better power-to-weight ratio.
0OWing
ofbydraulic
factors are to be considered
for selection 5: Very low starting torque is requirca.
motors.
6. Can be used for an indefinite period without damage.

P eis

Scanned witn camScanner

 Pumps and Actuatr
Industial Hydraulics & Pneumatics (MSBTE Sem-VI) 2-40

(a) Vane motor

2.10 Pneumatic/Air motors (Rotary MSBTE
actuators) N-
vans
of vane
warking of
iwith neat sketch ype.of air
QSExplain
DeinitionT is the pneumätic actiüator uhicn
Onberts energy of compressed air into rechanicul OLOE
sliding varesth rotor
Definition When
eneresain the forn ofrotary motion
g com
motion by USTng compressed
Air motors are used for pneumatic
hand tools Ike sed to obiain rotar
as vanemotor
grinders, drilling machines, mixers, etc. a itis kown
Construction:
Casing(Camring
Vanes-

Inlet Exhaust

Fig.2.10.1:Actual air motor Rotor

2.10.1 Types of Air Motors

MSBTE: W-15, W-17 S-18

Q Siate diferentypes ofair motors. Explain any one

(W15,S18)

Cst varOuS Des of a motors. xplin vane iype ar

oro wn neat skelch W 17

a Listand explain varioUs ypes otar moiors

marks)
QClassiy air motors and explan any one of them
(b)
marts)
Fig. 2.10.2: Vane motor
The pneumatic motors
are classified as per the
mechanism used in construction It is similar to vane compressor in construction.
it
It mainly consists of
Types of Air motors
(1) Rotor with
slots: It is the circular disc with slots tD
accommodate the sliding
(a) Vane motor vanes.
() Cam ring: It is the outer casing in which rotos
) Turbine motor
mounted eccentrically.

)Piston motor
6) Inlet/exhaust ports: They are provided for inket
hugh pressure air and exhaust low pressure air to u
() Gerotor motor atmosphere.

Fig.C2.6:Types
of Air motors

Scanned with Camscanner

 Industrial Hydraulics & Pheumatics (MSBTE _Sem-VI) 2-41
Pumps and Actuators
(c) Piston motor:
Working:
enters through inlet of the motor Definition
.The compressedtheairvanes. It will push the vane in the
When reciprocating
movenment
of
and strikes on piston is converted into rotury motion
toith thehelp
forward dircction. ofcompressedairitis knoun aspiston motor.
mounted with rofor, it will produce
. As vanes arc In
angular movement and
produces rotary motion. Cylinder 1

The air at low

pressure at the outlet is exhausted to the
atmosphere.
leakage due to wear of
motor has possibility of air Connecting rod
.The for speeds 100 to 200 m
vane tips. It is suitable

(o) Turbine
motor

Definition her rotaling bheelhüs similar

runneras used to obtaun rotary Cylinder-4
feature o turoune Cylinder-2
as turbine
maton jrom compressea air t1sENOUn
Crank disc

motar

Construction:

Runner whee Cylinder-3

(a)

Curved vanes

Compressed

Nozzle

Fig. 2.10.3:Turbine motor

It consists of
(b)
Nozzle: It is used to increase vclocity of compressed
air and produced jet of air. Fig.2.10.4:Piston motor
0 Runner vwheel: It is the circular disc with number of
It consists of radially mounted cylinders along with
curved vanes on it peripheries.
pistons. The piston red is attached to the connecting rod
(m) Casing : II encloses the nozle and rurner wheel with for each cylinder.
inlet and outlet ports. (not shown in figure)
The connecting rods are mounted on the crank disc
Working
along with output shaft

When compressed air enters in the nozzle,

it increases Working:
its veto city by dropping the pressure, and
jet of air When compressed air enters in the each
cylinder, it wil
strikes on the curved
vanes of the runner whecl. dissection. This
The jet will push push the piston in the downward
the curved vanes and produces
moion by striking
rotary movement is given to the connecing rod
on vanes one by one in series,
attached to the crank disc
They are low torque The connecting rod end is
high speed motors, suitable push the crank in the
low temperature for away from its centre, hence it will
application.
forward dissection to produce angular motion.
TecKalelgi
YPbCatiss

Scanned witn amscanne

 Pumps and Actuathn

2-42 motion at th utput shaft.

givesrotary
ndustrial Hydraulics & Pneumatics (MSEE This action 200-300 rpm.
me
rotary
motion by for low pm up to
This cycle will continue to produce They are used
the sequence of cylinder 1
to 4. Symbols of AirMotors
rotary
mounted radially to
obtain 2.10.2
It has 4,5,6, cylinders
displacement
motion. Unidirectional fixed
(d) Gerotor motor:
MSBTE W.18 (specd)

working of
gear type OI Unidirectional variable
displacement
neat sketch
ain with 18 (speed)
motor: elemenits re
gerotor shaped
nitionWhen niotion using compressed ait
obtaun rotary
eato motor displacement
calledasgreater Bi-directional fixed
2s 3.
Construction:
Exhaust

Casing
displacement
Bi-directional variable

Limited rotary air motor.

Motors
2.10.3 Specification of Air
ZZZIA Gerotor
1. Kilowatt rating:
high kW ratig
They are available in market at low to

Inlet
eg. 0.05 kW to 20 kW.
Fig.2.10.5:Gerotor motor 2. RPM of the motor:
rpm requirement
It consists of: Hand tools like grinders, drills has
range up
(1) Gerotor pair : The gerotor shaped elements are
high, motors may be available in the rpm "
mounted in a pair similar to gear pair,
20000 rpm.

Tool holder size:

(2) Casing: The gerotor pair is enclosed in a casing with
3.
a the casing surface are hold n
proper clearance The tools like grinding whel, drills
(3) Inlet and exhaust ports are provided for compressed air motor opening, the size of tool to be held s
eatry and exit. specified on label showing specifications.
Working
2.10.4 Applications of Air Motors
.When compressed air enters in the casing
through inlet1. Hand tools:
port, it will strike on the gerotor and pushes
it forward,
the next gerotor shape will come in front Grinders, borers, drills, hammers, etc.
of inlet and
moves in forward dissection. 2. Material handling devices:
To operale trolleys, conveyors, etc.

TrdPsalo

Scanned witn camScanner

 Hydraulics&P
Pneumatics (MSBTE Sem-VI)
Industrial 2-43

Dentist: Pumps andAchuators

by pneumatic motor.
Tooth cleaning is done

Mixers

Small mixers in
chemícal industries, ctc.

Fig.2.10.7: Hand grinder

Fig. 2.10.6 :Nut runner

2:10.5 Difference between Air Motor, Electric Motor and Hydraulic Motor
MSBTE S-09W09.S-10.W35

0Diierentiate airm wit eletnicaland hydrauic

wlieectri W-15)

moto draulicn mtor

Compressed air Electric current Pressurised oil
Medium

Construction Simple Complicated Simple

2

Shockproof May occur Shock proof

Shock
Easy using Flow control
Speed control Easy using flow control valve | Difficult ànd costly
valve

Low High
Weight/Power ratio High

Moderate
Operation Smooth
Noisy
canse
Short circuit may
Explosion proof Less chances
7. Explosion
burning

Less
High
Eiciency Less
Cheaper

9. Cost Cheaper
High
Limited
available
10. High power
Power Limited
TeKel

Scanned with Camscanner

 Pumps
andAciuaton
Industrial Hydraulics&Pneumatics (MSBTE Sem- 244

motor Electric motor aulic motor

SNo Point Afr Winding frewinding
Electrical equipments reel,
Hand tools feed drives, etc,
11. Applications fan, mixer, machine|
Tools

12. Symbol:

to considered
redfor
State any four factors be
forsselectin
Q. 17
ofpump. (Section 2.7.2)
Review Quéstions
actuators.
Q.18 Classify Hydraulic/pneumatic
positive displacement (Section 2.8.2.7)
Q.1 State the meaning of
pump.(Section 2.1.1) 2.8.2.A and 2.825
Q.19 Draw symbols of (Sections
pumps in detail. (Section 2.2)
Classify oil hydraulic
Q.2 Single acting cylinder (i)Double acting cyfind
pump. (Refer 2.3.1)
0
Draw and explain External gear
a.3 Gi) Tandem cylinder (v) Through rodoyinder
Explain working principle of vane
pump? List the
a.4 Explain with neat sketch working of double
types of vane pumps (Section 24,2.4.2) Q.20 acdrn
ding

pump. air cylinder. (Section 2.8.2.4)

Explain with neat sketch unbalanced vane
a.5 State
(Section 24.2(a) Q.21 Explain tandem cylinder? any
n
pump,
advantages. (Section 2.8.2.7)
Q.6 State pressure balancing in balanced vane
Show with neat sketch. (Section 2.4.2(b)) a.22 Explain cylinder With end CUshioning

(Section 2.8.2.5)
Differentiate between gear pump and vane pump.
a.7
(Section 24.3) Q. 23 List specifications of hydraulic cylindera

(Section 2.8.2.10)
Q. 8 Draw and explain characteristics curve of gear
pump.(Section 2.7.1) Q.24 List the methods of cylinder mountings

(Section 2.8.3.1)
Q.9 Draw and explain characteristics curve of vane
pump. (Section 2.7.1) Q.25 Classify air motors and explain any on

(Section 2.10.1)
a.10 Explain internal gear pump with neat sketch.
(Section 2.3.1b) Q. 26 Explain turbine motor with neat skelcn

Q.11 Explain gerotor pump with neat sketch. (Section 2.10.1(b))

(Section 2.3.10))
a.27 Write practical applications of air motors

a.12 Draw and explain screw pump. (Section 2.5) (Section 2.104)

a.13 Explain swash plate axial piston pump. State

the.28 compare air motor with hydraulic and elecine mou
function of swash plate. (Section 2.6.1(b)) (Section 2.10.5)
Q.14 Explain bent axis piston pump with neat sketch. a.29 Explain double rod double acting cyilinder
(Section 2.6.1(6) sketch. (Section 2.8.2.6)
a. 15 Explain radial piston pump with
neat sketch.30 State any two advantages of telescop
yinde
(Section 2.6.1(¢)) Draw its symbol. (Section 2.8.2.8)
a.16 Differentiate between gear pump Wne
and piston
on the basis of function, construction,
pump.31 Xplain telescopic cylinder with neat sketcn
pressure its applications. (Section 2.8.2.8)
range and delivery of oil. (Section
2.6.3) actuatos
Q.32 Compare rotary
linear and
(Section 2.9.4)

Scanned with Camscanner

 (MSBTE_Sem-VI)
Industrial Hydraulics & Pneumatics 2-45
mps andActuators
Classity. hydraulic notors, explain any one. Q.39 Explain clevis
33 mounting with
(Sectilon 2.83.1(©0)) neatsketch.
(Section 2.9.2)
with nèal sketch. a.40 Select actuator for (Section
Explain vane motor
Q.34 2.8.2)
(Section 2.9.2.2)
1.Handtools
sketch radial piston motor,
Explan with neat
Q. 35 2. Dentist drll
(Section 2.9.2.3(8)
3. JCB am
factors for selection of hydraulic
0.36 State any four
motor (Section 2.9.5) 4. Hydraulic dumper trolley movement
actuator. Draw its symbol.
Explain limited rotary Q.41 Suggest actuators which can produce
a.37 equal push
(Section 2.9.2.5) and pull force during its movement.
(Section2.8.2.6)
Explain pivot mounting and foot mounting.
a.38
(Section 28.3.1(¢) and (b}) Q.42 Differentiate between Hydraulic Purmp and
Hydraulic Motor. (Section 2.9.1)

'

wIun
Scanned
ambcanne
 UNIT 111

Chaptor 3: Control Valvos 3:1 to330

Sylabus:
3.1 Classification of Control valves.
3.2 Prossuro control valves reliot, unloading, sequenc9, countar
balance, pressuna roducing valves.
3.3 Diraction control valves Check valve, 2/2, 3/2, 4/2, 4/3,82
-

5/3 D.C. Valves used in Hydraulics and Pneumatics,

3.4 Standard centre posilions, Mathods of actuation
3.5 Flow control valvas Non-compensated, Prossuro and
temperature compensated.

3.1 Introduction to Control Valves..

*******19919979ITTI

3.1.1 Noed or Function of Control Valves

3.1.2 Definition of Valves. ***"**'19 1nrere

3.2 Classification of Control Valves.
3-
3.2.1 Seal Valves (PoppetValve).
3.2.2 Sliding Spool Valvas ,3
3.2.3 Pressure Control Valves.
3.2.3.1 Types of Prossure Control Valvos .
3.2.3.1(A) Prossure RoliefValva..

3.2.3.1(B) Pressure Reducing Valv....

3.2.3.1(C) Unloading Valve... .3-8

3.2.3.1(D) Sequence Valv ... ,3-8
3.2.3.1(E) Counterbalanco Valvu. 3:9
3.2.4 Direction Control Valvos..

3.2.4.1 Classification of D.C. Valvos.. 1

3.2.4.2 Symbolic Represontatlon of D.C Valves .
3.2.4.3 Construction and Worklng ofvarlous D.C, valvas3-1
3.2.5 Non Ratum Valvo/Check Valve

3.2.6 Pilot Operatod Check Valva...

3.3 Standard Centre Posltlons and Mothod

of Actualion.
3.3.1 Standard centro poslions of D.C. Valvo
 Industrial Hydraulics & Pneumatics(MSBTE_Sem-VI) 3

3.3.2 Methods ot Actuaton/Operation of D.C. Valves . 3-22

3.4 Flow Control Valves.. .3-24

Principle of Flow Control. 3-24
3.4.1

34.2 Types of Flow Control Valves .3-24

3.4.2.1 Throttle Valve. ... .3-26
3.4.2.2 Non Pressure Compensated Flow Control Valve..3-27
3.4.2.3 Pressure and temperature Compensated Flow
Control Valve... 3-28
3.4.2.4 Flow Dividers -3-29
 CHAP
Control Valves

UNIT II

Syllabus
3.1 Clasification of Control valves.
counter balance, pressure reducing valves.
3.2 Pressure control valves- relief, unloading, sequence,

Check valve, 2/2, 3/2, 4/2, 4/3, 5/2, 5/3 D.C. Valves used
in Hydraulics
3.3 Direction control valves - and
Pneumatics.

3.4 Standard centre positions, Methods of actuation.

3.5 Flow control valves-Non-compensated, Pressure and temperature compensated.

(d) Flow quantity:

3.1 Introductionto Control Valves
To increase/decrease flow of oil to vary the speed
of
In a goneral layout of bydraulic system, after pump the actuator.
next immediate important componenls ae locate (e) Other special function:
which are control valves. They are placed in between
pump and actuators.
Tt includes flow of oil in only one direction, diverting
flow of oil, etc.
pump generates flow of oil which is fed to the
The
actuators through a controling element known as3.1.2 Definition of Valves:
valves. Hence valve is nothing but a device which

controls the oil energy.

DelinitionValve isd mechanical tevice which contro
he oil energy us perrequirementof the systent
3.1.1. Need or Function of Control Valves vSTArE

Example: In our domestic plumbing, we use water tap

The valves are fluid controlling element which has
to as a ON/OFF valve, Gate valve while flow regulator is also
perform following functions:
a type valve connected to LPG cylinder.
(a) Blocking/stopping offlow
of oil:
3.2 Classification of Control
When the oil supply is not required
to the other part of
Valves
the hydraulic system.
Classiy Hydraulidpneumatic controlvalves
(b) Direction of flow: Mars
4
The oil is to be fed to the
inlets of the actuator Control valves used in pneumatic system are classl
to obtain
output motion. Hence
flow direction is on the basis of construction, control parameter, et
to be changed.
(c) Pressureof
ol:
Pressure is to
be reduced or excess
pressure is to
relived using be
control valves.

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI)
3-2
Control Vaves
Classification of Control Valves

1. According to construction

(a) Seat valves

Poppet

(b) Spool valves

2. According to control parameter

H (a) Pressure control valves Fig. 3.2.1: Poppet valve

(b) Direction control valves Advantages :

1. Compact in space
Flow control valves
2. Easy for operation using spring

() Check vaves or non retun valves Disadvantages:

1. Valve finishing is difficult and costier
According to methad of control
3. 2: wear and tear of valve area is not uniform.

a) Direct controlled
3.2.2 Sliding Spool Valves
F6) Pilot controlled Spool valve consists of sliding spol like a small piston
sliding inside a finely finished bore in the valve
Fig.C3.1: Classification of Control Valves
housing
3.2.1 Seat Valvas (Poppet Valve): Ttsconstruction is simple and the position of spool
connects or disconnects the ports of the valves.
MSBTE:S:16
It is used of direction control valves and spool is loaded
a0vantages:and aisS jes of poppet ype with the help of spring.

drectional controLvalve Valve bore and spool finishing is easier and simple and

Seat valve consists of poppet which sits on specially uniform wear and tear of valve spool and bore.
machined and finished seat. The poppet is either a ball Spool-

or cone mounted with the help of spring.

Spring
The position of poppet from the seat helps to operate
the valve. The seat valves are used for pressure control
Spool rod
or flow control of compressed air.

Valve finisbing is difficult and costlier and wear and

tear of valve area is not uniform.
Fig. 3.2.2:Spool valve

Difference between Seat Valve and Spool Valve:

MASBTE: W-10.S-11

Q (W-10
Whatis difference between spool type and seat type D,Cvave
Mompare Spool valve and poppet valye? Draw sketches
also.

Ted Teled
Pelltatlass

Scanned witn camScanner

 Control Valves
Hydraulics & Pneumatics (MSBTE Sem-VI) 3-3
Industrial
Spool valve
Sr. No. Point Seat valve
Poppet, ball, cone
Spool (piston type)
Valve clenmcnt

2. Figure

Simple
Construction Complicated
3. Difficult and costlier
Simple and cheap
4 Valve Finishing
uniform
Valve wear Not uniform
5. actuations
Suitable for all types of
Actuation possibility Limited
6. |
Direction control valves
Application Pressure cotrol, flow control|
7. control parameter
Classification of valves according to the
function as given in the
table:
according to the control parameter and its
The valves are classificd (4 Marks)
circuits
fluid controlling
elements used in hydraulic
a. State and explain three basic
Nameiypes-
Function
Sr. Control parameter

pressure as per requirement of Pressure control valves

Oil pressure To increase/decrease the oil
the hydraulic system
(a) Pressure relief valve

b) Pressure reducing valve

)Unloading valve

(d) Sequence valve

Flow or quantity of | To control flow of oil to obtain

variable speed of the | Flow control valve
oil actuators in the hydraulic system (a) Two way valves
(6) Pressure compensated

(c)Non pressure

compensated

(d) Throttle valve

3. Direction of oil feed To change the oil feed path to obtain output motion of | Direction control valve
cylinder/motor of hydraulic system 2/2 D.C. valve
a)
(b) 3/2 D.C. valve

() 4/2 D.C. valve

(d) 4/3 D.C. valve

valve etc.
(c) 5/3 D.C.
operated D.
() Pilot
valve

llcatia

Scanned witn camScanner

 (MSBTE_Sem-VI) 3-4
Hydraulics & Pneumatics
Industrial ControlValves
4. To achieve sequential
Valves operation of
Pressure Control circuit withpressure actuators
in
3.2.3 control:
pressurecontrol valves: When the numbers
Need of of actuators are
to be operated
pressure if oil pressure is after another in one
excessive a sequence, with
To relief the system: control, sequence the help of pressure
working presSure ofthe
valve of pressure
control
greater than is used.

Working prossuro (P)

resuro
ress (og.15bar)
gauge If ol pressure by pump
Po-20 bar
Actuator 1
PaP Object

Pump Drain the 5 bar

oil pressureB

Res
esevoir To reservor
SE
3.2.3:Relief function
Fig. reservoir

is exceeded by the pump oil

When working pressure
hazards and damage of pipe lines
pressure, it may cause equencaB
vaive
components hence as a safcty device,
PurnP
Actuator 2
and other
provided.
pressure relief valves are
Fig. 3.2.5: Sequence functilon
Regulating and reducing pressure
in certain
2. In this example, the object is moved from X to Y by
portions of the circuit: actuator 1 and after complete movement of actuator 1, the
When actuator 1 requires pressure of 30 bar while oil will pass through sequence valve to the actwator 2 and
actuator is operating at pressure of 15 bar. In this case,moves the object from Y to Z
reduced from 30 bar to 3.2.3.1 Types of Pressure Control Valves
te presure of the oil is to be
15 bar. This function is performed by
pressure reducing
MSBTE: S-18S-19
valve.
C State the different types any four pressure control

Rraustor 1 valves yith their specific appicalion. S-18, S-19

Actuiator 2
Pressure control valves are classified according to their
pressure
fünction, type of connection, size and
operating range.
P=30 bar Commonly used pressure control valves are:
Pa15bar
Function (Application)

pressure
Pressure relief valve To relieve excessive

Preesure in the system

reducingvalve
oil in
Pressure reducing To reduce presure of
Fig. 3.24: Reducing pressure in the subsystem 2. circuit
certain portion of
valve
in the
3. Unloading system pressure:
. Unloading valve
Unlgad the pressure
system
Wben it is required
to unload the pressure to save
the
system from undesired actuate actuators
heat energy, this function Sequence valve To
performed by is 4.
unloading valve sequence

euledse
Teaatis
PDE

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI)
3-5
Coniroi
Valveg
Types of Pressure Control Valves Function of pressure relief valve:

When working pressure is exceeded by the

thepurmp
1.Pressure Relief Valve .
pressure, it may cause hazards and damage of oil
pipelineg
and other components hence as a safctv y
) Direct operated pressure relief device,
valve
pressure relief valves are provided.
in) Pilot operated pressure relief
valve It will relief pressure which is more
than working
pressure to the reservoir by lifting valve elemen
ment
2. Pressure Reducing Valve
It will divert flow to the reservoir till the pressure
3.Unloading Valve is
equal to the working pressure.

4. Sequence Valve Types of pressure relief valve:

i)Direct operated pressurerelicf valve

5. Counterbalance Valve

ii) Pilot operated pressure relief valve

Flg.C3.2 :Types of Pressure control valves

3.2.3.1(A) Pressure Relief Valve )Direct operated pressure relief valve:

Construction:
MSBTE: W-12,5-14,5-16,S-17Z
ITTEE Pressure seting knob
a. What is the function of pressure relief valve? Where it
is located? Sketch direct.operating pressure reliet V
valve Vave
a
W12,S17 body
With aneatsketch,explain the funcioning of simple Spring
Symbol

pressurerelietvalve
State
(14S17
the functionsof pressurereiet vave
pneumatic systemExplain
or
skerch. is orkng Mih neat
Poppet
16 To raservoir

Deiinition: When presure contro

valve is used to tinit
Lhepressure
ir a Systemto aprescribed, maximimavaliue
by draining8 5ome or ihe punip output
nl tothe reservoir
tark when designed set pressure Inlet
pressture
isreached,it is knowr as
relief valve Frompurmp

Principle

It works on the principle

of lifting the valve element
with oil pressure
against the spring
(designed set) pressure.
When set pressure
is greater than oil pressure,
closed and opens the valve is
when oil pressure
exceeds the set pressure.

spring

Pa Actual PRV
Fig. 3.2.6:Principle Fig. 3.2.7:Construction
of pressure relief of pressure relief valve
valve
It consists offollowing
main parts:

Scanned with tamscanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI) 3.6
main valve component of conical
a)Poppet: Histhe Definition When Control
Valves
shape seated in
the valve body. Its upper end is the valve
element
through is actuatedindirecty
attached to the spring which exerts compressive force pressure
the intemal pilot line
to relief the
on it
i is krown. us excessive
pilot operated pressure
Valve.
to set the designed pressure relief
b)Spring: It is provided of
the hydraulic system
with the help of setting knoh Principle
Pressure setting knob: t s screw which can be
a
It works on the principle
adjusted to set the spring force as per requirement produced in the of throtling
main spool which by orifice
is provided with the mict and drain operates the
Valve body: It element using spring and throttle oil valve
pressure.
above components.
ports and accommodate all Construction:
Working: Poppet
pnng
Jt is normally closed valve connected between pressure
AGjUSng

line and the oil reservoir.

www= SereN

. When inlet oil pressure is less than the spring force, it Pia ine
means that it is insufficient to overcome the spring
Symbd
force, the valves remains closed, The pressure of oil is Main
safe for the system. spod

Throttfe
When oil pressure is greater than spring force, it
the (ormce

pushes the poppet against the spring force and unseated Drain
the poppet. Now the valve opens and oil flow from inlet Idet othe1 tank

port to the reservoir. The valve will remain open until Fig. 3.2.8:Pilot operated pressure
reliefvalve
the excessive pressure is diverted to the tank
It consists offollowing main parts:
Cracking pressure : The pressure at which the vaive (a) Main spool: The main spool is seated with the help
first opens is called the cracking pressure: of
spring force and it is provided with orifice
It is essential for every hydraulic system to
provide
pressure relief valve as a safeguard against the pressure
b) Poppet and spring: It is provided as a second stage
pressure controlling element which is connected with
Ovemide.
the help of pilot line. The spring is used to seat the
Limitations of
direct operated pressure relief valve poppet.

*0yare une suitable where the fow rate and the system C) Adjusting serew: It is provided to vary the ptessure
reasonably smaller.
seting.
There is no much variation in system
pressure (a) Port Pand R: They are provided for inlet and
rate. of flow
diverting flow to the tank.
S.tisnotfeasible to use bigger spring Working
Tquirement for
due to more space
higher system pressure.
10 overcome Oil will enter through main port P and passed through
above problems,
Telief pilot operated pressure orifice in the main valve spo0ol
valve are
designedand
used. pressure
Pilot operated When it flows through the orifice, there is a
pressure relilef valve the oil is
Compound dropdue to throttling effect. If the presure of
reliefvalve): remain in
less than the set pressure the valve will
closed position.
MSBTE: W-18 to som
However, if there is increase in pressure due
Wth neat sketch working
pressure reasons, the throttle value of a pressure in
the chamber
relgivay of pilotOperaeu value
a higher
above main spool will also change to
W-18) poppet through pilot line.
and thus act against the ueuledgë
Tech

Scanned with Camscanner

 Control
V:
Pneumatics (MSBTE
_Sem-VI) 3-7
IndustrialHyraulics &
the poppet and I consists of
is higher it will lift
As oil pressure
Sliding spool: It is a main entwk:
valve clemcnt which
creates pressure
difference betwecn throttled oil(a) is
mounted with the help
of spring.
pressure. The main spool
pressure and supply oil
P to port R, so that is provided to
automatically moves up to open port (b) Pilot
line : Pilot ine Control

spool.
oil will be drain out to
the tank. movement of sliding
provided in a valve bot.
outlet ports are
3.2.3.1(B) Pressure Reducing Valve: (c) Inlet and
with
leakage of oil.
MSETESW5SH7 a drain for
setting of valve
is provided for
(a)Setting knob: It
as per

working of pressure
Q. Descnbe construction and requirement.
sketch (W-15, S-17)
redtucing valve with line
operated||Working9:
working of directy
Explain with neat sketch
Q Normally open position:
oressure reducing valve. 4 Marks)]1. is belowte
When the main
supply pressure at the inet
valve is provided to
When a pressure contfol fluid will tlow freely from the inlet h
Deliron pressure to part of system that is valve setting, the
maintain a constant a will emaia
open.
the outlet. The valve
lower thar
ressure n the rest ofthe
system,
t is
ereducing valve, 2. Actuating position :
is greater, the oil will fow from
When inlet pressure
Priniple through internal pilot line and act on
utilizes the the outlet passage
type valye, which
t is a no ally open blocking the sliding spool to
oppose the spring force.
the pressure by partly
spool movement to reduce valve setting, the
outlet pressure rises to the
outlet port When outlet port. Now only
spool moves to partly block the
Construction maintain preset
enough flow is passed to the outlet to
Inlet pressuro Spnng
P, supplied to the
pressure and reduced pressurized oil is
system.
Satbng
Tob

ot Symbol

Body

partly blockag9

Fig. 3.2.9: Construction of pressure

reducing valve

Difference between pressure relief valve and pressure reducing valve :

MSBTE WSIW-14S17

Give the comparison between pressure relief valve and pressure reducing valve. (W-11, S-17)
Q.
pressure relief vave and pressure reducing valve ith respect to its function symbol, nom
O. Dferentiate between element
position and oparated
(W-14
Sr. No. Point Pressure relie?valve Pressuré reducing valve
. Function To relief excessive pressure for safety To supply reduced pressure in the cena
of system portion of the circuit
2.
| Normal position Normally closed Normally open
Kavalndgt

ech tiees

Scanned with Camscanner

 (MSBTE_Sem-VI)
Pneumatics
Hydrauilics& Control Vahves
Industrial
Pressure relief yalve Pressure reducing
Point valve
everyhydraulic systemtis required only if pressure
Sr. No. Necessity It is essential for reduced is desired
Slidingspool
Direcuy poppet operated operatedthrough pilot
line
Construction

. Symbol

Now the port P and Port R get connected and oil will
3.2.3.1(C) Unloading Valve:
go to the reservoir to unload the pump.
PTESNre control
DelfinitionA rame maicaes oLET
This unloading valve is generally located before the
valve is used0 nload the
energyala lov pres5ure to
O pressure relief valve.
save energy 1Is called
uwiloadüng valve. s
The advantages of unloading valve are it helps to
Principle: reduce heat energy to a great extent and used in
through
operated valve which is actuated
II is spool systems where two pumps provide a large volume of oil
the pressurised oil from
external pilot line and unloads at low pressure and one of them must be unloaded
pump. during a specific period.
Construction and working:
3.2.3.1(D) Sequence Valve
Setting screw

Vave body
MSBTE S-15,5-185
9
a Draw sybols of Sequence valve

Explainathe working o sequence välve

(S-15)

Sprng Draln
0 ith neat
S18, 5-19)
Inlet Unloading to
rom plup eservoir Q Explain with neat sketch the function of sequence
p sym
Spool 4 Marks)
valve.

Definition When a pressure control valve i placed in a

SuLChmanner that it
ill actiate the operatiors in a
Extemal piot ine
Pressurised
equence one djter another, il Ls called as sequence valve.
ol
Fig.3.2.10:Unloading valve
Principle:
t consists of sliding spool mounted with
the help
spring. The sping force is
of. Itis spool operated valve in which internal pluo
set with the help of setting circuit in a
USed to build up prèssure to actuate the sub
SCTew.
sequence.
Tbe external pilot line is provided
through which
is pushed up, against spool. Eramples where sequence valve can De u
the spring force.
location to another.
The pamp port P and 1. Movement of material from one
the unloading port R is provided.
workpiece as given in the
When it is
required to unload Z. Machining and clamping of
the pressure from the
pump the oil
is allowed to enter through Fig. 3.2.11
lifts the spool pilot line and
in the upward direction.

Tecduledge
F
iass

Scanned with Camscanner

 Control
Industrial Hydraulics & Pneumatics (MSBTE_Sem-V Valves

enter in the pilot line and exerts a pressurefrom

It will

bottom side of the spool. The spool moves upward

To the connecte
when sufficient pressure is build up and
tank inlet
Hydraulic cylinder port to the sub circuit port to supply oil to the another

WP actuator.

EŽZZZZ227/ Scquence valve are commonly used in pressure

Table
dependent sequencing circuits.
To the tank

3.2.3.1(E) Counterbalance Valve:

Builtup Sequence
)Pump pressure valve
Definition: When cortrol valves are used in hydrm
Fig. 3.2.11:Example of sequencing operation SySems working with oerriding (running-away)
retem
In this example, there are two operations (1)
Clamping pendedload to createhackpressuare at the li
the actuator to prevent losing controfE over the load, i
of job (2) Drilling. The scquence valve is used to actuate as Counterbalance valve.
&7ow
scquence of clamping and drilling. First clamping is done by
It is providing counter (opposite) force of oil to preyent
hydraulic cylinder and it holds w/p firmly, then build up
rapid falling (balance) of heavy load due to gravity or
pressure will open the sequence valve and rotates the
Overrunning
hydraulic rotor for drilling

Construction and working

Over runringka
The sequence valve consists of spring loaded spool,
setting screw knob, valve body with inlet port, port for Counterbalance
as
sub circuit and drain port shown in Fig. 3.2.12. vave
knob
Seting

Valve bod

Fig.3.2.13(@):Concept of Counterbalance valve

Spnng Drain
Counterbalance valve is also a type of normally closd
To the subcircuit valve which permits the flow of fluid in one direcica
Inlet-
but will offer resistance in fluid flow in other direction
Internal Spool until pressure reaches up to a level at which vave
pla line Symbal opens.

In the case of lowering, the vertially loaded bydraulic

cylinder with higher speed due to gravity, we could nx

control valve to reduce flow of oil and we wil
Use flow
have to go for counterbalance valve here.
Fig. 3.2.12: Construction of sequence valve
f hydraulic cylinder falls and stops suddenly at e
the

The internal pilot line is provided to operate the spool. of motion then it may damage the load, cylinder a
Drain is provided for any internal leakage of oil. also it may harm the surrounding people.
This valve is mainly placed in the oil path of two Principle
actuators where sequence is desired. When the first ut
bu
actuator completes it operation, the oil will flow Counter Balance Valve is basically a relief valveorevent
pre
towards the inlet of the sequence valve. is used,to set up a back pressure in a circuit to
load from falling.

Scanned with Camscanner

 (MSBTE Sem-VI)
Hydraulics& Pneumatics( 3-10
Industrial
counterbalance valve creates ontrolValves
applications, the a When the pressure
In such in the port A
prevent the movement of piston rod of certain value, increases
Dressure to it acts on the beyond
spool from
cylinder. direction. downward
Working:
Construction and The spool moves against
the spring force and
consists of sliding spool operated with the the passage for provides
mainly, the fluid to
i spring, internal pilot
line and check valve as descending of
tank. This allows
,

help of the load. As this valve

gets actuated line
figure. pressure, it is known
shown in as direct operated.counterbalance
cylinders to safely
Counterbalance valves are uscd with valve.
loads
suspended loads and deal with over-unning Applications:
hold

They are frequently employed

in vertical presses,
loaders, lift trucks
and other machines that must
maintain a particular position
or hold a suspended load.
3.2.4 Direction Control Valves:

MSBTE: W-14W-16,S-17

2
QGive the classification of D:G (Direcion Contro
valve with respect to fallowing
points
0 Valve element uSEd in construction

Number of ports and pos tions

Mettiods of actiatiorn/operation W-14
QWhatis the use o directonal controlvalve? Explain
with skeich -16)
OWhatishe funcion of direction oontrol yaive? (S-17)

Need of Direction Control Valves:

1. To alter the oil inlet/outet of the actuator for entering
Counterbalance
and leaving the oil to perform the given application.
Symbol
In the given example, the task of lifting and
Fig.3.2.13): Counterbalance valve heavy object («g. crane) is to be
lowering of the
The pressure and the weight of the load will cause the Completed.
valve to open, allowingthe load to lower. The load
dfroping too fast would cause a pressure drop in the
. When ol enters through inlet A it
moves the load

is B, the load
Cxlemal pilot
in the downward while if the inlet
ine. The counterbalance valve's spool to be admitted
wOnld then moves upward, it means oil is
partially close, preventing an uncontrolled
altermately.
drop of the load. through port A and port B
oil path to
ng. 3.2.13b) shows a typical function requires the change of
counterbalance valve. At This altermately. Hence direction
De present pressure (due to
load) acting at port A, the port A and port B
change the path of oil
LVe Temains closed under the spring force. The fluid control valve is required to
n the port Ais trapped thereby prevents movement backward movement of
the
of theload. To obtain forward and
actuator.

eli

Scanned with Camscanner

 Control
Vaves
3-11
industrial Hydraulics & Pneumatics (MSBTE Sem-
to supply oil through inlet
Unk
D.C. valve is used the Ain
while the oil path is changed to tha
Push
Fig. 3.2.17(a) inler
3.2.17(b).
B in the Fig.

recirculation of oil from reservoir

oil from
D.C. valve helps to Tee.
to
A to
moves pump and actuator and back the reservoir.
Ol in down

Pull
Load gets
ifod
(upward
A
Oil out

Fig. 3.2.14: Need of direction control valve A B

2 To change the direction of hydraulic motor. D.C.Vave LIIX

A B P

in Pump
Clockwise Out

(a)

in
Counter clockwise

Fig. 3.2.15:Change of direction of motor

3. To stop movement of actuator intermittently
Piston stops

LT (b)
Fig. 3.2.17: Location
Pl of D.C. valve
No flow 3.2.4.1 Classification D.C.
of Valves
Fig 3.2.16:to Stop movement
of actuator (A)According to
Location of D.c.
the valve element used in
valve: construction:
Thedirection controlvalve (D.C. valve) ) Seat valve or poppet
between pump is located valve:
and the actuator. In this valve,
In the given figure, poppet, a ball or similar item like a plate
1S madeto sit overfinely
machined valve seat.
Ted I
Pluti

Scanned with Camscanner

 Pneumatics SBTE_Sem-VI) 3-12
Hydraulics &
trial
Control
Vatves
(B) According
to number of
positions of ports (ways) and
the D.C.valve
Bal
Ports or ways:
Plot In D.C. valves, the flow
are connected to paths of oil
various ports
supply port, outletinlet or ways which
may be
port of actuator,
pilot port, etc. reservoir port,
O

Commonly used
ports are:

Fig. 3218:Seat valve/poppat valve PortDesignation

Meaning
Spol valre
orsliding valve:
( 1 Pumpport
piston with small width and slides Pump supplies
is cylindrical
. i opening/closing the ports. It pressure oil
high|
inside the valve casing for
2. Inlet port
ar four lands as shown in Fig. 3.2.19. A Oil will enter through
has two, three
of
piston face side
actuator of
linear actuator
.
HAGG-
Outlet
porttof
Oil will drained out
from piston rod side to
actuator
the t nk
4. Reservoir
Fig. 3.2 19o):Sliding spool R/T
Oil drained to
port the
spool has two types: Eservoir
.The
(a) Sliding spool: It has linear motion to operate the. NoteRot A and Bare intet/outiet pots whien oil
flow path wil
valve which is shown in above bechanged by D.C.valve
Fig 3.2.19a).
**

Position of D.C. valve: In D.C. valves,

(6) Rotary spool the ports are
:
Ithas longitudinal grooves in a get connected depending upon the position
circular disc (rotable piston)
as shown of the
Fig. 3.2.19(6).
in sliding/rotary spool. It is required
to start, stop or
reverse actuator movement as
per need of the system.
Commonly two or three positions
are provided with
D.C. valve. They are:
Rotary spool 1. 0position-> Neutral position (Actuator stops)
2. 1 position> Actuator starts movement
3. 2 position Actuator reverse movement
The D.C. valves are represented by number of ports and
positions together. As per this designation, D.C. valves
are classified as:

(a) One way/Non return valve/ Check valve

(b) 2/2 D.C. valve Two way two position D.C

valve
Fig.32.19b):
Rotary Spool )3/2 D.C. valve Three way two position D.C.
valve
te rotary movement valve
E nieed helps to connect
of the system. the ports as per 4/2 D.C. valve Four way two position D.C
pressures. They are suitable () >
for lower valve

(e)4/3 D.C. valve -> Four way three position D.C

valve
Techoele

Scanned with Camscanner

 ndustrial Hydraulics & Pneumatics Control
(MSBTE Sem-VI) 3-13 Vaves
() 5/2 D.C. valve
» Five way two position It consists of a valve body in which
sliding ,
spool
valve
D.C.| is
placed with spool rod.
) SI3 D.C. valve port A are cut in the
Five way thrce position D.C. The inlet port P and outlet valve
valve body as shown in Fig. 3.2.20.
with the help of lever, pedal
The spool can be moved
3.2.4.2 Symbolic Representation of D.C
other actuation method.
Valves
Working:
1. Ports/ways are designated by alphabets like
1. Position 1(P->A):
P,A,B,R,T,X, etc. Their paths which are conccted are
shown with the help of arrows. In this position, the spool is located in the
e vave
v

such that the port P and A are get connected

2. Positions of D.C. valve are represented by square. For
oil can easily flow from P > A. This postüon
cach position one square is required. If there are three
starts the oil supply to the system. It is
showmi
in the in
positions, it means three squares are shown
symbol.
symbol.

3. Actuation method is shown at the outside of the valve

outline represented by the symbol, of actuation method.

Example: Lever operated 3/2 D.C. valve.

Arow for
Connection A
Lever operated

2. Position 2 (P*A):
P,A
Three poris In this position of D.C. valve, the spool is shitel
RP. R towards left envelope so that the port P get closel
3.2.4.3 Construction and Working of various and port P and A get disconnected.
D.C. valves
The oil will not flow from P to A. This posin
MSBTEKS5W-15.W15 stops the oil supply to the system.

constructiontand working priniciple ot Rolar

Eplain
Spool ype DO Vave with sketch (S-15,W-15, W-16
Al 2/2 D.C. Valves:

Meaning:
P
2 Two ports/ways (P and A)
Symbol:
2 Positions
(PA,P#A)
operated 2/2
Construction p4-Lever
D.C.valve
Valve body

It is similar to ON/OFF electrical switch or ater

Spod for water supply.
P
P A) P B] 3/2 D.C.Valve:
(PA)
Fig.32.20:2/2D.C. S-12.W-13,5H4S
valve MSBTE

Draw a neat sketch of 3/2 D.G. valve

NOrKing:

Scanned with tamscanner

 Industrial Hydraulics & Pneumatics (MSBTE
Sem-V) 3-14
Control Valves
O. Draw sketch of
3x2DCpneumaticvalve, explain is Symbol
Working
(W-13)
a. Sketch the two positions of sliding spooltype
3/2
DCV and explain in biel Push button operated
S14) 3/2 D.C Vave
Q. Explain 3 x2
DC yalva wih neat sketch and
Symbol S1714 Marks) P RP
Application:
Q. Draw a neat slketch and symbol df 32 normally
closed pOppet typo D. G.valve It is used to actuate single acting cylinder, uni-
S-19)
directional hydraulic motor, pilot control of valves.
Meaning:
C] 4/2 D.C. Valve
3 ports P, A, R
MSBTES-11.S-14.S-16
2 positions: (a) P>Ä, R closed
(b) A->R, P closed O.DraWa sketch ot.nomal and actuated posifions of
DCV S-1
Construction and working: 42
Sketch thefwo postions of roary Spooltype 4/2
DCV

and explain in briet

Body. h of 412 valve Explain its workini9
CE Drawnea

Spring
S16
Spool a Draw aneat sketch of rnomal.and actíating position
roa
P o142 D EMarks)
Spoof Meaning

4 ports: P, A, B, R
(a) Open position
2 positions: (a)P>A
B-R
(6P-B
ww AR
Construction and working:
P
Construction:
IP R
(b) Normally closed (a) Spool type
Fig. 3.2.21 : 3/2 D. C. e A
spring. The
ZAZZAVZILTA
It consists of sliding spool mounted with
and as shown
R
valve body is provided with port P, A
in Fig. 3.2.21
Sliding
Position 1: In this position, the port P and port A is get pool button
will supply the oil to IP
connected and R port is closed. It
blocked. (a) Actuated postion of 4/2 D. C. valvee
the actuator while flow to the tank port is
PA,B-R))
Position 2:When spool is shifted, it will block the port
P of the pump to stop the supply of pressurized oil
to Fig. 3.2.22 (Contd)
the system. The port A and port R are get connected so
that oil will drain to the reservoir.

TedT

Scanned witn camScanner

 Control Valves
Industrial Hydraulics &Pneumatics (MSBTE Sem-V
shows seat type 4/2 D.C.
value. in
The Fig. 3.2.23
A which the ports are
connected or disconnected with the
requirement.
help of valve plate as per

AP It consists of sliding spoolseat

loaded with spring and

controlled with the help of suitable method like push

button shown in Fig. 3.2.22.
body named
The four ports are provided in the valve
PABR.
(b) Normal position of 4/2 D. C. valve
Position 1 (P>A, B-> R): În this position of D. C
P-A,BR)
Valve, the spool is placed such that the pump port P get
Fig.3.2.22:4/2 D.C. value (Spool type)
connected to the port A of actuator and port B of
(b) Seat type actuator is connected to the reservoir port R to drain out
Push button the oil.

Position 2 (PB, A->R):In this position, the spool

Pushrod
Seal is shifted with the help of push button and spring. Now
the port P is get connected port B of actwator and port
Valve body
A of actuator is connected to the reservoir port R to
drain out the oil.
-B
Valve seat
Symbol:
Vave plate Sliding seat A B A
Fxed seat
R

(e) Normal position (P-A,

PR P
B--R)
Push button operated 4/2 D.c. Vabve

Applications :

To operated double acting cylinder, bi-directional

hydraulic motor in hydraulic system.

(b) Actuated position (P-B,

A-R)
Fig.3.2.23:Construction of 4/2 D.C. valve(seat
type)
Fig. 3.2.24: Lever
The Fig. 3.2.23 shows spool type operated D.C valve
4/2 D.C. value in
which the position of
the spool helps to connect the
ports P, A,B and R as pet requirement.

dlrald
atinis
Peliat

Scanned witn camScanner

 Industrial HydraulicS &Pneumatics (MSBTE Sem-VI) 3-16 Control Valves

Construction and working :

Position (a) and (o) are shown in Fig.3.2.28, here the

position (b) is shown.

Fig. 3.2.25:Push button operated D.C Valve

P
Fig.3.228:43 D. C. Valve

TT
Fig. 3.2.29:Normal position of 4/3 D. C. Valve

Fig. 3.2.26: Actual construction of spool type D.C. valve

Tits construction is similar to 4/2 D. C. valve. But it has
three positions.
Position 1:t is similar to already discussed in 4/2 D. C.
valve. It connects P-> A, B»R

Position 2:1t is the normal position shown in

Fig.3.2.29.
In this position, the spool is shifted such that port P is
closed and oil will not flow from it to the port A or port
B. Similarly there is no oil path from port A or B to the
reservoir port. It means that all ports of the valves are
Fig. 3.2.27:Solenoid control D.C. Valve closed or blocked off. This position called as closed
D] 4/3 D. C. Valve: centre position.
Position 3: It is similar to 4/2 D.C. valve in which
MSETE:S17 connections are P-> B, A->R.

Q. Epan 43direction contro valve used in hydrauli Symbol:

Systemwith sketch. S17,4 Marks

wW X
Meaning:

4 ports: P,A, B, R
3 positions (a) PA
BR P R
TIL P R
P
(b) P#A Application :
BR It is used to actuate double acting cylinder/bi-
(c) PB directional hydraulic motor with intermediate stoppage

AR of the cylinder or motor.

Scanned witn camScanner

 Contral
Sem-VI) 3-17
vaves
Pneumatics (MSBTE spool operated D. C.valve,
Hydraulics& It is sliding valve
Industrial consists
five ports P,A,B,R and T, T also Teservoit
is
D.C. valve: n lso
positinns of4/3
Other
position:
used independentdly. on
centre
(a) Open
is operated in two positions:

LHX
A B
It
Position 1:
mects
In this position, the spool connects the
thepot
oil
port A for to enter in the system P
P While port B to port R to divert flow
internally. used
all porls are connected
In this position, the reservoir, the other eservoir port'Tise oilh
all ports P, A, B and R.
Here oil lows through

6) Tandem centre position:

B

wXIX P R
Position 2:
PRT

In this position, the spool connects the port P

to enter oil in the system and port A to port T
to
b

Port P of pump is connected to port R to to

used oil to the reservoir, R port is closed.
divert low of purmp to the tank.
A B
Port A and B of actuator are closed.

5/2 D.C. Valve:

MSBTE WE15:5165-19
A
RP T
QDraw a neat sketch of Korking of PUSh bUto
Symbol:
operated 52 DC valve USed in pneumaic system,
A B
15,S19)
Sketch and explain Working ol 5/2 D G pneumatic

Meaning:
S16)
P
ulTA
RT R
ports P,A,B,RT (T-reservoir port) F 5/3 D. C. Valve:
2 positions: (a) PA,T-closed Meaning:
BR
ports: P,A, B, RT
6) PB, R-closed
3 positions
a) PA
AT
Construction and working: BR
T closed
|P
(b) P-B
AR
LX (c)
R-closed

P#BET
RP
la T A#R
Fig. 3.2.30:5/2 D. C. valve position blocid)
(P-B, A-T)R (All ports
closed

Scanned with Camscanner

 Industrial Hydraulics& Pneumatis (MSBTE_Sem-VI)
3-18
Control Valves
Construction and working:

Ils construction is same as S/2 D.C. valve. Only normal

position is added: The other two positions are als0
ame.
Normal position (P, A, B, R, T closed).
In this position port P is blocked to disconnect port A, B
or B and similarly port R and T are closcd off. There is
no flow of oil ii the system and actuator stops working
during this position.

Symbol:
AlTT|
A
,B Spool rotaton

Lever

Valve
base
PRT RPT RP
G Rotary Spool Valve (4/3 D.C. Valve):
Fig. 3.2.31: 43 Rotary spool valve
MSBTE W-18
H] Pilot Operated D.C. Valve:
Explain rotary SpoofBDON Witineat sketch
As the hydranlic machines arc worked on moderate to
high pressure, sometimes bigger size valves may
It consists of rotary spool as a valve element and require higher amount of actuating force.
internal passages are cut in the valve body to provide
In such cases, the D.C. valves are actuated with the
port P, A, B, R as shown in Fig. 3.3.31.
help of oil pressure to operate the spool which is known
When rotary spool is rotated with the help of lever, it
as pilot operated D.C. valve.
connected the ports as per position of D.C. valve
required for hydraulic system

The Fig 3,2.31(a), (b) and () shows the connection

pors for 4/3 D.C. valve. Fig. 3.2.31(a) shows the
connection of ports P-> B, A R. Ag, 3.2.31(6)
shows the blocking off ports PA,B and R Fig. 3.2.31(C) Piot pressuro Pilot pressurO
A

shows the connection of P A, B R the

coresponding symbols are also shown below thec Fig 3.2.32: Pilot operated D.C. valve
Fig. 3.2.31.

) Rotary spool type 3/2 DC Valve:

rotary spool valve requires less space compared
The
sliding spool valve. They are suitable for low pressure. S18
MASBTE

It is diffcult to maintain adequate sealing for high ype 3/2DO

Sketch the two positions of rotary spool
pressure between rotary spool and inside surface ofa. in bief
&Explan S-10)
valve body.
which
consists of a rotating spool
A rotary spool valve
that
stationary valve casing, so
connects with ports in
fluidis directed to required port.
Trcheledgi
Y PRlIatls

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 3-19 Contro Valves

Pressure port (P), Actuator port (A) and Receiver port Construction
(R) are the ports in casing. The port ,P" is a pressure Popp

port though which pressurized fluid is coming in the

R port is the port through which used fluid is

ww
valve.
returming to the tank/reservoir.

Position 1: Fig. 3.2.33(a) which indicate first position

of the rotary spool type 3/2 DCV connccts port P to
port A While tank port R remains closcd.
Valm boty
Position 2: In second position shown in Fig. 3.2.33(b) ()(Mo Tom)

of rotary spool type 3/2 DCV port A is conncted to

port R whilc port P remained closcd.

Body

Freo ow

) Free Dom)

Fig. 3.2.34: Non return valve

It is simple in construction consists of
P folowing
Components:

Spool 1. Poppet with spring

(a) The movable member is the poppet/bal placed with

the
help of spring

2. Valve body:

It is provided with ports and accommodates the

popet
with spring.

3. Inlet and ontlet ports:

The inlet port is provided for entry

of oil and outet for
R discharge of oil.

Working:
(6)

Fig. 3.2.33 It operates in two modes as shown in Fig. 3.2.34(a) and (D.

3.2.5 Non Return ValvelCheck Valve (a) No flow:

ich and explain thewoking of nonreturn It is functionally a one way traffic control sign which s
valve
obtained by no flow position.
Marks)
When fluid attempts reverse direction of flow frong
Deinition:evalvewhichalowsflow ofoil
direction ouly and
doot allaw reyerse fow
inonky one
ofoil is
A to port P, the spring holds the poppet at the vale
at port P and block the oil path, hence oil cannot u
a
Ovn.as cheekvalve,
port A to port P.

utins

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 3-20
Control Valves
(b) Free flow: Flow controlvalve
As shown in Fig. 3.2.34(6), the pressurised oil will
enter through port P at inlet port and the oil pressure is
high enough to overcome the spring force on the
POPpet
L No flow

The poppet is pushed off and moves towards the spring Fig.3.2.37
and opens the port P and port A. Thus oil will frecly 3.2.6 Pilot Operated Check
pass from port P to port A. This is free fHow condition
Valve:
of check valve. MSBTE S-13.W177
.Check valves can be direct acting or pilot operated. The
Q. Explain with
neat sketch,Construction
above discussion is related with direct acting check of pilot
Operated check valve
valve. E S13,W17
Definiio When pilot signolo pressurized oil
Applications of check valves: t
O
is used
ControL mmovement:of poppet
n the check valve, it i
1. Pamp suction line: Calledl as pilatoperated check valve
It is used when no flow characteristic
of the valve is
desired only for a portión of the system cycle.
Pump Oil out
Plunger
IA
No flow
Check valve
Spring Pilot
point

Reservolr
PPoppet LVave body
Fig. 3.2.35 Ol in
Fig.3.2.38:Pilot oporated check valve
2 Puimp delivery line:
Construction andworking:
It consists of a valve body with inlet and outlet ports
Freeflow No fow and poppet loaded with the help of spring.
Plunger and plunger piston is provided with spring at
the pilot port:

When the oil enters through the pilot port, it pushes the
Pump plunger towands the poppet and it will move the poppet
to connect inlet port P and port A. The oil will flow

frecly P to A.
Fig. 3.2.36
When pilot port is out off by oil supply, the poppet
3. Along with
flow control valve:
block the valve as plunger force is removed and
To restrict flow
of oil in the backward direction restricts the reverse flow of oil.
pressure drop due to
at flow control valve.
Symbol:

Pilot lihe

chmdndg
Plati

Scanned with Camscanner

 ontrolValves

Hydraulics& Pneumatics (MSBTE

Sem-VI) 321
Industrial
Methods of Actuation
3.3 Standard Centre Positions and
of D.C. Valve:
3.3.1 Standard centre positions positions. Valve
centr conditions change
centre
centre
Various standard punp
like 4/3 may have actuator and une
Three positions D.C valves functions in relation
to the
perform different
connections between ports and
Center
Position of
D.C.Valve

HHDH
(a) Open centre (b)
Closed centre (e)
Tandem (d) Float (e)
Regenerative

Fig 3.3.1
acroSS the spool lande
In actual use, leakage ol nds
Valve:
Centre positions of 43 D.C. pressurises port A and B. This is not a good
option

(a) Open centre position: stop or hold the cylinder.

HX
Tandem centre position:
A

P
Fig. 3.3.2
w
In this position, all ports are connected intermally. Here PR
oil lows through all ports P, A, B and R.
Fig. 3.3.4
The open centre condition unloads the pump and allows
causes
the actuator to stop or float It litle shock dusingIn this position, Port P of pump is conected to pot&
changeover to other conditions of valve. Fixed volume to divert flow of pump to the tank. Port A and B of
pumps are used for this centre condition. actuator are closed.

6) Closed centre position: It will unload the pump to the reservoir while blocking
A B the cylinder ports A and B. Fixed volume pumgs a

w XD
used for this centre condition.

d) Float centre position:

P
R

In this position,
not allow oil
to flow.
PR
Fig. 33.3
P

all ports are blocked

R

or closed and do
wIHIX P R
Fig. 3.3.5

edl

Scanned with Camscanner

Industrial Hydraulics& Pneumatics (MISBTE Sem-VI) 3-22
P
In this position, Port of the
pump is blocked and
ports () Push button Control Valves
R are connected with cach other. operated
A, B,
actuator to float while blocking the It is push type
It allows to the and spring
electrical return similar
output is available for other valves switch.
Dump flow. Pump to
and actuatos.

e)Regeneratire centre position:

wEX Fig. 3.3.6

(i) Pedal operated:
It is foot
Pedal

Fig. 3.3.8

operated similar
to brake of 4
wheeler and used when
hands of the operator
.In this position, Port R of the tank is blocked and ports need to be kept free.
P, A, B are connected with cach other. Port B of
cylinder is connected to divert its oil fow to the port A

tosave energy of oil going to the reservoir.

It will regenerate and supplies more oil energy to the
actuator during this centre position. It is nseful in
regenerative circaits for rapid movement of actuator.
Fig. 3.3.9
3.3.2 Methods of Actuation/Operation of
D.C.Valves (b) Mechanically actuation :

The D.C. valves are operated by changing the spool| It includes use of mechanical elements like roller,
plunger, tappet roler, spring, etc
position. This valve spool can be actuated by various
techniques by application of force on the valve () Roller operated:
spoolpoppet. The roller is pressed to actuate the spool with

The actuating of spool can be : the help of cam.

a) Mamually actuation:
It uses the muscle power or spring force to actuate
thespool. It includes
Lever operated:
In this valve, the angular movement of leveris
transmitted to move the sp0ol.

It is commonly used for JCB and material

handling equipments.
Fig. 3.3.10

operated:
(2) Plunger cam which
can
actuated by a
The plunger is
cylinder.
the
be attached to

Lever
Fig. 3.3.7
Tec nvele
P
ls

Scanned with Camscanner

 Control Valves
ndustrial Hydraulics & Prneumatics (MSBTE Sem-V)3-23
actation:
Cylinder
Electro hydraulic/electro pneumatic
clectric with hydraulic or
This is a combination of
pneumatic control method.
-Cam
used to change
Summary of Actuation method
positions:

Fig. 3.3.11
Push button operated
(3) Spring operated:
A spring is commonly used for resetting of valve
position.

w i) Lever operated

Fig. 3.3.12

()Electricalactuation (i) | Pedal opcrated

It uses a solenoid to operate the valve spool. The
solenoid may be A. C. or D. C.

It can be coupled with bydra pnetumatic

actuation.
(iv) Plunger operated

d) Pneumatic actuation:
Fig.3 3.13

The D.C. valve is actuated

by using air pressure to eliminate higher force of

(v) Spring operated
MI
actuation and eliminates mechanical control

(vi) Air operated

Fig. 3.3.14 (vii)Solenoid operated

(e Hydraulic actuation: The hydraulic oil pressure
can be used directly on the end face of the spool.

Combined air and

(Vii)
O solenoid

Fig. 33.15

Scanned with Camscanner

 Hydraulics&Pneu
eumatics (MSBTE Sem-VI 3-24
Industrial
Control
Control Valves Vice versa, when Valves
the flow passage
Flow necdle, it allows is reduced by flow
3.4
3.4
control valves
small quantity
enter in the actuator of pressurised
and its movement oil to
Needof flow rate. will be at slower
hydraulicactuators:
speed of Thus by varying the flow rate
change
To somctimes it is requircd to change the speed of the () of the oil, we can
hydraulic system, actuators. This function
In hydraulic actuator as
the spced of the performed by flow control valve. is
incrcase or decrease
application. eg.
3.4.1 Principle of Flow Control:
per return stroke is faster than the
hydraulic shaper, the
In cutting strokc. Hence actuator speed is
to be increased
The flow rate oil is the quantity of
oil flowing per unit
stroke. time. It is expressed in li/min by letter
during retum "Q.
various
motor 1s to be operated at
b)Similarly, hydraylic wherc
The flow rate Q and linear cylinder velocity related
is
drilling. lapping operations
spcd to perform
necessary. bythe formula:
specd change is
>Fast Slow v-
Actuator
Where V Cylinder velocity (cm/min)
Q Flow rae (cm tmin)

A Area of he cylinder piston (em)

flow Reduced foW
I|Increased
Flow needle Similarly rpm of a bydromotor is related by the formla.
Flow port
Flowcontrol
valve

a loilin alo1 n Where . V Volume capacity of motor (cm /revolutio)

The cylinder velocity (V) and rpm of hydromotor (n)

(Flow port area is reduced)
are directly proportional to flow rate (Q). Hence
by
(Flow port area ls increased)
Q High
Q-Less changing flow rate (Q) we can vary speed of cylinder

and hydromotor.
34.1:Flow control valve for speed
control
Fig. by varying the flow port
The flow rate can be changed
Fig. 3.4.1 show that, when flow
port area is area as shoWn in Fig. 3.4.2
The of oil to enter in the
increased, it allows more quantity
actuator and it moves at faster rate.

Orihca

Nodo
Increased 0 Flow
Reduced 0
Flow

flow control valve

Fig. 3.4.2: Principle of
may et
in the tiow area
needle or gate orifice, its position
When a 0DStruction is inserted in the flow passage like a

or decrease the fow quantity of oil passing through it.

3.4.2 Types of Flow Control Valves: S16.S-19

SBTE

(S-16, S-19)

EQ Classity Row control valves with

their applican
The flow control valves are classified
as:
Pltlass

Scanned with Camscanner

 Control Valves
(MSBTE Sem-VI) 3-25
IndustrialHydraulics & Pneumatics

Types of Flow Control Valves

1. Throtle valva
(a) Fixed throttle

0 Long

Gi) Short

6) Variabla throttio (Two way)

valve
Needle bype (a) Actual flow control

) Globe type

Gate type

2. Pressure dependent flow control

vave (Non compensated)

3. Pressure compensated
flow control valve

4. Flow dviders

Flg. C3.3:Types of Flow Control Valves

(b) FCV with check valve
Fig. 34.3
ypes anee Application
Loeation of flow control valve
Throttle valve Low accuracy
applications When the fixed delivery pump is used in bydraulic
system. The flow control can be located at various

points in the system.

2 Variable flow control Speed control circuits These are three primary locations for the flow control
valve valve.

Pressure and High accuracy (a) In between D.C. valve and the actuator:
temperature precision

compensated machine circuits

4 Flow divider Synchronization

circuits
Flow
control To the tank
vave

D.C.Valve

vave
flow control
(a) Oil entering through

Fig. 3.4.4(Contd)

Scanned wIn amScanner

 Industrial HydraulilCS & Pneumatics (MSBTE
Sem
VI) 3-26
Control Vales
(1) Flixedthrottle:

A In this fixed
throttle valve, there
Flow is a permanent small
aperture (orifice) is provided
control in the flow direction.
valve
At the throtle aperture, the velocity
of oil increases and
there is drop in the pressure.

The flow rate at the throttle valve calculated

is using
the relation.

D.C
Valve

P UR
(b) Oll leaving through flow control valve
Fig.3.4.4
control flow of oil
control valve is placed to Oriice
Flow actuator. These are two
entering or leaving from the. Fig. 34.6: Fixed nozzle
shown in Fig. 3.4.4(a) and (6).
methods as
3.4.4(a) shows that flow of oil is controlled
The Fig.
oil enters in the cylinder.
This method is called Q A
when
meter-in flow control.
oil is controlled QAP
The Fig: 3.44(b) shows that flow of
drain to the tank. This where Q Flow rate
while oil leaves the cylinder and
meter-out flow control. a. Dimensionless coefficient
method is called as
A Area of aperture (orifice
pump (by pass
() Between D.C. valve and AP Pressure loss
arrangement):
Gravitational acceleration
Flow control valve g
V Specifñic weight of oil
not
constant opening which can
Pump This throttle valve has
in the
gonerally inserted directly
be adjusted. They are
Filiter pipelines

E Symbol:

Resarvoir
Fig. 3.4.5:By pass flow control valve
*

In this method,
the flow control valve is placed ater
ic pump and some orifice (throttle):
of flow of oil is by pass (diverted) (2) Dlaphragm
O the reservoir. This
method is known as bleed-or
flow control.

34.2.1
ThrotleValve:

Den a small opening is provided

Canses
pressre to reduce the flow, 1T
sscalled
al drop across the Dlaphragm orfico
asthrottle
valve.
opening called as orifice. It Fig.34.7:
DIICatlgo

Scanned with tamscanner

 Control VaM
(MSBTE_Sem-VI) 3-27
Industrial Hydraulics & Pneumatics
Construction and working:
Adjustable
Two way valve: screw
MSETE S55

explain its workirng. Body

Q Draw sketch of needle valve and
(S-15)
Symbol Inlet Neede

ww Oudet

In this type of throttle valve, the needle with pointed

Non retum vave
valve
end is used for varying the flow opening. Fig. 3.4.9:Non compensated fiow control

Il consists of needle valve fitted with adjustable screw.

The needle is the flow control element.

Check valve (non retura valve) is provided along with

throtle valve to provide regulated flow in one
(a) Needle throttle direction.

This combination is commonly known as flow control

Gate valve with inbuilt check valve

The inlet and outet ports are provided for input of oil
Globe
Out supply and regulated flow at the outet respectively.

The needle position is adjusted to set the throtle

opening. The oil flow from the inlet and pass through
(b) Globe type (o) Gate valvee
Fig.3.4.8 throttle opening and delivers the required quantity ot
oil.
3.4.2.2 Non Pressure Compensated Flow
Control Valve: At the throttle opening, the reduced passage may canse
retum flow of oil which is restricted by the check valve
MSBTEH S17S19
fitted near the valve opening.
Q: What is pressure compensäted flow control vale2 Applications:
Epan wihsketch
S:17 nd
It is used where pressure is nearly constat
Q Slate function of flow control valve? Explain non
monitoring of speed is.not critical. t is used in sped
control

pressure.compensated fiow control

valve.(S.19circuits like meter-in, meter-out.
Defimition;When there is no pressure compensaion Symbol:
jor
drop in pressure in, lhe jlow control valve, it is called as
O7 ComperAsatéd
jow controlvalve
Principle:
It works on the principle of throttling i.e. Q
depends on the pressure difference between two
AP.Q
ports (inlet
--
and throtled port).

Olatines
Tdl

Scanned witn camScanner

 Incustrial Hydraulics & Pneumalics (MSBTE
Sem-VI) 3-28
Control Valves
3.4.2.3 Pressure and temperature
Compensated Flow Control Valve: The compensator spool is provided
with the spring to
compensate the drop in pressure
MSETE AIWAW12 across the throttle
WS131Wá14;S15 opening.
W-15, Wat7S18
WHB The inlet, outlet and other internal
Q. Explain pressure Compensated passages are
low contirol válve provided for all low
in the valve.
with neat sketch. Draw symbol of
it
W11,W13, Pressure compensation:
S:15,W17
Whal is pressure, compensated fow control valve? Due to change in the load
How does Pressure.compensation of the actuator, the work
fakes place, resistance also changes and
there is a variation in the
12 W pressure drop at the entrance
o.State the meaning O pressure compensated
Control Valve. Flow When there is a flow of oil
and the throttle.

pain the working ofpressure from the inlet, it will flow

Compensated flow through two passages, from
controlvalye used inhydraulic left hand pilot line it will
Systemwith neat sketch exert oil pressure on the compensator
W-14w 10) spool (F^).
Q With a neat sketch expla Similarly the oil flow from
essure operated throttle opening and flow
Controlvalve. Draw flow from right side pilot line
the syrmboorihesame (W 15) and exerts pressure P, in
a
QExplaln with neat sketchapressure
and temperature
addition withspring force
(Fptg)
Operatedtow controfvalva
S-18) Pressure on left side = Pressure
on right side
DefiuitionTie con
oi Callavr fon PrA
PA+F
control o lndep Pressre drop ard . (P-P,)A = Fp
emperature acios
SKnown as pressure
compensated low.conrobvalve AP Constant
A
Principle Where
P= Pressure before throttling
It works on the principle of maintaining ,A = Cross sectional area
a constant
pressure drop on the adjustable throttle path with
the help of ofvalve spool
compensating spring loaded spool.
ESpring force
Construction and working AsF, and A are both cönstant AP is also constant.
Outlet The spring force determines the position of
Compensator spool the spool
and the amount of oil allowed through the valve. As
F,
is constänt, AP is also constant and hence adjusted flow
Fsping rate (Q) is constant.
A
Temperature compensation:
Because the viscosity of hydraulic oil varies with
Temperature temperature (as do the clearances between a valve's
sensing element moving parts), output of a flow-control valve may tend
(Spoor IIL} to drift with temperature changes.
To offset the effects of such temperature variations,
Inlel Pi
temperature compensators adjust the control orifice
openings to correct the effects of viscosity changes
caused by temperature fluctiations of the fluid,
Needle
Flg. 34.10:Pressure and temperature compensated This is done in combination with adjustments the
flow control valve control orifice for pressure changes as well.
in
t consists of throttle in the fom of needle lócated
front of inlet port.

Tced

Scanned witn camScanner

 (MSBTE_Sem-VI) 3-29 valve with neat
neat sketch
Hydraulics&Pneumatics
Explain
pressure relief
Industnial Q.4 3.2.3.1(A))
(Section
Applications relief valve
equipments where function of pressure
tools and other Q.5 State the
Precision machine cxtcmal resistance
indcpendent of (Section 3.2.3.1(A)
speed is required
neat, sketch pressure
constant reducing
valve,
Explain with
and temperature. Q.6
(Section 3.2.3.1(3))
Symbol: valve is not
State the effect if pressure relief rovided
Q.7
system. (Section 3.2.3.1(A)
in hydraulic
valve and presua
Q.8 Diferentiate pressure relief SSure
temperature 3.2.3.1(A)(B))
Pressure and reducing valve. (Section
Pressure compensated compensated
of sequence valve with suitable
Q.9 State the function
3.4.2.4 Flow Dividers example. (Section 3.2.3.1(D))
divided equally so that it can
When flow of oil is to be of D.C. valve with example
simultaneously, flow dividers Q.10 State the function
control the two actuators
arè required. (Section 3.2.4)
oil flow is divided
In this flow control valve, the Valves. (Section 3.2.1)
Q.11 State the types of D.C.
as shown in Fig. 3,4.11.
equaly
showing normally closed
Q.12 Explain 3/2 D.C. Valve
Inlet
position. (Section 3.24.3(B)
A
symbcl
a. 13 Draw sketch of 4/3 D.C. Valve and its

(Section 3.2.4.3(D))
FloW Flow1
a.14 Explain rotary spool valve with neat sketch.

(Section 3.2.4.3(G)
Q.15 State the function flow control valve. List is tpes
(Section 3.4, 3.4.2)
Fig.34.11:Flow divider Explain non compensated flow control vave.
a.16
It is used in motion synchronisation of hydraulic (Section 3.4.2.2)
actuators.
Q.17 Explain with neat sketch pressure compensated fow
eg. lifting of load at same speed by two cylinders.
control valve. State ts aplication. (Section 3.423
Symbol:
a.18 Draw symbols of (1) Flow control valve with inlego
Contol
check valve (2) Pressure compensated flow
valve. (Section 3.4.2.3)

Q.19 Draw a neat sketch and symbol of three y y wo

Cantal
postion normally closed poppet type direcion
E uestions valve. (Section 3.24.1(B))
Q.1 Slate the types of Q.
Symbol
fuid controling elements 20 Explain meaning of
hydraulic system. used in 3 x 2 DC valve w
(Section 3.2) (Section 3.2.4.3(B)
Q.2 Classily
control 42
hydraulics/Pneumatics.
valves used in
Q.21 Draw a sketch of normal and actuating pos tonof
(Section 3.2)
cirection control
Q.3 Slale diferent types valve. (Section 3.24.3(0))
of pressure
their specific applications. control valves Q.22 Sketch and
with explain the working ot
(Section3.2.3.1)
Valve(Section 3.2.5)

Scanned with tamscanner

 (MSBT Sem-V) 3-30
Hydraulics& Pneumatics Control Valves
ndustrial
and state its application
symboland 2.
dentilygiven
a23 (Section 3.3.1(6))

LYTIIA Q.25 Explaln with neat sketch Counterbalance

(Section 3.2.3.1(5)
Q.26 State difference between
valve.

Counterbalance valve and

P R
P R
PR function.
Unloading valve.

ldentily 9given
symbol and state its (Section 3.23.1(6) and (Sectilon 3.2.3.1(C)
.24 (Section 3.2.6)
(Section 3.4.2.2) and

DO0

Scanned with Camscanner

 Table of Comtents

4.3.1 Cosluction, Working Principle ot FIL Unit. 411

4.3.2 Dual (win) pressure vave, Shutile valve,

Quick exhaust valve, Tume delay vave. - 16

4.32.1 Dual (twin) pressure valve (AND Gate Valve).. 416

4.3.2.2 Shuttle valve (OR gate Valve) --- 4-18

Exhaust Vave
. 4-19
4.3.2.3 Quick *******

4-19
4.3.2.4 Time Delay Vave.
4.4 Accessories: Qil reservoir, pipes, hases, fittings
air flters, seals and gaskets, intensifies,
oil filters,
accumulators, heat exchanger, miier.. 4-20
Accessories of Hydrauic System--- -4-20
4.4.1
UNITTV 4.4.2 Accessories of Preumatic System 4-21

Reservoir (0l Storage Element). 4-22

4.4.3
Chapter 4 : Compressor, Pneumatic Components and
4.4.4 Air Receiver
Accessories in Fluid System 4-1 to 4-41
Pipes and Hoses 4-23
445
Introduction to Pipes 4-23
Syllabus: 4.4.5.1
of Reciprocating and 24
4.1 Types, construction, working principle 4.4.5.2 Important Factors for Pipes and Hases
Rotary compressors.
(twin) 4.4.5.3Hoses-
4.2 Construction, working principle of FRL unit, Dual 4-2
valve, 1ine 4.4.6 FTiers *****

pressure valve, Shutle valve, Quick exhausl -29

4.4.6.1 Classification of Füters *****

delay valve.
cu futers, Filier Materials. 431
4.3 Accessories :Oil reservoir, pipes, hoses, fittings, 4.4.6.2
accumudators, -4+31
air filters, seals and gaskets, intensifiers, 4.4.6.3 Location of Filter .

heat exchanger, muiller. Seals and Gaskets 4-31

4.4.7 ******

. Introducion **************************** 4.4.7.1 Classification of Seals 432

Intensifier (Pressure Boester). 4-34
.2 ypes of Air Compressors. a****** ******** 4.4.8
Reciprocating Compressor. 4 4.9 Accumulators *** *******

4.2.1 ******

4.4.9.1 Types of Accumulators *****

4.2.1.1 Single Acting Compressor ********
*************e+**

44 4.4.9.2 Necessity of accumulator for every huge

42.1.2 Double Acting Compressor.
*********2***********
39
. nydraulic press
4.2.1.3 Diaphragm Type Compressor .46
4.4.10 Heat Exchangers (Cooler).
Specification of Reciprocating Compressor 4-6
4.2.1.4 .
******** ** - 4-39
4.4.10.1 Types of heat exchanger *******

********e***o**.9O
4.22 Rotary Compressors. 440
**********
4.4.11 Ol Heaters.**** *
*************

4.2.2.1 Liquid Ring Cormpressor. *************************** * **4-1 Mulfler (Silencer). ****"*****

4.4.12
4-7
4.2.2.2 Lobe Compressor.************************ *

4.2.2.3 Screw Compressor ******************************** *****************

4.2.3 Difference between FReciprocaing and Rolay

4-9
Compressors... ******************************

4-9
4.2.4 Dynamic or Turbo Compressor..**********************.

Selection Criteria for Compressors. ************ 4-10

4.2.5 **

4.2.6 Symbols of Compressor *s************************ 4-10

4.2.7 List of Manufactures of Compressors.. 4-10

9.3 Construction, Working Pinciple cf FRL Unit,

Valve,
Dual (Twin) Pressure Valve, Shutle

Quick Exhaust Valve, Time Delay Valve. 4*)

 AAPI Components
Compressor, Pneumatic
System
4
UNIT IV
and Accessories in Fluid

Syllabus:
working principle of Reciprocating and Rotary compressors.
4.1 Types, construction,
FRL unit, Dual (Twin) pressure valve, Shuttle valve, Quick exhaust
4.2 Construction, working principle of
valve, Time delay valve.
4.3 Accessories: pipes, hoses, fitings,
Oil reservoir, oil filters, air filters, seals and gaskets, intensifiers,
accumulators, heat exchanger, mutfler.

4.1 Introduction

As discussed in the chapter one, the fluid power is divided into two groups

(a) Oil bydraulic system and

b) Pneumatic system.
Oil hydraulic system as we know and studied, is related with use of pressurized oil for various
industrial applications.
While pneumatic system which is related with use of compressed air or gas variousfor applications.
"Pneumatics" is the technology deals with study and applications
of compressed air/gas for transmission and control of
motions and forces.

Pneumatic system utilities the power of compressed

air/gas to operate the actuator to perform
the given application.
Compressed air
Airfrom Service unit

Receiver
Atrmospher
Actuator

Compressor
Force

Punch
Workpiece
Die

Fig.4.1.1:Pneumatic
system
Fig. 4.1.1 shows that
air from atmosphere
compressed to high is get
presure and enters in CActuators : They are used to obtain motion or
to generate force which the actuator
is used for given application force by using compressed
air.
this case to cut sheet
metal work piece (n ad) Accessories: They
die). using punch and are auxiliary devices tor
mproving performance
.The various important of the pneumatic system
components In hydraulic system,
systemare of pneumatic we use pump to increase pie
Tessure
of oil similarly
a) Compressor we use compressor to increase pressu
SSure
: It is the source of atmospheric
compressed air to supply air, in pneumatic system.
to the pneumatic Compressor unit
system. consists of compressor w
b) Control valves: large
They are used for pressure, capacity air receiver
and direction
control of compresscd flow to store compressed air whien
supplied to
air. number of pneumatic and
cquipment located devic
nearby.

Scanned witn camScanner

 Ffuid Sys
Components & Acc.in
IndustrialHydraulics &
Pneumatics Pneumatic
-2 pressor,
. Compressor with drive
motor
compressors
and air receiver requires displacement
more space and it (9 Positive pressure
also makes noise increasing the
and vibrations principle of
during working, hence They work on the enclosed
it is kept separately.
volume by reducing it in an
of air
Definition of Air compressor: of a definite
chamber.
It is device which converts
mechanical ènergy groups.
into They are subdivided into two
pressure energy in the
form of compressed
pressure.
air at high (a) Reciprocating type:
or
motion of piston
The reciprocating
It is the device which sucks
atmospheric air volume of air
and diaphragm is used to decrease
compresses it by
suitable mechanism
to increase it
pressure and deliyer to forincreasing its pressure
the air receiver for storage, diaphragm
includes piston, labyrinth, and
which is further utilised
for operation of pneumatic It
system. CompressoOrs.

Examples: (b). Rotary type:

It utilises rotary motion of the mechanical

1) Compressor used for spráy painting
elements like vanes, gear, lobes, screws forT

2) Compressor used to fill air in the automobile

tubes and increasing pressure of air.
tyres.
It includes vane, screw, lobe compressors.

4.2 Types ofAir Compressors (i) Dynamic (turbo) compressors:

It employs rotating vanes or impellers to give velocity
Clasity cOmpressorin.gener 4Marks) and pressure to the flow of air being handled.
These are two basic type of compressors: The dynamiç effects such as centrifugal force
helps to
)Positive displacement compressors. achieve pressure of air.

It includes centrifugal, axial, ejector compressors.

i) Dynamic or turbo compressors.

Corpressortypae

POstive
OSplacament ynamic

Centitupe
CPrOcEg

Lobe Scew Vane

Single-actingpouble-acu

Dlaphrag igid ning Saol

alr compressors
Fig. 4.2.1(@): Types of

Tedleled

Scanned with Camscanner

 Fluid Svs
Components & Ac.in Sys
Compressor, Pneumatic
4-3
Hydraulics & Pneumatics compressor:
Industrial stage
(i) Two
to give
provided for compression
Two stages are

more pressure.
compressor:
(ii) Multiple stage
provided to obtain large
More than two stages are

pressure.

(o) According to position of cylinder:

vertically.
(9 Vertical: Cylinder is mounted
Lobe type is mounted hoizontally.
(i) Horizontal: Cylinder

() V-type:Cylinders are mounted along

V shape.

() Vertical ) Horizontal (i) Radial

Fig.4.2.2: Compressor cylinder:

Vane type
(d) According to drivelprime mover
Fig. 4.2.1(b): Actual air compressor used:
Compressor classification )Electric motor driven

Q Give cassificationofaircompressoton i) Diesel engine driven

lhe basisof
ii) Gas/turbine driven
marks
0 Slages
Djive ot compressor () Accordingto condition of compressed
(MColing medium (ý) Action air:
Based on geometryandoperationalfeatures) ) Oil free air
(a) According to compression i) Lubricating oil contaminated
by piston: air
) Single actingcompressor: 0 According to
mounting/portability condition:
Compression takes
place in the space ) Portable compressor
on one side
of the piston. :It can be moved easily.
i) Stationary compressor:
G) Double acting compressor: It is fixed and mount
firmly.
Compression takes place
on both the faces
piston. of the9 According to cooling
medium used:
(6) According
to number )Air cooled compressor
of stages of
compression: i) Water cooled compressor

() Singlestage compressor:
(ii) Liquid injected
compressor

Only one stage

of compression.

Tedlovaledg
PDllCat

Scanned witn camScanner

 Pneumatics
ndustrial
Hydraulics& 4-4 Compressor, Pneumatic Components
&Acc. in Fluid Sys.
Reciprocating Compressor A.Wite. costruction and working
of double acting
421 recprocaling compreseor with naat sketch.
MSETE AW15 (S-15, W-16)
The compression takes place on both
the faces of the
compressor used in pneumatic piston giving two compression strokes for
oExplain reciprocaung cach
revolution of the crank and crank
Sstem W15 shaf.
It can be used in multistage compressor
Definition When reciprocalimgmotion of
piston or system.
lingphragm Is uscd,
to compress the air to increase
itr
the depice now 0sreciprocating
ompressor

The reciprocating compressOrS are classified as

T
Piston type

t uses cylinder and piston mechanism for its operation.

tis furter grouped as:

421.1 Single Acting Compressor Fig. 424: Double acting compressor

Construction of two stage reciprocating

compressor
Reciprocating motion
The most commonly used air compressor in the
industry is air cooled two stage reciprocating
compressor with pressure up to 7 to 12 kg/cm.
The Fig. 4.2.5 shows outer construction of
reciprocating compressor. It includes following main
parts:
(a).Air receiver or tank It is large horizontal
Fig.42.3: Singleacting compressor cylinder (pressure vessel) mounted on base stand.
When suction and It stores compressed air. It is fitted with various
compression is caried out only from
face side
of the piston, it is known as single accessories.'
acting
COmpressor. (b) First stage cylinder: The atmospheric air enters
There is one compression stroke in this cylinder. The cylinder is mounted along V
per stage for each
revolution type of arrangement with inlet valve for suction
of crank shaft.
importantfeatures and outlet valve for supply of compressed air to
of single acting compressors: the second stage cylinder.
Theyareused for small capacity
only. (c)Second stage cylinder: This cylinder is mounted
The machine
is înore compact and along with first stage cylinder in radial manner.
3. They less costly.
are portable. The inlet is connected to outlet of first stage
They arecommonly air cylinder and outlet is connected to the air eceiver
.T are suitable
cooled.
tank.
when demand is infrequent or
cOmpressor d) Intercooler: It is itted between first stage
is to be installed
42.1.2 at the worksite. cylinder and second stage cylinder. It is provided
Double Acting
Compressor to reduce the temperature of compressed air nearly
equal to suction temperature. It has fins for
MSBTE: S-09.S55,W15,W16
cooling purpose

aDetneat
sketchot tWo stage ait compressor
its parts and ()Pressure gauge: 1t is fited on air receiver tank to
S09, M indicate the pressure of compressed air stored in
thetank.
etedg
Y latisas

Scanned with Camscanner

 & ACC. in Flud
Compresor, Pneumatic componenis \uid Sys.
Hydraulics & Pneumatics
4-5
Industrial belt
motor shaft is connected by elt drivedriva
tothe
mover to run the compressor. The
Electric motor: It is the prime
(0
compressor shaft. cylinder.
for filtration of
atmospheric air entering in the first stage
It is providcd
(e) Air inlet filter:
compressed air to the pneumatic system.
It is provided to supply
(h) Air outlet valve:
crank shaft.
used to store oil for lubrication of
(Oil reservoir: It is system.
valve : It is provided as a safety
measure against high pressure devcloped in the
) Safety
automatic trip-off when air receiver is filled with
desired set pressure.
(k) Pressure switch: Itis used for
Second stage
cylinder First stage
Electrical motor cylinder

Oil
Safety reservoir
valve
Pressure
gauge

compressor
. Air tank
Outlet

Fig. 4.2.5:Construction of reciprocating

compressor
fntercooler-
Second stage-
ylinder rFirst stage
oylinder

AAA Air in
-Piston

Fins

Crank and
Crank shaft
Crank case

Fig. 4.2.6:Two
stage air compressor
Working:
When the starting
of the electric motor, the crank
air through the suction
rotates and
filter and inlet valve. the piston in the mosptene
first stage cylinder sucks thea
On further rotation
of the crank, the piston reverses
and it compresses the
to open. air. The compressed outletva
air forces the
air forces te

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics 4-6 Compressor, Pneumatic Components & Acc. in Fluid Sys.

to the second stage

Then it enters in the intercooler Intercooler cools the compressed air by taking away the
cylinder forcing open its inlet valve. The air is further heat and reduces its volume. This helps to reduce work
compressed in this cylinder to the desired pressurc.
done and power in the second stage of compression.
fcd to the air recciver tank through the
4.2.1.3 Diaphragm Type Compressor:
condenser on compression through the outlet valve.

. The first-stage cylinder is called Low Pressure Cylinder In this compressor, the piston is separated from the
(LP). It can devclop presure up to 5 bar. The sccond friction chamber by a diaphragm. Tbe air does
not
stage cylinder is called as High Pressure Cylinder (HP). come in contact with reciprocating parts. Hence air
is
t can develop further pressure up to 10-12 bar. kept free of oil.
.Multistage compressors can produce discharge pressure
They are limited to a very small capacity, low initial
up to 300 kg/cm
cost, Himited life and need maintenance freqvently.
Important features of double acting compressors:
They are most suitable for food stuff, chemical and
1. Air deliery is double that of a single acting textile industries, pharmaceutical industries etc.
Compressor.
4.2.1.4 Specification of Reciprocating
2 They are mostly suitable for large capacity.
3. They are mostly water cooled.
Compressor:
4. They are suitable for continuous and heavy duty atethe cificationsc reciprocating compresso
work.
Function of intercooler
2merko)
Q. 1. Pressure of compressed air in kg/cn
State the location and.function ofintercoole
2. Volume of air receiver in cm /min.
Marks)
Fins for aircooing 3. HP of driving motor.
4. Volumetricefficiency.

5. Number of stages available for compression.

Compressed 4.2.2 Rotary Compressors

air in
Compressad
rout
Deinition of rotary compressors
TUUBUUU When rotary motion ofvanes, serew
obes, ete i used for
conpression of air, it is calëa as olary comptessor.
Fig. 4,2.7: Intercooler Delinitiono rotary yane commpressor
When shiding vanes are used
When air is compressed
in the first stage, wil mtor for compression.of
Emperahure will increases
due to heat generated during
air is knowT ATKOtaryvane
coyresSor
compression. Heat generated
may increase the volume Vane
ar by expansion and increases work done
on the
Compressor. Cyinder block
Rotor
Hence the
compressed air is passed through intercooler
iOcaled between
stages of compression. Intercooler is a
heat exchanger
Airin compsed
device designed with air cooling or
water cooling arrangement

The Fig. 4.2.7

shows intercooler with cooling fins
provided on outer
surface of the body for air cooling.
Fig. 4.2.8:Rotary Vane compressor

Tecetgi
PCatiis

Scanned with Camscanner

 Fluid S
4-7 Compressor, Pneumatic Componenis& Acc. in Sys.
Industrial Hydraulics & Pneumatics
Diagram:
Construction: - Casing

It consists of Liquid ring

Vane
(a) Rotor:
It has rectangular slots
provided along radius to
eccentrically Discharge
accommodate number of vanés. It is fitted
port
inside the cylinder block.
Sucion port
(b) Sliding vanes:

They are inserted in longitudinal slots in the rotor and

moves to and fro into the slots. Rotor
Fig 4.2.9: Liquid ring compressor
() Cylinder block:
It is circular block in which rotor along with vanes is
Construction:
mounted.
Itconsists of following coponents:
(d) Inlet and outlet ports : 1. Rotor with sliding vanes: It is similar to rotary vane
compressor, mounted eccentrically with respect to
They are provided with cylinder block for suction of air
casing
and discharge of compressed air
2. Liquid ring: Liquid ring is formed by water or low
Working:
viscosity liquid in between caing and siding vanes. It
The shaft of compressor starts rotation and causes rotor avoids metal contáct between blades and wall.
along with vanes to rotate. Initially vacuum is
created3. Casing with suction and discharge port: Itis circular
at inlet port for entry of atmospheric air. housing with suction and discharge ports at opposite

This air is carried out and get compressed as radius

ends.
of
rotation goes qn decreasing towards the discharge Working
port.
The high pressure compressed air is delivered It is modification of vane compressor. Its working
to the is
pneumatic system or stored in a air receiver. similar to vane compressor. Initially partial vacuum is
created for suction of atmospheric air.
It gives pulse freelcontinuous
discharge of compressed
The air is trapped between liquid
air. ring and rolatng
vanes. The radius of rotation
Advantages of vanes decreases and
compress the air near the discharge
port.
1. Smaller in size. Due to liquid ring, physical metal contact vanes
of
2 Lighter in weight. climinated and there is no wear of vanes and casing ar
3. It can work at high speed. contact surface.
4. Maintenance cost t necessary to maintain constant liquid level to
1s
is less. a
5. It may not require expensive which special arrangement
foundation. is made

4.2.2.1 Liquid Ring It is available in single age with wide range of

flow
Compressor: The
capacities with compression ratio up to hve.
Definition pressure range is
When water.or about 6 bar.
otherlow viscosity
Used in addition liquid
with casing and vanes is 4.2.2.2 Lobe
air,itis called asliquidrüng compressor to compress
the Compressor:
Definition:
Whenmechanic lobes are used to inc
ahe
as
Compressor r wih the impeller force.Iis krown

Scanned with tamscanner

 Industrial Hydraulics
&Pneumatics
4-8 Compressor, Pneumàtic Components
Diagram: & Acc.in Fluid Sys.

Casing Diagram:
r Casing
r Lobes
Female-
rotor screw

Inlet Discharge port

Air in Compressed
poit
r

Male
rolor screw Zin
Fig. 4.2.11:Construction of screw compressor

Construction
Fig. 42.10: Twin lobe compressor It consists of following main components

Construction Pair ofscrews

It consists of following main parts: In screw compressor twoSCTeWS one with convex

and the other with concave contour are used and

1. Casing: mostly called as, male and female rotor

It is the housing in which pair of lobes is mounted it respectively.

has inlet and discharge ports for entry and exit of air They are made to rotate by means of gear train or

respectively. other source outside the compressor casing

2. Timing gears:
2 Pair of lobes
They are fitted on the shaft of each screw and help to
The lobes are meshing elements with small clearance
maintain clearance between mating screws.
between them which is fixed by timing gears,
Casing with inlet and outlet ports
Working: outdet ports for
It is a closed chamber with inlet and
the delivery
The air is transferrèd from suction side to respectiyely.
entry and exit of compressed air
two lobes.
side with continuous rotation of the
volume, the air Working:
There is practically no change in tho one
the air rotates, the helical groove of
When screw pair
pressure is increased due to impeller forces another screw and air enters
back pressure of the SCrew will open with
through the discharge port against When female rotor screw is filled
through inlet port. complete.
the intake phase is
system. over its entire length, starts to
generally very low and the male rotor sCrew
The pressure generated, is With further rotation, rotor, helical
and with the female
pressure applications. mesh at the inlet during its
mostly used for low screws trap the air
limited to 1.7. ridges, at mating to squeeze the
singlé stage is rotor screw starts
Thecompression ratiofor movement. The male cove.
discharge end
trapped air towards the rotor
discharge pressure, the
422.3 Screw Compressor On reaching the maximum
expels the
trapped
MSBTE S-10 discharge pot and
uncovers the port.
pair to the
discharge
compressed air volume in case
discharge valves as
compressoi
wt the no of inlet and
Q Explain working of twin screw There is needcompressor.
4 Marks
S-10,
. It
reciprocating
2help ofskelche of
discharge of
compressedair.
givespulsation
pulsarno
free
einiton When pair at serew
1 He IIgives
erew movementn tie casing i
callene
called as serew compresor Techaeda
PDlllaas

Scanned with tamscanner

 Industrial Hydraulics & Pneumatics 4-9 Compresso, Pneumatic Components & Acc. in Fluid Sys.

4.2.3 Difference between Reciprocating and Rotary Compressors

O. Comparo recprocating compressor with rotáry compressor GMarks)

Sr Point Reciprocating compressor Rotary Compressor

Working principle It works on the principle of reciprocating It works on the principle of dynamic effect
motion of piston and cylinder of
rotary motion of impeller in a casing
2. Constnuction Tts construction is complicated with more
Ils construction is simple with minimum
mumber of parts
components
Delivery of Pulsating due to alternate suction and
Continuous as the flow of air from inlet to
compressed air | discharge strokes delivery is continuous
4.PresSurerange 7 to 12 kg/cm
Up to 2 kg/cm
(high pressure)
|(low pressure)
5. |Types Single acting, double acting, multistage Centrifugal, axial, ejector
6. Space required |More space needcd Less space needed
7. Air recciver
Air receiver is required to store compressed No need of air recciver
if application need
air continuous supply of compressed
& Appliations air
Continuous and heavy duty work
Air conditioning and cooling operations
4,24 Dynamic or Turbo Compressor
2. Impeller: It is rotating disc with number vanes
T1
works on the principle of
of dynamicturbo effect of which imparts kinetic energy
to the air. It rotates at
g ipeller which gives pressure to very high speeds.
the air.
The most common dynamic compressor
is centrifugal Snction port: It is provided for suctton of air from
compressors which work on
the principle of centrifugal atmosphere.
force produced by the rotating
impeller. Discharge port: It is provided for delivery of high
Discharge
pressure compressed air.

Working:

When compressor
Casing is started with the help of electric
Impeller
motor, the impeller
starts rotating mounted on the
driving shaft. The vacuum
pressure is created initialy
as air in the casing forced
is out.
The air from atmosphere
is sucked through inlet at tne
centre of the impeller.
As impeller has high speea,
Inlet (air from atmosphere) imparts kinetic
energy to the air.
Fig. 4.2.12:Centrifugal High velocity air
compressor ges
is passed through the pass
Construction: between impeller
and the scroll casing where diverga
It consists of passages convert
kinctic energy of air dynamucauy into
. Casing: It is spiral
pressure head.
shaped casing in
which impeller is
mounted.

Scanned witn camScanner

 Components & Acc. in Fluid Sys.
Hydraulics & Pneumatics 4-10 Compressor, Pneumatic
Industrial
are operated
point to their use. pneumatic hand tools
There is cotinuous passage for air from inlet
from intermittently hence air consumption is 10-20% of total
discharge point of compressor the compressed air
is absolutely oil free and very high volume.
these compressors
for high
discharge pressure and
capacity are achieved The vane/screw compressor are preferred
pressure compressors capacity while reciprocating compressor are suitable
Turbo compressors are 1ow
producing pressure lower than 2
kg/cm. for lower capacity.

used for air conditioning and cooling 3. Compressor configuration and cylinder
They arc mostly
operations. geometry:
Compressor configuration gives idea about single
4.2.5 Selection Criteria for Compressors
acting/double acting and number of stages for
a State the basc citena's forselection or.compressor compression..
4Marksy Cylinder geometry indicates the position of cylinder in

The various points are to be considered for selection of vertical, horizontal, vee, radial, etc.

compressor for pneumatic application. So that for a given aplication with respect to space
available and pressure requirement correct selection of
1. Pressure required by the system:
compressor can be done easily.
Most air operated systems and tools are designed to
operate at pressure from 6 to 7 kg/cm. The maximum 4.2.6 Symbols of Compressor
pressure is limited to 10 considering pressure loss due
to long distribution lines and fitings. 1. Unidirectional fixed volume

The output pressure range of compressor is useful for

sclection.

ypes at compresor ressure

2. Bi-directional fixed volume

1. Multistage Teciprocating 7to 12 kg/cm

compressor

2 Single stage reciprocating 3 to 7 kg/cm".

cOmpressor. 3. Unidirectional variable volume

3. Multistage vane compressor

7to 10 bar
Turbocompressors
4. Up to 2 kglem|
When small amount of air is required at lower pressure
for number of applications, then single compressor can 4. Bi-directional variable volume
be used with distribution points.

flarge amount of low pressure air is required it is more

economical to install a separate compressor.
4.2.7 List of Manufactures of Compressors
2 Capacity or alr volume:
The capacity of compressor is specified by the storage
1. ELGI
ot volume of air ( m ) in the air receiver tank. Turbo2 ngersO-KAnd
compressors has no air tank. 3. Atlas Copco
The various pneumatic devices may consume
Compressed air in m/min or m/hr depending upon

Tecledgi
Polatieis

Scanned witn camScanner

Industrial Hydraulics & Pneumatics 4-11 Cormpressor, Pneumatic Components & Acc. in Fluid Sve

4.3 Construction, Working Principle of Construction:

FRL Unit, Dual (Twin) Pressure
Valve, Shuttle Valve, Quick Exhaust
Valve, Time Delay Valve
4.3.1 Construction, Working Principle of
FRL Unit
MSBTESS12, S-13.W-18.,W-14,S15, Fig. 4.3.1: FRL unit Sketch
WA5:816
W:16WA7S18 FRL unit is combined box set made up of a filter,
Q. What is mean by FRL unit in pneumatic
crcuits? regulator and lubricatnr with the associated fittings
and
state the function
ofeach
Q. What is FRL unit? Explain
its wofking With
12 S13 wall mounting bracket used in Pneumatic system.

Importance of FRL unit:

symbo

a. What is FRLunit 2 Eplain tns function W13

Air leaving a compressor is hot, dirty, and wet--which
withithe help can damage and shorten the life of downstream
of sketch Draw separateand
combined symbol of equipment, such as valves and cylinders.
FRL unit: W-14,S 15,W-16)
Bcfore air can be used it needs to
Q. Give the funcion of FRL be filtered, regulated
untDraw it's symbol.(W-15) and lubricated.
a. What is FRL? State importance
ts S-16) Funetion of FRL unit:
Q What is FRL ? Statethe function.of
each Component Filter(F) : To remove the micron
and
of FRL
W17, S18) particles present in the entering
air of.
sub-micron

Delinition ot FRI Unit compressor. It is used to

separate out contaminants like
n pneunatic system, lhe lhreeE elemeits dust, dirt particles from
combined the compressed air
sirigle compact unit in the sequence in Regulator(R) : In pneumatic
filler regulator and system the pressure o
Lubricator known as FRL unit compressed air may not
stable due to possibility of line
fluctuation. Hence
there is a need to maintain and
They are commonly fitted to each and Tegulate the air
every pneumatic pressure. This function performing by
work station. In certain cases, is
the filter and the regulator.
regulator form a single unit referred
as combination LubricatorL) : Sliding
filler-regulator. components like spo
pneumatic cylinder
has sliding motion between part.
It is the service unit for the compressed may cause friction
and wear and tear at mating
combination of three units in
air. It is the
To reduce friction,
lubricating oil particles are addeu
P
a sequence as per their
operation in the pneumatic system. the compressed
air with the help of lubricator.

The main three clements of FRL unit are: Filter Regulator Lubricator
and Gauge
Filter

Regulator
Lubricator
3.

Flg.4.3.2: Actual FRL unit

Ptcatius

Scanned witn camScanner

 Pneumaticss 4-12 Compressor,Pneumatic Component:
Hydrauilics& &
Acc. in Fluid
Industrial Sys.
There are two types offilters
given below:
Symbol:
ofFRL unit:
6) Air Filter (Filter in air
line)
Combinedsymbol
i) Coalescent filter

Air Filter (Filterinairline):

r Body

Impureair
Common(simple) symbol of
FRL unit: n Clean, pure ar

ZFiter catidge
Bowl retainer

Deftector

Locatlon ofFRL Unit: Plastic bow

Baffe
outletof compressor. The filter is
It is located after
installed upstream from other conditioning
components. II protects the internal
moving parts in thee
contaminants and avoids
regulator from harmful
Regulator is Water drain vave
fouling of the lubricator reservoir.
mounted after filter. Fig. 4.3.3: Flter in alr line
Lubricators are installed at the downstream end of the
placed Constructionm:
FRL unit just after the regulator and should be
as close to the equipment they serve. It consists of :

1 Filter: (a) Filter cartridge: It is the filtér element made of

sintered brass or bronze.
MSBTE: W:15, S-17
(b) Body : The body is the outer case with inlet and
0 EXplain vaious ypes o sed preunale outlet passages.
fitted to
em ()Plasticbowl: It is the cylindrical bowl
valve
paf
aedi arks the body at the upper ends while water drain
transparent for easy
O
Drav the tigure of ar fiter used is located at the bottom. It is
in pneumatic.systen
visibility.
Marks
used to guide the
Give dassification of hlters used
(d) Deflector and baffle: They are
in hydiraulie SYsteut
flow of air from inlet to the outlet.
planantone Othem
W-15) bottom of the plastic
0. Slatethefunctons (e) Water drain valve: At the

Definition14
of
te bowl, there is an on-off drain
valve which could

Durities
d be manual operated to
drain out accumulated
ifom the conmprased
pLreairto1he system ait water and other solid particles:
A
Symbol: Working:
filter
impurities enters in the
When the air containing strike on the
allowed to
through the inlet, it will
deflector of the filter element
random
cartridge provides
LOcation thickness of the filter
: It is mounted
after the compressor The ffow and arest
the solid
before the
an ig-zag passage for the air to
pressure regulato.
passage.
particles in the cartridge
Tedaatd
Pobtlatlis

Scanned wIn amScanner

 Pneumatic Components & Acc. in Fluid Svs Sys
Industrial Hydraulics& Pneumatics 4-13 Compressor,
may have bad effect on
3. The presence of contaminants
The water vapour gets condensed inside the filter and
of the pneumatic
collects at the bottom of the filter bow. the fincly finished mating surfaces
components.
Major part of the bigger foreign particles may also get
separated from the air a collect at the bottom of the 4. Hcncc filter is the first component located after the
ne
bowl. compressor.

Function of the ilter removes moisture from air:

separate contaminants of size
(microns).
15 to 25 mm
MSBTE WET6

i) Coalescentfilter:
Q Whiat is function oflters W-16
If oil molecules and moisture arc to be separate out
from the compressed air, then coalescent filter is used.
O Frolain.ho iter removes moistiure from air (2Mars
The Fig. 43.4 shows the schematic view 1. To prevent entrance of solid contaminants to the
of filter
clement. system.

The filter is made of metal-wools 2. To condense and remove the water vapour.
which is kept
compressed inside a stainless steel shell and the 3. To arrest any submicron particles.
outer
shell is made of some porous material 2. Pressure Regulator
like ceramic or
borosilicate.
Contaminated air MSBTE WH2.W-14.W-18

Porous matenal Q Draw and3abelair regulator W-12

Q. Explain the working
of pressure regulatar with neat
Clean air
Clean air iW-14
Sketch of pressure regulator
GTCUIt an arplain its working npneumaic
DefinitionTt W-10
Support
Dhe incoming
is thedevice whichregulatestor
pressure controls
to the desired
LFilter material Steadycondition air pressure at a
(Metal woal)
Function:
Fig.4.3.4:Coalescent
filter Its function is
to supply air
Porous material regardless at constant pressure
like borosilicate of variations in the flow
has the capacity and upstream
absorb the finer to pressure.
oil molecules. The
fitted on a seat made filter medium is It is useful in pneumatic
of stainless steel. systemfor
It is used to filter (a) Supply
out moisture and of air at constant pressure
present in the air. other impurities regardless ot
The air enters flow variation
material where at medium and porous or upstream pressure.
oil and solid (6) Helps
impurities are to operate the system
The clean and pure filter out. more economicaly by
air is obtained minimising the
filter. from the outlet amount of pressurised air that is
of the
Wasted. This
happens when system operales a
Function of the pressures higher
filter than needed for the job.
1. It is the C) Helps to
first component promote safety by operating the acmau
indicates, of FRL unit. at reduced pressure.
it is used to separate As name
dust, dirt particles out contaminants ()Extends componeat
from the compressed like life cause operating a
2. It gives air. higher than recommended
clean, pure pressures inu
compressed and contaminations wear rate
air to the pneumatic free and reduces equipment lite.
system.
e Produces readily pressures
controlled variable aur ple
where needed.

0Increasesoperating efficiency.
dledge
PHatieas

Scanned with tamscanner

 Industrial Hydraulics & Pneumatics
4-14 Compressor, Pneumatic Components& Acc.
in Fluid Sys.
Symbol: Thus, it will move the poppet from the valve seat and
Creates opening to allow air to flow from the primary
side to the secondary side.
The opening of the valve helps to regulate the pressure
of air which depedds on the compression of the spring
by the setting screw.
Pressure regulator acts as a pressure reducing valve and
it ensures desired pressure level at various parts of the
Dampening spring
system.

The two vent holes are used to exhaust air if secondary

pressure to high level which is harmful to the system.
Poppet vake
Types of pressure regnlators:
Diaphragm
Vent- hole HSBTES-16, S19

O What are diferent typ uiator?

Main sping Pplain any cne with ne 16,S19
Body
Non relieving pressure regulator

Adjustment i) Self relievinig pressure regulator

screw

Fig:4.3.5:Pressure regulator 0 Non relieving pressureregulator:

LASBTE: S-13
Construction:
The value has a: non

Metallic body: It has two openings-primary and

pressuren S13)
1.
secondary. Function
Poppet valve : It is provided at the valve seat To regulate the pressure of compressed air with the
which helps for pressure regulation. help of unbalanced poppet by exhamsting air thnough
the application device (actuator/ioa).
3. Diaphragm: It is the elastic member fitted at
both the ends in a body of the valve. It is operated Diagram:
with the help of adjusting screw and spring. Astng
$ore
Vent holes: They are provided for veiting out
compressed air if pressure increases above certain
level
5, Dampening spring : It helps to stabilise the *********

pressure. Diphag
Working

The desired pressure is set with the help of adjusting

sCTew. It will move the diaphragm in the upward
direction. regulator
rellving pressure
Fig. 4.3.6: Non

Scanned with Camscanner

 Pneumatic Components & ACC. in Fuid Sys.
4-15 Compressor,
Industrial Hydraulics & Pneumatics

Diagram
Construction:

It consists of:
which moves up and
1. Poppet: Il is the valve clement
compressed air.
down to regulate the pressure of
is
2. Diaphragm : It is the clastic mcmber which Vent holes
provided vith spring on top side and poppet on bottom Orifice

side.

3. Adjusting knob : It is the adjustment screw which Diaphragm

Valve-
helps to set the pressure of compressed air for the
pneumatic application.
Inlet Outlet
4 Valve body : It is the outer case which holds all the
components fitted properly with inlet and outlet ports.

Working Fig. 4.3.7:Self relieving pressure regulator

This valve regulates the pressure of compressed air Construction and Working:
in
followingways: It.consists of adjusting screw, diaphragm and valve
(a) When pressure of air is low: element fitted in the valve body. The inlet and outlet
are given for air supply.
When the inlet air pressure is less than
the spring
The screw setting is adjusted so that will push the
pressure, the force ofthe spring forces
the poppet it
valve in the downward direction and
in the downward direction. The opens the valve
inlet port is openings to allow flow of air
direcdy connected to outlet from inlet to outlet.
port.
When higher pressure is desired
b)When pressure of airishigh: at the ontiet, spring is
compressed to higher value
by adjusting screw which
The high pressure air forces allows maximum opening
the diaphragm in the of the valve to allow more
upward direction and air.
compress the spring,
the
poppet get lifted and fcertain problem causes
reduces the air flow pressure at outlet to bgn
from
inlet to the outlet. The value the air pass through
air is vented through orifice located at diaphragm
the
load to maintain the pressure. and vented through
vent holes to relieve ex
pressure.
() Self relieving pressure
regulator: 3. Lubricator
Function:
MSBTE:W-12. S-17
When the air is vented
through regulator
control presure of compressor itself to 0eledisketchofair lubricaltor W-12
air, it is known
relieving pressure regulator. as self
peoubrcator used in praunais
Marks

efinitionIs thedeyicewhich.adds or
bricatingol n tte compressed air for tn ubrican

Symbol:

Scanned with tamscanner

 Industrial Hydrauics & Pneumatics 4-16 Compressor, Pneumatic Components
&Ac. in Fluid Sys.
Principle: Construction:

.I works on the principle of venturimcter. The sketch It consists of

shows the use of venturimcter principle for obtaining . Plastic bowl: It is transparent plastic bowl which
air and lubricating oil mixturc contains sufficient quantity of lubricating oil. Usualy
When compressed air passes through the venturimcter servo spin 12 or shell tellus 15 or SAE 10 grade
-
oil is
there is a pressure drop at the throat duc to reduction is recommended.
flow area. 2. Venturimeter: The venturimeter is fitted in the body
The throat is connectod to the oil tank with the help of of the lubricator with inlet for air and outlet for mizture
dip tube (oil pickup tube) which lakes oil due to low of air and oil.
pressure pushed at throat and by high pressure at the 3. Oil pickup tube: Oil pickup tube is dipped at the
inlcttA. throat section to take the oil from the bow.
The oil from the pickup tube will get mixed with the Working
compressed air at the throat ánd further to the outlct of
The compressed air from the regulator is allowed to
the venturimeter with the help of divergent cone.
pass through thie venturimcter. The air from the inlet of
This mist of air and oil is suppliçd to the pneumatic
venturimeter is allowed to flow inside the bowl
system.
plckup
containing oil.
O1 tbe
As there is a drop in pressure at throat section, the oil
Campressad-
AR+Ol michre pickup tube sucks the oil and it is feed to the oil drop
E(Mis)
(LOw pressure)
0 parfides tube.

The oil drop tube collecting lubricating oil located at

Lubicatirg the sight feed dome allows fall of oil drops in the throat.
ol tank
portion where they are mixed with air supply.
Flg, 4.3.8: Principle of lubricator
The air with high velocity at throat brakes the oil
Diagram particles and from mist of air and oil which flows out to
Sight feed doma
thesystem.
-01 dropping tube
Function of Lubricator (To add lubricating oil in the
air):
Z Air+Ol Im pneumatic system, components like sliding spool,
Alrin
pneumatic cylinders have sliding motion between parts.

I may cause friction and wear and tear at mating

surfaces.
Hence to reduce friction, lubricating oil particles are
added in the compressed air with the help of labricator.
01 pickup tube
4.3.2 Dual (twin) pressure valve, Shuttle
Plastic bowl
.
valve, Quick exhaust valve, Time
delay valve
-Lubdcatingo
4.3.2.1 Dual (twin) pressure valve (AND Gate
Valve)

QEpaiwith neatsketch Twin pressura valve

Fig. 4.3.9:Construction of lubricator
4 Maris)

aWiteuuh able ot Twnpressure.vale (4Marka

PUGatieis
Scanned with tamscanner
Industrial Hydraulics &Pneumatics 4-17 Compressor, Pneumatic Components & Acc. in Fluid Sys.

As narme indicates, it is provided with twin (two) In pneumatic logic, a two pressure-valve works as an
pressure inputs and a common output. AND gate Ifa compressed air signal is applied to input
This valve is very similar to the shuttle valve in shape P and input Pa at the same time, this will producea
and construction, but the function and the principle of signal at output as shown in Fig. 4.3.10(a). However,i

operation is diffcrent. there is no signal, there is also no output signal.

If only one input signal is applied, there will be no
It is used for the logic AND connections. The picture
output signal as shown in Fig. 43.10(b)
and the symbol of the valve are shown in Fig. 4.3.10(a)
In case of time differences between the input signals,
and (b) respectively the signal arriving last reaches the output.
Construction and working In case of pressure diiferences between the inDut
signals, the signal with the lower pressure reaches the
Output output.

Symbol

P2

(a) P and Pa same time gives output

Output
Truth table for AND gate valve

Input nput0hutput
P

No No No
Yes No No
No Yes No
(b) Only P input, P2 closed No
output
Yes Yes Yes
Truth table for AND function

0
0

:
Application

t is used in safety circuit when two operalos

which
handling single machine like
huge press macu
both theoperators will netal t
place the large sheet of
Ttne ators a
heavy punching ram and when both operau
perform
(c) Actual nea they will operate their valve push butos
Twin pressure
Flg.4.3.10:Twin valve press operaions.
pressure
valve

RTdli
Pnbilcat

Scanned with Camscanner

 Industrial Hydraulcs& Pneumatios 4-18 Compressor, Pneumatic Components & Acc. in Fuid Sys.

4.3.2.2 Shuttle valve

(OR gate Valve) Construction:
MSETE W-14 S18 It is also known as OR GATE valve. It has three pors
(a) P, and Pa inlet ports
Explain shutle valve with neat
sketch. (W14, S-18)
Q. (b) Outlet port
a Wite trurto table of Shuttlae valve, 4erts) The control clcment is the ball which is placd in the
is the valve which allows air supply through
t passage of port P, and port P
1
or port 2 with the help of control clement,
either port
Working:
which moves like a shuttle
in the valve passage.

Need or
purpose: (a) Poutlet,P,> closed:
. Certain pneumatic systems, the supply of compressed
When an air supply is ailowed to enter in the port P, it
moves the ball and closes the port P. The air will low
air to a subsystem must be from more than one source from port P, to the outlet
to meet system requirements.
6) P-outlet, P -closed:
In some systems an emergency system is provided as a
When an air supply is allowed to enter through
source of pressure in the event of normal system
port P, it moves the ball and closes the port P.
failure.
The air will fow from port P, to the outlet.
The main purpose of the shuttle valve is to accept the
pneumatic signals from two different locations. Hence it will supply air throngh either port P,or
port P
Diagram:
Oudet
Truth table for OR gate valve:
Valve body
npin
No No No

es No Yes

No Yes Yes

Yes Yes Yes

Ball

Fig. 4.3.11: Shutte valve

Truth table for OR fünction
Symbol

Applicatlons:
subsystem must be
compressed air to a
The supply of
to meet system
from more than onc source.
requírements.
provided as a
emergency system is
In some systems an nornal system
in the event of
source of pressure
Flg. 4.3.12 : Actual Shuttle Valve failure
edncatlaas

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics 4-19 Compressor, Pneumatic Cormponents & Acc. in Fluid Sys.

4.3.2.3 Quick Exhaust Valve: Return Motion: During return movement of piston,
exhaust air from cylinder is directly exhausted
EMSBTE WE14WAB to
atmosphere through opening R (usually larger and
O. Explaln quick exhaustvave.
W14
fited with silencer). Port P is sealed by the diaphragm.
Thus exhaust air is not required to pass
Q. Explain with neat sketch and oymbol working
and through long
application of Qulck exhaust valve: and narrow passages in the working
W-18) line and final
control valve.
When air is exhausted from the cylinder without
passing in the D.C. valve and exhausted Symbol:
quickly
through the valve known as quick
exhaust valve.
It helps to induce higher speed
in a cylinder through
quick exhaust of air.

Construction and working

During the movement

of cylinder, air from the cylinder
will exhaustthrough
port A to port R to the atmosphere
without travelling through Application of a Quick
port P and thus quick exhaust Valve :
exhaust occurs.
They are available in variety
a of shapes and sizes and
Diagram are used in the industry
to speed up the performanoe
From oylinder moving cylinder, of a
evacuate air directly
atmosphere and increase out into the
1 PortA
the cylinder rod reaction time,
valve actuator. or

4.3.2.4 Time Delay

Valve
MSETE W14 S-15,S-16.W-17.S-18.W-18.S-19
Port
P-
Port R
n with neatskgicr
nokngotnedeay ae

ynboland.working of time
Fig. 43.13:Quick
exhaust valve
A quick exhaust Nay vave (W 18
valve is a typical
consist of movable shuttle valve. As name indicates,
a It this valye is used to initale a
disc (also called delayed signal
three ports namely, flexible ring) in the pneumatic
Supply port and system.
to the output
of the
P,whichis connected tis useful in sequencing
final control circuis to actuate the cyhne
control valve). element (Directional Or motor with
The Output certain time delay.
directly fitted port, A of this
on to the working valve is Construction:
exhaust port, port of cylinder.
Ris left open to The
It consists of four the val
the atmosphere ports P, A, R, Z provided inte
.Forward Motion: body. The port valve
During forward P is inlet supply port of 3/2 D.O
piston, compessed movement 32
piston through
air is directly
admited behind
of while A is the outlet port and R is exhaust pui of
vahe
ports P and the D.C.valve. Zis the pilot port to äctmate 3/2 D.C
the supply pressure A, Port
R is closed due
acting on
the diaphragm. to This valve has three main componenls
usually provided
with a silencer Port R
due to exhaust. to minimize
is
the noise a) In built air reservoir (air chamber)
b) In built non return valve
valve
D.C.
Pilot controlled spring eturn 3/2

Scanned with tamscanner

 Pneumatics
Industrial Hydraulics& 4-20 Compressor, Pneumatic Cormponents&Acc.
in Fluid Sys.
Diagram: 4.4 Accessories:Oil reservoir, pipes,
Ar chamber 32 D.C. valve
hoses, fittings, oil filters, air filters,
seals and gaskets, intensifiers,
Spring
accumulators, heat exchanger,
Adusting
SCTeW muffler
4.4.1 Accessories of Hydraulic System
Introduction:
Vahebody-
1z Non rehtum pl A R In the oil hydraulic system the main components which
valve

4.3.14:Construction of time delay valve

we have discussed are pump, control valves and
FIg.
actuators. These clements are primary clements which
Working:
are must for every hydraulic system.
Initially when compressed air is supplied to the port P
The other elements which are required in the system are
of the valve, it is prevented from flowing to port A
of sècondary importance, hence known as accessories
from port P, as the spool blocks this port A
ofbydraulic system.
When air is allowed to enter through pilot port
Zit The system can work without accessories but will not
flows through needle operated flow control válve where give better performance and efficiency, hence to
its flow can be regulated. enhance performance and operational efficiency it is
necessary to use various accessories.
The air then enters in the air chamber where pressure
starts building here. when sufficient amount of pressure The vanious accessories used in the system are:
isgenerated,itpushesthespoolof3/2D.C.valve. Function
Now the opening port P is get connected port A and
port Ris closed. Air can flow easily from port P to port 1. Reservoir. At the base. To store the
A to actuate the actuátor. |hydraulic oil1

time required to build up Filter Before To remove

The the pressuire in the
pumplafter D.C. | impurities
Teservoir is the amount of time delay of the time delay
vave from oil
valve.
3. Pipe lines, | Between- various Caries
The time delay can be set by using needle adjustment
hoses components for pressurised
SCrew to control flow rate of air. connection oi.
,
the joints, | T0 avoid
pncumatic time delay valves, typical time delays in. Seals and At
mating parts 1eakage of oil.
range 5-30 seconds are posible. The time delay can gaskets
To store
be extended
with the addition of extenal reservoir Accumulators Near the tank
Symbol: hydranlic
energy.
To cool the
Before the tank.
Heat
hot oil.
exchangersS
the tank To heat the oil
Heaters Near cold
in
weather
conditions.

Pltlsss

Scanned witn camScanner

 Components & Acc. in Fluid Sys.
Industrial Hydraulics & Pneumatics 4-21 Compressor, Pneumatic

3. Reduced life of components:

4.4.2 Accessories of Pneumatic System
It decreases life of the components due to corrosion.
Introductlon:
poor surface finish, etc.
In pneumatic system, the compressor, valves and
Methods of molsture separatlon:
actuators are the primary and essential clements
without them system cannot work or perform. 1. Using air dryers
removes moistare by
The auxiliary or secondary clements are mounted along The air dryer is a device which
with main clements to improve performance and dehydration using mechanical or chemical principle.
reliability of system is known as accessories.
The commonly used dryer is efrigerated dryer. These
In pneumatic system following accessories are uscd :
dryers use a refrigeration circuit to chill the compressed
)Moisture separator It helps to remove water
:
air to a specific temperature (dew poini).
particles from the air by following methods:
Water vapour in excess of this temperature condenses
) Air dryer: It helps to reduce moisture in the
and separates at the dryer
air with the hclp of dryers. .

(i) Water trap: It is the device to separate out Chemical dryer:

water particles.
In this dryer, the compressed air is passed through
(b) FRL Unit: It is combination of filter, regulator some kind of desiccant (chemical with an affinity for
and lubricator which performs filtration, pressure water) for a certain period of time to remove a portion
regulation and lubrication of air.
of water vapour.
c) Pipes and hoses: They are used to cary out
Desiccant are usually crystalline substances and are of
compressed air from compressor to the various
components of the pneumatic system.
two types:
d) Pipe fittings They are used for making (a) Absorb type : Which changes physically when it
connections during plumbing of pipe lines in the will absorb moisture. It is salt base or urea base
pneumatic system. chemicals. It is known as deliquescent dryers.

)Mullers/silencer They are noise reducing They have tendency to melt away in contact with
devices used in the pneumatic system. the moisture. e-g. salt, sugar.
use desiccants
Moisture Separator: (6) Adsorption type: These aîr dryers
vapour
that do not change physically as the waer
The air which contains moisture in atmospheric
is absorbed.
condition, contains the same even after compression
and
over and over
hence before this air is fed to any pneumatic
system, it They can be regenerated and used
ane activalrcu
requires separation of moisture. again. The most common chetnicals

Effects of molsture on pneumatic system: alumina and silica jel.

1. Corrosion of components 2. Using water trap':

Water particles are increasing the tendency

of corosion WEWiR
of components like valves, actuators which
are made
from ferrous metals.
Principle:
2 Poor performance
When flow of air is diverted
to abrupt direeton an o
Moisture also reduce the system performance
due to through number of abrupt
changes in
imppedat
botomda l
corosion, noisy operation and increased wear get
and tear theheavy moisture particles,
of components.
to inertia.
catns

Scanned wIn amScanner

 &Pneumatics 4-22 Compressor, Pneumatic Components& Acc. in Fluid Sys.
Hydraulics
Industrial
(a) Storage of oil : It is main oil container which has
Construction:
OWatpr free capacity in liters.
(b) Cooling of oil It acts as a cooling device for
:

dissipation of heat in the oil through large surface area

Weter rep dum of the tank.

Air inlet oil.
Expansion of uid: It allows thermal expansion of
wear
(d) Seperation of impurities: The dirt, dust,
particles settled down in the reservoir.
Ar out ON Offvate pump-motor
Simple water
trap e)Structural support :It acts as a base for
assembly, relief valve, etc.
Water partides
Construction of Reservolr:
Check Baffles Breather/Fiter
valva
Fig. 4.4.1:Water trap
Sight
glass
Working:
which is
trap consists of (1) water trap drum. SUction

.The waterwith inlet pipe för entry of compressed air. strainer

attached
the top of the drum
The outlet pipe is also connected at
Sampting
to supply water free
air. taps
to drain
drum, valve is provided
the bottom of the
At Drain plug
out moisture particles. reservolr
enters in Fig. 4.4.2a): Construction of
through the inlet and
The compressed air pass 90° reservoir.
diverted to the flow path at detailed construction of
a water trap dum. It is The Fig. 44.2 shows
to sudden change in
towards the outlet pipe. Due
It consists of
:
the drain valve. the level
bottom of the drum and collected at (oil level indicator)
: It is
drain out the water (a) Sight glass quantity of oil
available in the
drain valve is pulled out to indicator to show the
The
particles.
tank.
the return pipe to
Symbol: valve : It is provided in
(b) Check
prevent back flow. foaming ofoil.
are provided to reduce
: They
Bafles provided for air
cireulation in the tank.
Deiscator Breather: It is
Water trap. Water trip (Chemical alr dryer) d). the air
pasing throagh the
Maxnal dratn) (Automatic drain) removes dirt from
)Filter: I
44.3 Reservoir (O1I Storage Element) breather. used oil.
provided to drain out
MSBTE S-17
( Draln plug: It is sample offor
provided to collect
tap: It is
Samplingviscosity, etc
Whatis funcionof Olreservor testing of
reservoir should
not close each
a Draw
cat sketch ofollreservolrand ibeltihe
palrs inlet and
outlet of
dissipated easily
during
(h). The can be
AZCMsrk) otherso that
heat
recirculation times the fow
niton s7k atant wach star be three
reservoir capacity should
Urculaion througt thethydraulic The
yenai ) pump. better beat
limporlance rate ofthe helps for
of reservolr: Squarerectangular shape
volume.
t hasfollowing functions: ) dissipation per unit Pebtleatiaes

Scanned witn amscanner

 A-23 Compressor, Pneumalic Componens & ACC. in Fluid
Industrial Hydraulics & Pneumatics Sue

2. Airinlet pipe:
Symbol:
The compressor delivers high pressure air and
allow to
cnter in the inlet pipe of recciver.
3. Pressure gauge:

Closed Receiver It is provided to indicate the pressure of

Open Recciver compressed
air
which is stored.

4.4.4 Air Receiver 4. Airoutlet pipe:

It is provided with outlet valve to supply
MSBTE: S-10. W10S15 compressed
air to the pneumatic system.

Q. Sketch and label air receiver (S10)5. Safety valve:

Q. Wite function of air receiver and pressure gauge It is the safety against the excess pressure
generated
due to some failure in case of emergency situation.
W10
recever. Water drain:
Q. Sketch and label construclion details of ait ot6.
pneumatio syst Itis provided to drain out condensate water particles.

Air receiver is a pressure vessel used to store Construction

compressed air supplied by the compressor.
Air intet
The reciprocating compressors and other intermittent Safety vave
discharge compressors will require an air receiver to
discharge compressed air in the tank for storage and
further use.
Vave
Pressure
Air receiver is a cylindrical vessel mounted vertically
gauge
or horizontally with inlet and outlet connections of. Pessie
Yessie
compressed air.
Water
has following functions
It drain tap

1. It stores the compressed air. Fig 4.4.2(6): Construction of air receiver

2. It smothness out the pulsations in flow of 4.4.5 Pipes and Hoses

compressed air (intermittent discharge) from
Teciprocating machine. 4.4.5.1 Introduction to Pipes

3. It helps to cool the air. In a hydraulic system, it is necessary to carry out the
4. II condensate moisture of compressed air. pressurized oil from one point to the another such as
tank to pump, pump to actuator, actuator to the tank,
. The size of air vessel is specified by the volume of air
m etc.
in stored under pressure. The capacity of air
reciver should be at least equal to hold air delivery of Hence pipes are the closed conduits which are used to
compressor in 1 min. Generally, the receiver capacity carry or supply the pressurized oil through various
should be about 1/10 of free air delivery per minute. connection points in the hydraulic system. It is simlar
to domestic pipe fitting suplying water at rarious
Air receiver is provided with various mountings as
shown in Fig, 44.206). points.

1. Water separator: A pipe can be defined as a functional connection for

lt removes the water particles from

fluid flow in the fluid power system. It may termed s
the compressed air.
pipe, tube and hoses each one has specii
characteristics.

Ted al

L Scanned with Camscanner

 Industrial Hydraulics &
Pneumatics
4-24 Compressor,
Pneuma
Components&
must be of sutficient size to pass the fluid A
The pipes inFluddSys
pressurc loss. Pipe materials:
without excessive
The pipes are manufactured
Piping layout: form of seam less by cold drawing
(without in the
are arranged to supply oil to joint)
tubes to the required
When pipes and fittings size. They are
also coated
or subjected
various desired points. It is known as piping layout of resistive treatment to corosion
the to improve its life.
hydraulic system.
the oil The materials used for
pipes are

4.4.5.2 Important Factors for Pipes and Steel:

Hoses Steel is an alloy
or iron and carbon with alloyng
elements. It has good
MSETES16 surface appearance and
S7 corrosion resistance."

0. What, are the various materals Steel tubes anre made of amealed mild
steel or soft
hydraulioe crcuig ductile carbon stel. Stainless steel is also used

Q. List the actors to be considered for selectng the ppe They are costly and suitable for marine
application
wille desigingdne piraunalie syeten Give
tinn PiBes for thne predmate systemi S17 ()Copper:
speciicatio
1. Types of pipes - Rigid, Semi-rigid ant flexible Copper is a non ferrous metal with high doctility.
It has good corrosion resistance.
2 Material of the pipes
Pipe specification Copper is suitable for low pressure aplication as
3.
it has tendency to get harden at high temperature.
4. Pipe fitings
Itis manufactured for smal bore sizes only.
5. Energy loss
) Cuprons nickel alloy:
which has good
Iis the alloy of copper and nickel
is more costly bence
LTypes of pipes corosion resistance. If
limited and spècific use.
(a) Rigid
Civ) Aluminium:
The pipes are straight and can not be casily change low density metal
which

their shape. They are. suitable for longer Itis ductle non ferpus They are
the form of tabes.
can be easily drawn in
connections which are permanent in the system. of piping is
inmportant.
prefered where low weight
E.g.pump and suction strainer connection.
Aerospace applications.
' Eg.
They are made of steel, cast iron, galvanised iron,
()Galvanisediron:
etc. corroded hence zinc
easily get
The iron pipes are zinc
) Semi-rigid: material is known as
is done and the oaly
.* coating are suitable
galvanized iron. They
It has flexibility up to some extent hence known as coated antionidant
treated with
the oils are
when
Semi-rigid. It includes tubes of aluminium, copper addidives. deterioration of
and other soft materials. chemical
promote the
They may
() Flerible: certain oils.

A of connection. It is required to
5ome points (vi) Cast iron: domestic water
supPplyat 25
suitable for m
ange the shape of pipe and rigid / semi-rigid They are system, they
are ISed
hydraulic in
Pipes are to no use. bar: In oil where
presure is low
connections
nC 1lexible pipes known as hoses are used for return line
to 20 bar
such application. the range of 15
TedKd

Scanned with tamscanner

 4-25 Compressor, Pneumatic Components & AcC. in Fluid Ste
Industrial Hydraulics &Pneumatics

pipe for Scamless, cold drawn, etc. is also mentioned

Factors to be considered while selecting the on pipe
to
pneumatic system give process used for pipe manufacturing.
line.
.Pressurc of compressed air in the 4. Pipe fittings:
Total flow rate per unit time through the linc.
MSBTES15,
Permissible pressurc drop in the line. S17
.Type of tube material and type of linc fting C. PName any eight py
Length and diameter of tube or other pipclines. application

Working cnvironment. ain what is Jemile ining use

Pneumatic

3. Pipe specification:
Q
Pipe fittings are needed in following cases
Eplain schedúle 40:80, 160 plpes Used in hydraulie
(a) Ends of pipes or tubes is to be attached
System 4 Marks) to the ports
of the hydraulic components like actmators,
In general, pipes are specified by: valves
etc.
)Inside Diameter (D) (b) Pipes are to be joined to form plumbing
layout
i) Wall thickness which incindes flow diversion, flow reduction,
ete.
(ii) Pressure rating The pipe fittings are generally called
as:
Giv) Manufacturing method
Adaptors:
Inside diameter is expressed in terms End connectors of valve, actuator ports.
of inches (old
method) like butmetric () Connectors:
2,etc, size such as 15
mm, 18mm, 25mm is commercially used. For joining of pipes ends.

(ii) Endfittings:
Wall thickness of the pipe is the difference between
inside and outside diameter. The outside diamcter size End of pipes and hoses for easy assembly.

remains constant while inside diameter may change The various hydraulic fitings are:
to
vary the wall thickness. The wall thickness indicated
is
by using schedule number. Schedule number has three
grades:

Schedule 40: It is standard size

i) Schedule 80:Extra strong for high pressure
Fig. 44.4(): Straight coupling
(ii) Schedule 160: Double extra strong for very high
pressure.

o10 0.20

Schedude 40 Schedule 80 Schedule 160

Fig. 4.4.3:Wall thickness of pipe

Pressure rating is in terms of proof pressure/Burst

Pressure (B.P.) labeled on pipe. indicates
It maximum
pressure of pipe. () Tee joint
Fig. 44.4(Contd..)

Scanned witn camScanner

 PmCumatics
uhrswal
yanes o& Compressor,
Pnourna

**

(c) Elbow

(o) Cross

Flg.444:Pipofitings

Sclection of fitting depends the sine

on of tre pipe or
tubes. Flanges may be used for size up to 63.5
mn.
Flare less cormpression fitings are used from
1/ o 1
diameter tube. Flared Frttings are used on 50 mm (2)
and below. Compression fitingy are fer cary diamade
(d) Bend
flanged joints are wed above 2.

Plared fiting is shown in Fig, 445. 1 has eod enlarged

by flaring tool and fited by using nut and
flarecd fiting
FAdng

Nut Flarod
end

Tube

(e) Reducer

fitng
Flg. 445:Flared

AN
(9 Flanges
Fig. 4.4.4(Contd..)

44.6:Adaptors
Flg.

PaBHatini

Scanned with tamscanner

 4-27 Compressor, Pneumauc Components & Acc. in Fhe
Industrial Hydraulics & Pneumatics
4.4.5.3 Hoses:
5. Energy losses in pipes
MSBTE: W15
ASE
ISBTE:W-13. S15:S-16:N-16.WA7W-18.S19

Fo. Draw construcional delais ot preumatoh

pneumauc sysiEin
fhe varñous !osses in pipes
in hoso is required in pnauaticcircuits
Sate W-15)] G Sketchi: and label coistut
W13
preumaic
. When hydraulic ol flows through a pipe
or fiting. hose
Q What is hose? Enist tactors aiiecing on S15
there is a encergy loss due to: seccin
tose in hýdraulicssystem. State different layeis
() Pipe friction
hose 16, S19
)Duve to pipe fittings, valves Q Slata tte four mertS anditemeris of using rus
)Leakage at joints hosa in pieumatic circit
The eoergy loss due to pipe friction is given by the oShaw the layers othydrauichose with naat
skelc
Darcy's equation and Chezy's equation. State imalenals used for each layer
W:18
Energy loss dae to pipe fiting is givea by the relation There are number of applications in the hydramš
system where rigid piping is not suitable.

&tto k factor for valves, fittings)

Eg
The various losses due to pipe fittings are: (1) When pipe is to bend for sbort distance
()Sudden contraction: The flow area is reduced connection.
suddenly and loss of energy occurs.
(2) Drive unit is to be moved with the pipe line.
Deinition fledble pipes wiich car
ary shape are used
be eanly berd
bydraulic System These jieribe
e
Lpes are kown as ydraitic hoses
Construction details of pneumatichydraulic hose:
2g
(6) Sudden enlargement:
The fîlow area increases,
and canses energy loss. Outer proteclive.
ayer
Reirforcamant
Inner
Ube

of hase
(0) Cross section of hose (b) Construction
()Bend: Loss of energy due to showing layers
change in flow
or direction. path
Fig.447
rm of
material in the toru
ney are made of composite
wire brading
Tubber reinforced with fibre or steel showa
layes a
Usually hoses are constructed in three
in Fig 4.4.1.

(a) Inner tube: throu

material tube
synthetic
-bend k-bend coefficient) t is mbber or other comes dirdy
which the luid passed and it
is
pressurised oil.
contact with the

Scanned witn camScanner

 Pneumati
Hyafrauihcs& atics 4-28 Compresso eumatic Componem
ntstia Aor. in
FuidS
)Reinfoeent Type of fluid
to the hose in the form of wire 4. Temperature.
gives strength
t gridddesign, it uses stccl wirc of high tensile
ingrid Type of application.
aTangrd
withstand very high working pressure,
strength to Various Types
longer lifc, and
more durability to the hose. of Hoses:
emit
1. As per pressure rating
The
stecl wirc may be ciher spirally woven or cross
wDVen. a Low pressure boses
b. Medium pressure hoses
KANAN
c. High pressure boses
Spiral woven Cross woven 2. As per no. of layers
Fig.4.4.8 a. Single layer

() Oater protective layer: b. Double layer

The reinforcement of the hose is protected by the c. Multiple layer
utercover from corrosion, abrasion
and other Requlrement of good fluld
damage power plumbing:
.Various types of synthetic elastomers having Fluid power plumbing consists
excellent abrasion resistance of arrangement of pipes
and weather and hoses in a particular designed
resistance materials are used for outer manner for givea
protective application.
layer.

Neoprene, synthetic GRS rubbers Following ae the' requirements of good fluid power
arc commonly
nsed for this cOver. plumbing.
Sometimes sleeves are provided (a) The pipe material
for protection of and size should be properly
hoses from extemal rubbing, abrasion,
etc. selected.
Acvantages of hoses: (b) The pipe should hbave sufficieat
strengh to
1. Flexible in nature. withstand pressure of the system

2 High capacity to absorb

shocks/vbrations than metal
) There should be minimun joints fittings
d
tubes. diversion to rednce frictional losses.
3. Easy for installation
and dismantle.
() Pipe joints should be leak proof with propr seals,

4 They can be manufactured

4.4.6 Filters
in long lengths.
5. They are capable
to take high pressures.
Disadvantages of
Deiniion tlers are the icdiums in ol ei
hoses: ystem usedto arest contaminants (irpurities.nd
the ofl to tnprove the operational eiicieny gurui
a
1. Poor abrasion
resistance. CoEpanenits
2 Iniial costis higher.
Need/Tunction of the filtler:
*Dey ae damaged due to incompatible
oil and ASBTE:S-15 S-17
abrasion.

Poor in
weathering resistance. Q Emlaln impoiance o1f
Factorsfor
selection of hoselplpe:
,i. Pressure
Préssure
of fuid to be conveyed. various contaminands
2 bydraulic oil may contain
Flow capacity: The poor perfonmanc
result in wear, corasion,
which may
1o decide failure of the
equipment
diameter and length of pipe. and ultimately

Scanned with Camscanner

 Acc.in F
Compressor, Pneumalic
mponents& in Fluid
Sys.
4-29
Hydraulics & Pneumatics Filiterss
Industial Classification of

filters to emovc
Hence it is necessary to use
the system. 1 of fiter medium
contaminants and supply pure oil to (A)
According to construction
contaminanis
separate out
Tunction of the filler is to
filler
from the oil and clean it. Surface
contaminants present in
thec oil are filler
The various (i) Depth
tapping compound
)Welding scales, metal chips, wcar to quantity of oil fo be
fitered
seal materials, (B) According
(i) Sand particles, bits of
particles filter

biological materials,
etc, H0 Full flow
(ii) Stodge, rust, water, dirt,
fitler
4 () By-pass
Principle of filter:
List types of.oilfilers C4.1:Classification of Filters
Q State the tunction ofol fiter: Fig.
4 Marks)
construction of fnilter medium:
removes CA) According to
hydraulic element which
Oil filter is a screen of filter material
supply clean oil to
the
@ Surface
filter: It is a thin
impurities from the oil and layer of materal
system. Depth filter: It is a thick

Most of the filters work on

the principle of
trapping the
to quantity of oil to be filtered:
pass (B) According
pores. The fluid may
particles in small holes or fow filter: The entire
oil flow is filtered
through filter element and
particles above a certain
size Full flered.
Only a portion of oil is
become trapped. By-pass filter:
Oil consiruction of filter medium
Pores (A) According to

) Surfacefilter:
Filter medium
Contaminants
constructed from thin
Surface filters are normally
many sections and turned
sheets of material folded in
shown.
into multipointed star shape as
Fig. 44.9: Principle filter
of
small spao.
There is large surface area available in a
Effects of Contaminant in the oil The filter is fitted inside a bowl.
traps the solid
The thin sheets full of pores/holes
particles as the oil passes through them.
nants in the .al?
eWhatare theefed

components
1. It will cause chocking or blocking of
components
2. It will cause friction/ wear of

3. Poor performance of system

4. Reduces life of components Fig. 4.4.10:Cross section of surface flter

4.4.6.1 Classification of Filters: The material used for surface filters are cellulos,
woven, steel fibers, woven nylon fibers.
MSBTERW:13. S-17
i) Depth filter:
O Gvo tie clasicalion of fiters used in hydraulic
any twe othene Depth fillerS are constructed with a thick layer u
6temEXplain 13 S17
material with small through which the
passages i
oil filters are classified on the basis of:
must pass.

Teca Levd
ti
Scanned witn camScanner
 HydrauliCS&Pnoumatics
Industrial 430 Comprossor,,Pioum
Compone
Aro. n fhdd
The passages
may be formed Imm granules compacted (lv) By pnss filter: y
intothick cylindrical laycer or libers compactedl into
When only a portion
of the oil is panced
tube. thtnughs the
filtcr clement and
frappcd in the passages and oil is main portion
The particles become
of vil is directly
witlhout riltration. pasord
It is called as
fitered out. by pane filter.
this fillcr, duc to pressure
depth filter is more than the surface differenece
he capacity of inlet and restricted Ietween the
arrest finer materials which can assagr, a purlion
filter as well as also
it of oil ie drawn
towards the filter cartridge
surface filters. for removing contaminanta.
not scparated by
The lig. 44.13 shows by pass
filter mnunted
.The filter materials used in depth filter are cellulosc,
pass valve. Tho valvo
opens to bypass
with aby
synthetic fiber, metal fibers, glass fiber, sintcrcd metal quantity of oil and only the largs
tmall portions is allowed
granules, ctc. iltrations. fo
Filter element
Bypann vatv
+Out

Oil in Oil In
Inlot
Outt
Trapped
pardce

Olh Fitor
olomot
Cloan oll

ZZ -Thick layor of fitor

Fig.44.11:Depth filter
Fig.4.4.13:Filter wilth bypass valvo
B) According to quantity of oil to be filtered
Advantages of by pass flter:
0 Full flow filter:
1. Filtering is independent of system in operation.
As name indicates, full flow filter is used to filter out
the entire flow of oil from inlct to the odtlet of filter.
2. Easy replaccment of filter clement without shut down
the main system.

Inet- 3. Less down time, less maintenance.

Outlet
4. Cheaper.
5. High dlirt retention capacity.
Filter element
Magnetlc Fler
Magnetic filter uses a permanent magnet to attrat
ferous metal particles in the oil. They are in the form
Bow
of a simple plug to long magnetic pole suspended
inside the reservoir.

Fig. 44.12: Full

low filter Pomanont -Tank
The Fig. 44.12 magnet
shows full flow filter which consists
thick depth of
filter element formed
into cylindical shape
and it is
placed'in a bowl.
Flg. 44.14: Magnetie fliter
he fnter has inlet
for impure oil and outlet for conventional filters
oil clean tanks to
They are normally ftted in
as wear
meal particles such
he size is such
that and atract lerrous
fnltration.
it can allow entire flow of oil
lor particles, mctal chips, cte.
secondary fillers.
They are used as a

Scanned witn camScanner

 4-31 Compressor, Peumatic components&
Acc.
Industrial Hydraulics & Pneumatics inFhid
pump, into other componenis such assvalves,i
S
4.4.6.2 Filter Materials: clc.
acualon,

non fixcd pore oM line filter: Somelimes a separate

Filter materials arc fixed porc type on pump
prefcrable to non fixcd solcly for the purpose of
circulating the is
type. Fixed pore matcrials arc luidth used
pressure. This filter indene h
typc. filtcr with litle
dent
ofT line filter. ofthe.
in the following main system is called
The various filter materials are listed
table
Characteristics
Sr Type iltration
No. Pump
Suction/retun
Paper 10microns|
strength
filter low

2 Fabric 20microns|Higher strength

Felt 25-50 Resin impregnated
3. OIntake filer 2) Retum line
filter
microns
Suction strainer Fig. 44.15: Locatlon of filter
4. Wire gauge of 35 microns
stainless steel Symbol offilter:

5. Glass fibre Very fine Fine filtration

good dirt holding

capacity

Phenolic resin Fine Fine filtration

6.
good dirt holding
4.4.7 Seals and Gaskets
capacity
strength, low ISBTE W5 W17
7. Sintered 2 micronsHigh
cost Explain any
powder the purpoSe of hydraulicol seal?
Ghais
8. Membrane Submicron | Poor dirt capacity,
one iype of oi seal
seal ? State the iactors tor seal section
W-15

lowstrengthh
Clogs casily.
W-17
Impregnated Fine
power
DeinitionSedls and gaskets àre the fluid
paper elemens ohich ure lsed to reduce eakage eifectoey
comiponents
4.4.6.3 Location of Filter saticaynaniC portions okyihaulic

1. Intake or suction filter: A

full flow filter may be| Importance of Seals and Gaskets:
that, it can restrict the prevenled
placed before the pump so Leakage is a common problem which is to be
contaminants before entering in the pump through to keep the system at optimum efficiency.
suction line. absolutely leak-prot
t is very difficult to design an
: When oil is circulated through
Return line. filter elements.
system due to limitations of fluid power
various components and may contain wear particles,
esag
hence filter is located in the return line to separate them Wear and tear of moving components increases

before going to the reservoir. chances.

3. Pressure filter: A pressure filter is used at the pump

outlet to prevent entry of contaminants generated in the|
Tedalde

Scanned with Camscanner

 Pneumatics 4-32 Compressor, Pneumatic Components
& Acc. in FluldSya.
yarauiiCS&
Industnal
intenal/e b) Non positive seal:t may
aulic system may be
hydrauli allow small amount a
Leakage in a of internal leakage for lubrication
plays
important role to prevent leakage purpose.
tiny. seal spool movement in valve body. Eg,
and
efectively.
static (stationary parts) and 2. As per area of application:
ed
used in both
Seals are
portions of hydraulic
dynamic
(moving componcnts) (a) Static seals: They are used between
stationary
components. parts.
stationary mating parts
Static
seals are used for (b) Dynamic seals: They are used between
S valve bodies, pumps,
reservoirs, pipes,
surfaces of moving hydraulic
the
hetween parts.
couplings, ctc. 3. As per shape of the seal:
as pump, hydromotor
Similarly dynamic parts such
(a) O-ring
cylinder piston and wall, valve spools,
shafts, bearings,
are protected by dynamic seals. (b) T-ring
having motion
(c) V-ring
Functions ofSeals:

MSBTE:S-14, S-15 ()U-cup

() Quad-ring
Q Gve he uicionsot
( Flat ring
0Sale any Ouduncions offhvdrai
4. As per seal material:
Seals are basically used to:

(a) Leather seal

( Prevent both internal and external leakage of fuid.
(b) Metal seal
6) Prevent entry of dirt, dust and other contaminants in the
system. (c)Polymerseal
Improve efficiency of the system. (d) Plastic seal
()Maintain oil pressure by minimising pressure drop due (e) Elastomer seal
toleakage
(0 Asbestos seal
() Prevent loss of fluid
from the system.
Nylon seal, etc.
0 Fahance working
life
functional reliability
of hydraulic components and
over a longer period
44.7.1 Clasification
of Seals:
MSBTE S-14,W-17.S-19 O-ring

T-ring
eatarddynamic seal

pe State 1fhefactors
assiyhydra
CaigKetohi one type Wit
permethod
As of sealing:
19) V-ring Ucup

Positive seals:
The seals preventseven Flg. 44.16: Seal shapes
amount
of fuidleakage. a minute
E.g. piston seals.

Scanned witn camScanner

 4-33 Compressor, Pneumalic Components &
Hydraulics&Pneumatics Acc
Industrial
The examples of sliding scals are
1. Static Seals: (a) U-ring seal for pistons: prevents
Definition:When seals are
placed between suifaces
of
from top to the bottom of the piston.
It
fluid n
passing
components, it is known as static
moving)
stationary (non Barrel

seal
usually compressed
scal is made of soft material is Rod
The
matcrial into the
the surfaces and force the seal
between
surfaces, with the help of
imperfcction in the
small U ring

fastners.
seal
cut out of thin
the fom of gaskets
Static seals are in Piston
mating surfaces
and placed betwecn
shects of material (a) U cup seal for sliding pistons
bolts.
squcezed together by serews or
which arc then

examples of static seals are

The various
Seal

-Hange

Inlet
Outet pipe
pipe

pipes (b) Pipe joints (pump) (b) Cup seal for simple pistons
(a) Flange
joints of
Fig. 44.17:Static seals

movement of the mating

static seals no relative
.In pertfect static seal is difficult
components is allowed. A
over a period of time due
to Cup seal used
to achieve perfectly
load, chañge in for simple
vibrations, shocks, mechanical piston designs
pressure, etc.

The static seal is in the form of flat gasket, 0-ring, U- FTIT

ring or washers. Ring used in
pressure cooker is also a

example of static seal.

Fig. 44.18
2 Dynamic Seals:

Delinition When seals are used between lhe surfaces of

kydraulic parls wlhere motion ocus
and contros 2botr
eakage tand librication are known us dynanieseal

The dynamic seals are divided into two types:

) Slidingseals:
Slhiding seals
are mainly used with cylinders to prevent
luid escaping around a piston rod
or from passing from
one side of a piston
to the other.
Generally sliding
seals arering type may be solid
like O-ring or rings ring
with rectangular
sections. U-ring,
cup are also used.

Fig. 4.4.19:Sliding seals

Scanned wIn amScanner

 Pneumatics
ndustrial
Hydrauics& 4-34 Cormpressor, Pneumatic
Components& Acc.
Wiper ring in Fluid Sys.
cleans off (2) Environmental condition
(Wet, Dry, Hot).
oily dirt from
(3) Fluid medium.
the outsidao
(4) Type of application (static
or dynamic)
(5) Temperature ofthe system.
(6) Functional reliability ad cxpected
life.
Failure of Seal:MSBTE
S15,WH5 S16,S-17 S-18B
Fig. 4.4.20 : Wiper ring a State any four reasons of failure of hydraiufic
seal
) Cup
seals: They, are suitable for simple single (S-15,W-15, S-16,S-17,18)
acting cylinders with low pressure (Fig. 4.4.18(6). Seal failure is progressive in naturc and
it has following
ring for removal of dirt: They are used causes for its failure:
Wiper
to wipe out oily dirt from the rod during (a) Excessive clearance : Excessive clearance between
movement from the cylinder. moving parts causes extrusion of the 0-ring and other
rings and reduces the performance of the seal.
) Rotary seals:
(b) Fluid temperature : High working temperature of
They are used on pumps and motors to prevent fluid
fluid may cause seal abrasion.
leakage out through the, gap between the shaft and shaft
bearing ) Damaged or wornout parts: Causes improper fiting
of seal.
They are designed with a spring loaded lip which
presšses to the shaft. ( Incompatibility of the seal material and oil : When
Shaft oil is improperly selected with respect to type of oil.
(c)Excessive side loads/overloading: It causes wobbling
Rotary sea
of piston rod and dislocate the seals.
( Vibrations: Caused due to bent shaft, broken vane,
Shaft misaligned damaged bearing, defective coupling,
beanng
etc.
(g).Low speed: It causes spiral failure of seals.
6) Lack of labrication : It increases heat and reduces life
of seals.

4,4.8 Intensifier (Pressure Booster)

Ol side Oil side
O Write the functan of tydraullo tntensifier in hydrauic
Fig. 44.21: Rotary seal for piston
circuit 2 Marks)
Efectof Leakage on Hydraulic corstruction woring hydraulic
and of
System: plain
0) Loss in volometic 14Marks)
efficiency.
is a device
2) Lossin systempower Hydraulic intensifier or pressure booster
pressure of
which is used to increase the intensity of
Lack of control and
loss of sensitivity and accuracy with the help of the
4)Geaeration any hydraulic fluid or water,
huge quantity off
of undesirable heat. bydraulic energy available from a
Resultant low pressure.
system malfunctioning water or hydraulic fluid at a
Factors require high pressure for
for Seal Some hydtaulic machines
Selection: MSBTE S-16 can't be obtained by
Ent working but this high pressure
machines are
eJactors to be considered for selection of these hydraulic
USing pump. Some df etc.
and hydraulic lift
(0) Working (S-16) hydraulic press, hydraulic ram
operation
pressure for this
pressure
and pressure range. These machines require high
pressure.
required amount of
to obtainthe
lcatlens

Scanned witn camScanner

 Su
Pneumalic Cornponerts & Aec, in Fluid
435 Copressor,
Pneurmatis
Hydeavlics&
the inner most
and srnallest part of the hydrauli
Industrial Iis
Hydraulic Intensifiers
(or Boostern) intensifier. It is
murrounded by a sliding cylinder. The
The Nocd for machinery ued, the
usual
is supplied to the machine throuh
rough
hydraulic high pressure liquid
monst of the to
.In 1O0 psi may not
be sulficient
to this fixed ram.
pressure of 0 mechanisns.
spool valves and
other cylinder
operate certain Hollow inverted sliding
high presure
requirement for a|2.
Tomeet the eed for a time, pumps and A hollow inverted sliding cylinder, containing water
comparativcly short period of
high under high pressure, is mounted over the fixed ram
accessoriesare definitely not able to generate
is the middle part of hydraulic intensifier ic. it slides
pressure,
which can
t
hydraulic intensificrs in betwcen the fixed ram and
fixed cylinder.
But it is possible with
100 psi 40,0X0 psi, using
to
increase the pesure from This is the only moving part of this device. It slides
small volumes of fluid. under the action of hydraulic force. Sliding cylinder
betwcen the punp
hydraulic intensifier is mounted in
A
contains high pressure liquid which is supplied to it
and the working machine. It has two
types one is single
through the fixed ran.
acting and other is double acting.
3. Flxed inverted cylinder:
Constructlon and Working:
From Supphy The inverted sliding cylinder is surrounded by another
(Low Prenaure
inverted fixed cylinder which contains water from the
main supply at a lower pressure.

A large quantity of water at a low pressure from the

To Exhauste- supply enters the inverted fixed cylinder. The weight of
this water presses the sliding cylinder in the dowaward
LoW
Preezure direction.
!! Vlater
The water inside the inverted sliding cylinder gets
High
compressed due to the downward movement of the
Precsure
Water sliding cylinder and its pressure thus increases.
Fixed
Cylinder This high pressure water is forced out of the sliding
cylinder through the fixed ram, to the hydranlic
Sliding machinc.
ylinder Valves
Low
Presure
Hydraulic intensifier consists of four valves named A.
-Fixed RAM
V/ater- B, C and D. 'A' and "D' allows low presure liqnid
From
Supply from the supply into the device.
the liiea
High The liquid comes in from valve "D' goes into
Prenaure Water
cylinder and the liquid goes in through the valve
To Machine
Fig.44.22a):Constructlon of hydraulic goes into the sliding cylinder. Valve is for exbaus
intensifier
purpose.
It consists of three ure
main parts as shown
Fig, 44.22(a). They in The outlet valve "B' is used to supply high pres
are ith
is atlached
1. Flxedram iquid to the outlet of intensifier which
hydraulic machines.
A hydraulic intensificr
consits of fixed ram through
which the water,
under a high pressurc,
hydraulic machinc. flows to the

Tedlo
Scanned with Camscanner
 Pneumatics 4-36 Compressor,Pneumatic
Hydraulics &
Industrial Components
& Acc.in Fluid Sys.
(c) To provide emergency power
source:
The fluid encrgy stored
in an accumulator
sufficient to give an emergency maybe
supply in case
failure causing the pumps of power
to stop.
()Holding high pressure:
Accumulator gives fluid
energy back up for
longer
periods without keeping the pump
running.
They are usedin
Fig.4.4.22b) :Actual hydraulic Intensifier
) Large hydraulic presses
Applcations
(i) Farm machinery, diesel engine startes.
t is most commonly used where high intensity of () Hospital beds, aeroplane landing mechanism.
pressure is required for lift the loads in hydraulic press,
Civ) Lifts, trucks, etc.
bydraulic ram, hydraulic cranes and hydraulic lifts etc.

Symbol:
4.4.9.1 Types of Accumulators:
MSBTE: S-15. W-15. S-16. S-18

Sale diferent yes ofacumulator arid erplaly any,

4.4.9 Accumulators
Onewi'sKethy S15)
ACTuators are casSiTed 7Xplain any ore
MSBTE S-15. W-15. S-16, S-17: S-18 s19 Rit W15
ero accimulaior in neat

he uncionofacaumuatogintiyorauic.cic ngdoaded accumuatoni eat sketch:

15 W15S16.S10S1
S1)
They are classified on the basis of element used to store
oil under pressure:
Definituon
A ypes of Acumulators
ake the
toj Daad weight bpo
Functions of accumulator:

aTo meet peak demands of power: PSpring baded tpe

chapod type
when excessive power is available during lower Gas
capacity, there will be loss
of power if pump, runs Fig.C42:Typesof Accumulators
continuously, hençe during the slack period, some of
he fluid energy is used to charge an accumulator. Then
(a) Dead welght type:
it is used to meet
peak demands of power. oil energy.
It uses dead weights to store
6) To smooth out
pressure surges/shocks
Construction:
weight and
When fluid flow is suddenly changed pressure surges
piston loaded with dead
It consists of a pressure on the
are developed, moving
fluid may canse fluid hammer within a cylinder which exerts
moving
and shock waves.
Accumulator will absorb the pressure oil. constant
piston pressure will remain
CES and ripples and reduces vibrations and pressure The stroke of the
unchanged.
Surges. because the load remains

Scanned with Camscanner

 4-37 Comoressor, Pnaumatic Components & Acc. in
hdustial Hydrauies & Pneumatics F.
hPidn
The dead weights may be of some heavy material such 2. More space requred hence not
suitable
as inn, onTrte blek er even water. space is limited. where

The pistom is fited prvisely in to the cylinder to Symbol

minimire leakage.
They can te used to sene sveral bydraulic systems at
a time are usad in mill and central hyuruulic system.
Dedwoghts

(b) Spring loaded accumulator:

Platom
It used spring force to store hydrmlic
energy.
Construction:

A spring loaded accumlator consists

Piston of cylinderbody
yinder
a movable piston and a spring. y
The spring applies a force to
the piston. As dead
accumulator requires weight
more bulky weights,
spring
provides large force
in a limited area for
the same
pressure.
oi riet/ odet
The spring used in this accummlator
Fig. 44.23:Dead weight accumulator is compression
spring which exerts force
on the piston.
Working:

Wben oil from pamp enters

throngh inlet port, it pushes
the piston upwards against Ccrmpresson
the load exerted by the dead
spng
weight placed on the platform.

The dead weights are used

to maintain oil pressure
charging of the accumulator. for
Cyinder
Wben piston moves
fromlower end to upper end,
accurmulator get the
charged and when
the application
it is connected to
point, the oil under Piston
pressure releases
energy through
the outlet A.
When pistons
moves down completely,
is unloaded and discharged. the accumulator

Advantages
:
1. It supplies oil at
constant pressure. Ol in/out
2. Simple
in construction.
3. Large capacity, Fig.4.4.24:Spring loaded acumulator
it can serve
systems at several bydraulic Working:
a time.
Disadvantages
at the boltots
. It haslarger
size.
Den pressurized oil enter from the inlet
pushes the piston in the upward direction
agauns the

spring force.

Tdiangi

Scanned with Camscanner

 & Acc. in Fuid Sys.
Hydraulics &
Pneumatics Components
Industrial Compressor, Pneumatic
-38
moves from lower end to the Working
When piston upper cnd
inlot
npressed. When piston reaches
the upper
Gas charging
end, the accumulator is fully chargcd
stop

When accumulator is conncctcd to the

application
point, spring pressurc forces the oil under Compressed gas
pressure
through the outlet port. When spring is fully
expanded
the accumulator is unloadcd and dischargced

Advantages -Gas bladdor

1. They are compact and smaller. Stoel shell

2. Mounting is casy.

Disadrantages

1. They supply a small lume (less capacity).

Inlst valve
2. Operate at low pressure.

3. The pressure is not uniform

and does not remain
constant
o nlet
Symbol:
Fig. 44.25: Gas charged accumulator
Initially the accumlator is pre charged to the required
pressure with the compressed gas in the bladder.
When oil under pressure enters in the accummlator
through inlet, it starts pushing the bladder with the
oil
pressure
As the gas inside the bladder is compressible,
the oil
(c) Gas charged accumulator: push the bladder in the upward direction and
compress
MSBTE W-18 the bladder when oil pressure is more than
force of the
bladder.
Explairi wilh neat sketch wonkiig of piston ype gas
The accumulator is completely charged when bladder
Charged accumula 4Marks is
compressed sufficiently. Gas expands during
unloading
0Explain with figure worling öfbag pe accumatori the accumulator to the required application device

Advantages
compressed
They store energy with the help of force of 1. The accumnlator is compact in design.
gas. 2. Quick response for loadingfunloading
of
Construction accumulator.

It consists of a synthetic
polymer rubber bladder fited Disadvantages:

inside a metal shell. The

bladder is filled ith 1. Constant pressure cannot be maintained due to

compressed gas. compressible nature of gas

port get
located at the discharge 2. Higher pressure ratio and higher temperature may
A poppet valve is cause failure of bladder.
completely charged.
closed when accumulator is
(oil is 3. Special care required to prevent airloxygen to enter
precharged when it is empty
The accumulator is in the accumulator which may cause danger of
gas charging inlet
not present) with the help of explosion.
bladder.
nitrogen gas is used to fill the 4. Limited capacity.
Generally dry
Pebatn

Scanned with Camscanner

 Conmprestor, P'nournatkg Cornponents B Na. In Fluld Sy
4 9
lntntrtadtlydaulon & P'aeumtin
Symol tources of Heat Generatton

) rdction

Gil) 11ockaga ol fiter, valn ard catuH dernents

4.4.9.2 Necessity of nccumulator for every
tnconypalilblo oll
huge hydraulle press: ()
MSBMER S-7 (Uso of rollof valves arnd orificos

a, Why nacammulato noçobary, for hugo Hydrmulic Flg. CA.3:Sources of heat

Prusso
(6) Pump: There is some encrgy from electric motor to
Oil rquirement of the system is not continuous but
intermittent. A hydraulic press necds the oil only during the pump which is not convertcd into work. The

the liting operation. unutilied power may generated heat in the system.

While, during the lowering of load, okding the onad or (Gi) Vrictlon : Pipe friction, joints, line fitings, moving

during idle period, it doesn't not require nny supply of componcnts with vibralions nay generale heat in the

oil. system.

During such period, the hydraulic pump has to stop or (i) Mockage of filler, valves and other elements

delivercd oil must be daincd back to the reservoir. Bu Cloggcd filter causes interruptions in the fluid flow in
frequcnt starting and stopping of pump is not desirable the valves and other elements and heat is generated.
as it reduces the punp life. (iv) Incempalihle oll : If oil viscosity high and is is not

Also, draining the pressurized oil is wastage of power properly choscn, it may incrcase friction and generales
which reduces the systcm efficiency. Hence use of heat.
accumulator is requirced in the system.
()Use of relief valves and orifices: Oil pasing through
4.4.10 Heat Exchangcrs (Cooler): valve may gcnerate heats, due to change in flow area
and path.
Definition oJuid powet devicewhich i rukedlto
remave hiedt rom the syoemfor cooling purpoNe 4.4.10.1 Types of heat exchanger:

Sources of heat:
Types of heat exchanger
MSBTE: S-16
(a) Air cooled heat exchangers
aX List out aoyfoursoureeuof heat genoraionin
hydraulic system, 8-16) Water cooled heat exchanger
(6)
There are varicty of reasons for heat generation in
(c) Gas charged type
hydraulic components and system. Some of the sources of
heat generation are: Accumulators
Flg. C4.4:Types of

sd
YP
tin*

Scanned witn camScanner

 PnGurnatica 4-40 Cormpresncr, Prumatic Comccnets 8 Acc. in Fuic Srs
&
ustialyraulca
exchanger: Symbol:
cooled heat
Air
a) Warm alr
a. Draw syrbcis of Hiest enchanga

0Cod a Oil Heaters

44.11
ASBTE E16
a In coid dimate wty oi t
heaters? Expair
Natural alr
.Oil heater are used to beat the ol wbea tydrmše
conditices
system is to be installed in cold weather
Fan Due to lowest temperature ol mmy get feee d oe à
viscosity.
FIg. 4.4.26:Alr cooled heat exchanger
A thermostatically cootrolled beater is
instaled in he
cooler are used where water is not readlily available woriing
Ait reservoir which heats the cil to is normal
and the air is 3 to 5" C cooler than the oil. temperature so that the oil can function efictively.
comparatively
Use of air cooled heat exchanger is
chcaper and hence cconomical.
of heat
Natural air or fan can be used to improve rates
transfer.

(0)Watercooled heat exchanger:

Water coolced hcat cxchangers are more compact,
Fig. 4.4.28:0il heater
reliable, efficicnt and high heat transfer rale.

'But watcr may cause corrosion of tubes, scale Symbol:

formation, ele,. Disposal of warm water directly is also (2Marks)
O. Draw.symbols at Heat erchanger hers
drawback.
Hot
oll In Hot wator out

Wator Jacket

44.12 Muffler (Slencer) :

a. Draw pneumatic symbol of : Muifet (2Maria)

Symbol

there is no need to provide return

In pneumatic system,
the atmospbere directly
Cool oil out lines and the air is cxhausted to
Cold wintor In
through the exhaust poris.
Pg.44.27: Water cooled hoat In exchanger
in nature, it will produce high
As air is low density
noise during its application as well
exhanst

P auis

Scanned with Camscanner

 1iyutrnuliecn & P'nounaticn A41 Compronsor, P'netfvallg Congponerits & AA, Io Fudad fy
Induntinl

.The high noise prneed during exhawst enn be reduced (o) tor (0) Flovitlo hose

wilh the help of zilencer ic. moico eulhu es kmown ".11 Ist vnronn typon of lones rsMl In preurntlo systen
mufller.
(ectlon 44A)
I is similar to the vilencer litted to he vaton
a,12 Lnt thio Faotorn to ho tomlklored tor saletling
automobile vehicles to rdwe wise lovel. ho
pipo wllo donlgnimg pneunntle system.
It eonsists of balle plates niangod in n 2 7ayg mamne
(Goctlon 4.44.3)
to avvid diuret exit or air and theve by oiso lovel
i a. 13 (Gtvo npoclticatton of pipes for tho pournatio syston.
reduced by inserting obstctions in the path eof nir.

-
(Soctlon A4.A.2)
They ae monnted at the exhust ponts of D.C. valves
from which nir is exhausted. a. 14 Explnln constructilon of Pneunnatic hora? Writo
s
advantagon. Stnto tho npercilcanllons of plpes.
Balles
Airin Oulor sholl (Sectlon 4.4A.3)

a. 15 Draw labolod tkotch of alr lubrlcator. (Section

4.3.1())
a. 10 LLst diforont typors of presuro roguaator valves?
Fig. 4.4.29:Sllencer conslructlon Explanln any ono with noat tketch. (Sectlon 4.3.1(2)

Revlevw Questlons a.17 Namo any lght ppos or tubo fting with their
appllcalion. (Sectlon 4443)

a.1 Classily comprossor in gonernl. (Sectlon 4.2) Q. 10 Dollno nccumulator? Why nccumulator is nocossary

Q.2 Gvo classiliction of nir comprossor on tho banlo of

for hugo Hydraullc Presses?

Stagos (i) Drvo ol compros0or Q. 19 Skotch Symbol and working of limo delay valve.

6i) Cooling modium (v) Action (Sectlon 4.2) (Sectlon 4.3.2.4)

Explain working of twin scrow comprossor wilh 20 Explain limo dolay valvo with neat skotch.
a.3 tho.
help of sketch (Section 4.2.2.3) (Sectlon 4.3.24)
Q.21 Stato lour morits and demerits of using a nubber hoso
Q.4 State tho Function of FRL unit and draw lts detnilod
In pnoumalic circuit. (Section
symbol. (Sectilon 4.3.1) 4443)
a.5 Explain Dual pressuro valvo wilth skolch 0.22 Show tho layors of hydraulic hoso with a neat sktch.
(Section 4.3.2.1) Stato matorials used for cach layer. (Section 4.443)

Q.23 Draw symbols of : (Secttons 4.32. and 4.32)

a.6 List tho functions of soals usod in hydraulic circuitls.

(Section 4.4.6) (a) Shuttlo valvo

a.7 Classifly soals. Explain any ono wilh neat skelch. (b) Twin prossuro valvo

(Sectlon 44.6.1) (c) Spring loaded accumulator

a.8 State tho various roasons for seal falluro? (d) Intonsifior
(Section 4.4.6.1)
Q.24 Explain construction and working of hydraulic
Q.9 List sourcos of hoat in hydraulic circuits. (Sectlon
Intonsilor. (Sectlon 44.7)
44.9)
a.25 Stato tho tunction of accumulator? Explain doad
Q. 10 Draw symbols of: (Section 4.4.9) wolght typo accumulator. (Sectlon 44.8)
(a) lil heater (b) Oil coolor

O00

Scanned with Camscanner

 UNIT V

Chapter 5: Oil Hydraulic Circuits 5-1 to 5-28

Syllabus:
5.1 Simple oil hydraulic circuits Single and Double Acting
Hydrautic cylinders, moturs.

5.2 Speed control Meter-in, Meter-out, Bleed Off circuit.

5.3 Regenerative, counterbalance, sequencing circuits
synchronizing, two pump unloading.
5.4 Hydraufic circuits for Mlling machine, Grinding macrine,
Shaper machine, sloting machine.
5.5 Remedies and fauit detection in Hydraulic circuits

Toeirdi
 Industrial Hydraulics& Pneumatics(MSBTE_Sem-V
=
5-1
5.1 Introduction.. ***********

5.2 Definition of Hydraulic Circult.. ***********************

5.3 Main Components of Hydräulic Circuits.. .5-1

5.4 Hydraulic Power Pack. *********************************************

5.4.1 Types of Hydraulic Circuits. ******************* C

5.4.1.1 Preliminary Simple Circuits.. *******************

2

5.5 Speed Control Circuits.. **********************************5-8

5.5.1 Typas of Speed Control Cirauits.

5.5.1.1 Meterin speed control circuit.. .... ..5-8

5.5.1.2 Meter-out circuit...

******i.5-10

5.5.1.3 Bleed-off speed control cirtuit . .5-12

5.5.1.4 Speed 'control of bi-directional hydroinotor.. 5-133

5.5.2 Diference between Meter-in'and Meter-out

Circuils . ********************************-* .5-14

5.5.3 Difierence belween Meler-Out and Bleed-Off

Circuil..********* ******************************************************** .5-14

5.6 Regeneraüive Cicuit.. ***************** ***********

15
5.7 Counter balance Cicuit. *************** ************* 5-16

5.8 Sequencing Circuits. ***************************************** .5-17

5.8.1 Sequencing DevicesS..

..o*****-***** 5-17
5.8.2 Types of Sequencing Circuits .5-17

5.9 Motton Synchronisation Circuit .. *********

. -19

5.10 High-Low Double Pump Hydraulic Press Circuit

(two pump unloading).. 5-21

5.11 Machine Tools Hydraulic Circuils.. **************************** -22

5.11.1 Hydraulic circuit for milling machine table.. -22

5.11.2 Hydraulic clrcur for surface ginder
table.. 5-23
5.11.3 Hydraulic shaper machine circuit . "******* .5-24

5.11.4 Hydraulic Slotting machine circuit

***********************i* .5-25
5.12 Maintenance of Hydraulic System. *************************** .5-26

5.12.1 Remedies and Fault detection in Hydraulic Circuits...5-26

 APT
5 Oil Hydraulic
Circuits
4UNIT V
Syllabus:
Simple oil hydrau
raulic circuits -Single and
Double Acting Hydraulic oylinders,
motors.
52 Speed cotrol Meter-in, Meter-out, Bleed Off circuit.
sa Regenerative, counterbalance, sequencing circuits, synchronizing,
two pump unloading.
S4 Hydraulicircuits for Milling machine, Grinding
machine, Shaper machine, slotting
machine.
55 Remedies and fault detection in Hydraulic circuits.

5.1 Introduction It shows the interconnection of various components like

.

pump, D.C. Valves, actuator etc.

The main objective of a hydraulic system is to give A circuit diagram is drawn without consideration of
specific solution related to power, sequence physical arangenent of the hydraulic components in
or speed
problem of any mechanical system such the system.
as machine
tool, equipments, ctc.

Hydraulic systems are to designed for: 5.3 Main Components of Hydraulic

Circuits
) Movement of a machine tool table

6) A machine slide, clamping of workpiece Main Components of Hydraulic Circuts

) Apress ram, loading the job

(d) Mechanical transfer 1.Hydraulic power pack
of load
(e Cating, pressing or metal cutting/forming
2 Hydraulic control vahes
operations, etc.
3.Hydraulic actuators
The various hydraulic components are mutualy
MCreonected by pipes to forma hydraulic system for
performing the given task
or application.
4. Accessores

Ordcr to avoid complicated drawings, it is the Fig. CS.1: Maln Components of Hydraulic Circuits
ctice in hydraulics and pneumatics to uise symbols
r each element
the symbols
and hydraulic circuits are drawn with
only.
1. Hydraulle power pack
mechanical ouplings
It consists of pump, drive motor,
coolers, etc.
5.2 oil reservoir, strainer, filters,
Definition of Hydraulic
Circuit
2. Hydraullc control valves:
Definition
of Lydnpilecirait Udranlic ireuit and flow control
ed as the gruphieal repreyeniatan Pressure control, direction control
CUmponmentsAsug
valve, etc.
machin syibols) n ydrailic operaed valves, shut off valve, check
une
actuators:
Hydraulic 3. Hydraulic
circuit the arangement of ydraulic
is single acting, double
acting
amponents
in application to Linear actuators like
beperformed a particular manner as per cylinders and rotary actuators ie.
hydromotors.

Scanned with Camscanner

 Incdustrial Hydraulica & Pnournatics (MSBTE Sem-VI)52 Ol Hydrau Cirois
2 Speed control circuits
4. Accessories:
(a) Meter-in speed control circuit
gaskets,
includes pipes, hoscs, filters, scals and
It

nccumulator, pressure gauges, ctc. b) Meter-out speed control circuit

lydraulic dlesigncr has to sclect proper components

for (c)Bleed off speed control circuit
showing
the desired functions and prepare circuit for (d) Speed control of bi-directional hydro
motor
their interconncctions. Regenerative circuit, Counterbalance
3.
cireuh
4. Sequencing circuits:
5.4 Hydraulic Power Pack
(a) Pressure dependant sequence circuit
of hydraulic system in which
It is the basic subsystem

pump, motor, reservoir, filler, ctc are grouped into 6) Travel dependant seqpence circuits
single combincd unit known as hydraulic
power pack. 5. Motion symchronisation circuits:

It compulsory subsystem in cvery hydraulic system

is (a) Using flow dividers for two D. A. cylinders
commercially, it is available as a single unit now days.
(6) Using rack and pinion arrangement
Procsura gauge
)Mochanical coupled bydro motor
Shutaff valv
6. Two pump unloading circuit

7. Machine tools hydraulic circuits:

(a) For milling machine table movement
Motor
(6) For grinding machine table movement
Pump
D Relit vahe

(c)For shaper machine tool movement

- Suction pipe () For slotting machine
Oil - Strainer 5.4.1.1 Preliminary Simple Circuits:
level
Indicator
-Resorvolr ) To actuete single acting cylinder
Purpose of the circuit:
Fig. 54.1:Hydraulic power pack
Movement of the single acting cylinder to produce push
5.4.1 Types of Hydraulic Circuits: force by using oil pressure.
1. Preliminary simple circuits Circnit components:
(a) To actuate single acting cylinder
1. Hydraulic power pack.
b) To actuate double acting cylinder
3/2 D.C.Valve
Using 4/2 D.C. Valve
3. Single acting cylinder (spring returm)
Using 4/3 D.c. Valve
4. Pipes and hoses, pressure gauge, shut off va
(c) To actuate unidirectional hydro motor
etc.
(d) To actuate bi-directional hydro motor

Using 4/2 D.C. Valve

Using 4/3 D.C. Valve

Kavtol
Ted

Scanned with Camscanner

 Industrial Hydraulics & Pneumatics (MSBTE.Som-Vi)
53 Oil HydraulicCircuits
Cirruit dinggram: Selection of D.C. valve:
PAush foreo

As the ports involved in this circuit

are (1)P-> pump
SA OMtidor (2) A inlet of actuator and (3) R
-* reservoir port and
forward and backward movement
of piston (two positions).
Hence 3 port/2 position i.e. 3/2 D.C. Valve
is used.
Lewr opentod
32 D.C.
ProuD Explanatlon of circult:
vave gaugo
1. Actunted position to produce pnsh force:
PR PUR Fig. 54.2{a)

In this circuit, the oil flows from tank

Shut off valve to the pump
inlet through the filter. Pump gives pressurized
oil
Pressure
elof vave PRV Pump to the D.C. Valve.

In the position of D.C. valve, the

port P is
Fiter
connected to port A and portB is closed. The
port
Rosorvolr A is connected to inlet of the S.A. cylinder. The
oil will flow from D.C. Valve to eter in the
Fig. 54.2(a): Hydraulic circuits for S.A. cylinder
cylinder through pipe line.
(actuated position) (push force)
Pull forceby spring) .The oil in the cylinder pushes the piston from face
side. When oil pressure is greater than spring
SAcylinder force, it will push the piston towards right end of
the cylinder. When it reaches to the right end
completely, the stroke is completed known as

extending of the piston.

Lever operated
2 Normal position to give pull fore : ig 5426)
3/2 D.C. Pressure
valve gauge When D. C. Valve is operated using lever to
TIT occupy the normal position, the port A of the
PR PLua
actuator (now worked as outlet) is connected to
Shut off vahve the port R and pump port Pis closed.

Pressure
Mobor Pump
As the supply from the port P is closed, the spring
relef valve expands and pushes the oil to the reservoir port R

Filter through outletA.

The piston will reach the left end when oil is fally

L Resorvolr
discharged through the port R. In this way

retraction of piston will be completed.

Fig. 54.2/b):Hydraulic Applicatlon of clrcuit:

cireits for S.A. oylinder
(pull force) (normal posiltion) direction only eg.
Used to perform work in forward
clamping of workpiece.

tisis

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-V)
5-4 GAH

acting cylinder:
(b) To actuate double

actuate double acting cylinder using 4/2 D.c.

To
Valve

Parpose of he circuit:

Movement of the double acting cylinder to produce to

and fro motion by using oil pressurc.

Circait components:

. Hydraulic power pack

2. 4/2 D.C. Valve (lever operaled)

3. Double acting cylinder

4. Pipes, hoses, pressure gauge, etc.

Circuit diagram:
D.ACylinder

Fig.543(b): Normal position

Explanation of circult :
1. Actuated position (forward stroke) Fig, 543(a):
Lever operated In this position, the port P
4/2 D.C. Pressure and port A a
vave gauge connected to enter the oil from pump to the
A
P cylinder inlet A. The oil pressure moves the pista
in the forward direction while the oil on the piston
Shut off valve rod side is pushed from port B to port R to divert
the flow to the reservoir. It completes the forward
Motor
stroke of the cylinder.
Pump
Relief
valve
Normal position (Retraction stroke) Fig, 5430):

Fiter When D.C. Valve is operated to get rormal

position, the oil from port P will enter through ti

Reservoir port B from rod side and push the piston towards
the left end.

The oil from the face side will drain out to te

Fig.54.3(a):Actuated position
reservoir through port A to port R. Thus retractod
of cylinder will be completed
This circuit will give to and fro motion
changing the positions of D. C. Valve.

Scanned with Camscanner

 Hydraulics & Pneumatics (MsBTE Sem-V) 5-5 Oil Hydraulic Circu
Industrial
circuit: Explanation of circuit:
Applicationof
to perfor task in both the 1. Actuated position:
circuit is sed
This or the cylinder movement. It
directions (push and pull
direct The piston moves from left end to the
cranes, materia handling
devices, JCBaarms, right end to
is used in complete forward
movement with D.C.
Valve
elc. conncction P>A and BR. Refer
movement of milling, grinding Fig. 5.4.3(a).
used for table
is
I movement of shaper, etc. 2. Normal position:
machine, tool
actuate uble acting cylinder using 4/3 The piston moves backward from right
(IJa. To end to the left
D.C. Valve: end to complete retraction movement with
D.C. valve
connections P->B and A
circuit: R. Refer Fig. 5.4.3(b).
Purpose ofthe
3. Centre closed position : (Fig. 5.4.4)
Movement of the double acting cylinder to produce to
stoppage of the It is the intermediate position of D.C. valve in which
and fro motion with intermediate
cylinder. port P, A, B, R are blocked. There is no
low of oil to
the actuator. Hence the piston movement will
Circuit componenis be
stoppcd. We can stop the piston at suitable location
1. Hydraulic power pack
along the stroke length of the cylinder.
2. 4/3 D.C. Valve (lever operated)
3. DA.cylinder.
It will help to hold the piston the desired point in the
application like lifting of heavy object to the desired
4 Pipes, hoses, pressure gauge, etc:
height in the hydraulic crane.

Cireait diagram: Applcations:

.In this circuit, there three actuating positions of Material handling equipments, construction equipments
DC valves. Normal and actuating positions, are same like JCB, etc.
as per previous cirçuits.
b. Automation of actuate double acting cylinder
The intermediate position
of D.A. cylinder is.shown. in using solenoid operated 4/3 D.C. Valve
the circuit
No movement of piston

Double rod
cylinder
Limit switch Limit switch

Leveroperaled

valve
operated
P
RPLR 4/3 D.C. valve

L
Relief valva

Fig. 54.4(b):Double acting cylinder using solenoid

operated 4/3 D.C. Valve
Fig.54.4a):No
movement
of piston using
losed position centi
of D.C. Valve

Tochkaoledgi

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-VI) 5-6
ydrauilc
Circauits
In this circuit, no manual control is nceded because,

limit switches will sense the movement of cylinder and

actuates the position of solenoid operated D.C.Valve

as shown in circuit.

It will give automatic to and fro movement of Double

acting double rod cylinder.

(c) To actuate unidirectional hydraulic motor:

Purpose of the circuit:

To obtain rotary movement

of hydromotor in one
direction.

Citcuit components:
. Hydraulic power pack
2. 3/2 D.Cvalve

Unidirectional hydromotor

Pipe, hoses, gauges, etc.

Fig.5.4.5b]:NormalHydraulic circuit
for hydromotor
Circuit diagram: Explanation of circuit:

Unidirectional 1 Actuated position:

hydraulicmotor
Fig 545(a) shows the actoation of hydromotor
which the oil from port Penters in
through port A
of
the bydromotor through D.C.
Push button valve.
The oil rotates the inner element
2D.C ofthe motor and
Totarymovement is
valve obtained al the motor shaft.
P The motion iseither clockwise
lcounterclockwise
depending upon direction
of inletof oil
-A- 2 Normal position
When D.C. Valve
is actuated for normal position,
the port P is closed
and oil flow is cot off. Hence
no movement of
the motor.
Application:

To give rotary motion

in one direction.c.g. movemen
of conveyor.

() To actuate Bi-directional
hydra motor
Flg.54.5a): Actuatad
Hydraulic circuit
To actuate Bi-directional
for hydromotor D.C.Valve: hydraulic motor using
k
Purpose of
the cireuit:
To obtain rotary
motion in both clockwise
clockwise and counle
direction of
bi-directional hydromotot

TecLwaledi

Scanned with Camscanner

 Hydraulics &
IndustrialHyaraulics &Pneumatics (MSBTE Son
em-Vi) 5-7
Oil Hydraulic Circuits
conponenís;
Explanation of circuit:
Cireait powerpack
. HydrauliC
Valve
Actuated position: Tn
this position of D.C. valve,
the
A/2 D.C port P is connected
to port A of the hydio motor
Bi-directional hydro otor acdmit the
oil in the hydro motor.
to
The oil will rotate the
gauges, ctc. hydromotor in
clockwise direction.
Pipes, hoses, The oil which is
4 used and at low
pressure is drain out through
the port B
to port R to the reservoir.
diagram: 2. Normal position:
Circuit Push button is operated to change.
the position of D.C. valve.
In this position, the port P is
connected to port B to
enter oil from inlet B bydro
of
motor. The oil will
rotate the hydro motor in counter
AL
clockwise direction.
The port A is connected to port
R
to drainout the low pressure
Pushbuston oil to the reservoir.

-
operated 4/2Dc.valva.
P1R
- Application:

To give rotationin
winding/rewinding of cable.
bol directions e

() To. actuate. Bi-directional motor. nsing 4/3 D. C.

Nalve:

Purpose of the circuit:

To obtain rotary motion in both directions.and
intermediate stoppage of the motor.

Circait components:

(a Actuated pasitiom 1) Hydranli power pack

(2) 4/3D.C: valye
(3) Bi-direcional hydro motor

(4) Pipes, hoses, gauge, etc,

Circait diagram: Fig 5.4.7

Pushbutton Explanation of circuit:
operated
4/20va gives clockwiso
R Actuated position and normal position
rotation of the hydto motor
and counter clockwise
fespectively.
port P and port A are
Centre closed position : As
blocked off. Similarly
disconnected. The flow of oil is
movement of
closedt. Hence no
port B and port R are stops the
position of D.C. Valve
hydto motor. This
motor intermittently.

(6) Normal position

Fig.5.4.6 Tech
Kaoaledgs

Scanned witn camScanner

 OitHydraulic
(MSBTE_Sem-VI) 5-8
Industrial Hydraulics & Pneumatics Circuits

Need of speed control circuits

Bldirectional hydromotor
. In most of machine tools and other mechanical
cquipments, speed control is adjustable
table in orde
increase the working versatility of the machine
hine.
o

Push button oporatod 2. Thesc are some machining operations in which

poed
sTo
4/3 D.C
to be regulated according to type of material,
is
vala 1achine
and process of manufacturing.

5.5.1 Types of Speed Control Circuits

a. State the method for sSpeed ot double acting cylinder

is controlled? Name three circuits used to control
the
PRV
speed. (4 marks

There are three types of speed control circuits as per the

location of flow control valve in the circuit

Speed control circuits

Fig 5.4.7: No movement of hydromotor (closed centre
position)

Application:
Mater in Meter out Eleed-aft
Hydraulic equipments like mixers, conveyors, machine
drives, ctc.

5.5 Speed Control Circuits AHE

EMSBRE HWAE
Fig. 5.5.1
0.How, he.speed:af, hydraulic. mator, s controled?
Explain it with neat circuit diagram. 5.5.1.1 Meter-in speed control circuit
.(w-13
MSBTE
Definition When actuator speed is varied placing
by SKS 12WE12SS3NA3S14SI5,S16
fow control valve in the pressurt line or rètim line of the SH7 S 1818,S-19
bydraulic circuit it is konown as sped comtrot circuits, Q Explain with neat sketch the working and applicaton

Methods of speed control :

.of meter-in circuit. S-11,S-16)

Draw and explain meter in citcuit

1. Using variable displacement pump :
W-13, S-17, W-18)
S-12,
In this method, discharge of the pump is
change the speed of actuator. The method
varied to What is. thepurpose af meter in cicüit? Draw t
is simple but meter in hiydraulic circuit ior regulating the spesd af
expensive and suitable in the
case of single load to be piston in cylinder. (W-12)
controlled.
Draw a circuit diagram of speed control when pision
2. Usingflow control valves: move farward in a reciprocaing hydraulic cylindet
It regulates the fluid flow
, S-13)
by enlarging or reducing
port area while oil is passing
the
through the passage. Thus Sketch and explain meter in hydraulic circUt, o
speed of the actuator
varies according to
flow rate control the speed ot extension of DAC. Explain wy
oil. of
6r n circuitis not preferred for over runnng
loads. (S-14, S-18)
TchKaouleda
ptIL

Scanned with Camscanner

 Hydratulic Circuits
Oil
deaulics&Pneumalics (MSBTE Sem-VI) 5-9
Hydraulics&
Industnial
et the
labe
componenis. In mererin
Drawand (S-15)
circuilt,
hydraulic
neat skelch the working and
Describewith circuit,
applcationofmeler- Ii hydraulic
between
coniralbalve.is placed
fnition:When Jlow

he
phen
mamp and the acauatorand

entering

eedcontrol
inthe
conlrolstheJlow raue
ylindet, if is, known
dfoil
us meter:in
IIX
Circail

I.
components

Hydraulic power pack Lo

D.C. Valve
2 4/2
Flow control valve, with
Integral check valve
3.

4.
D.A.cylinder

5. Pipes, hoses, gauges, etc.

Circuit diagram:
(b) Nospeed contro
DAcylinder circuit
Fig. 5.5.2: Meter-in speed control
Slaw/fast
Pressurej Explanation of cireuit:
line
The Fig. 5.5.2 shows meter-in speed
control circuit.
Flow control valve
Thie flow control valve with integral check valve
is
with integra
chetk valve
Retum line placed before the actuator in the pressure line so that oil
flowrate at thé inlet of the atuator can be regulated.

IX
Flow control valve is the main component in this circuit
4/2 D.G. which is used to roduce the speed of the actuator.
valve

PR 1. Stow movement of actuator:

When pressurized oil flows through the circuit, it

passes through D.C. Valve and enters in the ffow
control valve. The opening of the flow control valve is
Pump reduced to decrease the oil ffow rate.
PRV
Now, the less quantity of oil will enter in the cyliñder
Flter through inlet A. It will push the pistom in the forward
direction. As flow rate is reduced, the movement of
piston is sfow.

2. Fast movement of actuator:

Fig. 5.5.2a):Speed control- When flow control valve opening is increased
by
changing the needle position, more flow of oil
will
enter in the cylinder from face side inlet and increases
the speed of the piston. In this way we can
control
speed of the actuator.

tedise
Scanned witn camScanner
 OlL Hydraulic Circuits
NIndustrial Hydmulics&Pneumatics (MSBTE Sem-Vi) 5-10

The check valve is provided along with flow control Definition When actutor speed varied by placing it
valve to prevent oil flow in the reverse direction. low control Valve after the actuator in 1he retum line
conirol flow rute of oil leaving ous from the actuator,
In this circuit, we cannot vary the
actuator speed during
known as meter-out circuit.o
it
return stroko of the cylinder as flow of oil is constant..
Circuit components:
Important characteristics of meter-in cfrcuit:
. 1. Hydraulic power pack
Smooth movement for resistive load:
2. 4/2 D.c. Valve
This circuit gives smooth motion of iston for the
resistive load. (acting in opposite direction to the feed) 3. Flow control valve with integral check valve

2 Finer speed control: 4: D.A. cylinder

It will give accurate and finer specd .control, 5. Pipes, hoses, gauges, etc.
hence
preferred for precision equipments.
Circvit diagram: Rcfer Fig. 5.5.3
3. Pressure drop at the inlet of the actuator:
As tlow control valve is placed at the inlet, there will Explanation of circait:

be drop in oil pressure due to throttling effect. Hence it Meter-out means when oil flows out of the cylinder to
decreases pressure of oil at the inlet of the actuator. the reservoir and its flow rater is controlled using flow
This cireuit is not suitable for low pressure applicationcontrol valve. Tt is placed at the rod side outet of the
due to pressure drop at the inlet of the actuator. cylindet.

4. Heat increased in the actuator (a) Slow speed of actuator:

Due to throttling at the flow control valve, the heat is When oi flow pump to the actuator through D.C.
generated and it is fed to the actuator. Ii may rednce the Valve it will push the pisto in the forward direction.
life of the actuator. The oil from the piston rod side is pashed through the
outlet B of the D.A. cylinder, through the retun line.
5. Jerky motion when load is negative
D.A.cylinder
When load is negative (ating in the same direction of Slow/tast
feed) it causes jerky motion of the actuator.

6. Not suitable for hydro motors:

Due to pressure drop at inlet, it cannot be suitable to

run the hydromotor at various speeds. Pressure
| Retum line
ine
Applications
1. Hydraulic servo drives used in machine tools ,e.g.
milling machine.

Resisting loads. 4/2D.C

2.
valve E
5.5.1.2 Meter-out circuit

MSBTEWM5EWŠ7
a. Using double acting cylinder,
pressure
fiow contirol valve with

check valve, relief válve, filter and DC

valve, develop a circuit for. speed, control during a PRV

return stroke:" m (W-15)

'****

Q. Explaln wilth neat sketch "meter-out circult". (W-17)

Explain speed control ol double actingcylinder with

meter-oul CirGuit, (4 marks) Fig. 5.5.3(a): Speed contro

Scanned with tamscanner

 Hydraufi & Pneumatics (NSBTE_Sem-VI 5-11
strial
Hyrasic Creu
No loss of pressare
to the xuaor 2s tte fol ol
pressure is fed to the cyindez.

E 3. Self cushioning:

It provides the self-coshioning of forward or working

stroke, bence uses in mahine tools ke dling
machines.

4. Heat generated due to aroling is ed to te oi

eservoir. Hence effect of beat is ess on actsator znd
otber componeats.

5. Hydrometer speed control possible:

coabrcd f
Meter-out cireuit is saitable for speed
hydromezers as wed as over ruaning koads.

Highfriction ioss
theret
the entire punp pressare,
The cylinder is fed wih
fhigber friction foss
is possibilty of

Applications:
drilling
loads eg camping in
Suitabie for negative
machines, shaper machies, ete
machines, boring
hyromotors
Speedcoatrol of
() No speed cotrol Overruming lcads
contral circuit
Fig 553 Meter-out speed circuit tor clamplng of
oear the outiet B inUse of meter-out
locatéd af operation
he low control valve area component for driling
openíng ofthe flow and
a retura oil redpcesthe returmi line to which of the
foloning circ2
CEverS Snal quantiy of oil
through the QState componentduringdng
o

ue ReServoir. The piston

moves slowly to complete the forclamping of
forward stroke.

Fest speed ofuctuntar: Joursalecion

increased
2Meter-outjcSY
cóntrol valve is
Gpening of the low ont Selfcushkoing
faly opened), large quantity of oil will be drain
moves at fáster.
tragh tieieturm line, hence the piston
Red to compleie the advance stroke Vbratons rrg
portant characterictlcs circuit:
of meter-out clamptngof
wortplers
LSuble for
and postrespeedcontrol 5.5.4:Meter-outcireuit ciamping of
Fig. effecthve far
As the piston gets circuit is
more because
retn flow. is controlled, Meter out drilling
operatkan
cushioning of
other ide or during
with the oil on the
draulically darmped
component povides self sibrations
thepiston cicuit abscrb
Meter-out
which
belps t operatio
controlis (a) stroke drilling
forwand
stabletmovement with ositive speed
Hlence
produceddue to
nable. which are
It is suitablefornegative loads.
Na pressre
drop

wIun
Scanned
ambcanne
 (MSBTE Sem-VI) 5-12 Oil Hyd
Pneumatics CarCits
Industrial Hydraulics &
gets Slowitast
flow of oil is controlled, piston
(b) As the return
the other
hydraulically danped with the oil on
piston).
sidc of piston (face side of

(c) Metcr-in circuit provides jerky motion for the

negative load hence it is not suitable for clamping
operation.

5.5.1.3 Bleed-off speed control circuit

MSETEKIS12W121WA3SA5W1E:S13
Q. Draw bleed-off hydraulic circuit and label it.(S-12,W-16
0. Draw and explain in brif hydraulic bleed of,circuit.
(W-12,W-13)
X
a.Draw and explain working of Bleed-off hydraulic
Circuit (S-15, S-18)
Definition: When floiw control valve is pláced after punp
to divert the pump delivery to the reservoir
for speet|
control of the actutor, it is known as bleed-off
sped
Contro circuit.

Circuit Components

1. Hydrauic power pack

2. 4/2 D.C. Valve
b) Retraction stroke speed control
3. Flow control (by pass) valve Fig. 5.5.5: Bleed-off speed control circuit
4. D.A.cylinder Explanation of circuit:
5. Pipes, hoses, gauges, etc.
In this speed control circuit, the flow controd
valve is
located after pump to divert
some flow of oil to the
Circuit diagram: Teservoir.

Slowifast This circuit will helps to control

speed in both forward
and retum stroke of the
cylinder.
(a) Forward stroke
speed control:
When pump delivers oil
through the outlet, suppose,
delivery flow rate
of oil is 6 lit/'min, some of oil at the
same pressure is allowed
to pass through by-pass tlow
control valve. The
opening of the flow control
Bypass flow control
adjusted (e.g. to divert
2 li/min). Thas out of 6 lit, 2t
valve oil will be diverted
(Bleed of valwe) to the tank and pump wil supply +
lit/min oil to the
circuit
The reduced flow rate
of oil is allowed to enter in t
PAV cylinder from inlet
A and forward stroke will
completed at slow
speed.
Suppose flow control
valve is set to divert 1 lit ot Du
nen pump will
supply the oil at the flow rate of
U min to the
system. Now the flow rate is
Fig.5.5.5a): Forward stroke speed control increas
and more oil will
enter in the actuator. Hence forwa
movement
of the cylinder will
be at fasterspeed.

Scanned witn camScanner

 Hydraulics &Pneumatics (MSBTE Sem-VI) 5-13
Industrial Oil Hydraulic Circuits

Return stroke speed control: Circuit diagram:

(b)
D.C. Valve changes
When push button is operaled, the Slofast
to port R, port P to port
position and connect port A
its BBI directional ydraulc motor
B, to cnter
the oil from inlet B of the actuator.
forward stroke, flow controt Prossuro compensated
Similar to speed control of ow contrf valve
valve can be set to
divert or by-pass some quantity oil
by-passed
reservoir, when more quantity of oil is
to the
to the
reservoir, the speed of the actuator will be slower Push button oporatd
passed increases the flow
and less quantity of oil by
4/2 D.C. valve

rate in the cylinder and

faster
speed of the. actuator will be
IX
Important characteristics of bleed off circuit:

(a) No effect of heating due

to throtling: The heat
generated doe to throttling is fed to the tank. Hence it
L
not affect the actuator and othier components.
wil
diverted
b)Pump load is reduced: Pump flow is and it
work against the load resistànce only.

C)Nopositive speed control: The circait does not allow

positive speed' control£"
up to
d) Average speed variation- : Speed variaton is Fig.5.5.6:Speedcontrolof Bidírectional hydraulic
average valae only." motor
flow rate is not
2

e) Fluctuations in speed: It puimp

causes. fluctuations inExplanation of circuit
constant and flactuates: it, also
speed of the actuation. pressure compensated flow
The circait consists of two
(0 Not suitable for accmulator circuits: The 'circuit is control valves provided at the inlet A and inlet B of the
not suitablé for åccumulator circuits hydro notor. Pressure drop due to throttling tmay
flow is diverted, the decrease the performance of hydro motor, hence
Less use of relief valve: As pump exess pressure
relief valve has'no function tó rlieve pressure compensated flow contro valves are used
system is eficient
of oil. Hence less energy Toss and pressure compensated flow
When oil enters through
inlet A, it
Applications control valve T in the hydro motor from
variation in flow
rotates in ciockwise direction The
Itis used where accuracy is not important motor.
machine, area causes speed changes of hydro
f is suitable for broaching machine, shaping the oil will
When position of D.C. Valve is changed,
planner machine, ete. inlet B and flow is
enter in the hydro motor through
S5.14 Speed control of bi-directiona regulated by pressure compensated
flow control valve
hydromotor clockwise
The hydro motor rotates in counter
2.
'urpose of the circuit : To control speed of
between
direction at various speeds
nydromotor by. placing flow control valve
Applications :
DC. Valve and hydromotor
Hydraulic drives in machine tools
Circait components:
elc.
Cranes, mining equipments,
Hydraulic power pack
2 4/2D.C. Valve
S. Bidirectional hydromotor
4. Flow control valve
B7Tevalelgi
5 Pipes, hoses, gauges, ete. alies

Scanned witn camScanner

 Oil Hydraulic Circuits
Sem-VI) 5-14
Pneumatics (MSBTE
Industrial Hydraulics &
Meter-in and Meter-out Circuits:
5.5.2 Ditference between
MSBTE W:09.W-14W-16.5-17

and metor
meter out circuitdiagraI.
Outwith circuit aiagra ps W09,W-16,S-17)
Differentiate botweon eter-in and
a. with respect to well labeled diagram, working, features,
advatages
meter-in circuit with meter-out circuit
0. Compare
limitations and applications.
(W-14)
Meter-out
Points dlete-in
Noa
w.a.iroik

. Definition It means flbw control of oil entering in the It means flow control of oil leaving from
cylinder. the cylinder.
2 FCVlocation Pressure line (face side inlet of the actuator) Return line (rod side outlet of the
actuator)

3. Pressure drop at inlet Pressure drop at the inlet of the actuator No presure drop at the inlet of the
actuator.

Heat due to throtling

.
4. Given the actuator Given to the reservoir
Load application Resistive Toad (positive) Negative overrunning load
Moton Finer speed control Stable and positive speed control
7. Hydromotor speed LoW pressure at inlet hence not suitable
Full oil pressure at inlet bence snitable
control

8. Applications Milling machine

Drilling machine boring machine

5.5.3 Difference between Meter-Out And Bleed-Off Circuit

Point Meter out Bleed oft

PCV Outlet of the actuator

After pump to bypass flow
location

2 Pressure No loss of pressure to the actuator

Pressure drop after pump
drop
3. Flow of Constant fluid flow through flow
fluid
control| Less fluid through flow control valve
valve

Speed Speed control is possible separately

for Constant control speed in both forward a d retun
control forward and return stroke
stroke of the cylinder.
application Drilling machine boring machine
broaching machine, shaping machine

Teclswale
Yhati
Scanned with Camscanner
Intustrial HydraulicS &Pneumatics (MSBTE_Sem-VI) 5-15
Oil Hydraulic Circuits
Circuit components:
Regenerative Circuit
5.6 1. Hydraulic power pack
MSBTERS 13W13 WA16 W-18
2 4/3 D.C. Valve
any two
0 What is regenerallve hydraulic circuit? State
applications.ofit (S13) 3. D.A.cylinder
hydraulic circuit.
0. Explain the principle of regenerative W-13, W-16)1
4 Pipes, hoses, etc

Circoit diagram:.
aDraw and explainbydtalcregenerative.clrcuit
W1
Q. Explain and Slate he meaning ofregenerative 1
Rapid advancement

rc marks
DefinttouWher tnerettra liner of the actualar i
cornected t.die pressare lire wtk the hélp of DCVatve
to rerenerate oilenergy caled asTegenerative
AL 4/3

n the coniventiönal circuits, the oil from the return' oil

will be drain out to the rèservoir.
It is low pressure oil
and again reirculated with the help of pump.
HX D.C.vave

Instead of dram out the Iow pressure oil, it is connected

energy ín the pressure w PRV
to thie pressure line to add imore
line from the pump. Tt increases the speed of cylinder in Pümp
its forward fmotion (rapid àdvancement0
Circuit concept: Filler

Flg.5.6.2 Regenerative circult

From
thapump } Tothe tank Explanatfon of circni:
Valve is used in suct a way
In this circuit, the 4/3 D.C
side instezd
Pressure Retum that the retum line ( )from the rod end
ine ine
a Comventional circut of being connected to the tank line, is coinected back
Vaive ( Q ) as shaw i
to the supply line of D.C.
Fig. 5.6.2
returm oil from the red end of
the cylinder adds up
The
piston end increasing the
to the pump delivery to the
motion.
Fetuint lirne speed of the cyfinder in its forward
of the cylinder
The flow entering the head end
From the
pump From thie roturh Ilis ,+a
Pressura3
Iine

b) Regenerathve cireult
Flg. 5.6.1

Q+
Scanned witn camScanner
Industrial Hydraulics & Pneumatics (MSBTE Sem-VI)
5-16 Hydraulic
Circuits

Q+ Circuit diagram:

- Load lited

Counterbalance
valve

(A-a)
Pumpsupply
B
annual area

Applications:
regenerated speed
IHX
To obtain equal speeds in both directions

Rapid advancement of the cylinder

5.7 Counterbalance Circuit

MSBTE 2W

Q Explain the working of counterbalance vatve in

Fig. 5.7.1(a): Counterbalance circuitLiftüing of load)
hydraulic circuy W-17
State the meaning of Counterbalance circuit?
Load lowered
Exptain. (4marks
DelinitionWhen the rerurn Tine of the actuator is
conmected with the help of counterbalance valve during Counterbalance w
downvard movément of to
actiator mder heavy Toad valve
prevent its overruanning, is called- as counterbalance
it
Circui

During the dowaward movement of the cylinder, the

counterbalance valve is set to open at slighly above the
wwT
pressure required to hold the piston up (a check valve
does not permit flow in this direction) TTAB
LR

-
Circuit components:
. Hydraulic power pack

2. 4/3 D.c. Valve

3 Counterbalance valve

4. Pipes, hoses, gauges, etc.

Fig. 5.7.1(b): Counterbalance

circuit (Over running load)

Scanned with Camscanner

 Industrtial yaraulics & Preumatics(MSBTE
Sem-V) 5-17
Explanation ofcircuit
Oi Hydraulic Circuits
Load lifted: 5.8.2 Types of Sequencing
Circuits

In tthe first position of D.C Valve, The oi will entera MSBTE W-09S19
from lower inlet of cylinder and it will
lit the load in
Draw a near diagramfor
sequétiathydraulic circut
the upward direction as shown in Fig. 5.7.1(a), Theo and explainitsworking W-09,4Marks)
will free flow through check valve With
and oil wil returm the help of simple example,
explain seguencing
thróugh upper port connected to port R: Circuit

Load lowered:
6-19)]
2 a) Pressure dependant sequencing:
.1f the counterbalance. valve, is not provided, the oil will. When first operation is completed,
the oil creates
low rapidly due to heavy wejght of load with piston pressure to open the sequence valve
to actuate second
and may cause.over running of pison to cause
damage operation, it is known as pressure dependant
of end cover of cylinder.
Sequencing. e.g. clamping and drilling in
a sequence.
In theNext. position of D.C Valve, The oil wil enter| b) Travel
fromUpper inlet of cylinder and it will lower dependant sequencing:
the load
in the downward direction as shown in Fig. 5.7.1(b) It is the sequence circuit in which the first actuator

oil from return line will provide counterbalance travels (moves) upto certain distance and then actuate
.The
pressure at the piston side. When the pressure below the sequence device to perform the second operation. It
piston will reach to the pre set value of counter balance is known as travel dependant sequencing. eg
valve, it will open and allovw to flow of oil for cylinder movementof object fromone location to another.
retraction stroke.

Applications: Operaton Clamping

Heavy press machines, heavy cranes circuits

Cpeatom Dilia

5.8 Sequencing Circuits

operate
Delnition When hydraulic circuit is designed 10
riore:than one actuators in a sequential, manner one afier TO Uhe tank

another. It is known as sequencing circuit.

Pump

Fig. 5.8.1.: Pressure dependant

sequencing
actuating bydraulic
Sequencing .can be used for
Actuator
cylinders or. Halet
Cam"

Sequencing .circuits are useful for

(a) Material handling like feeding, ejecting

(b) Lifting. pushing and clamping.
Ta the aonor
(c Machining operations.

5.8.1
Sequencing Devices
Acttor1 iraespspo
e oller
CGaIOr distance an p 2
1. Sequence valve o cperan ecuu
dependent)
ravel
2. Roller actuated valve
3 Cam actuatedvalve
4. Time delay valve
sequencing
5. Salenoid valve Fig.5.8.2:Traveldependant
6. Electical switch
eeuedg

Scanned witn camScanner

 Oit HydraulicCin
RIndustrial. Hydraulics& Pneumatics (MSBTE Sem-VI) 5-18
2. Sequencing of cylinder with hydromota.
tor
(a) Pressure Dependant Sequencing:
Oylinder
O-rmovenet
1 Sequencing of twa linear actuators:

E otcder
molot

DAcyinder 0

8equeno Hydromotor A
valve

Levor
per quince valve
2 D
vave
4) aperalon

211 opentiort
B-C

Fig. 5.8.3:Sequencing of.two cylinders

Movement of object from (A) to (B) using D.A.

Fig.5.8.4:Sequencing of cytlinder and motor
eylinder (1):

When pressurized oil enters from port P to port A and ) Linear movement of cylinder:
enters in the cylinder (1). It will push the piston in the When pressurized oil enters in the cylinder through

forward direction and moves the object from (A) to (B) inlet A forward stroke of the cylinder 1
will be
as shown in Fig. 5.8.3. The oil on the rod side is drain
complcted. Thus first operation is completed. The ol
out through the return line B>R.
from rod side is drain out through the path B->R.
i) Movement of object îrom: (2) to (3) using D.A. Gi) Rotary movement of kydromotor:
cylinder (2):
When oil pressure in the cylinder is increased, it wil
Wben piston of cylinder is in extended position at the
flow through the pipe line towards the sequence valve
right end, the oil from the pump will fow through the
and opens the sequence valve. Now pressurized ol wil
pipe line towards the sequence valve. When oil
enter in the. hydromotor and rotates the motor n
pressure is sufficicnt to open sequence valve, it will
clockwise direction.
enter in the cylinder (2) from inlet C.

f reversible sequence valve is used. In the secona

The oi moves the piston in the upward direction to
position of D.C. Valve, the pressurized oil will enter in
move the object from (B) to (C) linearly. The oil from
the piston side will be drain out through return line -the hydromotor to rotate in counterclockwise direction.
D

+BR When oil pressure is developed it will

open

from ie
Sequence valve and oil enters in the cylinder

B. The piston moves to complete retum stroke.

Tedlael
Platues

Scanned with Camscanner

 ics & Pneumatics (MSBTE So
Hydraulie
ndustrial.
SBTE
pendant Sequencing
Sem-V) 5-19
OithHydrauticCircuits
ravelvel It consists of cam operated
Sequencin oftwo cylinders: cylinder and bydromotor. . roller4/2.D.C.Valve, DA.
1.
SA Cyinder . Linear moyement of D.A.cylinder:
der
Limit The: oil wil enter in
the cylinder througr inlet
Switch moyes the piston A and
rod in the forward direction_The cam
Solenoid is located at the piston end. It press the roller to actuate
Lever operatod operated roller operated 4/2 D.C. Valve
4/2 D.C. Valve.
. 3/2 D.C.valve

(i) Rotary movement ofhydro motor

The oil fromn the pump will enter
in the roller.operated
4/2DC. Valve: The pump port P is connected to inle
Cof the hydro motor. The oil will epter in the hydro
motor.and rotates the motor shaft in clockwise
direction: The oil. from port D» is drain out
to the
reservoir.
Fig:5.8.5:Sequencing oftwo cylinders.
cicuit consist of limit swtch and solenoid5.9 Motion Synchronisation Circuit.
This
operated 3/2- DCvalve, för sequencing,
.. MSBTE W:14
Movement of D.A. cylinder:
0 t
neat sketch the iorking of moion
push the piston in
The oif enters in.the cylinder, it wil Synchronization circut witi tha hep of fow divid
forward: direction, The piston travels. linearly and
tie control tre movementoftwo double actirnig cyinders:
position.
tOuches the limit switch located at specific AN-14)
Movement of S.A. cyinder:

When the piston rod end touches the limit

switch, it eo
en wo or more actuators üre operaled
SUENEHD 7here uctONE SEhroized (na
TS

actuates the: 3/2 E:C: Valve. and; oil will enter in the annerjinECrcuit 15 cailed asmotion
SA ylinder.
stroke.
..
The piston moves to-complete forward
'.
e
EnOKTAEON Circun
This type of circait is useful wher
simultaneous action:
clamping movement of
2Sequencing of.cylinder and hydromotor: of actiators s. required for
same. speed in mass
Eidfrectional
material, mutiple operations, at
DAGihder romoto
productio,
Cam

Roller operatea
Bvtpersted 4I2.DC NaMve
VaCvava.

Pump Fig. 5.9.1

Flifer

.5.8.6:Sequencing of cylinder and hydromotor

Scanned witn camScanner

 Incustrial Hydraullcs&Pneumatics (MSBTE Sem-VI) 5-20 Oil HydraulicCircuits

Methods of motlon synchronlsation: Both the cylinder will extend at the same
peed
regardless of load resistance differentials they
1. Using flow divider may
have to overcome.
2. Rack and pinion arrangement
Application :
3. Mechanical coupling of actuators
Lifting of load in crancs, lifts at the sarme speed
1. Motlon synchronisation using flow divider:
Clamping assembly work, ctc
Purpose of the circuit: Simultancous movement of two
linear actuators using flow divider. Motion synchronization using rack and pinion
arrangement:
n
Circuit:
DAOylindor 1 D.A Cylndor 2 . Pürpose of the circuit: Simultaneous movement
actuators using rack and pinion arrangement.

(=V) Circuit components:

Flow divider D
1. Hydraulic power pack

2. 4/2 D.c. Valve

3. D.A.cylinders (2 NOS)

4. Rack and pinion arrangement

Cylinder1
Push button operated

X 4/3 D.C.
Valve

Cylinder 2

Fig. 5.9.2: Motion synchronization using flow divider

Circuit components:
. Hydraulic power pack
2. 4/3 D.C. Valve

3. Flow divider

4. Two D.A. cylinders

5. Pipes, hoses, etc.

Explanation of Circuit:

The flow of oil from the pump is divided using flow

equaliser (divider) with the hep of flow control valve
f
and f. Fig. 5.9.3: Motion synchronization using rack and pinion
The oil will enter in the D.A. cylinder I from inlet arrangement
A
and at the same time in the D.A. cylinder 2
from inlet Explanation of Circuit:
C. Both the cylinders will move
the piston in the
forward direction at same speed. ne piston rods are attached with rack and pinion

arrangement at the ends. The flow of the oil will eter

Check valves C and
C prevents the flow in the
n he cylinder and 2 through flow divider valves C
1

backward direction.
and C

YTchkelesi
t

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE_Sem-
521 Oil Hydraulic Circuits
The cvlinder
1
and 2 moves at same
speed and gives
ntion to rack and piniOn. Pinion Explanation of Circnit:
gives rotary motion
clockwise direction.
in Hydro motors (1) and (2) shafts are coupled
This
circuit
will give motion synchronisation mechanically as shown in Fig. 5.9.4. The oil flows
forward stroke only. in
through inlet A and C of bydromotor (1) and (2) and
Application : rotates the motors at same speed.
When valve position is changed to third position, the
Multi spindle machines.
direction of rotation of the hydromotor will be reversed.
aMotion synchronisation of hydraulic motors Application:
with mechanical coupling:
Simultaneous motion for multi cylinder/ spindle
Purpose of the cireuit :. Simultaneously machines.
movement of
hydro motors mechanically coupled.
5.10 High-Low Double Pump Hydraulic
= Hydromotor Press Circuit (two pump unloadin9)
Hydromator
MSBTE S1W-18
0 Explain.circuif for high-low doublé p system for
Sapplications
4/3 D.C.valve
nd explain two punp State
iloading citcuit
ication. W-18)
High-low double pump :

High-low system of pump consists of two pumps

in
which one pump has high flow rate and other has low
Fig.5.9.4: Motion synchronization of hydromotors flow rate. They are used to save the system power.
Both pumps can be used simultaneously
depending
upon system requirement or high
flow rate is diverted
through unloàding valve if needed in the system.
. It is useful when combination of rapid and
slow
movement required in the circuit.

Purpose of the circuit:

To obtain vertical reciprocation of punch mounted at the piston rod.

IHX A13 D.C valve

Unloading valve

LP
Punch

Die

Fig. 5.10.1:Hydraulic
press circuit

Tecanle
Pieattess

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-V) 5-22 Oil Hydraulic Circuits

Circult component: 0Draw a hydraulio circuit diagram,fór miling machine

to confrol.itstable movement S13)
1. Hydraulic power pack with HP and LP pump. a Explajin: with neal sketch hiydraulic circuit for milling:

4/3 D.C. valve. machine W-12,W-13)

2.
Q Explain neat sketch the working of hydraulc
ith
3. Flow control valve with check valve.

4. Unloading valve.
circut ysed lor miling machine:
14 WA7

Draw
diagrami
hydraulic circuit for rmiling machine, label
Erplain tis working
he
4 Marks)
Binhaan
xplanation of Circuit Purpose the circuit: To obtain to and fto movement of
milling machine table on which work piece is mounted for
The circuits has low pressure (LP) and high pressure
machining.
(EP) pumps are provided as shown in Fig. 5.10.1.

.When rapid movement of the punch is required, both

LP and HP supply the oil so that the piston retraction
To and from
will be faster compared to advanced cutting stroke. movement
of table
Initially slow movement is required when punch starts Machine table
movemeat towards the w/p, the flow of HP is diverted Fig.5.11.1
through unloading valve and only LP wil supply the
oil| Circuit components:
to the actuator.
1. Hydrauic power pack
When punch reaches near the w/p, high force is needed
for press operations, HP supply will be started to 2. 4/3 D.C. Valve

combine with LP and high pressure is generated for 3. Double rod cylinder
performing press operation.
Flow control valve
Applications: Pipes, hoses, etc

Hydraulic press machines.

Circuit diagram:

5.11 Machine Tools Hydraulic Circuits

Face milling cuter
Hydraulic circuits are useful for machine tools like
milling machine, shaper machine, drilling machine,
Workpiece
laan Machine tble

The
copy turning, copy miling. press machines, ctc.

circuits which are designed to obtain movement of

componeats (such as table, ram, etc) of machine, tool
LIIIIII.
are knowa as machine tool hydraulic circuits. Double rodA
cylinder
Some important circuits which are useful in machine
tools are
LiTt Swich Limil switch

5.11.1 Hydraulic circuit for imilling machine

Solenaid operated
table 4/3 D.C. valve

MSBTERWD9:SE10:S12W12.S13M13W14W17

Q Explain with circuit diagram sequential hydraulic

(W-09)
circuitfor milingmachine Relief valve

aWite, the. funcdion of each elenentin hydraulc

SYstem used in miling machine. 0)
Fig.5.11.2:Milling machine table movement hydraulic
Q Draw the hydraulic circuit for milling machine,(6-12)
circuit
Trelovtei
PblIatiass

Scanned witn camScanner

 Pneumatics (MSBTE
Hydrauics & Sem-VI)
dustrial 5-23
Oil Hydraulic Circuits
Circuit: Circuit diagram:
lanationof

fovement of table
in ward direction: Grining wheel

enters from the pump to inlet A

When i of the
ylinde
inder it
moves the piston to complete forward
-Machlne table
stroke.
Doutlo acting
cyirder
Morement table in reverse direction:

Vhen oil cnterffrom the pump to inlet B of the

cylinder
(position 3 of D.C. Valve) to pull the piston Linit swtch
to svdtch
complete reversë direction. Solenoid operatad
4/2 D.C. vale

3. No movement of table:

In the middle position of D.c. Valve, no oil flow

hence
there is no movement of table.

Applications:
Fig.5.11.3:Hydraulic
circuitfor grinding m/e
. To obtain reciprocation of machine table in milling, table
Explanation of
planer machine.
Circuit:
It consists of solenoid operated
5.11.2 Hydraulic circuit for surface grinder 4/2 D.C. Valve which
actüated by using limit is
switches (1) and (2).
table end will touch the limit
switch (1) and (2) during
The table
and fro movement. its to
Purpose of the circuit::
1. Table movement
To obtain to and fro in forward direction: When the
motion of surface grinder position of D.C. Valve
table on is as shown in Fig. 5.11.3,
which work piece
is mounted. oil willenter in the cylinder the
through pressure line
Circait components: and moves the piston and P- A
table in forward direction.
2. Table movement in reverse
direction: The table
Hydraulic power
pack during forward direction.travels
to sufficient stroke
2. 4/3 D.C.Valve length and touches the limit
switch (2). It activates
3. D.A.cylinder solenoid coil and changes the position
of D.C. Valve in
the right envelope.
4. Pipes,hoses,
ete
The oil will enter in the cylinder from rod end side
and
causés retraction movement towards cylinder end.
When retraction movement is completed, table end will
touch the limit switch (1) to obtain position of D.C.
Valve in the right envelope.

Applications:

To obtain antomatic reciprocation of machine table in

various machines.

Ird laselelgi
Tbluattois

Scanned with Camscanner

 Pneumatics (MSBTE
Sem-V) 5-24 Ol Hydraulic
Hydraulics& GirettsA
Industrial
Parpose of thecircuit:
machine circult
Hydraullc shaper
5.11.3 WA.S-14.W15.S16W-16 This circuit is used to obtain to and fro
MSBTE iromovement
working of hydraulic shaper ram which holds the shaper of
cuting to
a Explain wth hoat sketch,,
(W-11
shaper Shaper Ram
Circuit dlagram, explain the
QWith the:help:of neaf
functioning othydraulio shaper, S14
of hydraulic Culting
Explain wth neat sketch the wonking
Q tool
circait for shaping machine w-15, S16)
Draw the hydraulic arcuit for shaping machine: Fig.5.11.4/a):Shaper ram
OENplatn W-10)
working.
its

Circuit components:

Hydraulic power pack 2. 4/2 D.C. Valve (lever type)

3. Fow control valve with check valve 4. D.A. cylinder

5. Pipes, hoses, etc.

Circait diagram:
Cutlng stroko Ratum stroke

Ram

ylnper

2
Ouftng tnol
Shaper dags

.achino
able
Lver
opratpd
4/2 D.C. valve
R PRP

Filtor

Fig.5.11.4(b): Hydraulic circuit

for shaper machine
Explanation of Circuit:

Cutting strokeofhydraulic
ram:
Tne cutting stroke is required
for cutting of material
pump P enters during forward stroke of ram
in the cylinder through of shaper machine. Tne Ou
inlet A and moves
rale ot oil coming out he piston connected to ram in the forward direction.
1
low
of the cylinder is adjusted
circuit is used using flow control valve located
to vary the speed of in the return line. 1he mEter-out
ram during forward cutting
y nen 1orward stroke of ram stroke.
is completed, the
Valve. Now lever of D.c.Valve hits
the port P-> B and the shaper dog C and changes tne pus D.C.
A- Rare get connected.

Techfadedgi

Scanned with Camscanner

 IHydraulics& neumatics (MSBTE
Sem-VI) 5-25
ressurized Oil Hydraulic Circuits
The oil will enter from inlet
B (rod end Explanation of Circuit:
ide) and pushes the piston towards the right
completes the retum stroke. The return
end to
movement of Cutting stroke:
ramshould take less time than that of cutting stroke
productive stroke (no cutting as
it non during this stroke). The cutting stroke is required for cutting of material
It is quicker then is free flow during oil lcaving
as
cut during downward stroke of slotting machine.
The oil
of the cylinder. from pump P cnters in the cylinder through
inlet A and
When returm movement ot ram is completed, moves the piston connected
it will hit to ram in downward
the shaper dog D to obtain position of D.C. Valve the
for direction.
forward stroke.
The flow rate of oil coming out
Applications of the cylinder is
adjusted using flow control valve located
in the return
Hydraulic shaper machine to obtain rapid line. The meter-out circuit
return stroke. is used to vary the speed of
tool during cutting stroke.
5.114 Hydraulic šiotting machine clrcuit:
When downward stroke
of slotting is completed, by
Purpose of the circuit: using limit switch, the solenoid
changes the position
D.C. Valve. Now the port
This circuit is used to obtain to and fro movement P-> B and A-^R are get
of connected.L
slotting machine tool mounted vertically.
The pressurized oil will enter from inlet B (rod
Circait components: end
side) and pushes the piston towards upper
end and
1. Hydraulic power pack completes the return stroke. The return movement of
2. 4/2 D.C. Valve tool should take less time than that of cutting stroke
as
it non productive ströke (no cutting during this stroke).
3. Flow control valve with check valve
It is quicker as there is free flow during oil leaving cut
4. D:A.cylinder
ofthe cylinder.
Pipes, hoses, etc. Whien return movemçnt of tool is completed, spring of
DC valve helps to obtain position of D.C. Valve for

Circait diagram: cutting stroke.

Other Circuits:
1. Hydranlic pres using aceumnlator

AB
X Accumulator

Limit switch

PRV
PRV

accumulator
Fig.
5.11.6:Hydraulic circuit using

ig. 5.11.5: Hydraulic circuit tor Slotting machine

Tedle

Scanned witn camScanner

 Sem-VI) 5-26
Hydraulics&Paeumatics(MSBTE
Industrial

save power Eauses Remelial

accumulator is used to action
this circuit,
In utilized during
upward stroke and it can be
during
overheating of
working stroke. It will
help to reduce (b)Misalignment/wom Make proper
alignmenn
out parts Replace
oil. nd ovethand
Hydraulic System Won out parts
5.12 Maintenance of
hydraullc system (c) Cavitations in Adjust motor
Need of maintenance of rpm if
itto
reliability of the system.
pump high Clean filers,
1. To enhance the
operational oiltat
breathers
ability of system.
2. To improve maintain

functioning of the system. (d) Clogged filter Clean thé filters,

3. To ensure trouble free strainee
Check filter capacity
To detect faults and
provides remedy for the same.
4.

(e) Too high spced of Check speed and select

5.12.1 Remedies and Fault detection in
the pump proper pulley or gears
Hydraulic Circuits to
reduce speed
MSBTE : S.17,S18
problems were mentioned, Wrile 2. Problem : Overheating
QBelosome
(S-17)
probable causes and remedy of
it
Causes Remedisl action
Excessive noise in hydraulic pump.
O.

Excessive hcat in oil Damaged pimp Replace damaged pump

) Pressure control valve not functioning correctly. if can't repair

Q State tie causes and remedies for the follo:wing: (b) Misalignment, won Make proper alignment
out arts
0Punp ini delvering oi Replace worn out parts

Exceseive pump noise

C) Improper selection of Check oil viscosity and

)System excessively hot. oil viscosity

use compatible oil

(y) Low pressuren system (S-18)

(d) Faulty cooling system Inspect oil coolers and
0 Slateany two reasons for faiture of hydraulic circuits. set them propely
4Marks)
() Improper tank design Check tank design and
1. Problem: Excessive noise in pump and
provide comect size
shape of tank
Causes Remedial action
layout
No. ( Wrong pipe layout Use proper pipe
with more
(a) Air in fuid Check leakage at inlet obstructions

medium Pipe and make joints leak

proor

Scanned witn camScanner

 ulaues (MSBT
Sem-
No pump
delivery 5-27
3.
5. Pressure
controlvalve
l HydraulicCircuits
CAuses Remedial actior notfuncioning
correctly
Sr Causes
Remedialaction
Wrong rotation of Should be
corrected
pump
Broken spring Remove/replace
viscosity too spring
b) oil high| Use correct grade (6) Valve
of spool Chcck oil andclean
oil. it
sticky

c)Oil level in rescrvoir Fill the oil up C)Leakage

is too low sufficient level.
to inCheck source of leakage
and
stop if.
thevalve
Air leak in inlet pipe Make leak proof
joints. ) Wear out Check and replace it

()Filerstrainer Clean strainer/filters at seatspool

clogged
inlet e) Drain ine
line Clean and flush the valve

0 Pump speed low Check speed the set blocked

properly inlet Remove dirt and clean it

(Valve
4. Low pressure in the system clogged

6 Erratic movement
CAuse Remedialaction
Remedial action

) Pressure set too Check relief valve setting

(a) Pressure. Check PRV, accumulator,
low and set properly.
fuctuations oil
(6) |Faulty pressurc | Repairfreplace .
the relief
them
(b) Wom out/dainaged | Repair and replace
relief valve. valve
parts
make
Leakage' in the| Check for seal failure, Air present in oil
Bleed off air, stop leakage

system. leak proof connections, of air.

joints. proper oil, filter it

(4) Sticking of spools, | Use
regularly
Repair/replace the same. pistons etc
Worm out pump

parts Review Questions

(e)Filterclogged Clean the filter circuit, ist important

elements of i
Q.1 Define hydraulic

rpm Correct the motor rpm (Section 5.2) sketch.

OW of|
Explain hydraulic power pack
with neat
motor/pumnp
Q.2
(Section 5.4) acting
to actuate single
hydraulic circuit
Draw
Q.3 5.4.1.1(@)
cylinder. (Section
lata

Scanned witn camScanner

 oil Hydraulic Circuits
Industrial Hydraulics &Pneumatics (MSBTE Sem-V) 5-28
pressure
Differentiate between travel dependant and
.4 How double acting cyflinder is operated using 4/2D.C. a.14
(Section 5.8.2)
Valve? Explain with circuit. (Section 5.4.1.1(b)) dependant sequencing.
dependant sequencing aircunt
a.5 State the methods of speed control of D.A. cylinder Q.15 Explain travel
(Section 5.5) (Sectlon 5.8.2[b))
circuit for shaping machine.
Q.6 Explain meter-in circuit and give its applications. Q.16 Explain hydraulic
(Section 5.5.1.1) (Section 5.1.1)
hydraulic circuit for Slotting
machine.
Q.7 Explain meter-out circuit and write its advantages a.17 Explain

(Section 5.5.1.2). (Section 5.11.4)

balance hydraulic circuit with
Q.8 Compare meter-in with meter-out circuit. Q.17 Explain Counter
example. (Section 5.7)
(Section 5.5.1.3)
synchronisation ? Draw
Q.9 State the concept of regenerative circuit ? Explain. Q. 18 State the meaning of motion

(Section 5.6) any one circuit. (Section 5.9)

5.12)
Explain bleed-off speed control aircuit. Q.19 Write causes and remedy for (Section
a.10
Low pressure in the system.
(Section 5.5.1.5)
) Overheating.
Q.11 Explain speed control circuit for bi-directional
hydromotor. (Section 5.5.1.6) in) Noisy pump

Q.12 Explain sequencing with the help of suitable example. (v) Eratic moverment.
(Section 5.8.1)

a.13 State the methods of sequencing circuits? Explain.

(Section 5.8.2)

Scanned with Camscanner

 UNIT VIL

Chapter 6: Pneumatic Circuits

Syilabus:
of Single and Double Aclir
6.1 Direct I Indirect Control
cylinders, motors.
motors
6.2 Speed control circuit for cytinders and
circuits, Tme
6.3 Sequencing circuits, Logic AND/OR
circuits, piston continuous back and forth.

6.4 Simple Hydro-pneumatic applications.

6.5 Simple Electro-Pneumatic circuits.
6.6 Remedies and fault detection in Pneumatic circuits
||6.7 Maintenance of hydraulic and Pneumatic systermS
6.1 Introducticn.*****************************-*******
6.1.1 Definition of Pneumatic Circuit

6.1.2 Main Components of Pneumatic Circuits.

6.1.3 Types of Pneumatic Circuits...

6.1.3.1 Preliminary Basic Circuits (Direct control)..

6.1.3.2 Indirect control/Pilot Control Crcuits

(Impulse Operation).

6.2 Speed Control Circuits..

6.2.1 Speed control of single acting cylinder using

3x2 DC valve..
.
6.2.2 Speed control of double acting cylinder

6.2.3 Speed control of uni-directional air motor

6.2.4 Speed control of bi-directional air motor ********

6.3 Sequencing Circuits ******** *e***

6.3.1 Typas of Sequencing Circuits.

6.3.2 Logic controlled Circuit..

6.3.3 Time Delay Circuit.. ******o*~*******

6.3.4 Piston continuous back and forth .********

6.4 Simple Hydro-pneumaic Applications. *****

6.4.1 Types of Hydro pneumatic system..************

6.4.1.1 Air oil reservoir ...
6.4.1.2 Hydraulic check unit . *****
**°°°°*

*********°*************
*°******°*****

6.4.1.3 Air hydraulicintensifier. *****-****..******

6.5 Simple Electro-Pneumatic Circuits.. *******

6.6 Comparison of Hydraulic and Pneumatic Systam.

6.7 Maintenance of Pneumatic System.********
 AT
(6 Pneumatic Circuits

4 UNIT
VIS
Syilabus

a1 Direct/ Indirect Control of Single and Double Acting Air cyinders, motors.
circuit for oylinders and motors.
62 Speed control
6.3 Sequencing circuis, Logic AND/OR cirCuits, Tine delay circuits, piston continuous back and forth.
Hydro-pneumatic applications.
64 Simple
6.5 Simple Electro-Pneumatic circuits.

66 Remedies and fault detection in Pneumatic circuits

6.7 Maintenance of hydraulic and Pneumatic systems

6.1.1 Definition of Pneurnatic Circuit

6.1 Introduction
Deinition of Pheunatic Ciruit Paeurna
represéntutio
The various components of pneumatic system ,were derted ds the graphical synibholic)
PleiaiefiCCOmporents eumat
discussed in detail in the chaptes. The required
machuteeqinpiie2
components are selected and connected with each
other
Pneumatic circuits do not require return lines which
in the form pneumatic circuit to perform given
task or
saves a cost of piping and fitting, also reduces leakage
application. and other problems. The air from exhaust port is
cylinders are linked allovwed is escape to the atmosphere.
Pneumatic elements like valves and
connections to form Air is compressible and expands in the space available
together through pipe lines and
predetermined hence case should be taken while designing pneumatic
pneumatic circuit diagram, to present

interelated motion of machine functions. circuits.

6.1.2 Main Components of Pneumatic

Poeumatic circuits are to be designed for
Circuits
a)Clamping of the work picce.
Main Components of Preumatic Circuits
6) Air operated hand tools.

c)Material handling equipments. (a) Compressor unit

() Machine tools, etc. ) Control valves

to avoid complicated
drawings, pneumatic
Order (c) Actuatos
are drawn with the help of
symbols of vanous
Cuits
Components. d) Accessories

Fig. C6.1: Maln Components of Pneumatic Circuits

Scanned witn Camscanner

 (MSBTE Sem-V) 6-2 Pneumatic Circuits
Industrial Hydraulics& Pneumatics
consists of compressor with air 6.1.3 Types of Pneumatic Circuits
(a) Compressor unit
: t
receiver. Types of Pneumatic Circuits

Pressure control, D.C. Valves, flow

(b) Control valves:
control valves, check valves, etc.
1.Preliminary basic or Direct control circuits

(c) Actuators: Pncumatic cylinders and motors. (a) To actuate single acting oyinder
moisture separator,
(d) Accessories: FRL unit, air dryers, 6) To actuate double acting cyinder

pipes, hoses, fittings, muffler, etc.

(c) To actuate uni-directional air motor

H (d) To actuate bi-directional air motor

(Impulse operation)
2 Indirect(Püot ) control circuits

(a) Pilot control of single acting cylnder

H (6) Pilot control of double actng cylinder

uni-directional air motor

(c) Pilot control of
motor
() Pilot control of bi-directional air

Speed control circuts

3.
acting cyinder
(a) Speed control of singtle
Speed control of doubla acting cylinder
H0
Fig. 6.1.1:Pneumatic press machine
) Speed control of unidirectional air motor

(c) Speed control of bi-directional air motor

Sequencing citrcuits
4.
a) Position based sequencing circtit

Logic controlled circuits

5.
H (a) AND gate circuit

A (b) OR gate circuit

cup making machine

Fig. 6.1.2 :Pneumatic paper 6. Time delay circuits

(a) SA.Cylinder time delay circuit

(6) DA. Cylinder time delay circut

7.Piston continuous back and forth

Circuits
Fig. C6.2:Types of Pneumatic

Tedt
PBatias

Scanned with Camscanner

 tydraulics & Pneumatics (MSBTE:SSem-V)
Indust 6-3 Pneumatic Circuits
Freliminary Baslc Circuits (Direct
6.1.3.1 control)
ctuate singleacting cylinder
1.
To
MSBTE:S-16
o
position contro,
artuated position
Explain actuated. of ot single acting gylinderwith neatcircuit (S-16)
d
circuit:
Purpose of the
ement the single acting cylinder to produce
Moveme of push force by ising compressed air.
components:
Clrcuit

Compressor
1.

2. FRL unit,

3. 3/2 D.C. Valve

4. S.A. Cylinder

5. Pipe and hoses

6. Moisture separator, mufler, ctc.

Circuit:
S.A Gylinder

A Push force
Pull force
(By spring)

Push button operated

3/2D.C. vave Muffler

o-0-
FRL unit Moisture
separator
Compressor

(b) Normal position

(a) Actuated position
Fig.6.1.3:Pneumatic circuit for S.A. cylinder

In the position of D.C. valve port P is connected to port

Explanation of circuit: A of the cylinder to enter compressed air in the cylinder
cylinder
()actuated position of control of single acting while port R is closed. The compressed air pushes the
to produce push
fore: piston against the spring force. The piston moves
is given by the forward to produce push force by compressing the
Fig. 6.1.3(a), the compressed air
From separator
compressor is passed through moisture spring.
in the FRL unit.
eDve water particles and then enters

Techaernledgi
Peslcats

Scanned witn camScanner

 Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 64 Pneumatic Circuits
When spring is fully compressed and piston reaches the Applications of circuit:
right dead cnd of the cylinder, the forward stroke will
1. Shifüng or moving simple jigs
bercompleted.
2 Clamping of work pieces.
(b) Normal position to give pull force
3. Shect mnctal press machines.
Fig. 6.1.3(6)
2. To actuate double acting cylinder:
When D.C. Valve is operated using push button to
obtain next position of D.C. Valve, the port P is closed Purpose of the circuit:
while port A and port R are connected. Movement of the double acting cylinder
to produce to
As the supply of compressed air is closed at and fro (reciprocating) motion by using
port P, the compressed air.
spring expands and pushes the air to the port R through
Circuit components:
outlet port A.
1. Compressor
The piston will reach the left dead end when
compressed air fully exhausted through 2. FRL unit
the port R
using noise reducer (muffler). Thus refraction stroke ND.C. Valve
of
the cylinder will be completed. 4. D.A. Cylinder
5. Pipe and hoses
6. Moisture separator, mufiler, etc.
Circult:
Push Pull

L
X P
MIX

(a) Actuated position

o-0-
(6) Normal posiion
Fig. 6.14:Pneumatic circuit for D.A. cytinder
Explanation ofcircuit:
(a) Actuated position (forward/extension
of eylinder):
n tiis position, the port P and ports A are conected to enter compressed air from compresor to tie cylinder inet
ne compressed air moves the piston in the forward direction while the air from rod side is pushed from port 5 top

to exhaust air to the atmosphere through mufífler.

It completes forward stroke of the cylinder.

TecTaale
PBtlgst
Y

Scanned with Camscanner

 Industnalydraulics & neumatics
(MSBTE_S
Sem-VD
D)Normal
(Res
position etraction
stroke): 6-5 Pneumatic Circuits
When push huton is operated to get normal
compressed air will enter from position,
the port P to port B
cylinderfromo side. It will push in
the piston
direction towards left dead end. in
the

The from other side will be cxhausted

to.the
sphere throughport A portR. to
Thus retraction
cylinder will be completed. of

This ci reuit will giveand fro motion continuously

to Mufltler

positions by
changing the of D.C. Vave

4pllcation of circuit:
Compressor
This circuit is used to perform work
Airecions. cg. material
in both the () Normal position
bandling cquipments
ike ig.6.1.5: Pneumatic circuit for uni-directional motor
cranes, lifts, clamping, machine tools, etc.
Explanationof circuit:
To actuate unidirectional air motor
(pneumatic
motor): (a) Actnated position (Rotation of motor)

In this position, the compressed air from FRL unit wil

Purpose of circuit:
enter in the D.C. Valve. It connects the flow of air from
. To obtain rotary movement of air motor in
one port P to port A to enter compressed air in the ar
direction. motor. The motor will rotate in clockwise direction.

Circuit components: (6) Normal position (No rotation of motor):

1. Compressor When D.C. Valve is actuated for normal position. The

2. 3/2 D.C.Valve port P is closed end air flow is cutoff. Hence no
movement of motor.
3. Uni-directional motor
4. Pipes, hoses, muffler, etc. Application of cireuit:

Hand tools.

Circuit 4. To actuzte bi-cirectional pneumatic motor:

Unidiredtional motor
Purpose of the clrcult:

O To obtain rotary motion in both clockwise and counter

clockwise direction of bi-directional pneumatic motor.

Circuitcomponents:

Lever operated 1. Air compressor

3/2 D.C valve FRL unit

3. 4/2D.C. Valve

4. Bi-directional air motor

5. Moisture separator

0 FRLunit Moisture
6. Pipe, hoses, muffler, etc.

separator

(a) Actuated position

. Tecetad
Pllatleis

Scanned witn camScanner

Industrial Hydraulics& Pneumatics (MSBTE _Sem-VI) 6-6 Pneumatic Circuits

Circult: ()Indirect control Pilot control of single acting

cylinder

Purpose of the circuit:

Movement of single acting cylinder to give push force
using impulse operation.

Circuit components:
1. Air compressor

-0
(a) Actuated position
-0-
(b) Normal position
2.
3.
FRL unit

3/2D.C. Valve
4. Pilot controlled 3/2 D.C. Valve
Flg.6.1.6: Pmeumatic circuit for bi-directional air motor
5. S.A.Cylinder
Explanation of circuit:
6. Pipe, hoses, etc (push button operated)
a)Actuated position:
In this position of D.C. Valve, the port P is connected Circuit:
to port A of the air motor to enter compressed air in the
air motor. The air will rotate the pneumatic motorin
clockwise direction. The low pressure air is exhausted
through port B to port R to the atmospbere.

b) Normal position:
Impulse d
air
W Pilot contolled
32 D.C. valv

Lever is operated to change the position of D.C. Valve, P

the port P and port B are connected to enter pressurised Push button
3/2 D.C.
air in the air motor through inlet B. The air will rotate valve
the motor in counter clockwise direction. The port A is
connected to port R to exhaust the low pressure air to
the atmosphere.
Application:
LTo--0 FRL unit

Hand tools like grinders, drill, etc. Fig. 6.1.7: Impulse operation of S.A. cylinder
Circuits
6.1.3.2 Indirect control/Pilot Control Explanation of cireuit
(Impulse Operation)
Fig. 6.1.7 shows a circuit diagram with pilot controlled
WSBW-17
MISBTE S09, S-13, W-13 N15S16 3/2 D.C. Valve. The air from FRL unit will enter in the
push buton operated 3/2 D.C. Valve. The port P and
neat sketch wonking of impulse.operaton
O Explain with port A are connected and compressed air comes out of
09 S13, W-13, W 17
pneumatic circuit port A. The air from this port is given to the pilot line
rcuft? Expain.
circuit? EXpla of pilot controlled 3/2 D.C. Valve.
pneumatic
a What is impulse The compressed air make impulse action on pilot D.C.
(W-15,S-16, W.16)| P
Valve and occupy position of D.C. Valve. The port
for
compressed air is used and A are connected through which the supplyof
energy of
When pressure obtained by compressed air from connection after FRL unit
is
Valve, and pilot operation is
enter in the single acting cylinder
controlling D.C. is known as given. The air will
impulse of ait energy it direction.
momentary
and push the
piston in the forward
sending a
impulse circuits.
control circuits or
pilot
FTetanled
Pslicati

Scanned with Camscanner

 Hydraulics neumatics (MSBTE_Sem-Vi)
Industrial
6-7 Pneumatic Circuits
Application:
The compressed air will make impulse action on pilot
control of singic acting cylinder. operated 4/2 D.C. Valve and occupy first position D.C
pilot
Valve. The port P and A are connected to admit
tadirect controlPilot control of Double acting
Indir
compressed air in cylinder. The supply of
the,
cylinder:
Conpressed air is given from connection after FK
MSETERWE16 the double
uniL The air will enter through inlet A, in
the forwaru
DAcylinder. acting cylindér and push the piston in
Q. Draw pilot operated circuif using
4x 2 port
valve direction. The air from port B, is given to the
vaNeand3 x2plot W16)
DC for exhaust of air to the atmosphere.

Purpo
of the circuit:
Application:
Movement of double acting cylinder to produce
Pilot control of double acting cylinder.
reciprocating motion using inmpulse operation. Uni-directiona
components: () Indirect control /Pilot control of
Cireuit airmotor:
compressor
Air Purpose of the circuit:
1. motor using
2. Moisture separator Rotary movement of unidirectional air
impulse operation.
3.
3/2D.C. Valve.
Circuit components
4. Pilot operated 4/2 D.C. Valve
1. Compressor
5. D.A. Cylinder
2. FRL unit
6. Pipe, hoses, etc. 3. 3/2 D.C. valve

4. Pilot operated 3/2 D.C. valve

Circuit: 5. Unidirectional air motor

DAoinder 6. Pipes, hoses, etc.

Impulse of ar Circuit:
Plot oparatod 42 D.C. vahvo Uni-directional air motor

Mutfler
uton

32 D.C

PR Moisture W Plot controlled 3/2 D.C valva

Bparator

-0 Lunit
Compressor
Lever operated
3/2 D.C. vave
Fig. 6.1.8: Pilot control of D.A. cylinder
Moisture
Explanation
of circuit:

LIs
S

0
circuit, the push button
toUSed
operated 3/2 D.C. Valve
actuaté 4/2 D.C. Valve (pilot operated)

compressed air will enter in the 3/2 D.C. Valve in

o-0
Fig. 6.1.9: Pilot control of unl-directional air motor
from
CDport P and port A are connected. The air
tA willis given to the pilot line of 4/2 D.C. Valve.

Teceenledgi
Pblatlas

Scanned with Camscanner

 Industrial Hydraulics & Pnaumalics (MSBTE Sem-VI 6-8 neumatic Circuits
Bdirectional motor
6.2.1 Speed control of single acting
cylinder using 3x2 DC valve:
MSBTE57 W:17
IXw Pilot controlled
4A/2 D.C valve
QDrawspeed control af singleacting cylinder
Ppeunatitc circuit using3
2
DG valve:
17
Lever operated
HH Muer O Explain pneumatic circiit for speed control of single
acting cylinder withi neat sketch.
3/2 D.C.vave W-17
FRL.unit Moisture Purpose of the circuit:
operated separalor
R
3/2.D.C. vae Speed control of forward movement of cylinder
using
flow control valve.
Compressor
Fig.6.1.10: Pilot control of bi-directional air motor Circuit components:
Explanation of circuit: 1. Air compressor
The circuit is similar to pilot control of single acting 2. Moisture separator
cylinder only change is in the actuator. The S.A
3. 3/2 D.C. Valve
cylinder is replaced by uni-directional motor.
4. Flow control valve with check valve
It produces rotary motion with the help of pilot
5. SA.Cylinder
controlled 3/2 D.C. Valve.
6. Pipes, hoses, muffler, etc.
Application:
Pilot control of unidirectional motor when direct Circuit
control is not possible.
S.Acylinder
(C) Indirect control Pilot control of bl-directional Slowfast

i tor:
The circuit is similar to pilot control of double acting
cylinder. The cylinder is replaced by bi-directional air A
motor. It produces rotary motion using pilot operated
N Push button controlled
4/2 D.C. Valve. 3/2 D.C. valve
PA
6.2 Speed Control Circuits
Need of speed control of actuators
Flow control valve
with check valve

1. Some operations are related to machining of complex

profiles which rèquires slow speed while drilling, FRLunit
Air reciever

2.
reaming, grinding multipoint cutting operation necds
fast speed.

Non productive movements should be faster to reduce

o0- Moisture
separator
Compressor

cycle time. Fig. 6.2.1:Speed control of S.A. cylinder (forward

3. Speed regulation increases versatility of the machines stroke)

cquipments.
Explanation of circuit:
DefinitionWhen speed.of the actualoris
varied by sing The flow control valve with check
valve is placed
OW contro ave in the preumatic .circuisitis called a The flow of
peed controlcircui. between FRL service unit and D.C. Valve.
in the cylinder.
air can be regulated before entering
Techlowaledi
Plicati#et

Scanned with Camscanner

 Circuits
Pneumatic
tial Hydraulics& Pneumatics (MSBTE Sem-VI) 6-9
hdu
aSlow.nmovement Circuit components:
actuated position of D.C Valve, the flow control . Aircompressor
e
adjusted to reduce flow area to admit less 2. Moisture separator
valve is
ait. The reduced quantity of
air will enter 3. FRL unit
antity of
guantitg NOS)
Flow control valves (2
port A in the cylinder. The piston moves 4.
frompo P1o
5. 4/2 D.C Valve
slowerrate.
at 6. D.A. Cylinder
movement
(b) Fast
control valve is opened to increase flow Circuit
en flow
When
quantity air is allowed to pass
through flow DA cylinder
area, more air, willenter siaw/fast
The increased quantity of
cmtrol passage.
Now the movement of
A in the cyinder.
from port Pto
faster
piston will be
cylinder during vave
will control
the speed of SA. Flow control
t rètum stroke will
be.completed with check valve
forward stroke only, the
force shown in Fig. 6.2.2.
by using spring FCV,
B
FCV2
Lever operated
4ZD.C. vavo

T Mastr

Lol-Oo0-
Fig. 623:Speed
controt of DA. cylinder
(forvvard strolke).

Exglanation of.circuit
movement
(a) Slów Valve to the
Compressed: air will enter from D.C
valve- i (FCV,. The port
actuator with the ffow cotrol
by
SA.cylinder (return strola) and flow of air is reduced
Fig 6.22:Spaad control of P connected to port A will
less quantity of air
Application: partially closing the valve and
piston.
material handling devices like enterin the D.A. cylinder from inlet A The
Punch press operations,
moves forward at slower speed.
cranes, etc.
the atmosphere
6.22 Speed control of double acting The air from outlet B is exhausted to
throughconnection BR with the help of muffler.
cylinder:
MSETE EW-0 W09.W-14,W.18S9(b) Fast movement:
When lever of the D.C. Valve is.operated, the. D.C.
Xplain pneumatic circuit for controllng: speed o
Valve will get next position to connect ports P> B
Double Acing Cyinder with circuit diagram
and A> R.
fM-09, W149 The,compressed air will pass through flow control
Strpke ot a doubte acting pmeumatic cyinder
egds to be controled as Draw alve 2 (FCV) in which the flow area of he valve will
pefseg be fully open and admits full-quantity of aïr in. the
suta
rCtand:name each companentinit{W1D)
cylinder through inlet B. The actuator will move at
Purpose
afthe circuit . faster speed during retraction. Thus by varying the flow
quantity of compressed air, the speed of the actuator
EYeat of the D.A. cylinder at slow/fast speed using
OW Controt valves can be varied.
in the pneumatic Circunt.

B7 Tech Knsulege
PubICations

Scanned with Camscanner

 Industria Hydraulics& Pneumatics (MSBTE_Sem-VIy 6-10 Pneumatic Circtits

The air will be exhausted through path decreased by partialy closing the flow control valve.
to the atmospherc.
AR The reduced air flow will enter in the motor through
Application inlet A.
(1) Automation The motor will rotate at slow speed as less quantity
is
i) Small cranes, punch press machines available for running the air motor.

6.2.3 Speed control of uni-directional air 2. Fast speed:

motor:
When flow control valve is fully opened to increase
Purpose of the circuit: the
flow area, more quantity, of air 1s allowed to pass
Vary the rotational speed of uni-directional air motor
through flow control valve.
by using flow control valve in the circuit.
The increased quantity of air will enter in the
Circuit components: motor and
rotate it with high speed.
Compressor
2 Moisture separator Application:
3. FRLunit Hand tools, machine drives, etc.
4. 3/2D.C. Valve
5. Flow control valve with check valve
6.2.4 Speed control of bi-directional air
6. Uni-directional motor
motor

Circuit: MSE 10,S15,W15,5-16W16

Uni-direcdianal motor S17W-17,S-18.W.18
e Sketcth and explain speed.conirol Brdirectionat
of
Slowfast motorin pmeumaficsystem. (S-10,S16S17,9
ar
10
Q From a given circuit answer the fcllowing quesions.
Flow control valve
sth integral check valver
referFici1

Lever operated
4/2 D.C. valve

O-0- FRLunit
Moisture
parator
omprassor

Fig. 6.2.4:Spead control af uni-directional air motor

Explanation of circuit

The flow control valve is placed before inlet of the air

motor, so that flow of compressed air can' be regulated,

before entering in the air motor.

give its äpplication
the circuit and
1. Slow speed: 1Name componenis represeted by
aro
Namethe
The compressed air from port P' to port A is allowed to
2
Cnter in the flow control valve where the flow area is Tectoowin

Scanned with Camscanner

 LHdraulics& Pneumatics (MSBTE
Sem-VI)
6-11 Pneumatic Circuits

With a nea8Ketch, how Speed o Explanation ofcircuit:

DescD Air motoris contollen
bidirectionaf
thespeedion ofanyaquatOE
hauspeedcontrol,
0
Wi
W-15)
1 Slow speed:
HoW can bee
o 49 EXplain tha speed cohfrol circuit OTmpressed air is passed through D.C. Valve from
por
of b
arca
irectionalaik.motor.with sketch. Pto port A: l will enter in the FCVI where flow
(M16)
O e ei
bidectional pneumatic motor
h
H
nabi of the
Of partially closing the valve:
the FCVI is reduced by partialy
clos5
A
the- ait motor
oDerated at vanaole SpOEU mboth the dirpi ience, small. quantity of air will enter. in
labelled circuit dagram and explain through inet A. It will rotate the motor at slow speedt
Draw a its
State wtether it is.a meter n or meter
out2 Fast.speed.
Cuit, AW-18)
Similarly, when flow area of the FCV1 is increased bY
DravS Ppeumato clrcuit tor full. quantity of.
*Huly opening the valve, it will supply
BFdirectiOarataNoior.
"
Compressed air to the aïr motor through inlet:A.
Purpose of fhe circuit': the motorat
AS large quantity is suplied it willrotate
'
Ta vary the spoed ot BL-directional air motor by using anotier
high speed..We.can controf the.speed in.
flow control valýes in the.circuit direction using FCV2' and second. position: of D.C.
.
Circuit components:. Valve

1 Air compressor Hence by varying the fow. quantity of air we can.

Moisture separator: changethe speed of bi-directional motor.
2
3FRL unit Application:
FHow controf valve (2NOS)
Hand toois,Tmaehine tool dives, etc.
4/2 D.C. Vaive
Bi-directionalair motor 6.3 Sequencing Circuits
*** * i**
Cireuit MSEE
Slowilas 0Develepie phcimatios position. based seguencing
:Bidirectional air motor using ak trecessary coamponents
Crcut bY
19
DelinitionVen mDers OL actuatoS (lineaifton ar
operted one uter unotherna predétermined order is
nowas eduencing anil thecircuiis used jor it are.called
as sequenCrg circtLS
FOV FCV2
Sequencing:of number of. cylinders in a particular
sequence is required for work movement in machine,
Lools, jigs and fixhures, etc

NMufar By sequencing namber of pneumatic cyinders, various

machining and. tooling. operations may
be easily
obtained in a machine.

Applications of sequencing circuits

Clamping, feeding and ejecting.
motor.
contralof 5idirectional air
pushing
Speed 2 Lifting.

TechKnealed
P9bilcaties

Scanned witn camScanner

 Pneumatic Circuits
Industrial Hydraulics &Pneumatics (MSBTE Sem-VI) 6-12
8A.Cylndor
Low cost automation in factories.
3 D.A cylinder
Devices used in sequencing Pilot Ine

1. Sequence valves

2 Time delay valve

Pilat operated
opemted
4/2 D.C
3. Roller operated valves 3/2D.C. vavo
valve
Raler
Limit switches operated
32 D.C. valve
5. Electrical switch

6. Cam operated valve a2D.C.vahve

6.3.1 Types of Sequencing Circuts Lunit

(a) Positon based sequencing:

The sequencing circuits works on the principle of travel
Lolo Compressior

of one achuator will decide the actuation of the second Fig.6.3.1:Sequencing of SA. cylinder with D.A. cylinder
actuator when it reaches to particular position.
Explanation of circuit :
It is useful for assembly operation in a mass production
Iine. 1. Operation 1: Movement of S.A. cylinder up to roller
operated valve
) Sequencing of S.A. cylinder with D.A cylinder
using roller operated DCvalve: The compressed air from FRL unit will enter in 2/2
ESBTES15S-18 D.C. Valve and then lever operated 3/2 D.C. Vave.
Howwil you sequence o DA pneumalic cylinder Through inlet A, the air will push the piston of S.A
and one SA pneurmatic cylinder using roller operated cylinder amd, moves the piston towards the roller
S-15) operated valve.
FExplai wilhe neat sketch working ot sequencing
circuit for teo single acing air cyfinders When piston moves and its rod end touches the roller of
S18)1
e Sequencing
nne.nep.osumexanplo.erd xplain
circuits
rmesta)2.
the 3/2 D.C. Valve, it completes operation No. I
Operation .2: Movement of D.A. cylinder in the

Sequence: forward direction.

1. Actuation of S.A. cylinder. The piston rod end of S.A. cylinder press the roller of

2. Actuation of D.A. cylinder. 3/2 D.C. Valve, and open the valve to connect air
supply from FRL unit.
Circuit camponents:
The air from roller operated 3/2 D.C. Valve wll enter
I. Compressor, FRL unit
in the pilot line and operates pilot operated 4/2 D.C.
2. 2/2D.C.Valye Valve.

3. Lever operated 3/2 D.c. Valve The air from 2/2 D.C. Valve will enter in the D.A
4. Roller operated.3/2 D.C. Valve cylinder through inlet A and moves the piston rod in

5.
forward direction. The B port connected to port R for
Pilot operated 4/2 D.C. Valve
exhaust of low pressure air to atmosphere. Thus
6. S.A. and D.A. cylinder.
operation No. 2 is completed

Application :
. Automatic material movement
2. Automation
Techoealedgi
uBtiass

Scanned with Camscanner

 lics&Pneumatics (MSBTE
InctustralHydraulics
Sem-V} 6-13 Pheumatic Circuits
D.A ylinder with S.A cylinder press the rollerof
Sequencing of he piston rod end of S.A..ylinder
operatedDcVa
valve conneet air
uslngroller 2 DC Valve and open the valve to
D.A.Cylinder press the raller
piston rod end of
mepis of SUpply from FRL unit.
Valve, and open the valve to connect air Valve will enter
3/2DC fromFRLunit C ar from roller operated 3/2
D.C:
Supply operated 3/2. D.C.
in the pilot line and opera pilot
operated 3/2 DC. Valvewill
from roller enter
The air Valve
pilot line and operates piot operated 3/2 D.C.
the
will enter in the S.A
Valve neair from 3/2 D:C. Valve
in
through inlet A and moves
the piston rod
from 3/2:D.C Nalve:will enter in the S.A.
3

Theair 7nder
cylinderthrough
inlet.
tA.and moves the pistom wd in forward direction.
direction" acting.cylinders
forward Soquencing oftvo double S19W-15:S-17W1
DA.cylnder
MSBTE
8A. yimder
sequeneiny
nea sketch working ot
pand actingarcylnder (S13 SA
CrcCEitfortwo double
doUble
working oftwg
ey andabelthe ciret for 15)
42DCV acting alr Cylnder
operaiOn af wa-DA
Roler
gkep apheunaiccircuit for ptRE sng
lDg
perulo after operates. after odker
3/20.G.valve,
uers suCH halone
ant:seguenIGHTg

D.Acyindor

.*Compressor.

Fig, 6.3.2
FDAoidor®
vaivo Roler
cylinders using roller acualed
eguencing of twoS.A 42 D.C. valNe
operated Dvalve Mufler

ylnder
SA.O

Pilot me 320Csae
"

A
DCY
Level FRL unitCompressor
operated
32 D.C.valve
Aoller cyfinders
oporare
Fig.
63.4:Sequencing of two datuble acting
2D.C. Yave

vae Sequence:
a2 0.c.
Actuation of D:A. cylinder
1.
Actuation ofD.A: cylinder
2
Compressor

Fig. 6.3.3
Publlcatlass

Scanned with Camscanner

Industrial Hydraulics & Pneumatics (MSBTE Sem-VI) 6-14 Pneumatic Circuits
Aoller operated spring
Circuitcomponents : Cylinder'A' retum 3/2 DCV Cylinder B

1. Compressor, FRL unit

2: 3/2 D.C. Valve

3. 4/2 DA. Valve

4. Roller operated 4/2 D.c. Valve

S. D.A.cylinder (2 NOS)

Explanation ot circuit:
Detent lypa spring
1. Operation 1: retum 5/2 DCV

Lincar movement of D.A. cylinder (1).

The air from 3/2 D.C. Valve enters in the 4/2 D.C.
Compressor
ralve and inet A of D.A. cylinder. (1). II moves the FRL Unit

piston towards roller located at certain distance from Fig.6.34fa)

piston rod end. (0U) Sequencing of cylinder with motor:
When piston rod end touches the roller of the roller Sequence
opcrated 4/2 D.C. Valve, it completes the operation 1.
1. Linear movement of cylinder.
2 Operation 2
2. Rotary motion of air motor.
Linear movement of D.A. cylinder (2).
Circuit components
The piston rod end of cylinder (1) press the roller and.
connects the ports for position P->Aj, B,R. . Compressor

The air will enter in the cylinder 2 through inlet Afand 2 FRL mit

moves the piston in the downward direction. The air 3 4/2 D.C.Valve
4. Solenoid operated 3/2 D.C. Valve
from other side is exhausted to the atmosphere from
5. D.A.cylinder
port B>R Thus operation No. 2 is completed. 6. Unidirectional motor
Application:
Circuit:
Automation of material movement, automation of DA. cylinder
machine tools.

O. There are twa pneumatic.cylinders whica operale. in.

Bequence Forvard stroke of first cylinder take place Limit
SWICn

followed by aütomalic fonward ströke of second Solencid

alve
32D.
cylinder. Howevat retraction takes placa: first in valve

Second cylinder folowed by the same in first.oylinder

FRLunit
Draw.sutable circuit and name all components:
W18)1
Compressor

Fig.6.3.5:Sequencing of D.A. cylinder with

unidirectional air motor

Tecatta

Scanned witn camScanner

 PneumaticGrcuns
industrafHydraul Pheumalics (MSBTE em-V 6-15
circuit
Explanationof Circuit:
S.A. cylinder
ircuit consists of limit switch
This
and, solenoid
D.CcValve for sequencing
berated3/2
Pera

. Operaltor 1: Movement fDA. cylinder Push force

mpressed air will enter in D.A. cylinder through
Shuttle valve
un p.C Valve and causes movement of, piston in the
travels linearly and
orward direction. The piston
located at specific point ADC vaive 2
touchesthe Imit switch DC valve-1
movement of
2
:
Operation 2 Rotary
Uni-directional motor:,

the imit switch, it

When piston rod end touches
.
actuates thie solenoid' operated 3/2 D.C. Valvë and air
will enter from port P; to A în the uni-directionar
motor. The motör rotates in ckockwise
direction. "

operátion
The circuit is usefu for clamping and driling
FRLunit. Moisture Compressor
sequènce. separator
in
Application actuated using shuttfe valve
Fig. 6.3.6 S.A: cylinder
Aitomation ofäriling tmachine. Explanation of cirenit
"

lled
5.3.2 Logic controlled
Circüit
Circuit
This circuit consists of shutte
vave connected using
EwO DUush bution operated 3/2 D.c.Valve for two hand:
Actüation of SA Cylindér using Shuttle valve (OR
Gate Välve) operations.

Purpbse of the circuit: 1 D.CValve 1

produce ]
The compressed air will enter in 3/2 D.C.Valve and its
Movement" of Single acting cylinder to
output is given to the shutle valve from left sîde. is
(Two Tt
'
reciprpcating motion using two D.C Valves
operators) wien operator 1 or Operator 2 actuates input for shutle valve
heir DC valve D.CValve 2
Cireut components.
The compressed air wilenter in 3/2 D.C. Valve and its
compressor output is given' to the shuttie valve froim right side. It is
Air
2 Moisturc separator inpat for shuttle valve:

3. 3/2 DCValve -2 Nos 3 Shuttle valve:

4. Shuttle'valve. When any' one D:C valve is operated then as per
3. 5A.Cylinder working of shutle valve, it will give output to the.S.A.

6. Pipe,hoses, etc. Cylinder and causes forward stroke.

Application:

Control of machine from diferent locations when

cylinder orvalve is to be controlled from one or several
positions.

Tec asuladge

Scanned witn camScanner

 Indiustrial Hydraulics.& Pneumatics
(MSBTE Sem-VI) 6-16 Pneumatic Circuits
2. Actuation of S.A Cylinder using.Twin pressure D.cValve
valve(AND Gate Valve)
1.
1:
The compressed air will enter in 3/2 D.C. Vaive and its
Purpose of the cirenit:
Output is given to the twin pressure valve from left side
Movement of Single acting cylinder
to produce push Itis input 1 for twin pressure valve
motion using two D.C Valves (Two 2. D.C Valve 2:
hands/operators) .

when operator I and Operator actuates

2 their D.C The compressed air will enter in 3/2 D.C. Valve and its
valves. n is safety circuit.
output is given to twin pressuTe valve from right side. It
Circuit comipónents is input 2 for twin pressure valve

1. Air compressor 3. Twin pressure valve:

When operator 1 and operator 2 operate their D.C
2 Moisture separator
valves then as.per working of twin pressure valve, it
3 3/2 D.C. Valve -2 Nos
wil give output to the SA. Cylinder and causes
4. forward stroke.
Twin pressure valve
If operator 1 actuates his D.C valve and operator 2 do
5. S.A.Cylinder
not actuates his D.C Valve, then no output signal is
6. Pipe, hoses, etc. give to the S.A. Cylinder
Similarly, f opertor 2
actuates his D.C valve and
operator 1 do not actuates his D.C Valve, then no
Circuit
output signal is given to the S. A. Cylinder
S.A. cylinder
Applícation

A Pus force
It is safety circuit for two hand/operators when
handling press machines. When both operators
are.safe after
thieir task completion, thiey can operate D.C
valves to actuate
yvin pressure valve cylinder to performoperation.

6.3.3 Time Delay Circuit:

A DC valve1 A DC valve 2 SETES58-6

a Stketch time. calay
preunaic circuit and. exalain.
WOrking ofit
PR Explain time delay preunatk circuit
eS15
viit reatsketci. |
i16)
GDrawand explain pneumafic
Citcuit tortwo double acingcyinders.
lime delaysequenicng
S1)
DelfinitionWhenactuationof man
DC-Vave is elowed
FRL unit Moisture
separator
Compressor
ter predetermined tinte delay using time
delay alve, it is
konowt as tim delay circuit.
Fig. 6.3.7:S.A. cylinder actuated using Twin pressure
1. Time deiay circuit for S.A.
valve Cylinder
Explanation of circuit: Purpose of the circuit:
Movement of Single acting cylinder
This circuit consists of twin pressure valve connected with required time
delay using time delay valve.
Using two push button operaled 3/2 D.c. Valve for two
handoperations.

TechKaeadgi
Pobttatioos

Scanned with Camscanner

 Hydraulics &Pneumafics(MSBTE Sem-V) Fneumatic Circuis
HDouske 6-17
components'pi.
Cireuit C Pilot controlledt 3/2 D.C.Vave
compressor to
Cylinder
1. Air comptessed air to the SA:
Moisture
separator. wladmit
Valve perform the forward stroké
3/2 D.C D.A.Cylinder
valve 2 Time delay circuit for
Time delay
D.C.valve
Pilot3/2 Pturpose of the circuít:
: S.A.Cylinder require
acting cylínderwith
6 Movemént' of Double
Pipes,hoses
time delay using time delay: valve
Circit: Cireuit components:
SA Cylinder
Air compressor
.
Moisture sepäiratór
2
3 3/2D.C Valve
4 Time delay valve
Pilot 3/2 D.Cvalve:
5. Piot 4/2DC. valve

Timedelay valve 6 DA.Cylinder

7. Pipes, boses

Ciruit: DAcylinder

Pusft button 4/2D.C.valve

operated Plot operated
3/2 D.C valve

actuated using timer delay

veiveTime delay valbe
Fig6.3.8:9.A eylirder
Explanatonof cireait*.*
delay valve connected
consists of time
This circait Valve änd pilot
bùton' opèrated 3/2 DC
usingpush.
operated 3/2D.CVafve.

. Pashbutton
operated 32D.C. Valve:
will.enter in 3/2 D.C
Vaveand its Push button
compressedair operated.
tie valve. 32 DC valve
oufputis given to the ime delay

b. Timedelay valve valve of time delay

passes through fiowcontrol and
he air required time delay
to provide cylinder actuated using time delay valve
and air reeiver trolled 3/2 D.cFig. 8.3.9:D.A:
contolled
output signal to the pilot
gives TechNuladga
Valve PUDIlCatleds

Scanned with Camscanner

 Pneumatc Ciruits
(MSBTE Sem-VI 6-18
Industrial Hydraulics & Pneumalics
Circuit

Explanation of circuit:
of time delay valve connected
This circuit consists pilot
operated 3/2 D.C. Valve and
using push button
Maln 4/2
opcrated 4/2 D.C. Valve.
*****

DC. Valve

D.C Valve
a Push batton operated 3/2
Time delay valve Tme delay velve
in 3/2 D.C. Valve and its
The compressed air will enter
************

valve.
output is given to the time delay

b Time delay vafve

valve of time delay
The air passes through flow contròl
*
and air receiver to provide required time delay and
gives output signal to the pilot controlled 4/2 D. C. Pusth butto
Rotler
3/2 D.C vabo 3I2D.C.Vav
Valve
Valver
c Pilotcontroed 4/2 D.C
It will admit compressed air to the DA. Cylinder to Fig.6.3.10: Time delay circuit for hoth strokes
perform the forward stroke.
Explanation of Círcuit:
3 Time delay circuit (for advancerment and First push: button operated valve is operated to start tre
retractionboth): cycle. The nomally closed time delay valve ()
SBTE W actuates the main impulse 4/2 D.C. Valve at is pilet
port Y and time taken by time delay valve (T) to
Develop a pneumatic circun for operation of two DA
transmit the signal is the time delay for the forward
Cylinders such Ihat one operaies 'after other af a
motion of D.A: cylinder.
cenain tiute interval using time delay valve -15
It advances and at the end of its stroke actuates the
The circuit is designet for advancement of cylinder
rofler valve. The teversing of cylinder piston rod takes
after a time delay and retracts to its original position a time determined by the seting of the time delay valve
baskfrom its advanced position also after a time delay. (2). This valve when actoates permits the air to operate
at pilot port main 4/2 D.C. Valve. Main valve
z of
It consists of two time delay valves for pilot control. of
reverses and the cylinder retracts and is ready for rext
4/2 D.C. Valve to actuate D.A. cylinder.
cycle.
delay
Circuit components: Application: To actuate DA. cylinder with time
1. 3/2D.C. Valve (push button) for sequencing operation.

forth :

2. 3/2 D.C. Valve (roller operated) 6.3.4 Piston continuous back and
forth circuit for
3. Time delay valves (1 and2) 1. Piston continuous back and
4. 4/2 D.C. Valves D.A.Cylinder

S. D.A.cylinder Purpose of the circuit:

automaticaly
cylinder
Double acting
6. Pipes, hoses, etc.
Movement of limit switches
solenoid operated 4/2 D.C Valve and
using

Scanned witn camScanner

 &p
ydraulics& PneumaticS (MSBTE em-V}}
ndtusitnaAydraulics
6-19 Pneumatic ArcuS
coponenis; 1or
Piston.continuous back and forth circuit
Circil Aircompressór
Double rod D.A. Cylinder
1. Moisture
separator
Purpose of the circuit:
2 olenoid operated4 D.C.Valve Movement of. Double rod, Double
acting eylina
3 Valve, a
switches
Limit Auomatically using solenojid operated 4/2 D.C
SA.Cylinder limit switches

Circuit components:
Pipes,hoses
Aircompressor
Moisture separator;
Cireuit:
Valve
3. Solenoid operated 4/2 D.C

4 Limitswitches:
acting
Double
Ynder 5 SA.Cylinder

6. Pipes, hoses
Solenaid

Solenoid Limit
Swilch
Limit switch
Circuit
9 Solenoid pperated
P R' *4/2.D:Cvalva
FRLUn

L Double rod
cylinder
Compressor switch
forth circuit for Limúwitch
Imit
Fig. 6.3.11:Piston continuoirs back,and
Solenoid operated
0A:Cylindar AUGD.G. vave

ExplanationofCircuit
FRL unit
& Forward stroke
cam atached to the piston rod
During this stroke; the
causes change in
will touch to the
limit svwitch.2 and Compressor
energisingsolenoid 2of
Valye by contnuous back and forth circuit for
"the position.of D.C Fig. 6.3.12:Piston
Double roc D.A:. Cylinder
42 D.C. valve.
2 Return stroke: Explanation of Circuit:
piston,.rod,
During.this stroke the
cam attached to the
causes.change in}
Forward stroke :
to: the limit switch I and cam attached to the piston rod
wl touch During this stroke the-
Valve.by.energising solenoid.1 of on right side and causes
the position ofD:C will toucl to the limit switch
Valve by-energising
A/2D.C.valve change in the position of Dc
movement of solenoid 2 of 4/2 D.C. valve.
produce.continuous back and forth
wi 2 Returm stroke:.
D.ACylinder
distanoe
can be chamgedby changing During this stroke- the cam attached to.
the pistom rod
lhe stroke iength
Detween Limnit switches. will touch to the limit switch on leit side and. causes
Aplication change in the position of DC Valve by energising
Saw
solenoid 1of 4/2 D.C. valve. It will give continuous
hack
Diachine. table movement, Pneumatic.
back and forth movement of D.A Cylinder.
.ine, Pneumatic pipe cutting machime, ec.

Scanned with tamscanner

 Industrial Hydraulcs& Pneumetlcs (MSBTE Sm-VI) -20 Preumatic
Circuits
The stroke lengrth can be changed by changing position 64.1.1 Air oil reservolr
of Limit switches.
Applicatlon:
FOi
Machinc, table movement, Pneumatic hack saw Air -
machinc, Poeumtic pipe cuting machine, cte

6.4 Simple Hydro-pneumatic

Fig.64.1: Alroil rescrvoir
Applications Compressed air will enter
and exert pressure on
piston
to force out oil with desired pressure
Air is compressible in nature and may not give accurate at outlet. It gives
smooth motion of piston
motion when steady force against luctuating load is due to oil incompressibility.
required. When great accuracy is désired in machine. Sample circuit using air ollreservolr
feod units, then compressibility causes errors and not in this circuit, air is supplied to the air oil reservnde
d
prcferrod. pressure of air forces the pison
ofbydraulic cylinder.
Therefore to achieve. precision control, pneumatics .The flow control regulator is
provided between
cylinder and air.oil reservoir D.A
actuators are to ibe combined with 'hydraulic system to contro flow of oil.
which can give better solution. This combination The speed control in forwárè stroke
of is possible nsing
variation in oil flow admitted
hydraulics and pneumatics is known as Hydro in D.A Cylinder.
During returm stroke the oil
pneumatics is collected in the air
reservoit. Using FeV ol
rehurn stroke speed can
DefnittonWher ydranlic systen wil cOmbined witt controlled by changing
be
PHeaticS CANeyebenejts ofccuracy return flow of oil.
ahd
ecanomiCs, Jt IS kitONEAS Hyara pieuriatics. DA.Cylinder
Hydro pneumatic system:

Typicat hydro paeumatic system consists

of pair of
hydraulic and pneumatic cylinders coupled
mechanically. FCV and
checkvalve
The hydraulc cylinders and pneumatic.cylinders can be
interchanged using oil or, ait. It means hydrauliec
Airoil
cylinder can work as pneumatic cylinder and vice rosonvoir
versa.

When pneumatic system works as power

unít,
hydraulic cylinder work as a cbeck unit. This
combination of twa. cylinders known.
as hydro, Push button 42
pneumatic cylinders, The air in the combined system DCV
for DA
provides power and oil provides control and rigidity. Fig. 6.4.2: Return.stroke using Air oil reservolr
Cylinder
6.4.1 Types of Hydro pneumatic system: reservolr
Speed control both strokes using ol
alr

Ait oil reservoir for D.A Cyfinder

provided tor
oil reservoirs are
2 Hydranlic check unit n this circuit, two air
Cylinder.
3. cach stroke of the D.A
Air hydraulic Intensifier

Scanned witn camScanner

 R.Pheumatics.(MSB1E
Industrnalkydtaulics Sem-VI) 6-21
PneuRaticCircuiis
regulator iis also provided separately
control regulator 6.4.1.2 Hydraullc check unit
mDA cylinder and air ol reservoir to control
ketwca In this system, instead of combination of air
and oil
oil.
LiOW of forwa
Teservoir in one unit, they are separately provided and
in: forward stroke. is possible. using
controk in;
ntrol
specd . mechanically coupled as shown in Fig,
64.4.
The
fow admited inD.A.Cylinder similarly
aristionil
filowa
inoil The one cylinder will provide check over another hence
stroke.
retun known as check unit. The power is provided by
fo
forward
stroke,the oil is supplicd by air oil
.

During pneumatic. cylinder 1 with. pneumatic circuit and

provided in the lelt: side, the, another air oil
Teservoir
nit control is provided by attaching slide mechanically to
provVIded will act- as a Teservoir and during.
eservoir the hydraulic cylinder 2 with hydraulic circuit
stroke, tbe oil 1s Suppied by air oif reservoir Oil reservoir
Tetun.
right sde, the Ieft end air oil teservoir

he
ided in the
provnd

will acts
as aTeservoir.

uses ofitwo air

oih. reservoirs.

but it is economical for

make the system
speed controlconsidefing.
AL Hydraulic
cylinder
E
bulky
with
unit
check
igidity.
connected parallel
:DA. Cylinder

Pneumatic
cylinder

Afr

FHg.6.4.4 Hydraulic check unit

It is important that, both hydtaulic _and pneumatic

FCVand cylinders shquld have equal stroke' length: Cylinder
check yalve
arrangement may be paralel or tandem

Ait oil:
teservoir

E
ww Oil reservoir

Push button
Fig.645:Tandem
hydro.pneumatic cyinder
4/2 DCV .
cylinders
The two
this cylinder as shown în Fgb.45 andit
In common pistom rod
643:Speed.controlboth:strokes using alr oll. series witt
are mounted in installation. Limitation is
resèrvoirfor D.A Cylinder compact and easy for
is more. more and, limits"
the
dimensions are
its. linear
space is.less
application where
ledededgi
PbltI

Scanned witn camScanner

 Pneumatics (MSBTE Sem-VI) 6-22
Industrial Hydraulics & malic Circusits

Asthe piston rod passes through

both end covers of the .1orsram,totalto forceoutput
is exerted hy means
of thepiston
the section of the Booster. od,
is same in either
cylindeis, the displacement of pistons section.contains. a.hydraulic The o
fluid. Just
direction. the end o
fod applies pressure to this fluid. he
feecd unit
Hydro pneumatic

Hydraulic cylinder

Fig.647

6.5 Simple Electro-Pneumatic Circuits

Pneumatic oylinder
Electro: pneumatics is. a combination of electrical
system witr pneumatics. It 1s now commonly used in
many areas of Industrial low cost automation. They are

Control block also used extensively in production, assembly,

pharmaccutical, chemical and packaging systems.

aElectro-pneumatic. control consists of electrica control

systems operating pneumatic power systems. In this
V solenoid valves are used as interface between tlhe

Fig. 6.4.6: Hydiro pneumatic feed unit electrical and pneumatic systems. Devices like Himit

sSwitches and proximity sensors are used. as feedback

When compressed aîr is applied to pneumatic cylinder,
elements.
thepiston of hydraulic cylinder is caried out along
Electro Pneumatic contro iategrates pneumatic and
with it. Oil is transferred from one side of, actuator to
electrical technologics, is more widely used for large.
the other side through throtle valve.
applications.
The throtle or FCV helps to change feed speed by In Electro Pneumatics, the signal medium is the
regulating flow of oil, The,smooth and fine speed can electrical signal either AC or DC source is used.
te possihle. During retura stroke the oil can be flow Working medium is compressed air. Operating voltages
quickly thorough check valve and perform.return stoke from around 12 V to 220 Volts are often used. The fina
quickly. control valve is activated by soenoid actvation.

Control of Electro Pneumatic system is carried out

This circuit helps for constant feed movements at slow.
either using combination of Relays and Contactors or
speed. The feed speed may be 30 to 6000mm/min using
with the help of Programmable Logic Controllers
throttle valve, and bydraylic cylinder.
PLC
6.41.3 Ait hydraulic intensifier basic electrical devices commonly used in the control.
Pressure Boosters are ideal for. limited of fluid power systems are
operation
applications requiring intermittent high pressure 1. Manualy actuated push button switches
when you
only have low-pressure air. Air 2. Limit switches
Oil Tanks supplement a
booster system by providing source
a of low pressure oil, 3Pressureswitches
while also providing an outlet for entrapped
air. 4 Solenoids
1. Low pressure air, coters the input 5. Relays
section of the booster.
It pushes against a large area piston. 6. Timers
7. Temperature switches

Tech euladgi

Scanned with Camscanner

 Eydraulics eA
Pneumatics MSBTESem-V
6-23
nsimal Pheumaticcircrts.
used in electropneumatiCS are Push buttons areoftwo types
Otberdevi sensors.
.'

Proximity )Momentary pust butto

COunters

2
ElectrcC
.
switches
) Maintained contact,or detent pust button
buton Momentary push buttons return to their unactuated
Push CIose, or open an.'
is a Switcn Sca 0 position when they are released. Maintained, (or
A
push.hutton,
comtrol circuit They
are primarily used-for mechanically latched) push buttóns has.a latching
clectic operation of machinery. They mechanisn to hold it in the selected position.
startingandstopping of :

provide manual.
overide when the. emergency contact. of the push "buttons distinguished
so The
switches are achuated by pushinig the according to their functions,
es.Pushbutton
causes setof contacts to
cator into the houing: 1ms iNomallyopen(NO)typ
openorclose: i) Normallyclosed(NC)type.
) Change over (CO) type
Push burtton
Switching element

Normadlyopen (NO)

COnta
,
Normal position
. Actuated position
. Symbol

Normally closéd (NC)

Normat poHIO Actuated posiion Symbot.

Changeaver (CO)

Actuated position. Symbo

Normat position. .

symhols
Fig,6.5.1:Push button switches and
2 Limitswitches
Amyswif
nathe
Shaft oe
18.actuated
position of load is temed as limit switch.
.
due to the position of a fluid
power component (usually a piston rod or yuruui

system.response
Dde actuation causes an appropriate
provides an clectrical signal that
of a limit switch,proy eeds.
* ch

Scanned with tamscanner

 ndustrial Hydraulics & Pneumatics (MSBTE Sem-VI) 6-24 neumatic
Cicuits
Linít switches performthe same function as push 4.Eectrically actuated directionalcontro a
button switcies. Push buttons are manually açtuated (Solenaids) valves
whereas limit switches are mechanically actuated.
Electrically actuateddirectional
There are two types classification of Limit switches control valves
fomthe
interface between the two parts
depending upon method.of actuations of contacts of an eletro-pneumatic
control. The most important
a) Lever actuated contacts tasks of electicalliy
actuated DCVs include.
b) Spring loaded contacts
Switchingsupply air on or off
Extension and retraction of cylinder drives

Electrically actuated directional

control valves
are
switched with the aid of solenoids. They
can be divided
into two groups:

Spring. return valves only remain. in the

actuated
position as long as current fows through the solenoid
4
Double solenoid valves retain the last switched position
even when no current flows thirough the solenoid
Fig. 6.5.2: Limit switch construction and symbo the initial position, all solenoids of an clectricaly
In
3. Relays actuated DCVs are de-energised and the solenoids are
A relay is an electro magnetically actuated switch. It is inactive. A double valve has no clear initial position, a
a simple electrical device used.for signal processing. it does not have a return spring. The po0ssible volage
Relays are designed to withstand heavy power surges levels for solenoids are 12 V DC, 12V AC, 12 V5o6o
and harsh environment conditions. When a voltage is Hz, 24V 50/60 Hz, 110/120V 50/60 Hz, 20/230V
applied to the solenoid coil, an clectromagnet field 50/60 Hz.
results. This causes the armature- to be attracted to the
coil core. 5/2 Way single sofenoid valve, spring return

The armature actuates the relay contacts, either closing The cross section view of 5/2 way single solenoid in
or opening them, depending on the design. A return |
the normal and actuated positions are shown in Fig
spring retums the armature to its initial position when 65.4 In normal position, pot 1 is connected to port 2,
the cureat to the coil is jntermupted. port 4 is connected to port 5, and port 3 is blocked.
A large number of control contacts can be incorporated When the rated voltage is applied to coil 14, the vafve
in relays in contrast to the case of a push button station. is actuated through an intemal pilot valve. In actuated
Relays are usually designated as K, K, and Ks ctc. position, port 1 is connected to port 4, port 2 s
Relays also possess interlocking capability that is an connected to port3, and port 5 is blocked
important safety featre in control circuits. Interocking The valve returns to the normal position when the
avoids simultaneous switching of certain coils. voltage to the armature coil is removed. This type of
Retun Spring Return coll
valves is normally used as final. valve to control double
W
Armalure acting cylinders.

wwwww

21
Insulation

Coll core
Contact leminals

4.2
Fig. 6.5.3: Cross sectional view ofa relay Fig. 6.5.4 (a) cont..
Techauledgi
Plati4i
Scanned witn camScanner
 Hydraulics&Pheumat (MSETE Sem-V):
al 6-25
umatic Circuits

mmunimmbum
3 1
5
b) ..
6.54:Cross sectiona view ofa 5/2 way solenoid .1
F operatedvatve
pheuma Gs circuits for single actuator
Electro
using electro, 12
Pontrol of single cylinders
pTeumatics

Forvard stroke : The cirtuit-is closed when push V

+24
buttom PB closes.. A
magnetic field is produced. in the
opens the passage for
coil Y.The armature in the coil Pa
the compressed air. The cómpressed air flows from1 to

2of the 3/2 DCV to cylinder, which travels to thè final

farwardpositio 12
button PB is released;
Return stroke : When the push
circuit is idterupted. The magnetic field at coil Y
the
() Pasition when cylinder is refracted
collapses, the 3/2 wáy valve switchesback to its Fig, 6.5.5: Direct control of singie acting eyinder
origimal positiom as showi in Fig 6.5.5
Forward stroke :
The compressed. air in the cylinder then exhausts closes.
The circuit is closed when push button PB
through port 3 of the DCV and the cylinder. travel to the The
Closing of Push button PB energises a relay K.
Fnal rear position. open contact K"
coil Y is energised via normally
(indirect energising).
in armature
of the coil Y
A magnetic field is produced
passage. for the compressed air. The
opens the
Compressed air fows from:1 to Z of the 3/2 DCV to
forwárd position.
cylinder, which travels to the final

Retürn stroke:
released, the circuit is
When the push button PB is de-energises a
fnterrupted. Openingof
Push þutton PB
collapses due
The magnetic field at coil Yis
relay K. switches
3/2 way valve
opening contact K, the
of
tothe position as shown
in Fig 6.3.6.
"back to its oiginal
24N the.cylinderthen
exhansts
compressed air in to the
The the cylinder travel
DCV and
port3 ofthe
through
final rear position:"

Figa.5.5ta
Postion wrhen
cylinder
«
is extended Tedalede
YPeblICnens

Scanned wIn amScanner

 (MSBTE Sem-V) 6-26 PneumaticGircuits
Industrial Hydraulics &Pneumatics

Forward stroke The double acting cyfinder

is
controlled by 5/2 way valve. Wheí the
pushbutton PR
is presed, coil ¥ is energised and the directional
control valve is activated by conpressed.
air via
piloi
control. The piston travels to the final forward
posiion..

1.1
Return stroke:When the push button PB
is released.
the circuit is intérupted. he magnetic
ficld at coil
y

YZ
M collapses, the return spring of 5/2 becomes
actve and
the 5/2 way valve switches back to its original
position
V3 as shown in Fig. 6.5.7. The compressed air in the
cylinder then exhansts through port of the
24V 5 5/2 DCV
and the cylinder trave to the final rear position.

1.0

a) Positior when cyfinder io oxtended

1.0
AAAAA

YLZ1T

24V
MM
PE

24V 0V
extended
Fig.5.5.7(e) Position when cylinder is
PE
K

OV
6) Positionvhen cylinder
Fig. 6.5.6:ndirect
is retracted
Control at
single acting cytinder
is

Scanned witn camScanner

 (MSBTE Sem-V) 8:27
ustriál Hydaulcs Pneumatics.
&
eumatic Circuits
10 10

YZ YIZET
A
24V

24-V
PRE

o) Position whien cytinderis retracted

Flg. 657 Direct controf ofdoubie acting eyliider
() Position hencylinderis eitiended.
iadirect Controf of double acting cylinder (using
572way. single solenald

Forward stroke:: Fhe círcuit is closedš when push:

buton PB closesi Closing of Push button PB energises
a telay K The coil Yis éneigised via normally bpen
contact Ky (indirect energising).
A niagnetic field is producet in armature of the coil Y
opens the passage. for the compressed:
air through
internal pilot. The compressed ait flows from 1to 4of

thé 5/2-Dcy to cylinder, which travels to the final YZD

forwardposition
Return' stroke When' the push' butto PB is released,
+24V
the circuit is interrupted. Opening of Push button PB *** ****1***-****
.
do-energises a relayK, The magnetic fild at coil Y is
collapses due to the opéning contact Ki the S/2 way
of
valve switches back to its original póstion as showin in
Fig.6.5.8

The. compressed ai in the: cylinder then: exhausts

b) Position when cylinder is retracted
through pori'5 of the DCV and the cylinder travel to the
Fig:85.8: nlirect controt of double actingeyfnder
finalrear position.

Tedaalsd
PubCats

Scanned with Camscanner

 Pneumatic Circuits
Hydraulics &Pneumatics (MSBTE
Sem-V): 6-28
industrial
System
Comparison of Hydraulic and Prieumatic
6.6 4Marks)
QCoTpare ydrautic:system and pnëunatic.system

Hydraulic Pneumgtic
Poit

Oil Air
1 Medium used

Required Not requiredå

Storage of medium
2 Air receiver
3 Storage device Reservoir

Re circolated Not necessary

4 Reuse

Costly Freely available

Cost of medium

Power device Pump Compressor

6.,

Return lines Required Not required

Self lubricated Separate lubricator needed

8 Lubricatio
9. Drain In the tank To the atmosphere

Good Poor
10. Rigidity
Operatio Smooth Noisy
11.
High Less
12.Accuracy
- Possible
13. High speed Limited
14: Operating pressure 300 bar Linited to 10 bar

Overall cost Moderate/high Low

15:
16 Application Heavy equipments cranes, lifts, farm Hand tools, press machines, foundry
equipments, JCB buldozer, etc machines, small cranes, etc

) Pipe lines and pipe comections.

6.7 Mainternanca of Pneumatic Systom
(e) Operating trouble af compressor.
Preunatic systems are Iess. problematic amd hence it
()Problemsrelated to electrical devices.
gives more trouble free performance and life. Till some
problems may arise and system may fails and need
trouble shooting and maintenance of the pneumatic (a) No pressure in the pressure sa
system.
Remedies
Fanlt
Common problems that may occur in pneumatic system
are:
working
gauge
(a) No pressure in the pressure side. Check pressure
No pressure
(6) Service unit (FRL) failed to work properly. properlyand repairit

(e) Problem of positioning, controlling

and signalling
side.
PuBEIeas

Scanned with Camscanner

IndustnialHydraui
iraulis &Pneumafics (MSSTE Sem-Vl 6-29
Pneumatic Circuits

Serviceunit
fa
(FRL)faifed to work properly : (e) Operating trouble of
compressor"
)
Kemedies Faults Remedies
No
stopped Clean it to remove Inadequate
Filter
clogging pertormance due to:
condensation Discharge it
Too high (a) Dirt in suction filter Clean the filter

ressure regulator reads Set it properly

Fress (6) Defective sealing of Replace it
differently cylinder head
Change it
Manometer defective
(C) Worp out piston Keplace it
Absence 'of ol drops in Fillup oil contäiner, set rings
adjusting screw.
sight feeddome the Cylinder or pistons
Repair/replace ît
(d)
controlling. and
iel Problem of positioning,
SCratched

signaling side: Clhange it

Safety valveis blowing
Remer off
Check spiral-innet
Air flow from
ISéaling damaged Replaceit compressor to receiver is. tubes wvitk respect
to
Repair/change it congestiöns, eieck
2 Spool damáged/stopped disturbed
Change if non retum válve
Broken Spring
Broke Unctio
ebanections blocked Clear the koles
APort
aígniment Repairlre place it
5Misalignimenit of seals.Corect 4.Pressure switch faulty.
Mechanical dogs nSetthem right: Airescapes from vessef
Test alt fitings of
wrong position vessel as wel1as

. chéckvalve
7: FValve möunting in Change/set it
find
Corect: Use soap water to
6. Air escapes from pipes and
(4)
Teakage points
Pipe lines,and pipe connections and pipe fitings
Tepairthem

relief Adjust/stop leakage"

7.Leaking of cylinder

1Hosesfpipes Clean/remove dirt or valve

as per
compressor|Adjusti belk"
| blocked/bent changethem Eoose belt in recómmendations
wheel, motor pulley
Ongly" connectedConmect themproperiy Adust it."
hoses 9.
Excessiveplay in motor

Conne sha. stop

ports are Change or drillthem valves Replace it,
not drilledthroughi 10. Broken or loose
Ieakage

ncer stops iwórkingClean

it
dbeuledi
PDEatlups

Scanned with tamscanner

 6-30 PneumaticCircuits
Industrial Hydraulics &Prieumatics (MSBTE Sem-VI)

E termedie
06 Draw impulse circuit to operata S.A.tylinder "

Fadlts (Section 6.1.3.2{a))

4 Marks)
a.7 Explain impulse circuit to operate' D. A. cylinder
Sectlon 6.1.3.2/b) (4 Marks)
113 Air delivery dropped
Q.8 State need of speed control tircuits.
off (Section 6.2) (Atidarks
it
(a) Intake filter clogged | Clean Q.9 Explain speed control circuit for S. A. cylinder.

Stop leakage (Section 6.2.1

6) Leaking of cylinder (4 Marks)
relief valve a.10 Explair speed control circuit for D.A. cylinder
(Section 6.2.2
(c)Airleaksin piping Stop leakage Marks) (4
a.11 Draw ahd explain speed' controd circuit
for
d) Leaking., broken Stop léakage, replace: Bi-directional'air motor. (Section 6.2.4).
(4 Marks)
loose valves broken valves, tighten
loose valves
a. 12 What is sequencing? Give suitable example.
(Section 6.3.1) (4 Marks)
12. Oil not pumping for
lubrication:
a. 13 Draw sequencing ircuit for two double acting
cylinders. (Section 6.3.16) (4 Marks)
(a Clogged intake Clean i
a.14 How you will sequence S.A. cylinder with D.A.
filter
cylinder? (Section 6.3.1()) (4 Marts
(b) Oil viscosity too Change withright oil
a. 15 List vaious sequence controling devices.
high
(Section 6.3.1) (4Marks)
()Oil level is too high. Drain excess oil and
see the level Q.16 What is time delay circuit? Explain any one time delay
circuit. (Section 6.3.3) 4 Marks)
Improper functioning of electrical devices
a.17 List various problems that may occur in pnetumatic
Faults Remedies system. (Section 6.7 4 Marlks
No. Q.19 Define hydro-pneumatic: system and fist ts types

I. |Pressure switch cuts Adjust pressure setting (Section6.4.1 (4 Marks)

in or out either too properly a.20 Explain simple circuit using air oil reservoir.
soon or too late
(Section 6.4.t.1) (4 Rarks)
Switching relay| Check relay mechanism,
a.21 Define Electro-pneumatic system and list ils elements
malfünctioni line'voltage, switches, ete
(4 Merko)
(Section 6.5)
Exercise a.22 Expläin simple Electro-pneumatic circuit
(4 Marks)
Define pneumatic circuit, list. out elemernts of (Section 6.5)
a.1
pneumatic circuit. (Section 6.1.1) (4 Marks) Q. 23 Write causes and remedy for:
(4 herks
0.2 Draw pneumatic circuit to actuate single acting (Section 6.7)
service unit
cylinder. (Section 6.1.3.1(1)) (4 Markis (0Improper functioning of FRL
side
a.3 Explain pneumatic: circuit to aperated double acting i) No pressure in the pressure
cylinder. (Section &1.3.1(2) (4 Marks)
) Air escapes from vessel
Q.4 Draw pneumatic circuit using 4/2 D.C. Valve tor of.
(iv) Air delivery dropped
controlling D.A. cylinder.
(v) Piston moves slow.
(Sectior 6.1.3.1(2)) lubricatan.
(4 Marks) pumping.sufificlently for
Oil not
Q.5 What is impulse cirtcuit? Explainwith circuit. (
(Section 6.1.3.2) (4 Marks)

Scanned witn camScanner