LAB 1

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMM 2333 PNEUMATIC AND HYDRAULIC TECHNOLOGY

LAB SHEET 1

HYDRAULIC POWER UNIT

Learning LO2 Design and troubleshoot hydraulic and pneumatic system manually
Outcome (LO):
and using software.
Program PO3 Ability to design solutions for broadly-defined engineering
Outcome:
technology problems, and to design systems, components or
processes to meet specified needs with appropriate consideration
for public health and safety, as well as cultural, societal,
environmental and sustainability
concerns
Synopsis: This lab activity will enrich students’ knowledge on hydraulic pump and hydraulic
basic components. Students will be able to record and interpret the
characteristic curve of a hydraulic pump, able to measure the volumetric flow
rate in hydraulic controllers and will be familiar with the relationship between
pump delivery rate
and operating pressure.
Related Lecture’s 1. Hydraulic pumps (Topic 3)
Topic:
2. Valves (Topic 5)
3. Actuators (Topic 6)
Prepared by: Ts Shikh Ismail Fairus B. Shikh Zakaria Date: 26 October 2021

Approved by Dr. Muhammad Ilman Hakimi Chua Date

LM/SLM/HOD bin Abdullah

QMS : REVISION RECORDS

Revision Date Approved by

Description Prepared by :
No (DD/MM/YY) LM/SLM/HOD:
Revision of theory and
1 content to comply online 1 Nov 2020 AMHSL
lab delivery method
Revision of theory and
2 content to comply face to 26 Oct 2021 SIFSZ
face lab delivery method
1.0 THEORY

In the design of any hydraulic system, proper pump selecting will have a significant influence on overall
system performance, operating efficiency and cost. The expenditure which must be considered in
evaluating the total cost of any system include: initial component and piping expense, continual cost
for generating and dissipating unneeded power, and the money spent to obtain an acceptable noise
level.

Any variety of hydraulic pumps available today can be put into one of three general categories: gear,
vane, or piston. If the pump is variable displacement design, it must either be a vane or piston pump,
since gear pumps are available only in the fixed displacement version.

1.1. Pump basic principles

The hydraulic pump draws the working fluid from a tank through the inlet or suction side and transferred
it to the pump outlet (injection or pressure port). The working fluid is further transferred by means of
valves to the work) performing hydraulic components usually cylinder or hydraulic motor and return
back into the tank.

The pump draws in the hydraulic fluid and drives it out into a system of lines. The resistances
encountered by the flowing hydraulic fluid cause a pressure to build up in the hydraulic system. The
level of the pressure corresponds to the total resistance which results from the internal and external
resistances and the flow rate.

Thus, the fluid pressure in a hydraulic system is not predetermined by the pump. It builds up in
accordance with the resistances – in extreme cases until a component is damaged. In practice,
however, this is prevented by installing a pressure relief valve directly after the pump or in the pump
housing at which the maximum operating pressure recommended for the pump is set.

1.2. Pump Characteristics

The following characteristic values are of importance for the

pump i.) Displacement volume

The displacement volume V (also known as the volumetric displacement or working volume) is a
measure of the size of the pump. It indicates the volume of liquid supplied by the pump per
rotation (or per stroke).

The volume of liquid supplied per minute is designated as volumetric flow rate Q (delivery). This is
calculated from the displacement volume V and the number of rotations n:

Q = n × V ….(1)
ii.) Operating Pressure

The operating pressure is of significance for the area of application of pumps. Peak pressure is
specified. However, this should arise only briefly (see diagram) as otherwise the pump will wear out
prematurely.
 iii.) Speed

The drive speed is an important criterion for pump selection since the delivery Q of a pump is
dependent on the number of rotations n. Many pumps are only effective at a specific r.p.m. range
and may not be loaded from a standstill. The most usual number of rotations for a pump is n = 1500
r.p.m. since pumps are mainly driven by three-phase asynchronous motors whose number of rotations is
not dependent on the supply frequency.

iv.) Efficiency

Mechanical power is converted by pumps into hydraulic power resulting in power losses expressed as
efficiency. When calculating the total efficiency ηtot of pumps, it is necessary to take into consideration
the volumetric efficiency (ηv) and the hydro-mechanical (ηm) efficiency.

𝜂tot = 𝜂m × 𝜂v ….(2)

a.) Volumetric efficiency, 𝜂v

It related to the internal and external peripheral leakage in pumps and motor. Volumetric efficiency is
a percentage figure determined by dividing the actual flow, Qa by the theoretical flow Qt value:

Qa
𝜂v = × 100 ….(3)
Qt

b.) Mechanical efficiency , 𝜂m

Occur during in operation pump, motor and cylinder friction losses. If the pump were to be delivering
flow at zero pressure, then no force (torque) should be required. Therefore the mechanical
efficiency is :
(p×Qt)
𝜂m = ….(4)
(Ta×n×2π/60)

Symbol notation:
p = pressure [Pa, MPa]
Qt = volumetric flow rate [m3/s]
n = rotational speed [rpm]
Ta = Theoretical actual [N.m]
1.3. Hydraulic motors

Hydraulic motors are components of the drive section. They are power components (actuators).
They convert hydraulic energy into mechanical energy and cause rotary motion (rotary drive). If rotary
motion is confined to a certain angle range, we speak of oscillating motors.

Hydraulic motors have the same characteristic values as pumps. Displacement volume is specified in
cubic centimetres per revolution by hydraulic motor manufacturers, and the speed range within
which the motor works efficiently is indicated as well. The following applies to hydraulic motor
displacement volume:
𝑝 = M ….(5)
V

Q = n × V ….(6)

Symbol notation:
p = pressure [Pa, MPa]
M = torque [Nm]
V = volumetric displacement [cm3]
Q = volumetric flow rate [dm3/min]
n = rotational speed [rpm]

1.4 Measuring the volumetric flow rate

A simple measuring method involves the use of a calibrated vessel and a stopwatch. In the field of
hydraulics, the volumetric flow rate is designated q. The following definitions apply:

𝑄 = V ….(7)
t

Q = volumetric flow rate [cubic metres per sec.]

V = Volume [cubic metres]
t = Time [seconds]

Turbine and rotating-vane flow meters are recommended for continuous measurement.
Volumetric flow rate can be determined on the basis of the speed in rpm indicated at these
meters. Speed in rpm and the volumetric flow rate have a proportional relationship.

Volumetric flow rate can be measured in accordance with the back pressure principle with the
help of a float. The use of an orifice flow meter is a further option. The pressure drop ascertained
at the orifice is a measure of the volumetric flow rate (pressure drop and volumetric flow rate have
a proportional relationship). Measurement with an orifice is hardly influenced at all by the viscosity
of the hydraulic fluid.

2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

i. Hydraulics, Basic Level (TP 501)

ii. FluidSIM-H software
iii. 24 V DC power pack, max. 4.5 A
iv. Digital multimeter
Problem description

The main spindle of an injection moulding machine is driven by means of a hydraulic motor, and
feed motion for the tool carriage is executed with a hydraulic cylinder at the same time. It has
been determined that the hydraulic motor no longer reaches its specified speed during the
processing operation. The characteristic pump curve needs to be measured in order to rule out the
possibility of a defective hydraulic pump.

Figure 1. Injection moulding machine

3.0 PROCEDURES/ METHODOLOGY

i. Complete the equipment list in Table 1

ii. Draw the hydraulic circuit as in Figure 2 in the FESTO FluidSIM-H software.
iii. Run the simulation.
iv. Set up the controller as in Figure 2 .

Observe the following points when setting up the controller:

• Use the circuit diagram.

• Designate the components.
• Connecting hose lines
– Never connect or disconnect hose lines when the hydraulic power unit is running,
or while under pressure! Couplings must be connected in the unpressurised state.
– Set the coupling socket squarely onto the coupling nipple! The coupling socket and
the coupling nipple must not be fitted askew.

• Selecting and laying hose lines

– Select the hose line length such that adequate leeway is available in order
to accommodate changes in length which result from pressure.
– Avoid mechanical stressing of the hose line.
– Do not bend the hose line into a radius of less than its specified minimum bending
radius of 51 mm.
– Do not twist the hose line during installation.
– Make sure that hose lines do not become kinked.
 • Mark the completed hose connections in the hydraulic circuit diagram.

v. Double check the controller configuration.

Observe the following points when commissioning the controller:
– Before commissioning, make sure that all tank lines have been connected and that
all couplings have been securely fitted.
– Fully close the throttle at one-way flow control valve 1V1.
– Switch to pump recirculation by opening the on-off valve.
– Switch 24 V DC electrical supply power to the flow sensor on.
– Switch the hydraulic power unit on.
– Slowly close the on-off valve until a circulating pressure of approximately 1.5 MPa
has been built up.Immediately set the pump back to recirculation in the event of
leaks.
– Fully close the on-off valve and set operating pressure at the hydraulic power
unit’s pressure-relief valve to a value of 6 MPa.

vi. Record the characteristic curve of the hydraulic pump in Table

2. Execution
Fully open the throttle at one-way flow control valve 1V1. Pressure values, which can
be read from pressure gauge 1Z1, are adjusted by slowly closing the throttle.

vii. Interpret the characteristic curve of the hydraulic pump.

viii. Calculate volumetric efficiency through the hydraulic motor.
4.0 RESULTS

You should explain the following items that related to your Lab activity:

i. Equipment list Table 1.

ii. Snap shot of constructed hydraulic circuit Figure 2a & Figure 2b.
iii. Snapshot of assembled controller, put as Figure 3.
iv. Measured flow rate as in Table 2.
v. Transfer the values to the characteristic pump curve, Figure 4.
 Table 1-Equipment List

Item Component Description Identification Component Symbol Component Photo

1 1V1

2 1Z1

3 1M1

4 Flow Sensor 1Z2

5 0V1

6 0Z1
Figure 2a- Hydraulic circuit diagram.

Figure 2b- Electrical circuit diagram.

System Pressure, Measured Flow Rate, Q
P (MPa) Voltage, v (V) (l/min)
0
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
Table 2- Flow rate measurement

Figure 4 -Pump Charateristic Curve

5.0 DISCUSSION

For discussion, you should discuss the following :

1. Interpretation of the pump characteristic curve based on Figure 4.

2. Calculation of volumetric efficiency, 𝜂v through the hydraulic motor.

3. The roles of one-way flow control valve in this experiment.

6.0 CONCLUSION

Conclude your findings from this experiment based on the pump characteristic curve and
calculated volumetric efficiency.

7.0 OTHERS

1. The report must be prepared as per APPENDIX 1.

- Prepare the report in ENGLISH .

- Submit your assignment ONCE only in a SINGLE file.
- Submit your assignment ONLINE.
- This lab report/activity accounts for 5% of the total marks for the course.

2. ASSESSMENT CRITERIA

Your response to each task will be graded separately based on the checklist below. To obtain
maximum marks, ensure that your response addresses each of the tasks in the question
accordingly.

Assessment tasks Mark LO PO C/P/A level

allocation

Work Process (Ability to identify 20 LO2 PO3 P2 - Set

components, construct hydraulic
circuit, controller setup,
measured data)

Outcome (Results – Tables & 20 LO2 PO3 P6 – Adaptation

Graph)

Outcome (Discussion-Volumetric 15 LO2 PO3 P5 - Complex Overt

Flow Rate/Efficiency) Response

5 LO2 PO3 P5 - Complex Overt

Outcome (Conclusion) Response

TOTAL 60
 APPENDIX 1

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMM 2333 PNEUMATIC AND HYDRAULIC TECHNOLOGY

LAB REPORT 1

CHARACTERISTIC HYDRAULIC PUMP CURVE

INSTRUCTOR’S NAME

STUDENT’S NAME MATRIX NO:

S1.
S2.
S3.
S4.
S5.

ASSESSEMENT RUBRICS

MARK
NO ASSESSMENT TASK/ITEMS GIVEN MARKS
ALLOCATION
Work Process (Ability to identify
1. components, construct hydraulic circuit, 20
controller setup, measured data)

2. Outcome (Results – Tables & Graph) 20

Outcome (Discussion-Volumetric Flow

3. 15
Rate/Efficiency)

4. Outcome (Conclusion) 5

TOTAL MARKS 60

Checked By: ………………………………………………..…..

(Instructor’s Signature & Stamp)

Date: …………………………………………….........
WORK PROCESS
 i. Equipment list Table 1.
ii. Snap shot of constructed hydraulic circuit Figure 2a & Figure 2b.
iii. Snapshot of assembled controller, put as Figure 3.

OUTCOME – FLOW RATE & PUMP CURVE

i. Measured flow rate as in Table 2.

ii. Characteristic pump curve, Figure 4.

OUTCOME (DISCUSSION)

For discussion, you should discuss the following :

1. Interpretation of the pump characteristic curve based on Figure 4.

2. Calculation of volumetric efficiency, 𝜂v through the hydraulic motor.

3. The roles of one-way flow control valve in this experiment.

OUTCOME (CONCLUSION)

Conclude your findings from this experiment based on the pump characteristic curve and
calculated volumetric efficiency and relate to the problem statement.