KITE MECHATRONICS LABORATORY MANUAL

EXPT NO: STUDY OF BASICS OF HYDRAULIC, PNEUMATIC&

ELECTRO-PNEUMATIC SYSTEM
DATE:
AIM:
To study about the important features, about hydraulic, pneumatic& electro-pneumatic system.

BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Reservoir (or air tank):
A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid (usually oil).

Pump:
The pump is used to force the liquid into the system.
Prime mover:
A Prime mover, usually an electric motor, is used to drive the pump.

Valves:
Valves are refitted in the system to control liquid direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the liquid energy into mechanical force or torque to do
useful work. The actuator is the actual working element of the system. The actuators can be either
cylinders (to provide linear motion) or hydro motors (to provide rotary motion).

Fluid-transfer piping:
The hydraulic Piping is provided to carry the compressed liquid from one place to
another.

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
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Schematic Layout of Hydraulic System

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BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

Reservoir (or air tank):

An air tank is provided to store the compressed air required for the operations.

Compressor:
The compressor is used to compress the atmospheric air so as to increase the pressure of the
air.
Prime mover:
A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:
Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the air energy into mechanical force or torque to do
useful work.
Fluid-transfer piping:
Piping is provided to carry the compressed air from one place to another.

Schematic Layout of Pneumatic System

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BASIC SYMBOLS USED IN HYDRAULIS AND PNEUMATIC
SYSTEM:

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KITE MECHATRONICS LABORATORY MANUAL

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Symbols Description
DIRECTIONAL CONTROL VALVES
Directional Control Valve (2 Ports / 2 Positions)
-Normally closed directional control valve
with 2 ports and 2 finite positions.
-Normally open directional control valve
with 2 ports and 2 finite positions.
Directional Control Valve (3 Ports / 2 Positions)
-Normally closed directional control valve
with 3 ports and 2 finite positions.
-Normally open directional control valve
with 3 ports and 2 finite positions.
Directional Control Valve (4 Ports / 2 Positions)
-directional control valve with 4 ports and 2
finite positions
Directional Control Valve (4 Ports / 3 Positions)
-directional control valve with 4 ports and 3
finite positions
*-(center position can have various flow paths)
Directional Control Valve (5 Ports / 2 Positions) Normally A Pneumatic Valve

-directional control valve with 5 ports and 2

finite positions
Directional Control Valve (5 Ports / 3 Positions) Normally A Pneumatic Valve
-directional control valve with 5 ports and 3
finite positions

CONTROL METHODS
Manual Control
-general symbol (without showing the control type)
-pushbutton
-lever
-foot pedal
Mechanical Control
-plunger or tracer
-spring

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 Symbols Description
-roller
-roller(one direction only)
Electrical Control

-Solenoid (the one winding)

Pilot Operation
-pneumatic

-hydraulic
Pilot Operated Two-Stage Valve
-Pneumatic: Sol first stage
-Pneumatic: Air pilot second stage
-Hydraulic: Sol first stage
-Hydraulic: Hyd pilot second stage

CHECK VALVES, SHUTTLE VALVES, RAPID EXHAUST VALVES

-check valve -free flow one direction,

blocked flow in other direction
-pilot operated check valve, pilot to close

-pilot operated check valve, pilot to open

Shuttle Valve -to isolate one part of a system from an

alternate part of circuit

Rapid Exhaust Valve/Pneumatic

-installed close to an actuator for rapid

movement of the actuator
PRESSURE CONTROL VALVES

Pressure Relief Valve(Safety Valve) Normally Closed

- Line pressure is limited to the setting of the

valve, secondary part is directed to tank
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 Symbols Description
Proportional Pressure Relief

- line pressure is limited to and proportional

to an electronic signal
Sequence Valve

- When the line pressure reaches the setting of the

valve, valve opens permitting flow to the secondary
port. The pilot must be externally drained to tank.
Pressure Reducing Valve
- pressure downstream of valve is limited
to the setting of the valve

FLOW CONTROL VALVES

Throttle valve
-adjustable output flow
Flow Control Valve

-with fixed output (variations in inlet

pressure do not affect rate of flow)
-with fixed output and relief port to reservoir
with relief for excess flow (variations in inlet
pressure do not affect rate of flow)
-with variable output
-fixed orifice
-metered flow toward right free flow to left

-pressure compensated flow control fixed

output flow regardless of load
-pressure and temperature compensated
-with variable output and relief port to reservoir
Flow Dividing Valve

-flow is divided equally to two outputs

SHUT-OFF VALVE
-Simplified symbol

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Symbols Description
FILTERS, WATER TRAPS, LUBRICATORS AND MISCELLANEOUS
APPARATUS
Filter or Strainer
-filter

Water Trap
-with manual drain

-with automatic drained

Filter With Water Trap

-with manual drain

-automatic drain

Air Dryer
- refrigerant, or chemical removal of water from
compressed air line
Lubricator
-oil vapor is indected into air line

Conditioning unit

-compound symbol of filter, regulator, lubricator unit

-Simplified Symbol

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ELECTRO PNEUMATICS
Electro pneumatics is now commonly used in many areas of Industrial low cost automation. They
are also used extensively in production, assembly, pharmaceutical, chemical and packaging systems.
There is a significant change in controls systems. Relays have increasingly been replaced by the
programmable logic controllers in order to meet the growing demand for more flexible automation.

Electro-pneumatic control consists of electrical control systems operating pneumatic power systems.
In this solenoid valves are used as interface between the electrical and pneumatic systems. Devices
like limit switches and proximity sensors are used as feedback elements.

Electro Pneumatic control integrates pneumatic and electrical technologies, is more widely used for
large applications. In Electro Pneumatics, the signal medium is the electrical signal either AC or DC
source is used. Working medium is compressed air. Operating voltages from around 12 V to 220
Volts are often used. The final control valve is activated by solenoid actuation

The resetting of the valve is either by spring [single Solenoid]or using another solenoid [Double
solenoid Valve] . More often the valve actuation/reset is achieved by pilot assisted solenoid actuation
to reduce the size and cost of the valve

Control of Electro Pneumatic system is carried out either using combination of Relays and
Contactors or with the help ofProgrammable Logic Controllers [PLC]. A Relay is often is used to
convert signal input from sensors and switches to number of output signals [ either normally closed
or normally open] .Signal processing can be easily achieved using relay and contactor combinations

A Programmable Logic Controller can be conveniently used to obtain the out puts as per the required
logic, time delay and sequential operation.. Finally the out put signals are supplied to the solenoids
activating the final control valves which controls the movement of various cylinders. The greatest
advantage of electro pneumatics is the integration of various types of proximity sensors [electrical]
and PLC for very effective control. As the signal speed with electrical signal, can be much higher,
cycle time can be reduced and signal can be conveyed over long distances.

In Electro pneumatic controls, mainly three important steps are involved:

 Signal input devices -Signal generation such as switches and contactor, Various types of
contact and proximity sensors
 Signal Processing – Use of combination of Contactors of Relay or using Programmable
Logic Controllers

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  Signal Out puts – Out puts obtained after processing are used for activation of solenoids,
indicators or audible alarms

Layout of Electro Pneumatic

1.2 SEVEN BASIC ELECTRICALDEVICES

Seven basic electrical devices commonly used in the control of fluid power systems are

1. Manually actuated push button switches

2. Limit switches
3. Pressure switches
4. Solenoids

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 5. Relays
6. Timers
7. Temperature switches

Other devices used in electro pneumatics are

1. Proximity sensors
2. Electric counters

1.2.1 Push button switches

A push button is a switch used to close or open an electric control circuit. They are primarily used
for starting and stopping of operation of machinery. They also provide manual override when the
emergency arises. Push button switches are actuated by pushing the actuator into the housing. This
causes set of contacts to open or close.

Push buttons are of two types

i) Momentary push button

ii) Maintained contact or detent push button

Momentary push buttons return to their unactuated position when they are released. Maintained
(or mechanically latched) push buttons has a latching mechanism to hold it in the selected
position.

The contact of the push buttons, distinguished according to their functions,

i) Normally open (NO) type

ii) Normally closed (NC) type
iii) Change over (CO) type.

The cross section of various types of push buttons in the normal and actuated positions and their
symbols are given in the Figure 1.1 In the NO type, the contacts are open in the normal position,
inhibiting the energy flow through them. But in the actuated position, the contacts are closed,
permitting the energy flow through them. In the NC type, the contacts are closed in the normal
position, permitting the energy flow through them. And, the contacts are open in the actuated
position, inhibiting the energy flow through them. A changeover contact is a combination of NO and
NC contacts.

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 Type of devices Terminal Numbers
Normally closed contacts Normally open contacts
Push buttons and Relays 1 and 2 3 and 4
Timers and Counters 5 and 6 7 and 8

Designation of the pushbuttons

Type of contact Designation

Momentary contact type First digit indicates the function of contact.
PB station ( 2 NO +2 NC) Second digit represents a serial ordering. 3 and 4
13 23 31 41 represents NO contacts and 1 is the serial no.

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14 24 32 42 14
First digit indicates the function of contact.
Maintained Contact type PB station Second digit represents a serial ordering. 3 and
(2NO+2 NC) 4 represents NO contacts and 1 is the serial no.
13 23 31 41 13

24 32 14
14 42

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 Push button
Switching element

Normally Open (NO)

Contacts

Normal position Actuated position Symbol

Normally closed (NC)

2

Normal position Actuated position Symbol

2 4
Change Over (CO)

Normal position Actuated position Symbol

Figure 1.1 : Pushbuttons and their symbols

1.2.2 Limit switches

Any switch that is actuated due to the position of a fluid power component (usually a piston rod or
hydraulic motor shaft or the position of load is termed as limit switch. The actuation of a limit switch
provides an electrical signal that causes an appropriate system response.
Limit switches perform the same function as push button switches. Push buttons are manually
actuated whereas limit switches are mechanically actuated.

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There are two types classification of Limit switches depending upon method of actuations of contacts
a) Lever actuated contacts
b) Spring loaded contacts

In lever type limit switches, the contacts are operated slowly. In spring type limit switches, the
contacts are operated rapidly. Figure 1.2 shows a simplified cross sectional view of a limit switch
and its symbol.

2 4

1
2

1
4

Figure 1.2: Cross sectional view of a limit switch

1.2.3 Pressure switches

A pressure switch is a pneumatic-electric signal converter. Pressure switches are used to sense a
change in pressure, and opens or closes an electrical switch when a predetermined pressure is
reached. Bellow or diaphragm is used to sense the change of pressure. Bellows or Diaphragm is
used to expand or contract in response to increase or decrease of pressure. Figure 1.3 shows a
diaphragm type of pressure switch. When the pressure is applied at the inlet and when the pre-set
pressure is reached, the diaphragm expands and pushes the spring loaded plunger to make/break
contact.
Adjusting Screw
4

Contact set
Diagphragm

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 14

Figure 1.3: Cross sectional view of a pressure switch

1.2.4 Solenoids

Electrically actuated directional control valves form the interface between the two parts of an electro-
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pneumatic control. The most important tasks of electrically actuated DCVs include.

i) Switching supply air on or off

ii) Extension and retraction of cylinder drives 2

Electrically actuated directional control valves are switched with the aid of solenoids. They can be
divided into two groups: 14

i) Spring return valves only remain in the actuated position as long as current flows through the
solenoid
ii) Double solenoid valves retain the last switched position even when no current flows through
the solenoid.

In the initial position, all solenoids of an electrically actuated DCVs are de-energised and the solenoids
are inactive. A double valve has no clear initial position, as it does not have a return spring. The possible
voltage levels for solenoids are 12 V DC, 12V AC, 12 V 50/60 Hz, 24V 50/60 Hz, 110/120V 50/60 Hz,
220/230V 50/60 Hz.

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A) 3/2 way single solenoid valve, spring

1 2 1 2

Figure 1.4: Cross sectional view of a 3/2 single solenoid valve

The cross sectional view of 3/2 way single solenoid valve in the normal and actuated positions are
shown in Figure 1.4. In the normal position, port 1 is blocked and port 2 is connected to port 3 via
back slot (details shown in the circle) When the rated voltage is applied to coil, armature is pulled
towards the centre of the coil and in the process the armatures is lifted away from the valve seat. The
compressed air now flows from port 1 to port 2, and ports 3 is blocked. When the voltage to the coil
is removed, the valve returns to the normal position. Figure 1.5 shows 2/2 solenoid operated valve

Figure 1.5: Cross sectional view of a 2/2 way solenoid operated valve

3 3 Solenold
Electri Connectioncal

2 2
1 1

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 b) 5/2 Way single solenoid valve, spring return.

The cross section view of 5/2 way single solenoid in the normal and actuated positions are shown in
Figure 1.6. In normal position, port 1 is connected to port 2, port 4 is connected to port 5, and port 3
is blocked. When the rated voltage is applied to coil 14, the valve is actuated through an internal pilot
valve. In actuated position, port 1 is connected to port 4 , port 2 is connected to port 3, and port 5 is
blocked. The valve returns to the normal position when the voltage to the armature coil is removed.
This type of valves is normally used as final valve to control double acting cylinders.

2 4

14

3 1 5

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 2 4

14

3 1 5

Figure 1.6: Cross sectional view of a 5/2 way solenoid operated valve

c) 5/2 Way single double solenoid valve

The cross section view of 5/2 way double solenoid in the normal and actuated positions are shown in
the Figure 1.7 when the rated voltage is applied to coil 14, the valve is actuated to a one switch in
position with port 1 connected to port 4, port 2 connected to port 3, and port 5 blocked. When the
rated voltage is applied to the coil 12, the valve is actuated to the other switching position with port 1
connected to port 2, port 4 connected to port 5 and port 3 blocked.

Figure 1.7: Cross sectional view of a 5/2 way double solenoid operated valve

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The symbols for the various solenoid/pilot actuated valves are given in Table 1.1

Table 1.1 Various symbols for DCVs

Symbol Details
3/2 way Single solenoid valve (spring
return )

3/2 way pilot operated single solenoid

valve( spring return)

5/2 way single solenoid Valve (spring

return)

5/2 way double solenoid valve.

5/2 way piloted operated double

solenoid valve.

1.2.5 Relays

A relay is an electro magnetically actuated switch. It is a simple electrical device used for signal
processing. Relays are designed to withstand heavy power surges and harsh environment conditions.
When a voltage is applied to the solenoid coil, an electromagnet field results. This causes the
armature to be attracted to the coil core. The armature actuates the relay contacts, either closing or
opening them, depending on the design. A return spring returns the armature to its initial position
when the current to the coil is interrupted. Cross sectional view of a relay is shown in Figure 1.8

A large number of control contacts can be incorporated in relays in contrast to the case of a push
button station. Relays are usually designated as K1, K2, and K3 etc. Relays also possess interlocking
capability that is an important safety feature in control circuits. Interlocking avoids simultaneous
switching of certain coils.

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 Return Spring
Relay coil 14
12 22 24
A1
Armature

A2
11 21
Insulation

Coll core

Contact terminals

A1 A2 4 2 1

Figure 1.8: Cross sectional view of a relay

1.2.6 Timer Or Time delay relays

Timers are required in control systems to effect time delay between work operations. This is possible
by delaying the operation of the associated control element through a timer. Most of the timers we
use is Electronic timers. There are two types of time relay

i) Pull in delay ( on –delay timer)

ii) Drop –out delay (off delay timer)

In the on-delay timer, shown in Figure cc, when push button PB is pressed (ON), capacitor C is
charged through potentiometer R1 as diode D is reverse –biased. The time taken to charge the
capacitor, depends on the resistance of the potentiometer (R1) and the capacitance(C) of the
capacitor. By adjusting the resistance of the potentiometer, the required time delay can be set. When
the capacitor is charged sufficiently, coil K is energised, and its contacts are operated after the set
time delay. When the push button is released (OFF), the capacitor discharges quickly through a small
resistance (R2) as the diode by passes resistor R1, and the contacts of relay (K) return to their normal
position without any delay.

In the off-delay timer, the contacts are operated without any delay when the push button is pressed
(ON). The contacts return to the normal position after the set delay when the push button is released
(OFF).

The construction and symbols of the on-delay and off-relay timers are given in Figure1.9. Timing
diagram is shown in Table 1.2

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24
 +24 V

4 D

R2 K
R1

0V

+24 V

4
D

R2 C K
R1

0V

Figure 1.9: Construction features of timer and its symbols

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 Table 1.2: Timing diagram for on and off delay timer

Timing diagram Symbol

Voltage at relay coil On-delay timer circuit

Open
t
Contact
Closed

Voltage at relay coil Off-delay timer circuit

Closed
Contact
t
Open

1.2.7 Temperature Switch

Temperature switches automatically senses a change in temperature and opens or closes

an electrical switch when a predetermined temperature is reached. This switch can be
wired either normally open or normally closed.

Temperature switches can be used to protect a fluid power system from serious damage
when a component such as a pump or strainer or cooler begins to malfunction.

1.2.8 Reed Proximity switches

Reed switches are magnetically actuated proximity switches. Reed switches are similar
to relays, except a permanent magnet is used instead of a wire coil. Schematic diagram
of reed switch is shown in Figure 1.1. The reed switches comprise two ferromagnetic
reeds placed with a gap in between and hermetically sealed in a glass tube. The glass
tube is filled with inert gas to prevent the activation of the contacts. The surfaces of the
reed contacts are plated with rhodium or iridium. Whole unit is encapsulated in epoxy
resin to prevent mechanical damage to the switch. They are also provided with LED
indicator to show its switching status.

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When the magnet is away the switch is open, but when the magnet is brought near the
switch is closed. The reed switch is operated by the magnetic field of an energized coil
or a permanent magnet

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which induces north (N) and south (S) poles on the reeds. The reed contacts are closed by this
magnetic attractive force. When the magnetic field is removed, the reed elasticity causes the contacts
to open the circuit. The transfer type reed switch is normally ON, due to mechanical bias of the
common (COM) lead, which is between the normally closed (N.C) reed contact and the normally
open (N.O) reed contacts. When an external magnetic field is induced, the N.C blade is not affected
because it is non-magnetic but the COM lead is attracted by the N.O lead and moves. When the
magnetic field is removed, COM lead again moves to the N.C lead by mechanical.

Figure 1.10: Construction features of reed switch

The two wire reed switch consists of two reeds. One of reed is connected to positive terminal of
electric supply and other is connected to signal output. The three wire reed wire consists of three reed
contacts. One is connected to positive terminal of electric supply. Second one is connected to
negative terminal of the electric supply and third one is connected to the signal output. Symbol of the
three wire reed switch and two wire reed switch is shown in Figure 1.11

Figure 1.11: Symbol of 3 wire and 2 wire reed switch

Advantages of reed switches are

1. Reed switches are cheap.

2. They have long service life
3. They have shorter switching time ( in the order of 0.2 to 0.3 millis seconds)
4. They are compact and maintenance frees

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Disadvantages of reed switches are

1. They cannot be used in environments subjected to magnetic fields ( like resistance

welding machine)
2. Closing of contacts in reed switch is not bounce free

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