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(2 Marks):

Why is automation needed?

Advantages commonly attributed to automation include higher production rates and
increased productivity, more efficient use of materials, better product quality,
improved safety, shorter workweeks for labour, and reduced factory lead times.

What are the 3 benefits of automation?

The benefits of automation include improved accuracy, reliability, productivity as
well as improved employee morale.

Benefits of Automation
 Lower operating costs. ...
 Improved worker safety. ...
 Reduced factory lead times. ...
 Faster ROI. ...
 Ability to be more competitive. ...
 Increased production output. ...
 Consistent and improved part production and quality. ...
 Smaller environmental footprint.

Fluid System Components:

Hydraulic:
reservoir, pump, valve and actuator (motor, cylinder, etc.).

pneumatic

valve, actuator, compressor and reservoir

Types of pneumatics?
There are three main types of pneumatic cylinders, these include:
Single acting pneumatic cylinders.
Double acting pneumatic cylinders.
Telescoping pneumatic cylinders.
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Fluid power symbols:

Fluid Power Symbols. Circles generally represent devices that can deliver or use oil.
Notice that the symbol does not describe the component construction. Symbols
describe component functions only.
Following table depicts the various hydraulics pneumatics symbols which are ISO
symbols used worldwide
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What are the performance criteria of a fluid power machine?

The trade-offs necessary to choose a fluid involve a consideration of application
requirements such as health, safety, and environmental effects, and fluid properties
such as viscosity, stability, compressibility, gas solubility, and lubricity

How do you calculate fluid power?

(PSI) = Force (Pounds) / Area ( Sq. In.) (Pounds) = Pressure (psi) × Area (sq.

Selection criteria of working fluids:

The choice of working fluids is known to have a significant impact on the
thermodynamic as well as economic performance of the cycle. A suitable fluid must
exhibit favorable physical, chemical, environmental, safety and economic properties
such as low specific volume (high density), viscosity, toxicity, flammability, ozone
depletion potential (ODP), global warming potential (GWP) and cost, as well as
favorable process characteristics such as high thermal and exergetic efficiency.

Classification of working fluids:

1. pure (single-component) working fluids
2. Multicomponent working fluids
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Hydraulic System Components

The major components that make up a hydraulic system are the reservoir, pump,
valve(s) and actuator(s) (motor, cylinder, etc.).
Reservoir
The purpose of the hydraulic reservoir is to hold a volume of fluid, transfer heat
from the system, allow solid contaminants to settle and facilitate the release of air
and moisture from the fluid.
Pump
The hydraulic pump transmits mechanical energy into hydraulic energy. This is done
by the movement of fluid which is the transmission medium. There are several types
of hydraulic pumps including gear, vane and piston. All of these pumps have
different subtypes intended for specific applications such as a bent-axis piston pump
or a variable displacement vane pump. All hydraulic pumps work on the same
principle, which is to displace fluid volume against a resistant load or pressure.
Valves
Hydraulic valves are used in a system to start, stop and direct fluid flow. Hydraulic
valves are made up of poppets or spools and can be actuated by means of
pneumatic, hydraulic, electrical, manual or mechanical means.
Actuators
Hydraulic actuators are the end result of Pascal’s law. This is where the hydraulic
energy is converted back to mechanical energy. This can be done through use of a
hydraulic cylinder which converts hydraulic energy into linear motion and work, or a
hydraulic motor which converts hydraulic energy into rotary motion and work. As
with hydraulic pumps, hydraulic cylinders and hydraulic motors have several
different subtypes, each intended for specific design applications.
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Hydraulic system motor & pump selection:

Vane Pumps
There are many variations of vane pumps available between manufacturers. They all
work on similar design principles. A slotted rotor is coupled to the drive shaft and
turns inside of a cam ring that is offset or eccentric to the drive shaft. Vanes are
inserted into the rotor slots and follow the inner surface of the cam ring as the rotor
turns.
The vanes and the inner surface of the cam rings are always in contact and are
subject to high amounts of wear. As the two surfaces wear, the vanes come further
out of their slot. Vane pumps deliver a steady flow at a high cost. Vane pumps
operate at a normal viscosity range between 14 and 160 cSt at operating
temperature. Vane pumps may not be suitable in critical high-pressure hydraulic
systems where contamination and fluid quality are difficult to control. The
performance of the fluid’s antiwear additive is generally very important with vane
pumps.
Piston Pumps
As with all hydraulic pumps, piston pumps are available in fixed and variable
displacement designs. Piston pumps are generally the most versatile and rugged
pump type and offer a range of options for any type of system. Piston pumps can
operate at pressures beyond 6000 psi, are highly efficient and produce
comparatively little noise. Many designs of piston pumps also tend to resist wear
better than other pump types. Piston pumps operate at a normal fluid viscosity
range of 10 to 160 cSt.
Gear Pumps
There are two common types of gear pumps, internal and external. Each type has a
variety of subtypes, but all of them develop flow by carrying fluid between the teeth
of a meshing gear set. While generally less efficient than vane and piston pumps,
gear pumps are often more tolerant of fluid contamination.
1. Internal gear pumps produce pressures up to 3000 to 3500 psi. These types of
pumps offer a wide viscosity range up to 2200 cSt, depending on flow rate and
are generally quiet. Internal gear pumps also have a high efficiency even at low
fluid viscosity.
2. External gear pumps are common and can handle pressures up to 3000 to
3500 psi. These gear pumps offer an inexpensive, mid-pressure, mid-volume,
fixed isplacement delivery to a system. Viscosity ranges for these types of
pumps are limited to less than 300 cSt.
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linear actuator :
A linear actuator changes the rotational motion of a motor into a straight line.
Conventional electric motors move in a circle, while linear actuators move forward
and backward. The push and pull action allows the device to slide, tip, and lift items
with the push of a button.

There are three types of Linear Actuators used in manufacturing: Hydraulic,

Pneumatic, and Electro-Mechanical.

Types of cushioning

 Mechanical and elastic damping: With this operating principle, a material is used
that deforms elastically when the cylinder collides with it at a specific speed. ...
 Pneumatic and servo-pneumatic damping. ...
 Hydraulic damping.
Types of Mounting Methods
 Plate Type. Holes for mounting a caster are provided on the mounting base. ...
 Screw-in Type. Since a thread is provided on the stem, mount a caster by screwing
the caster on the stem. ...
 Insertion Type(Rubber Pipe Type) ...
 Angle Type.
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Hydraulic power pack

 A hydraulic power pack is a stand-alone assembly consisting of a drive motor,
hydraulic pump and hydraulic fluid tank. The drive motor is connected to the
hydraulic pump via a shaft and drives this. The motor and pump can be
installed on the tank, as well as inside the tank in oil.

circuit (flow) analysis:

Circuit Analysis provides the information required to determine if the

interrupting capacities of the power system components are adequate enough to
protect your power system. Load flow is basic requirement to conduct the short
circuit analysis of any system.

(PSI) = Force (Pounds) / Area ( Sq. In.) (Pounds) = Pressure (psi) × Area (sq.
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Direction flow and pressure control valves:

Those valves which are use to give a particular direction to the fluid in the circuit are called
direction Control valves, like spool valve. Spool valve is a valve which controls the direction of
hydraulic fluid flow. It consists of cylindrical spools which can block and open the channels in the
hydraulic system.

Pressure Control valves

This type of valves are used to control the pressure of hydraulic system or circuit and
called pressure control valves. It includes pressure reducing valve, pressure relief
vale etc.

Pressure relief valve

This type of valves are utilized to limit the maximum operating pressure in the circuit.
These are also called safety valves and protects the pump and other components from
overloading, etc. Pressure relief valve is provided in the circuit such that one port is
connected to the pressure line and the other port is connected to the the reservoir.

Pressure reducing valve

Pressure reducing valves are used to reduce the output pressure which is part of circuit
from rest of circuit . It generally limits the pressure in a branch circuit at lesser value than
the required in the main circuit. If in a hydraulic system, a branch circuit is required to
be limited to a pressure of 200 N/cm2, but the main circuit is to be operated at a pressure
of 600 N/cm2.
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Flow Control valves

Flow control valves are those which are used to control the flow rate of the fluid in
the circuit and also called volume control valves, like needle valve, globe valve, gate
valve, etc. Flow-control valves are generally used to control the speed of hydraulic
motors or actuators in work spindles and the travel rates of tool heads, etc.

Needle valve

Needle valves are generally designated as non-compensated flow control or

throttling valves. They are good metering devices when the pressure differential
across the valve remains constant. This type of valve is used in the hydraulic system
where there is no need of precise speed control because the flow may vary with
pressure difference. A needle valve and globe valve are similar in design and
operation . In this type of valve there is a long, tapered point at the end of a valve
stem which can be raised or lowered to control the flow through it. A long taper
allows a needle valve to open or close gradually.

Globe Valve

In the globe valve there is a disc, which is attached to the end of the stem which
controls flow of fluid through the valve. The valve is closed by lowering a disc into a
valve seat and opened by raising it off the seat. Since fluid flows equally on all
sides when a valve is open, there is no unbalanced pressure on a disc to cause
uneven wear.
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Gate Valve

This type of valves are normally used to allow or prevent the flow of liquids and
also used for regulating the flow of fluid. In this type of valve there is a wedge or
sort of gate which controls the flow. Opening and closing of a passage is done with
the help of a hand wheel, which moves a wedge or gate up and down across a flow
line. The gate valve is provided with good sealing surfaces between the gate and
seats. As the valve is opened, the gate moves up within the bonnet and as it is
closed, the gate blocks the flow by coming across the line where it rests firmly
against the seats.

Direction Control valves

Those valves which are use to give a particular direction to the fluid in the circuit are
called direction Control valves, like spool valve.

Spool valve

Spool valve is a valve which controls the direction of hydraulic fluid flow. It consists
of cylindrical spools which can block and open the channels in the hydraulic system.
A spool valve can change the direction of flow of hydraulic fluid from a hydraulic
pump to an actuator by blocking off the route of the fluid through which it takes
place.

Sequence valve

It is also a sort of direction control valve which gives the sequence of operation in
the hydraulic circuit. It gives entire fluid to one of the circuit until pump delivery
exceeds the requirement.
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What is fluid actuation?

Fluid power actuators receive fluid from a pump (typically driven by an electric
motor). After the fluid has been pressure, flow, and directionally controlled, the
actuator converts its energy into rotary or linear motion to do useful work.

What is Actuation type?

 Pneumatic Actuators.
 Hydraulic Actuators.
 Electric Actuators.

What are the five methods of actuation?

Valves can be actuated by five basic methods namely, manually, mechanically,
electrically, hydraulically, or pneumatically. In machine applications any one of
these methods, or a combination can be used to gain optimum control

Determind actuator sizing :

The safety factor for actuator sizing is assumed to be equal to 2. The calculated
breakaway valve force and torque were used as a basis for actuator air cylinder
sizing assuming an air pressure of 7 barg and system efficiency of 90%

What is spool overlap?

Closed center spool valves, also named “Overlapped Valves”, describes a valve in
which the spool land overlaps the edge of the port and completely block the ports
in the bushing, when the valve is centered.
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Electro hydraulic servo valve :

Servo valves are a close relative of the proportional valve and are based on an
electrical torque motor which produces a small deflection proportional to the
electrical current through its coil. They commonly use feedback between the main
and pilot spools to give precise control.

Advantages of electro hydraulics servo :

 High power density

 Easy motion control,
 high reliability and sturdiness,
 possibility of implementing customized solutions,
 Excellent resistance to vibrations and capability of absorbing impulsive loads
 simple thermal exchange management
How does a digital control valve work?
The Digital Control Valve consists of a valve tubed with two solenoid valves. The
solenoids are configured in normally open & normally closed position. These
solenoids are connected to electronic batch controller. The batch controller provides
signal to carry out two functions.
Types of control valves include:
 High Pressure Control Valves.
 V-port Ball Valves.
 Segmented Ball Valves.
 Butterfly valves and gate valves.
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How many types of hydraulic systems are there:

1. Open loop hydraulic system
2. closed loop hydraulic system

Open loop hydraulic system: An open loop hydraulic system is any system where all
of the fluid starts at the reservoir and is returned to the reservoir. The pump takes in
fluid from the reservoir, then sends the fluid to the valves and actuators, and then
ultimately, back to the reservoir via a filter.

Closed loop hydraulic system:when the hydraulic fluids flow continuously between
the pump and the actuator (normally motor) without going to the reservoir, then
the system is called as closed loop hydraulic system
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Hydraulic system Design methodology :

The design of a hydraulic system involves the following basic steps:

(1) selection and sizing of components,

(2) determining the system operating pressure and flow rate,

(3) finding the component specifications to meet the design objectives

What is a ladder diagram?

Ladder Diagram is a graphical programming language that you use to develop
software for programmable logic controllers (PLCs). It is one of the languages that
the IEC 61131 standard specifies for use with PLCs. A program in ladder diagram
notation is a circuit diagram that emulates circuits of relay logic hardware.

Cascade method pneumatic

The cascade methodology consists of dividing the pneumatic positioning system

model into two subsystems: a mechanical subsystem and a pneumatic subsystem.
This division allows the introduction of friction compensation at force level in the
pneumatic positioning system.

cascade circuits are used?

Cascade circuits are used in many places, some of the most common
include refrigeration and industrial production lines. Cascading is used to turn on
and off sensors to prevent: Out of sequence operation. Inadvertent operation.
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Truth table for PLC:

Karnaugh map method:

A Karnaugh map (K-map) is a visual method used to simplify the algebraic

expressions in Boolean functions without having to resort to complex theorems or
equation manipulations.
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What are the 7 types of logic circuit?

There are seven basic logic gates: AND, OR, XOR, NOT, NAND, NOR, and XNOR. The
AND gate is so named because, if 0 is called "false" and 1 is called "true," the gate
acts in the same way as the logical "and" operator. The following illustration and
table show the circuit symbol and logic combinations for an AND gate.

(OR)
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Sequencing circuit:
Sequencing circuits are those that automatically program two or more cylinders on a
machine to cause them to extend and retract in a predetermined sequential order
on every cycle.

Working:Sequencing circuits automatically move actuators in a predetermined

sequence. Shown and described here are three useful sequencing circuits using
standard components. Electrical control — Limit switches momentarily actuated by
the cylinders control the solenoid valves to sequence this circuit.

Applications of sequencing circuit

Sequence valves can be used to sense pressure (port 1) in one circuit and then open
and supply oil to a secondary circuit (port 2) at a predetermined pressure. A typical
application would be when maintained clamping pressure is required in the primary
circuit while work is being performed in the secondary circuit.

Advantage:

Sequence valves are normally closed and usually allow bidirectional flow when
equipped with a bypass check valve. Sequence valves always have an external drain
connected directly to tank
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What is programmable logic control system PLC:

A programmable logic controller (PLC) is a small, modular solid state computer with
customized instructions for performing a particular task. PLCs, which are used in
industrial control systems (ICS) for a wide variety of industries, have largely replaced
mechanical relays, drum sequencers and cam timers.

What are the 3 types of PLC?

PLC are divided into three types based on output namely
Relay output,
Transistor output,
Triac Output PLC.
The relay output type is best suited for both AC and DC output devices.

What is PLC and its application?

Programmable logic controllers (PLCs) are integral to industrial automation and
industrial process control. PLCs manage various actuators, analog, and digital
sensors, and communicate complex interfaces in changing protocols. Other than
control functions, PLCs execute data conversion and signal processing.

Combinational logic circuit:

A combinational circuit is the digital logic circuit in which the output depends on
the combination of inputs at that point of time with total disregard to the past
state of the inputs. The digital logic gate is the building block of combinational
circuits.
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Electrical control of pneumatic and hydraulic circuits:

Electrical control
These can be used to operate solenoid valves or servo valves that control the fluid
power element. Electrical control may be used to allow, for example, remote control of a
fluid power system without running long control lines to a remotely located manual
control valve.

Pneumatic circuits:
Pneumatic circuits can be controlled by electric circuits. The interface between
these two circuits is a solenoid valve. Solenoid valves perform the same function as
normal pneumatic valves but there are operated electrically.

4 Basic Pneumatic Circuits

 Air Preparation.
 Double-Acting Cylinder.
 Continuous Cycling Cylinder.
 Two-Hand Control.

Hydraulic circuits:
Hydraulic circuits transmit and control power from a mechanical input to a mechanical
output by means of liquids, mostly oils. Power is transmitted hydrostatically, where high
pressures make static forces dominate over dynamic forces, and energy is transmitted
mostly through static pressure at low flow velocities.
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Ladder Logic Programming:

In the very early days of PLC programming ladder diagrams were configured and
loaded into the PLC using dedicated hand held programmers. These hand held
programmers were extremely slow and tedious to use.

Ladder logic PLC circuit:

Motion controle PLC circuit: