HYDRAULICS AND PNEUMATICS LAB MANUAL

Assignment No.1 Title: SYMBOLS FOR DIFFERENT COMPONENTS AS PER STANDARDS

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering &Research, Ravet

Assignment No.1

Study of ISO Symbols used in Hydraulics & Pneumatics

Aim: Study of Different type of symbols used in Hydraulic & Pneumatic systems

Symbol Rules

1.Symbols show connections, flow paths and functions of components represented. They do not
indicate construction or any physical relationship such as location of ports, direction of shifting
of spool or position of actuators nor do they indicate values such as pressure, flow rate or other
component settings.
2.When a component performs more than one function basic symbols may be combined and
arranged to show each separate function.
3.With certain obvious exceptions symbols may be rotated or reversed without altering their
meaning.
4.Line width does not affect meaning of symbol.
5.Symbols may be drawn to any suitable size. Size may be varied on any given drawing for
emphasis or clarity.
6.Arrows are used within symbol envelopes to show the directions of flow through a component
as used in applications represented. Double ended arrows are used to indicate reversing flow.
7.Each symbol is drawn to show normal, at rest, or neutral conditions of component unless
multiple diagrams are furnished showing various phases of circuit operation. An actuator
symbol for each flow path condition possessed by component should be shown.
8.External ports are located where flow lines connect to basic symbol, except where component
enclosure symbol is used. External ports are located at intersection of flow lines and component
enclosure symbol when enclosure is used.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Assignment No.1 Title: SYMBOLS FOR DIFFERENT COMPONENTS AS PER STANDARDS

9.The words hydraulics or pneumatics may be added to description to distinguish between two
systems or between one of them and other technical fields, for example Hydraulic pump,
hydraulic accumulators, pneumatic motors, pneumatic valves, etc.
 Symbols used in hydraulics and pneumatics
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PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING
HYDRAULICS AND PNEUMATICS LAB MANUAL
Assignment No.1 Title: SYMBOLS FOR DIFFERENT COMPONENTS AS PER STANDARDS

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PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING
HYDRAULICS AND PNEUMATICS LAB MANUAL
Assignment No.1 Title: SYMBOLS FOR DIFFERENT COMPONENTS AS PER STANDARDS


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PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Assignment No.1 Title: SYMBOLS FOR DIFFERENT COMPONENTS AS PER STANDARDS


 

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Assignment No.1 Title: SYMBOLS FOR DIFFERENT COMPONENTS AS PER STANDARDS


 

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

Assignment No.2

Types of Actuator

Aim: To study Different types of actuators in Hydraulic and Pneumatics

Theory
Cylinders, fluid power motors, and rotary actuators Fluid power actuators

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. Cylinders account for more than 90% of the actuators
used in fluid power systems for work output. Of the approximately 10% of actuators that produce
rotary output, more than 90% are hydraulic motors, while the rest are some form of rotary actuator.
Single acting cylinders. Single acting cylinder has one working port. Forward motion of the piston
is obtained by supplying compressed air to working port. Return motion of piston is obtained by
spring placed on the rod side of the cylinder. Schematic diagram of single acting cylinder is shown
in Figure 1.1 Single acting cylinders are used where force is required to be exerted only in one
direction. Such as clamping, feeding, sorting, locking, ejecting, braking etc., Single acting cylinder
is usually available in short stroke lengths [maximum length up to 80 mm] due to the natural length
of the spring. Single Acting Cylinder exert force only in one direction. Single acting cylinders
require only about half the air volume consumed by a double acting cylinder for one operating
cycle.

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INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

Vent
(By spring)
There are varying designs of single acting cylinders including:
1. Diaphragm cylinder
2. Rolling diaphragm cylinder
3. Gravity return single acting cylinder
4. Spring return single acting cylinder

i) Diaphragm cylinder
This is the simplest form of single acting cylinder. In diaphragm cylinder , piston is replaced by a
diaphragm is replaced by a diaphragm of hard rubber, plastic or metal clamped between the two
halves of a metal casing expanded to form a wide, flat enclosure. Schematic diagram of diaphragm
cylinder is shown in Figure 1.2.The operating stem which takes place of the piston rod in
diaphragm cylinder can also be designed as a surface element so as to act directly as a clamping
surface for example. Only short operating strokes can be executed by a diaphragm cylinder, up to
a
maximum of 50 mm. This makes the diaphragm type of cylinder particularly adaptable to clamping
operations. Return stroke is accomplished by a spring built into the assembly or by the tension of
diaphragm itself in the case of very short stroke. Diaphragm cylinders are used for short stoke
application like clamping, riveting, lifting, embossing and riveting

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INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

ii) Rolling diaphragm cylinder

They are similar to diaphragm cylinders. Schematic diagram of Rolling diaphragm cylinder is
shown in Figure 1.3.They too contain a diaphragm instead of piston, which is this instance rolls
out along the inner walls of the cylinder when air pressure is applied to the device, thereby
causing the operating stem to move outwards. Compared with the standard diaphragm type, a
rolling diaphragm cylinder is capable of executing appreciably longer operating strokes
(averaging from 50 mm to 800mm) . Separate guiding of stem is not normally provided in these
designs, since the component being actuated by the cylinder usually cannot break out of set limits
of motion. Any off-center displacement is compensated by the rolling diaphragm with no loss of
power. Materials used for rolling diaphragms in present –day designs ensure good durability
under normal operating conditions. On the other hand, even very small cracks or cuts in the
diaphragm will generally lead to early failure because if high stresses are imposed on the flexible
material as it unrolls at each stroke. If the actuator needs to be dismantled for any reason, it must
accordingly be inspected carefully for any burrs or sharp edges inside. Metal cuttings also
constitute a hazard if they are able to enter the cylinder housing.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

Figure 1.4 shows gravity return type single acting cylinders. In a push type (a), the cylinder extends
to lift a weight against the force of gravity by applying oil pressure at the blank end. The oil is
passed through blank end port or pressure port. The rod end port or vent port is open to atmosphere
so that air can flow freely in and out of the rod end of the cylinder. To retract the cylinder, the
pressure is simply removed from the piston by connecting the pressure port to the tank. This allows
the weight of the load to push the fluid out of the cylinder back to tank In pull type gravity return
type single acting cylinder the cylinder (b) lifts the weight by retracting. The blank end port is the
pressure port and blind end port is now the vent port. This cylinder will automatically extend
whenever the pressure port is connected to the tank.

iv) Spring Return Single Acting Cylinder

Spring return single acting cylinder is shown in Figure 1.5 in part (a) push type the pressure is sent
through pressure port situated at blank end of the cylinder. When the pressure is released, the spring
automatically returns the cylinder to the fully retracted position. The vent port is open to
atmosphere so that air can flow freely in and out of the rod end of the cylinder.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

Part (b) shows a spring return single acting cylinder. In this design cylinder retracts when the
pressure port is connected to the pump flow and extend whenever the pressure port is connected
to the tank. Here pressure port is situated at rod end of the cylinder

B) Double acting cylinders.

Schematic diagram of double acting cylinder is shown in Figure 1.6. Double Acting Cylinders are
equipped with two working ports- one on the piston side and the other on the rod side. To achieve
forward motion of the cylinder, compressed air is admitted on the piston side and the rod side is
connected to exhaust. During return motion supply air admitted at the rod side while the piston
side volume is connected to the exhaust. Force is exerted by the piston both during forward and
return motion of cylinder. Double acting cylinders are available in diameters from few mm to
around 300 mm and stroke lengths of few mm up to 2 meters

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

Construction of Double acting cylinder

The construction features of double acting cylinder are shown in Figure 1.7. The construction of
double acting cylinder is similar to that of a single cylinder. However, there is no return spring. In
double acting cylinder, air pressure can be applied to either side ( supply and exhaust) of the piston,
thereby providing a pneumatic force in both directions. The double acting cylinders are mostly
commonly used in the application where larger stroke length is required.

The seven parts of the double acting cylinder are

1. Base cap with port connection
2. Bearing cap with port connection
3. Cylinder barrel
4. Piston

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INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

5. Piston rod
6. Scrapper rings
7. Seals

The base cap and bearing cap are made of cast material, aluminum or malleable cast iron. The
two caps can be fastened to the cylinder barrel by tie rods, threads or flanges. Cylinder barrel is
usually made of seamless drawn steel tube to increase the life of the sealing components, the
bearing surfaces of the cylinder are precision machined,. For special applications, the cylinder
barrel can be made of aluminum, brass or steel tube with hard chromed bearing surface. These
special designs are used where operation is infrequent or where there are corrosive influences

The piston rod It is preferably made from heat treated steel. A certain percentage of chrome in the
steel protects against rusting. Generally the threads are rolled to reduce the danger of fracture.
Piston seals are provided in between piston and barrel to avoid leakage. A sealing ring is fitted in
the bearing cap to seal the piston rod. The bearing bush guides the piston rod and may be made of
sintered bronze or plastic coated metal.
In front of this bearing bush is a scrapper ring.(wiper ring). It prevents dust and dirt particles from
entering the cylinder space. Bellows are therefore not normally required.
The materials for the double cup packing sealing are
Perbunan, for -20 to + 80 Viton,
for -20 to +190
Teflon for -80 to +200
O rings are normally used for static sealing.
Construction of Double acting cylinder There
are two types of double acting cylinders.
i) Double acting cylinder with piston rod on one side.
ii) Double acting cylinder with piston rod on both sides

) Double acting cylinder with piston rod on one side.

Figure 1.8 shows the operation of a double acting cylinder with piston rod on one side. To extend
the cylinder, pump flow is sent to the blank end port as in Figure 1.8 (a). Fluid from the rod end
port returns to the reservoir. To retract the cylinder, the pump flow is sent to the rod end port and
fluid from the blank end port returns to the tank as in Figure 1.8 (b).

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

A double acting cylinder with piston rod on both sides (Figure 1.9) is a cylinder with rod extending
from both ends. This cylinder can be used in an application where work can be done by both ends
of the cylinder, thereby making the cylinder more productive. Double rod cylinders can withstand
higher side loads because they have an extra bearing one on each rod to withstand the loading.
Double rod cylinders are used when there is bending load and accurate alignment and maximum
strength is required. A further advantage is that rod is precisely located and may be used to guide
the machine member coupled to it, dispensing with external guides or bearing in many cases most
standard production models are available either in single rod or double rod configuration A
disadvantage of double rod configuration is that there is a reduction in maximum thrust due to the
blanking effect of the rod cross section on the piston area and a slightly larger size of cylinder is
required for a given duty. The thus will be the same on the ingoing stroke as that of a single rod
double acting cylinder.
1.2.1.3 Based on the cylinder action
Rotating type of cylinders are used in applications where cylinder body is connected to a rotating
member and air connection to the cylinder in a stationary housing. They are not widely used.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

Non Rotating type of cylinders are widely used Industries. Cylinder body is connected air
connection are mounted stationary housing and piston rod moves and exerts force.

1.2.1.4 Based on the cylinder’s design

In industry , differentiation is made between special design of regular cylinder and the special
duty cylinders designed for a special purpose that are known by designation of their own. Special
design cylinders are basically natural variations of single or double acting cylinders. Variations
in special designs derived from standard production of cylinders and merely exchanging selected
parts for others of different shapes or material. Special duty cylinders on the other hand are from
the start designed to non-standard conditions of service or application.

Telescopic cylinder (shown in Figure 1.10 (a) and (b)) is used when long stroke length and short
retracted length are required. They extend in stages, each stage consisting of a sleeve that fits inside
of the previous stage. Figure 1.10 (c) shows the construction of a typical double acting telescopic
cylinder with two pistons (Two stages).
Extension stroke: When the pressure is applied at port A, air flow through port X and Y and
pressure is applied on both sides of Piston 1. But difference in areas causes the piston 1 to move
to the right. Once the piston 1 fully extends, Inner Piston 2 will extend.

Retraction stroke: To retract, air is applied to port B. Air pressure will act on the annulus of the
inner piston 2 and moves inner piston 2 to the left. When the inner piston moves to left and
started to close port X, air from port B goes to annular side of the piston 1 via port Y and pushes
the piston 1 to the left

Figure shows the construction of a typical double acting telescopic cylinder with three pistons
(three stages)
Forward stroke: when the pressurized air enters the port p, larger ram of diameter A moves first.
Since the diameter of Ram A is relatively large, this ram produces large force at the beginning of
the lift of the load. ( usually in many application, initial inertial is high and larger force is required
in the beginning, once initial inertia is overcome, smaller force is required to keep moving the

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
ASSIGNMENT NO: 2 TITLE: TYPES OF ACTUATOR

weight). When ram A reaches the end of the stroke, ram B begins to move, providing smaller force.
When ram B reaches its end position, Ram C will move outward to complete the stroke. Retraction
stroke: When the pressurized air enters the port T, then it acts on the annular area of Ram A and
ram A is retrieved. Once the Ram A is retrieved, pressure continues to act on annular area of Ram
B and retrieves Ram B. In similar way, the Ram C is also retrieved.

B) Tandem Cylinder

Schematic diagram of Tandem cylinder is shown in Figure 1.12. Tandem cylinders are two separate
double acting air cylinders arranged in line to one cylinder body so that the power generated by
the two is added together, thereby approximately doubling the piston output. A tandem cylinder is
used in applications where a large amount of force is required from a smalldiameter cylinder.
Basically, a tandem cylinder is simply two or more separate cylinders stacked end to end in a unit
and with all the pistons mounted on a common piton rod. Pressure is applied to both pistons,
resulting in increased force because of the larger area. The drawback is that these cylinders must
be longer than a standard cylinder of larger flow rate than a standard cylinder to achieve an equal
speed because flow must go to both pistons

Tandem cylinders are used where large output force is required with appreciable saving in bulk
and weight. Tandem cylinders are employed where a small diameter of the assembly is required. c
) Roadless Cylinder
A rod less air cylinder differs from a basic air cylinder in that no piston rod extends outside the
cylinder body. Instead, the internal piston is connected to an external carriage, by means of a
magnetic or mechanical coupling system
There are three types of rod less cylinders, they are i)
Cable Cylinder ii) Sealing band Cylinder with slotted
cylinder barrel iii) Cylinder with Magnetically Coupled
Slide

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: TEST ON VANE PUMP

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering &Research, Ravet

Experiment No: 1
Test on Vane Pump and determination of performance characteristics

Aim: Study of Vane pump and plotting performance characteristics.

Theory

Pump converts mechanical energy into hydraulic energy. Mechanical energy is delivered to
pump via a prime mover such as electric motor, petrol engine, diesel engine etc.
Classification of pump:

1. Non Positive Displacement pumps (Hydrodynamic Pumps):

These pumps are used for low pressure high volume flow applications. They are not capable of
withstanding high pressure and are of little use in fluid power field. They are primarily used for
transporting fluid from one location to other. Types: Centrifugal (impeller) and axial (propeller)
pump.
2. Positive Displacement Pumps:
This type is universally used for fluid power systems. As name implies, a positive displacement
pump is capable of overcoming the pressure resulting from mechanical loads on systems as well
as resistance to flow due to friction.
There are mainly 3 types of pumps:
 Gear pump
 Vane pump
 Piston pump
Advantages of Positive Displacement Pumps over Hydrodynamic Pumps
i) High pressure capacity
ii) Small, compact size
iii) High volumetric efficiency
iv) Small change in volumetric efficiency throughout design pressure range
v) Great flexibility of performance.(Can operate over a wide range of pressure
requirements and speed range)

Pumping Theory:

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: TEST ON VANE PUMP

All pumps operate on the principle where by a partial vacuum is created at the inlet due to
internal operation of the pump. This allows atmospheric pressure to push the fluid out of the oil
tank and into the pump intake. The pump then mechanically pushes the fluid out to the discharge
line. Principle of working of Positive Displacement Pump is shown in Figure 1.
These pumps do not pump pressure. Instead they produce fluid flow; the resistance to this
flow produced by hydraulic system is what determines pressure. If resistance to flow is infinite
there will be no place for fluid to go as pump continues to create flow. Thus pressure rises infinitely
theoretically unless some component fails or pressure relief is provided in same way. Thus for
positive displacement pump a pressure valve is needed.

Fig. 1 Principle of working of Positive Displacement Pump

Vane Pump (Construction and Working):

The main components of the pump are the cam surface and the rotor. The rotor contains
radial slots splined to drive shaft. The rotor rotates inside the cam ring. Each radial slot contains a
vane, which is free to slide in or out of the slots due to centrifugal force. The vane is designed to
mate with surface of the cam ring as the rotor turns. The cam ring axis is offset to the drive shaft
axis. When the rotor rotates, the centrifugal force pushes the vanes out against the surface of the
cam ring. The vanes divide the space between the rotor and the cam ring into a series of small
chambers. During the first half of the rotor rotation, the volume of these chambers increases,
thereby causing a reduction of pressure. This is the suction process, which causes the fluid to flow
through the inlet port. During the second half of rotor rotation, the cam ring pushes the vanes back
into the slots and the trapped volume is reduced. This positively ejects the trapped fluid through
the outlet port. In this pump, all pump action takes place in the chambers located on one side of
the rotor and shaft, and so the pump is of an unbalanced design. The delivery rate of the pump
depends on the eccentricity of the rotor with respect to the cam ring.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: TEST ON VANE PUMP

Fig. 2 Vane Pump

Experimental Setup

The vane pump is a positive displacement type of pump and consists of a number of vanes
on the rotor and oil chamber is formed between rotor, cam ring and pair of vanes. Rotor is fitted
with and external shaft that is coupled to AC motor (1440 RPM).
The test pump is coupled to a 1 HP AC motor (220 Volts single phase). A suitable switch
is provided. The pump sucks the oil from reservoir and delivers to the collecting tank that is
provided with an overflow arrangement. The collected oil is transferred back to the reservoir
through a ball valve. Suitable pressure and vacuum gauges are fitted in the pipe lines, to measure
suction and delivery head. A modified gate valve is fitted in delivery side that prevents complete
shut off. An energy meter with a stop watch is provided to measure the input power

Note: Regular diesel oil (HSD) can be used as a test oil in the gear pump test rig. This is
economical and widely available.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: TEST ON VANE PUMP

Procedure

1) Fill the supply tank with oil to the required height say three fourth of the tank .
2) Open the gate valve in the delivery pipe fully.
3) Start the motor. Oil flows in.
4) Throttle the gate valve to get the required head.
5) Note the following reading.
a) Pressure gauge and vacuum gauge reading
b) Time for 1 cm rise in collecting tank – t sec
c) Distance of pressure gauge on delivery side from the pump axis - X m
Take 4 to 5 sets of readings by varying the delivery pressure.

Specifications
1.
Collecting tank area: 0.248*0.248 m2

2. Distance of pressure gauge on delivery side from the pump axis = 0.825 m

3. Oil specific gravity – 0.88 (HSD)

4. Total Head = Suction Head + Discharge Head + Distance of pressure gauge on delivery side from the
pump axis

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: TEST ON VANE PUMP

Pump output = ρ*g*Qa*Hm

Pump Input = Watt Meter Reading
η = Output/input

Observation Table:
Sr. Discharge Vacuum Time Discharge Pump Pump Overall
No Pressure Gauge For 1 cm rise flow (Qa) I/P O/P efficiency
Reading Reading of oil in the tank *10^-3, kW kW ηo
(Pd), in (Ps) in in Sec. m3/sec
kg/cm2 mm of Hg

1 10 -310 72 0.104 650 94.3 19.34

2 15 -260 80 0.0936 670 124.72 24.82

3 20 -190 92 0.0813 730 142.918 26.10

4 25 -160 104 0.072 800 157.24 26.208

Sample Calculations:
Actual Discharge (Qa) = Area of measuring tank * Rise in oil level / Time m3/sec
Power generated by pump = Ɣ*Qa*Hm
Manomatric Head (Hm) = Suction Head + Discharge Head + Distance of pressure gauge on delivery side from
the pump axis -
Efficiency of pump = Output power/ watt meter reading
1.) Qact=V/t= (0.26 x 0.36 x 0.08)/ 72 = 1.04 x 10^-4 m^3/sec

2.) Hd=Pd/Y = (10 x 9.81 x10^4)/9810 = 100 m

Hs= (Ps x 133.33)/Y = (310 x 133.33)/9810 = 4.213 m

Zd = 0.825 m (given)

Hm = Hd + Hs + Zd = 105.038 m

3.) Density = 880 kg/m^3

Pout = (880 x 9.81 x 1.04 x10^-4 x 105.038) = 94.30 Watts

Pin = (0.75 x 650) = 487.5 watts
1.) Overall Efficiency
ηo = (Pout/ Pin) x 100

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: TEST ON VANE PUMP

ηo = (94.30 / 487.5) x 100

ηo =19.34 %
In this way rest of the calculations are done.
Conclusion:
1. The positive displacement vane pump is giving discharge irrespective of pressure (i.e. Qth is
horizontal). Actual discharge (Qa ) is deviating horizontal due to oil leakage from high
pressure side to low pressure side due to eccentricity of rotor and cam ring. Accordingly
efficiency varies.
2. High discharge pressure gives low efficiency as internal leakage increases with pressure.
3. Input to pump will not meet origin but will have a definite value at Pd=0 or at start this power
is used to overcome frictional losses.
Graphs:
Plot following graphs
1. Discharge Vs head
2. Discharge Vs output power
3. Discharge Vs efficiency
4. Discharge Vs input power

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

EXPERIMENT NO. 3

Experimentation on Pneumatic Trainer

Title- Experimentation on Pneumatic Trainer using

1. Automatic Reciprocating Circuit

2. Speed Control Circuit
3. Pneumatic Circuit Involving Shuttle valve/ quick Exhaust Valve Circuit
4. Electro Pneumatic Valve and Circuit

Aim- To study the practical working and understand applications of

1. Automatic Reciprocate Circuit

2. Speed Control Circuit
3. Pneumatic Circuit Involving Shuttle valve/ quick Exhaust Valve Circuit
4. Electro Pneumatic Valve and Circuit

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

5.

Theory-

By using all the mentioned circuits we can easily find a solution to a position, power, sequence or
speed problem of any mechanical system.

In order to avoid complicated drawings it is standard practice in hydraulics and pneumatics to use
symbol for each element. Because drawing all pneumatic circuits in 3-D and 2-D views is quiet
tedious task. A circuit diagram may be defined as the graphic representation of the pneumatic
components in a hydraulically operated machine.

The detailed experimentation procedure followed for the different circuits on hydraulic trainer are
explained below-

1. Automatic Reciprocating Circuit-

To get continuously the similar type of actuation we use an automatic reciprocating circuit.

Complete circuit is given in Figure No. 3.1

Pneumatic components required for automatic reciprocating circuit experimentation-

• Tapped source/ Compressed air

• FRL Unit
• 3/2 Push Button Operated Spring Return Direction Control Valve
• 5/2 Solenoid Operated Spring Return Direction Control Valve
• Double Acting Cylinder

Working/ Operation-

- As soon as compressor is started, pressurized compressed air is available at tapped source.

- This air will enter FRL unit where it will get filtrated, pressure will be regulated as per the
requirement and will be lubricated.
- In this circuit 3/2 Push Button Operated Spring Return Direction Control Valve is used as
on off source. Initially IInd position of this DCV is actuated because of which compressed
air is blocked at port P.
- As soon as push button of 3/2 Push Button Operated Spring Return Direction Control Valve
is pressed, air will be directed from port P to working port A and will enter in port P of 5/2
Solenoid Operated Spring Return Direction Control Valve.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

- 5/2 Solenoid Operated Spring Return Direction Control Valve has IInd positon already
actuated because of which air will be directed from port P to working port B.
- Pressurized air will enter in rod end of double acting cylinder and makes it to take retraction
stroke.
- At the end of retraction stroke, final position of piston rod will be sensed by proximity
sensor 1 (PS1) which gives signal to 5/2 Solenoid Operated Spring Return Direction
Control Valve to actuate Ist position of it by magnetizing solenoid attached to it.
- This will direct the air flow from port P to working port A and air will enter in cap end of
double acting cylinder.
- This will make actuator to get forward stroke.
- At the end of forward stroke proximity sensor 2 (PS 2) will sense final position of rod and
sends signal to 5/2 Solenoid Operated Spring Return Direction Control Valve to get
demagnetize and thus IInd position of this valve will be actuate.
- It will make the piston to take retraction stroke again.
In this way cylinder will reciprocate automatically and will stop only when push button of
3/2 Push Button Operated Spring Return Direction Control Valve is pressed again.

Applications of Automatic Reciprocating Circuit-

1. Stamping Machine
2. Material Feeding Machine
3. Flat Glass Cleaning Machine.
2.Speed Control Circuit-

To effect control of velocity of an actuator, one may use various types of flow control or throttle
valves. Both, ordinary flow control valves or compensated flow control valves are used depending
on the degree of control, accuracy needed for the machine element in question.

Pneumatic components required for speed control circuit experimentation-

• Tapped source/ Compressed air

• FRL Unit
• 3/2 Push Button Operated Spring Return Direction Control Valve
• 5/2 Push Button Operated Spring Return Direction Control Valve
• Flow Control Valve with Built in Check Valve
• Double Acting Cylinder
Speed control circuit can be categorized in two types depending on position of flow control valve
as-

A. Meter In type Speed Control Circuit B. Meter Out type Speed Control Circuit

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

A. Meter In type Speed Control Circuit During Actuator Forward Stroke- Working/
Operation-

Complete circuit is given in Figure No. 3.2

Extension/ Forward Stoke-

- As soon as compressor is started, pressurized compressed air is available at tapped source.

- This air will enter FRL unit where it will get filtrated, pressure will be regulated as per the
requirement and will be lubricated.
- In this circuit 3/2 Push Button Operated Spring Return Direction Control Valve is used as
on off source. Initially IInd position of this DCV is actuated because of which compressed
air is blocked at port P.
- As soon as push button of 3/2 Push Button Operated Spring Return Direction Control Valve
is pressed, air will be directed from port P to working port A and will enter in port P of 5/2
Solenoid Operated Spring Return Direction Control Valve.
- 5/2 Solenoid Operated Spring Return Direction Control Valve has IInd positon already
actuated because of which air will be directed from port P to working port B.
- Pressurized air will enter in rod end of double acting cylinder and makes it to take retraction
stroke.
- During retraction stroke air will go from check valve because it will find restriction from
flow control valve.
- Finally air will be directed from port A to port R to environment directly.
- When push button of 5/2 Push Button Operated Spring Return Direction Control Valve is
pressed Ist position of it will be actuated directing air from pressure port P to working port
A.
- Air will go from flow control valve because it will find restriction from check valve and
controlled compressed air will enter in blank end of cylinder making the cylinder to take
forward stroke and we get speed control during forward stroke of actuator.

Retraction Stoke-

- When lever of 5/2 push operated spring return direction control valve is again operated, it
gets IInd position actuated which directs the air flow from port P to working port B and
pressurized air will enter rod end of double acting cylinder resulting in retraction stroke.
- The fluid coming out of cap end of cylinder will be going through check valve because
there is no restriction at check valve and fluid finds restriction at flow control valve.
- The fluid coming out from check valve will be directed from working port A to port R and
released to environment.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

Applications of Meter In type Circuit-

• PCB Printing Machines

• Laminating Machines

B. Meter Out type Speed Control Circuit During Actuator Forward Stroke- Working/
Operation-

Complete circuit is given in Figure No. 3.3

Extension/ Forward Stoke-

- As soon as compressor is started, pressurized compressed air is available at tapped source.

- This air will enter FRL unit where it will get filtrated, pressure will be regulated as per the
requirement and will be lubricated.
- In this circuit 3/2 Push Button Operated Spring Return Direction Control Valve is used as
on off source. Initially IInd position of this DCV is actuated because of which compressed
air is blocked at port P.

- As soon as push button of 3/2 Push Button Operated Spring Return Direction Control Valve
is pressed, air will be directed from port P to working port A and will enter in port P of 5/2
Solenoid Operated Spring Return Direction Control Valve.
- 5/2 Solenoid Operated Spring Return Direction Control Valve has IInd position already
actuated because of which air will be directed from port P to working port B.
- Pressurized air will enter in rod end of double acting cylinder and makes it to take retraction
stroke.
- Air will come out from cap end and will be released to environment through port R.
- When push button of 5/2 Push Button Operated Spring Return Direction Control Valve is
pressed Ist position of it will be actuated directing air from pressure port P to working port
A.
- Air will enter in cap end of double acting cylinder making actuator to take forward stroke.
- During this stroke air will go through flow control valve because check valve will block
the flow through it.
- And we get meter out type speed control during forward stroke of an actuator.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

Retraction Stoke-

- When lever of 5/2 push button operated, spring return direction control valve is again
operated, it gets IInd position actuated which directs the pump flow from pressure port P to
working port B and pressurized fluid will enter rod end of double acting cylinder through
check valve because it will freely allow the fluid to flow forward resulting in retraction
stroke.
- The fluid coming out of cap end of cylinder will be going through working port A and will
be directed to port R which releases fluid to environment.

Applications of Meter Out Type Circuit-

• Biscuit Die Loading and Unloading

• Trimming Machines

2. Pneumatic Circuit Involving Shuttle valve/ quick Exhaust Valve Circuit –

- A quick exhaust valve is a typical shuttle valve.

- The quick exhaust valve is used to exhaust the cylinder air quickly to atmosphere.
- Figure 3.4 gives constructional details of shuttle valve. Shuttle valve contains 3 number of
ports i.e port 1 as inlet port, port 2 as outlet port and port 3.
- It has a movable disc (flexible) which slides between areas A and B.
- As shown in the figure, the movable disc is in contact with surface B, allowing the flow of
air to move from port 1 to port 2.
- Similarly if this disc moves leftwards i.e. in contact with surface A then air will be directed
from port 2 to port 3.

Complete circuit is given in Figure No. 3.5

Pneumatic components required for pneumatic circuit involving quick exhaust valve
experimentation-

• Tapped source/ Compressed air

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

• FRL Unit
• 5/2 Push Button Operated Spring Return Direction Control Valve
• Double Acting Cylinder
• Quick Exhaust Valve

Working/ Operation-

- In many applications especially with single acting cylinders, it is a common practice to

increase the piston speed during forward or retraction stroke of cylinder to save the cycle
time.
- The higher speed of piston is possible by reducing the resistance to flow of the exhausting
air during the motion of cylinder.
- The resistance can be reduced by expelling the exhausting air to the atmosphere quickly by
using quick exhaust valve or shuttle valve.

Extension/ Forward Stoke-

- As soon as compressor is started, pressurized compressed air is available at tapped source.

- This air will enter FRL unit where it will get filtrated, pressure will be regulated as per the
requirement and will be lubricated.
- Compressed air will enter in pressure port P of 5/2 Push Button Operated Spring Return
Direction Control Valve.
- 5/2 Push Button Operated Spring Return Direction Control Valve has IInd position already
actuated because of which air will be directed from port P to working port B. - This air will
directly enter in rod end of double acting cylinder through shuttle valve.
- But air will not find any restrictions in shuttle valve, and cylinder gets retracted.
- When push button of 5/2 push button operated spring return direction control valve is
operated, air will be directed from pressure port P to working port A.
- This air will enter in blank end of double acting cylinder making the cylinder to take
forward stroke.
- The air from rod end of cylinder exhausts out to the atmosphere via port A to R of quick
exhaust valve.
- In order to attain maximum benefit out of this valve, port A of quick exhaust valve should
be directly connected to cylinder port.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

Retraction Stoke-

- When II nd position of 5/2 push button operated direction control valve is actuated, then
pressurized fluid will be directed from pressure port P to working port B.
- This air will directly enter in rod end of double acting cylinder through shuttle valve.
- But air will not find any restrictions in shuttle valve, and cylinder gets retracted.
- And air will be released to environment through port R of direction control valve.

Applications of pneumatic circuit involving shuttle and quick exhaust valve Circuit-

• Applications where distance between direction control valve and actuator is comparatively
large.
• Cutting Applications
• Assembly Lines

3. Electro Pneumatic Valve and Circuit-

These circuits are same as that of pure pneumatic circuit except the type of directional control
valve used. These circuits use electro pneumatic direction control valves to direct the flow of
compressed air.

Complete circuit is given in Figure No. 3.6

Hydraulic components required for regenerative circuit experimentation-

• Tapped source/ Compressed air

• FRL Unit
• 3/2 Solenoid Operated Spring Return Direction Control Valve
• Single Acting Cylinder
Working/ Operation- Extension/ Forward Stoke-

- As soon as compressor is started, pressurized compressed air is available at tapped source.

- This air will enter FRL unit where it will get filtrated, pressure will be regulated as per the
requirement and will be lubricated.
- Compressed air will enter in pressure port P of 3/2 Solenoid Operated Spring Return
Direction Control Valve.
- 3/2 Solenoid Operated Spring Return Direction Control Valve has IInd position already
actuated because of which air will be blocked in pressure port P of it.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 3 TITLE: EXPERIMENTATION ON PNEUMATIC TRAINER

- As solenoid of this direction control valve is actuated, direction control valve will gets its
Ist position actuated.
- Because of this air will be directed in cap end of double acting cylinder making the cylinder
to take forward stroke.

Retraction Stoke-

- When solenoid valve is demagnetized or supply to solenoid valve is cut off.

- Cylinder will take its retraction stroke because of spring force.
- Air will be released to atmosphere through port P of 3/2 solenoid operated spring return
direction control valve.

Applications of Traverse and Feed Circuit-

4. Bottle Industries
5. Automobile assembly Lines

Conclusion-

In this experiment we practically performed pneumatic circuits like automatic reciprocating

circuit, speed control circuit, pneumatic circuits involving shuttle and quick exhaust valve, electro
pneumatic valve and circuit and also got proper understanding of their applications and various
combinations through which same circuits can be constructed and made to operate properly.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering &Research, Ravet

EXPERIMENT NO. 2

Experimentation on Hydraulic Trainer

Title- Experimentation on Hydraulic Trainer using

1. Regenerative Circuit
2. Speed Control Circuit
3. Sequencing Circuit
4. Traverse and Feed Circuit

Aim- To study the practical working and understand applications of

1. Regenerative Circuit
2. Speed Control Circuit
3. Sequencing Circuit
4. Traverse and Feed Circuit
Theory-

The main objective of performing experiments on various mentioned circuits is to find a specific
solution for the required application and a solution to a position, power, sequence or speed
problem of ant mechanical system e.g. machine tool, drilling machine, hydraulic crane etc.

Drawing hydraulic circuits in 3-D and 2-D views is quiet tedious task. Hence in order to avoid
complicated drawings it is practice in hydraulics and pneumatics to use symbol for each element.
A circuit diagram may be defined as the graphic representation of the hydraulic components in a
hydraulically operated machine.

The detailed experimentation procedure followed for the different circuits on hydraulic
trainer are explained below-

1. Regenerative Circuit-

Regenerative circuits are used to speed up the extending speed of a double acting hydraulic
cylinder. These circuits are sometimes used to obtain equal speeds in both directions in a
differential cylinder. Complete circuit is given in Figure No. 2.1

Hydraulic components required for regenerative circuit experimentation-

  Reservoir/ Tank
  Filter
  Pressure Relief Valve
  Unidirectional Hydraulic Pump
  Hydraulic Motor
  3/ 2 Lever Operated Spring Return Direction Control Valve
 Double Acting Cylinder

Working/ Operation-

Extension/ Forward Stoke-

- As soon as electric motor is started, the pump coupled with shaft on motor starts
pumping the hydraulic oil from reservoir towards the direction control valve.
- The oil will get filtrated before entering into the pump.
- This circuit can be operated by using both 4/3 direction control valve and 3/2 direction
control valve.
- When lever of 3/2 lever operated spring return direction control valve is operated, it gets
II position actuated which changes direction of fluid from port P to working port A.
- Pressurized fluid will be directed in cap end of double acting cylinder and cylinder
will take it forward stroke.
- During forward stroke, rod end port of double acting cylinder is connected with pump
outlet and it mix again with main supply of pump thus resulting in more pressure on
cap end of cylinder.
- Hence forward stroke speed in regenerative circuit is more compared t other circuits.
 - If in any case circuit pressure rises above designed pressure level the pressure relief
valve will get in action resulting in release of excess pressure generated in the system.

Retraction Stoke-

- When lever of 3/2 lever operated spring return direction control valve is again operated, it
gets I position actuated which redirects the pump flow directly in rod end port of double
acting cylinder (because pressure port P of 3/2 direction control valve is blocked off at
Ist position) and will take retraction stroke.
- And because of I position actuated the fluid coming out from cap end will the
directed from working port A to tank port T.
- Retraction stroke speed in regenerative circuit is less compared to forward stroke of same
circuit.

Applications of Regenerative Circuit-

1. Drilling Machine
2. Trimming Machine
2. Speed Control Circuit-

To effect control of velocity of an actuator, one may use various types of flow control or
throttle valves. Both, ordinary flow control valves or compensated flow control valves are used
depending on the degree of control, accuracy needed for the machine element in question.

Hydraulic components required for speed control circuit experimentation-

  Reservoir/ Tank
  Filter
  Pressure Relief Valve
  Hydraulic Motor
  Unidirectional Hydraulic Pump
  Pressure Relief Valve
  4/3 Lever Operated Spring Return Direction Control Valve
  Flow Control Valve with Built in Check Valve
 Double Acting Cylinder

Speed control circuit can be categorized in two types depending on position of flow control valve
as-

A. Meter In type Speed Control Circuit

B. Meter Out type Speed Control Circuit
C. Bleed off type Speed Control Circuit

A. Meter In type Speed Control Circuit During Actuator Forward Stroke-

Working/ Operation-

Complete circuit is given in Figure No. 2.2

Extension/ Forward Stoke-

- As soon as electric motor is started, the pump coupled with shaft on motor starts
pumping the hydraulic oil from reservoir towards the 4/3 direction control valve.
- The oil will get filtrated before entering into the pump.
- The oil will not flow forward because 4/3 direction control valve has centered
position blocked off.
HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

- When lever of 4/3 lever operated spring return direction control valve is operated, it gets
Ist position actuated which changes direction of fluid from port P to working port A.
- Pressurized fluid will be directed in cap end of double acting cylinder through
flow control valve as check valve will block the flow through it.
- Because of this, a controlled in flow will be directed in the cap end of cylinder resulting
in controlled forward stroke of cylinder.
- If in any case circuit pressure rises above designed pressure level the pressure relief
valve will get in action resulting in release of excess pressure generated in the system.

Retraction Stoke-

- When lever of 4/2 lever operated spring return direction control valve is again operated,
it gets IInd position actuated which directs the pump flow from port P to working port B
and pressurized fluid will enter rod end of double acting cylinder resulting in retraction
stroke.
- The fluid coming out of cap end of cylinder will be going through check valve because
there is no restriction at check valve and fluid finds restriction at flow control valve.
- The fluid coming out check valve will be directed from working port A to tank port T.

Applications of Meter In type Circuit-

  Tyre Specification Printing

 Food Industries to Push the product in controlled manner

B. Meter Out type Speed Control Circuit During Actuator Forward Stroke-

Working/ Operation-

Complete circuit is given in Figure No. 2.3

Extension/ Forward Stoke-

- As soon as electric motor is started, the pump coupled with shaft on motor starts
pumping the hydraulic oil from reservoir towards the 4/3 direction control valve.
- The oil will get filtrated before entering into the pump.
- The oil will not flow forward because 4/3 direction control valve has centered
position blocked off.
- When lever of 4/3 lever operated spring return direction control valve is operated, it gets
Ist position actuated which changes direction of fluid from port P to working port A.

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HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

- Pressurized fluid will be directed in cap end of double acting cylinder and cylinder
will take its forward stroke.
- During forward stroke, the fluid coming out from rod end of cylinder has to flow
from flow control valve because check valve will block the flow.
- Because of this, a controlled flow coming out from the cylinder will be directed in
working port B of 4/3 direction control valve resulting in controlled forward stroke of
cylinder.
- If in any case circuit pressure rises above designed pressure level the pressure relief
valve will get in action resulting in release of excess pressure generated in the system.

Retraction Stoke-

- When lever of 4/2 lever operated, spring return direction control valve is again operated, it
gets IInd position actuated which directs the pump flow from pressure port P to working port
B and pressurized fluid will enter rod end of double acting cylinder through check valve
because it will freely allow the fluid to flow forward resulting in retraction stroke.
- The fluid coming out of cap end of cylinder will be going through working port A and
will be directed to port T which takes fluid to reservoir.

Applications of Meter Out Type Circuit-

  Forging Industries
 Trimming Machines

3. Sequencing Circuit-
Sequencing circuits are used are used for the application where a systematic sequence is required
in the process.

If we take an example of application where Laser Marking is to be done.

In such a case we will need a cylinder which will clamp the component on which laser
marking is to be done and another cylinder which will make the laser marking head near the
area where laser marking is to be done.

A sequence of operation is achieved in the above mentioned application. Complete circuit is

given in Figure No. 2.

Hydraulic components required for regenerative circuit experimentation-

  Reservoir/ Tank
  Filter
  Pressure Relief Valve
 Unidirectional Hydraulic Pump

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

  Hydraulic Motor
  4/3 Lever Operated Spring Return Direction Control Valve
  Sequence Valve
  Double Acting Cylinder
 Single Acting Cylinder

Working/ Operation-

Extension/ Forward Stoke-

- A sequence valve causes operations in a hydraulic circuit to behave sequentially.

- In the given circuit a sequence valve is used to control the sequence of operations of a
double acting cylinder and a single acting cylinder.
- As soon as electric motor is started, the pump coupled with shaft on motor starts
pumping the hydraulic oil from reservoir towards the direction control valve.
- The oil will get filtrated before entering into the pump.
- This circuit can be operated by using both 4/3 direction control valve.
- At centered position pressure port of 4/3 direction control valve will not direct the
flow forward because it is blocked off port.
- When lever of 4/3 lever operated spring return direction control valve is operated, it gets
Ist position actuated which changes direction of fluid from port P to working port A.
- Pressurized fluid will be directed in cap end of double acting cylinder and cylinder will
take it forward stroke and fluid coming out from rod end of double acting cylinder will
be directed in tank through tank port T.
- At the end of forward stroke, fluid will continue to enter in cap end of cylinder and
also towards sequence valve, and will get blocked because of check valve.
- Pump continues to pump the fluid in mentioned components this results in increase of
pressure in sequence valve line which will shift the spool of sequence valve upwards
allowing the pressurized fluid to flow from pressure port P to working port A of sequence
valve.
- This makes single acting spring return cylinder to take its forward stroke.
- In this way sequence of double and single acting cylinder is achieved using single
sequence valve.
- If in any case circuit pressure rises above designed pressure level the pressure relief
valve will get in action resulting in release of excess pressure generated in the system.

Retraction Stoke-

- When II nd position of 4/2 direction control valve is actuated through lever,

then pressurized fluid will be directed from pressure port P to working port B.

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HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

- Because of this single acting cylinder will first retract because of spring force as it does
not find any restriction to return flow of fluid and then double acting cylinder will retract
because of actuation of IInd of 4/3 direction control valve.
- Fluid coming out from both the cylinders will be directed from working port A to tank
port T and will be delivered to tank.

Applications of Sequencing Circuit-

  Brewery Plants
  Cutting Applications
 Assembly Lines

4. Traverse and Feed Circuit-

These applications are used for applications where initial actuation speed of an actuator is
required slow and remaining speed required is fast and vice versa.

By using traverse and feed circuit two different speeds of an actuator can be achieved.

2/2 roller operated direction control valve plays an important role in the functioning of
traverse and feed circuit.

Complete circuit is given in Figure No. 2.5

Hydraulic components required for regenerative circuit experimentation-

  Reservoir/ Tank
  Filter
  Pressure Relief Valve
  Unidirectional Hydraulic Pump
  Pressure Relief Valve
  Hydraulic Motor
  4/3 Lever Operated Spring Return Direction Control Valve
  2/2 Roller Operated Spring Return Direction Control Valve
  Flow Control Valve with Built in Check Valve
 Double Acting Cylinder

Working/ Operation-

Extension/ Forward Stoke-

- As soon as electric motor is started, the pump coupled with shaft on motor starts
pumping the hydraulic oil from reservoir towards the direction control valve.
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HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

- The oil will get filtrated before entering into the pump.
- This circuit can be operated by using 4/3 direction control valve.
- Initially 4/3 direction control valve is at its centered position, where pressurized oil is
blocked off.
- When lever of 4/3 lever operated spring return direction control valve is operated, it gets
Ist position actuated which changes direction of fluid from port P to working port A.
- Pressurized fluid will be directed in cap end of double acting cylinder and cylinder
will take it forward stroke.
- During forward stroke fluid coming out from rod end has to flow from flow control
valve as check valve does not allow fluid to pass through it.
- And thus piston will take its forward stroke in controlled manner.
- 2/2 roller operated spring return direction control valve is positioned such that after half
stroke of piston, roller of 2/2 roller operated spring return direction control valve is
pressed by rod of double acting cylinder.
- When cylinder reaches half of the total stroke roller of 2/2 roller operated spring return
direction control valve is pressed and pressurized fluid from port P of 2/2 roller operated
spring return direction control valve starts flowing to working port A because of this
remaining half stroke of cylinder will be carried out as fast speed and fluid will be delivered
to tank through tank port T via working port B of 4/2 direction control valve.
- If in any case circuit pressure rises above designed pressure level the pressure relief
valve will get in action resulting in release of excess pressure generated in the system.

Retraction Stoke-

- When lever of 4/2 lever operated spring return direction control valve is operated, it gets
IInd position actuated which redirects the pump flow from pressure port port P to
working port B of 4/2 lever operated spring return direction control valve .
- Pressurized fluid will directly go to rod end side of double acting cylinder through check
valve as working port of 2/2 direction control valve will be blocked and fluid will find
restriction from flow control valve.
- And thus we get retraction of double acting cylinder.

As in a single stroke two different speed can be achieved though this circuit hence called
as traverse and feed circuit.

Applications of Traverse and Feed Circuit-

3. Bottle Industries
4. Automobile assembly Lines

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.2 Title: EXPERIMENTATION ON ADVANCED HYDRAULIC TRAINER

Conclusion-

In this experiment we practically performed hydraulic circuits like regenerative circuit, speed
control circuit, sequencing circuit, traverse and feed circuit and also got proper understanding
of their applications and various combinations through which same circuits can ne constructed
and made to operate properly.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

Experiment No.4:

Test on Pressure Relief Valve

Aim: Test on Pressure Relief Valve

Operation:
This relief valve remains closed as long as the pressure at 1 is lower than the "Cracking Pressure"
when the pressure at 1 is greater or equal to the "Cracking Pressure", the fluid flows from 1 to 2.
In this case, port 2 is already connected to its own individual tank. Port 2 is not accessible.
Features:
When the pressure in the system increases above a preset value, the relief valve opens and lets the
fluid flow to the tank. This component acts only in case of an emergency, to bring down the
pressure to its set value to protect components from pressure surges. The pressure setting can be
done when editing the valve or when simulating a diagram.
Experiment:

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

In this experiment we will observe the effect of Cracking Pressure on Linear Position of Piston
(load carrying Capacity of Piston) for a varying load which increases linearly over the Piston
Extraction Stroke.

Components Required:
Automation Studio Software
• Hydraulic Reservoir
• Displacement Pump
• Pressure Relief Valve
• 4/2 Way Directional Valve
• Double Acting Cylinder
• Pressure Gauge
• Filter

Procedure:

• To open the Automation Studio Software, double click on Automation Studio

Software Icon. You can adjust the Screen working area by using the Zoom options in
the top menu.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

• Now we have to build a Hydraulic Circuit. On the left hand side, Component library is
provided for different systems like Hydraulic, Pneumatic and Electrical Control etc.
• Click on Hydraulic Module. At the bottom of modules list of commonly used components
are provided.

• Now drag and Drop the following components on to the Working space as shown in
following screen. Components required are Hydraulic Reservoir, Fixed Displacement
pump, Pressure relief valve, 4/2-Way NC Valve, Double Acting Cylinder, Pressure gauge
and Filter.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

• Now connect the components to build the hydraulic circuit as shown in following figure.

• We need two Hydraulic Circuits to test the behavior of Pressure Relief valve. Press
CTRL+A to select all components. Right click on any component and click on Copy.
Paste it on the same page.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

• We will now load the piston and see the behavior of the piston with respect to the Linear
Position in Simulation for Different cracking pressures of Pressure Relief Valve.
i.e. We have to observe the Linear Position of Piston for a particular Cracking Pressure
of Pressure Relief Valve.

• Double click on Double acting cylinder. Its Property window will Open. Click on
Resistive Force curve.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

• By using Resistive Force Curve you can load the piston gradually. Select "1" from Curve
Parameter, which represents Extraction Stroke of the Piston. Also Define maximum
force for 100% position of piston. For 100 abscissa put 10000 daN force.

• Click on "Apply" and close the window. Do the same thing for second Piston of second
Circuit.

Now to measure Linear Position of the Piston, click on insert component dynamic measuring
Instrument.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

Click on Piston once, then again click on piston and drag the mouse and leave it. It shows
you Recorder Window where you can measure the different properties of Piston like
"Position".
Select "Linear Position" of Piston with Unit "mm".

• Do this for second Piston. Your Screen will look like the following figure.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

Pressure relief valve is having 80 bar pressure by default. Now simulate the
Circuit and observe the behavior of the Piston. For Simulation Click on
Green Button and operate the Directional Valves by clicking on the Push
Button on the Valve.

In Simulation you can see that Linear Position of both Pistons is the same (368 mm) for the same
setting of cracking Pressure(80 bar). Piston stops at 368 mm due to the applied resistive force.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

• Now let us increase the cracking Pressure of second pressure relief valve. Double click on
Pressure relief valve. Property window will open. Click on "Technical Data". Change the
cracking pressure to 100 bar. Click on "Apply" and close the window.

• Simulate the Circuit and see the behavior.

In first circuit, piston extension is same as previous due to 80 bar, but in second circuit for 100
bar cracking pressure Linear Position of Piston is 455 mm.
i.e. Piston is able to push the load further due to increased Cracking Pressure.
Similarly you can decrease or increase the cracking pressure of relief valve to see the Circuit
Behavior.

• Check the Linear Position of Piston for Following Cracking Pressure of Relief valve.
Sr. No Cracking Pressure of Relief valve (bar) Linear position of Piston (mm)

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 1 TITLE: TEST ON PRESSURE RELIEF VALVE

1 70
2 80
3 90
4 100
5 115
Conclusion: As the Cracking Pressure of the Pressure Relief Valve is Increased, the Linear
Position of Piston or Load handling capacity of the Piston Increases.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

Experiment No.5

Design of Intensifiers in Hydraulic System

Aim: Design a 3:1 Pressure Intensifier to achieve specific output pressure and Load handling
Capacity.

Operation: A hydraulic intensifier is a hydraulic device used for transforming hydraulic power at
low pressure at High Volume into a reduced volume at higher pressure. Hydraulic Pressure
Intensifier is also known as a “Pressure Amplifier” or “Booster”.

Pressure Intensifier has four ports.

Port 1 is inlet for Extraction of Intensifier.
Port 3 is inlet for Retraction of Intensifier.
Port 4 is a Pressure Measuring Port
Port 2 is discharge port (with high pressure) connected to the Cylinder.

Intensifier has three types of volumes i.e. Piston side Volume, Rod Side Volume and Rear Side
Volume. Pressure intensifiers are available with Volume ratio of 3:1, 5:1 etc.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

If we consider 3:1 ratio then Piston Side Volume should be three times of Rear Side Volume. Rear
side area produces higher pressure (Pressure at discharge) than the Input or system pressure. If we
consider intensifier with 1:1 ratio then Input pressure and discharge pressure will be same.

Pressure Intensifier is used to handle heavy loads with low pressure Pump which eliminates the
use of high pressure Pump in the Circuit. Suppose Cylinder is provided with some amount of load
and low pressure pump is not able to produce that much pressure which requires to carry the full
load. In such case Intensifier is used.
Port 2 i.e. discharge port of intensifier is connected to the piston side port of the Cylinder. Hence
Rear side volume of the intensifier should me equal or more than the Piston side volume f the
Cylinder so that it can handle the load with low power Pump.

Let us consider example of Rubber Compression Machine:

To compress the Rubber Sheet, higher output pressure is required and that can be achieved by
using High pressure pump but it is very costly. To overcome this Hydraulic pressure Intensifier is
used.
Suppose to compress a full Rubber sheet a load of 5000 daN is required i.e. Two piston will have
a resistance of 5000 daN Force. System Inlet Pressure is 70 bar.

Pressure Intensifier works on the following equation

(High Discharge Pressure/Low Inlet Pressure) = (Area of Poston/Area of Rod) Pressure
intensifiers are available with area ratio of 3:1, 5:1 etc.

If Area ratio is 3:1 then

High discharge pressure = 3 X 70 bar = 210 bar.

So output discharge pressure is 210 bar to compress the Rubber Sheet.

Components Required:

Automation Studio Software

• Hydraulic Reservoir
• Displacement Pump
• Pressure Relief Valve
• 4/3 Way Directional Valve
• Hydraulic Intensifier
• Double Acting Cylinder
• Pressure Gauge
• Flow Meter

PCCOE&R DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Procedure: To open the Automation Studio Software, double click on Automation Studio
Software Icon. You can adjust the Working Area of the Page by clicking on Plus sign which is
provided on the top.

• Now we have to build a Hydraulic Circuit. On the left hand side, Component library is
provided for different modules such as Hydraulic, Pneumatic and Electrical Control etc.

• Click on Hydraulic Module. At the bottom of modules list, the components which are
commonly used are seen.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

• Now drag and Drop the following components on to the Working space as shown below.

Components are Hydraulic Reservoir, Fixed Displacement pump, Pressure relief valve,
4/3-Way NC Valve, Double Acting Cylinder(2), Pressure gauge(5) and Flow Meter.

• We need Pressure Intensifier Component. Double click on Hydraulics module which gives
you the component wise list of hydraulic system.

• Double click on Pumps and Power Units which gives you list of different types of pumps.
Now click on Amplifiers and drag the Hydraulic Pressure Amplifier onto the working
space.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

• First we will build a hydraulic circuit without Intensifier. Now arrange all the components
as shown below.

• To rotate the Cylinder or any component you can use Layout Toolbar

Click on Cylinder and use left or right rotation icon from the layout toolbar to rotate the
cylinder. Do this for both cylinder and rotate them vertically.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

We need to change the connection point side of the right hand side cylinder so that it will
be easy to connect the two cylinders. For this click on the cylinder and use vertical flip
option from layout tool.

PCCOE&R DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

• We have to connect one component to other component. Each component has red colored
nodes for connections. For making a connection click on node of the component and move
cursor to the node of another component and click on it so that they will get connected.
Connect all the components as shown in following figure except Intensifier.

• We have to apply load to the Cylinder. Double click on Cylinder. Its Property window will
open. Click on Technical data.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

PCCOE&R DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Now change the values of following parameters and click on apply.

Piston Diameter-50 mm
Rod Diameter- 20mm

• Click on resistive force curve. Resistive force curve is used to define a opposing external
force on the Cylinder Rod during Extraction and Retraction. We have to define an
Opposing Force external force for the extraction of the cylinder.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Horizontal Axis represents the extraction of the cylinder from 0 to 100 % while vertical Axis
represents Force from 0 to 10000 daN. Here we will set a force of 5000daN for the 100% extension
f the piston.
On the second line of abscissa put extension as 100 and maximum force as a 5000daN and press
enter button of the keyboard and click on apply. Observe the following screen; Curve is showing
5000 daN force at the 100% of extension. Force is linearly increasing from 0 to 5000 with respect
to 0 to 100% Position of piston. Close the window.

• Apply the same procedure for second cylinder.

• Now double click on directional valve. Property window will get open. Click on Builder
property.

Here we have to change the valve operators i.e. lever and spring to push button.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Double click on lever. It will show you the entire list of different kinds of valve operators.
we have to replace the lever by push button.

• Double click on push button. You can see that lever is replaced by Push button. Do the
same for the spring. Close the window.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Now we will measure Piston position by using Insert Dymanic Component Measuring
Instrument

Click on 1 st Option and then click on Cylinder and drag the mouse. It will show you list of
parameters which can be measured during simulation. Select Linear Position and close the window
and do this for another cylinder.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

On the top menu, Green button is provided for Normal Simulation. Click on it.

• Click on the push button on the valve (Left hand side push button) to extend the Cylinder
and observe the behavior of the circuit

You can observe that piston stops at a particular position i.e. 182 mm due to the applied resistive
external force.
Note: Linear Position of the both cylinders may be different due to actual length of Hydraulic line
from the Valve. If it is same for both the cylinders then Linear position will be same.

Also system pressure is 70 bar and at output side (I.e. at cylinder) it is also 70 bar.
We need more pressure to extend the piston at the output side without changing the Pump
configuration. Stop the simulation by clicking on Red button

In such cases, Pressure Intensifier is used. Its basic function is to produce more pressure than the
system pressure to handle the loads. Right click on Intensifier and click on context Help. It will
show you basic information of the component.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

• Now connect the Intensifier into the Circuit as shown in following figure.

• Intensifier has a rear side volume which produces higher pressure according to load. Rear
side area is connected to the Piston side of the Cylinders, hence Rear side volume of
Intensifier should be equal to or greater than the sum of both the Piston side volumes of
both the cylinders, so as to push the Cylinders for its full stroke length.

Intensifiers are available with 3:1, 5:1 or 7:1 pressure ratio. We will consider Intensifier of
3:1 ratio. i.e. Piston side volume should be three times of Rear side volume.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

Design Considerations:
• Rear side volume of Intensifier should be equal to or greater than the sum of both the Piston
side volumes of both the Cylinders.
• Piston Side Volume of Intensifier should be three times of Rear Side Volume of the
Intensifier.

In above Example Both the Cylinders are having same specifications.

Piston side volume of one cylinder is 981.75 cm3 hence piston side volume of both the
cylinder together is
Total Piston Side Volume = 2 X 981.75 = 1963.5 cm3
Hence Rear side volume of the Intensifier should be equal to or greater than 1963.5cm3.
Also to have a 3:1 ratio, the Piston side volume of the intensifier should be three times of
1963.5cm3.

Piston side volume of intensifier = 3 X 1963.5 = 5890.5 cm3.

To achieve this value we have to resize the Intensifier by changing values of its parameters.

• Double click on Intensifier. Property window will get open. Click on Technical data option.
Put the following values
]
• Piston Diameter=61.5mm
• Rear piston diameter=35.5mm
• Rod diameter=20mm

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

• Stroke=2000mm

Click on the "More" option and change the Internal Leak value to zero.

In Calculated data you can observe that :

• Rear Side Volume = 1979.59 cm3 and
• Piston Side Volume=5941.14 cm3
• i.e. Piston side volume is approximately 3 times more than Rear side volume.

• Start the Simulation and operate the valve. Observe the behavior of the system

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

You can observe that System has produced higher pressure i.e. 210.86 bar to handle the 5000 da
N force. System pressure is 70 bar while intensifier output pressure is 210.86 bar. I.e. Output
Pressure is three times more than System Pressure.

• You can change the resistive force curve of both Cylinder and observe the pressure drops at
the Cylinder, Linear Position of any one Cylinder.

Sr. No. Force(from resistive Output Pressure(at the Cylinder 1 Linear Position
curve) in daN Cylinder) in bar in mm
1 5000

2 6000

3 7000

4 4000

Note: Linear Position of the both cylinder may be different due to actual length of Hydraulic line
from the Intensifier. If it is same for both the cylinder then Linear position will be same.

Conclusion:

1) When System pressure is 70 Bar and Intensifier with the 3:1 ratio is used then output pressure

is:

………………………………………………..……………………………………………..

2) If load is increased beyond 5000 daN, then:

………………………………………………………………………..………………
……………….……………………………………………………………………………………

PCCOE&R DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 5 TITLE: DESIGN OF INTENSIFIERS IN HYDRAULIC SYSTEM

………………………………………………………

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

Experiment No.6

Design of Air Distribution in Pneumatic System

Aim: Design a proper Air Distribution pneumatic System.

Operation:
An Optimum compressed air distribution is an energy pipeline like an electricity cable which
transports compressed air energy with as few losses as possible, i.e. with the lowest reduction of
the:
- Flow Pressure (Pressure drop due to narrow points in the pipeline)
- The air quantity (leaks)
- The air quality (rust, welding scale, water etc.)

In Practice, compressed Air tubes (Main and Distribution Line) are frequently selected without
sufficient knowledge and without taking energetic issues into consideration with the result that in
80 of 100 firms, often 50% and more of the compressed air energy are destroyed before they can
reach the usage points.

The correct planning of a network has direct influence on the performance of the machines and the
cost of producing compressed air. Select the Correct Diameter taking into account the Flow
Rate required and the permissible Pressure Drop. The pressure drop from the air receiver in
the compressor room to the final connection point should not exceed 0.1 bar.

In an optimally designed compressed air network, the pressure loss spilt into:

• Less than or equal to 0.03 bar for main line.

• Less than or equal to 0.03 bar for Distribution line.
• Less than or equal to 0.04 bar for Connection line.
• Less than or equal to 0.1 bar from the source to Equipment

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

In this experiment, we will consider air distribution design of Main Line. With following input
data we will design air distribution system to maintain a pressure drop of 0.03 bar across the main
line:

• Compressor: 1200rpm, 360LPMS, 300 cub cm/rev

• Pressure Relief valve: 8 bar
• Line Length fixed at 150m
• Flow to be Maintained approx. 340 to 370 LPMS
• Pressure drop to be maintained <=0.03bar
• Run the Simulation and observe Differential Pressure Drop on the Line
• Keep changing the value of the DIAMETER of the Line till you achieve the
DIFFERENTIAL PRESSURE as <=0.03 bar

Components Required:

Automation Studio Software – Pneumatic Library:

• Pneumatic Compressor

• Variable Pressure Relief Valve

• Bidirectional Motor

• Speed Gauge

• Pressure Gauge

• Flow Meter

• Exhaust

Procedure:

• To open the Automation Studio Software, double click on Automation Studio Software
Icon.

• You can adjust the working Space of the Page by Zooming in and out, by clicking on Plus
sign which is provided on the top.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

• Now we have to build a Pneumatic Circuit for the AIR Distribution System. On the left
hand side, the Component libraries are provided for different systems such as Hydraulic,
Pneumatic, PLC, Electrical etc.

• Click on Pneumatic Module. At the bottom of the modules list, the list of commonly used
components are seen.

• Now drag and Drop the following components on to the Working space as shown in
following screen. Components are Pneumatic Compressor, Pressure Relief Valve,

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

Bidirectional Motor, Exhaust, Speed Gauge, Pressure gauge (2 no's) and Flow Meter (2
no's).

Note: Select Speed Gauge from the Pneumatic Library -> Measuring Instruments -> Speed
Sensors.

• Arrange and connect all the Components as shown below. For the connection click on node
of the component and move cursor to the node of another component and click on it so that
they will get connect.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

• Now double click on Pneumatic Main Line, which is the line connecting the two Flow
Meters.
• Its Property window will open as shown below.

• Click on Visual Parameters in left menu. Change Line Thickness to 15. Click on apply and
close it.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

• Double Click on the Compressor. It's Property window will open as shown below. Click
on "Displayed Information" in the left menu.

• Enable Nominal Speed, Displacement and Rated flow properties so that they will be visible
on working space. Click on apply and close it.

Adjust the properties by moving them close to the component.

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

• Follow the same procedure for Main Line and enable the Diameter and Length Property.
For Pressure relief valve, enable Cracking Pressure Property.

• Now for Air Distribution System we need the following settings:

1) Compressor: 1200rpm, 360LPMS, 300 cub cm/rev

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INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

2) Pressure Relief valve: 8 bar

3) Line Length fixed at 150m
4) Flow to be Maintained approx at 340 to 370 LPMS
5) Pressure drop to be maintained <=0.03bar
6) Run the Simulation and observe Differential Pressure Drop on the Line
7) Keep changing the value of the DIAMETER of the Line till you achieve the
DIFFERENTIAL
PRESSURE as <=0.03 bar

• To measure the differential Pressure, click on the "Insert Differential Dynamic Instrument".

• Click on both the end nodes of Line to measure the differential pressure for Main Line.
Select "Differential Pressure" option and stability as 0.001. Click on apply and close it.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

• We have to maintain flow of Compressor approx 340 LPMS to 370 LPMS. So double Click
on Compressor and Click on Technical Data Property. Change the Displacement to
300cv3/rev.

On the right hand side you can see that calculated Flow is 360 LPMS. Click on Apply and
close it.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

• We have to fix the Main Line Length to 150m. Double click on Line. Its Property window
will open. Click on Technical Data and Change the Length to 150m. Apply and close it.

• Now Simulate the Circuit and see the behavior of the circuit. For proper Air Distribution
Design, Pressure Difference should be not more than 0.03 Bar.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

In the Simulation you can observe that differential Pressure across the Main Line is 7.27 bar which
is far greater than 0.03 bar. Now to maintain the system we need pressure difference near about
0.03 bar and also we have to maintain flow between 340 to 370 LPMS across the Main Line.

Now we can change the Diameter of main Line to maintain the Pressure Difference.

Double Click on Main Line and Change the Diameter to say 25mm. Apply and close the window.
Start the Simulation.

You can observe that Pressure Difference is 0.027 bar which is correct and Flow is also Maintained
which is 344.95 LPMS.

Now let us study the Complete Closed Air Distribution System. Open Air distribution closed loop
circuit which is provided to you.
In an optimally designed compressed air network, the pressure loss spilt into:
• Less than or equal to 0.03 bar for main line.
• Less than or equal to 0.03 bar for Distribution line.
• Less than or equal to 0.04 bar for Connection line.
• Less than or equal to 0.1 bar from the source to Equipment.

Simulate the Circuit:

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 6 TITLE: DESIGN OF AIR DISTRIBUTION IN PNEUMATIC SYSTEM

In the Simulation you can observe the entire Closed loop Air Distribution System. Observe the
Pressure Difference across the Main Line, Distribution Line and Main line to Equipment
connection.
Note: Due to Closed Loop Network, Second segment on the right hand side is getting air flow
from both directions of the loop.

Conclusion:
• Pressure Drop across Main Line is 0.02 bar which is less than 0.03 bar.

• Pressure drop across Distribution line 0.001 which is less than 0.03.

• Pressure Drop across Source and Equipment is 0.05 bar which is less than 0.1 bar.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

Experiment No. 7

Design of Hydraulic Lift Design of Hydraulic Lift

Hydraulic Forklift:

Most of us probably have a general idea of what a forklift is, but there are a number of different
classifications, power sources, sizes, uses and new technologies that make up these useful
machines. Some are used on rugged construction sites and lift heavy materials and equipment
while other forklifts drive themselves inside modernized warehouses. Whether indoors or out,
forklifts are a necessary tool in most warehouses and an integral part of our industries.

Forklifts might seem more industrial than inventive, but consider that they're typically the size of
a small car yet they can lift loads that are thousands of pounds, often several stories into the air,
all without tipping over. These machines work long hours each day lifting and moving heavy loads
to keep our manufacturing, automotive, aerospace and other industries humming along.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

Forklifts have been around for nearly 100 years and they continue to make our jobs more efficient
just as much as they did when they were invented. Whether they're forklifts that use batteries,
liquid propane, hydrogen fuel cells or another power source, without these machines we wouldn't
be able to build ship or move manufactured goods efficiently.

Experiment:
In this experiment, we have to study two different circuits. One is Hydraulic Lift circuit using
Pressure Intensifier to lift the Material or Load. Second Circuit is Hydraulic TILT Circuit which
is used for releasing the Material or Load and Un-Load to the particular space. In this circuit we
are using Flow Divider Component which divides Fluid flow in equal proportion.

Hydraulic "Lift Circuit" for Forklift:

Hydraulic Lift Circuit is nothing but a Pressure Intensifier Circuit. You can follow the Expt. No.
6 procedure for creating the Hydraulic Lift Circuit. But we will change the Directional Valve to a
Joystick operated Proportional valve. In Expt.6 we have used two cylinders. But in "Lift Circuit"
of Forklift, One Cylinder is sufficient to lift the Load. So we will use only one Cylinder for Forklift.

• We have to make some changes in circuit. To operate the Lift Circuit we will use Joystick
and a Proportional Valve instead of a Push Button Operated Valve.
• Click on Proportional Hydraulic Library. Drag 4/3 way electrically controlled valve and
Joystick from Library. Connect them as shown below.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

• Now this is the Hydraulic Lift Circuit. To operate it with Joystick we have to Link the
• Joystick to the Proportional Valve.

• Double click on Cylinder. Click on Builder tab. On the Right hand side Adaptor Option id
there. You can select any type of Adaptor for Rod. Select and click on apply.

• Now we have to load the piston. Provide following data to Cylinder by using Technical
data property.

Piston Diameter = 50 mm

Rod Diameter = 20 mm

Stroke = 500 mm

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USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

Inclination = 90 degree

External Load = 6000Kg

• Double Click on Joystick. Its property window gets open. Click on Configuration.

Set minimum signal to -10 and maximum to 10. Click on apply and close it.

• Now double click on Proportional valve. Its property window will open.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

• Click on the Left hand side valve operator (solenoid) of the valve symbol which is located
at the top left of the window. Under basic data set Minimum signal as -10 and maximum
signal as 10.

Set Minimum force to -12 daN and Maximum force to 12 daN. Click on Apply. Don’t close
the window.

• Now we have to link the Proportional valve to the Joystick. Click on variable assignment.

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USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

• This window shows Component variables and Internal links. You can link the Component
variable to the other component variables like Joystick X or Y signal, Linear position of
cylinder etc.

• Select "Input Signal" i.e. the second line from component variable and click on "JY_X"
signal which is the Joystick X i.e. Horizontal signal (-10 to +10). Click on apply and Close
the window. You can observe that question mark on the left hand side of the valve is
replaced with JY_X signal.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

• Now double Click on Pressure Intensifier. Click on "Technical Data". And feed the values
as shown in below screen.

This is a 3:1 pressure intensifier. Piston sode volume is 5449.42 cm3 which is three times
greater than Rear side volume, which iss 1815.84 cm3. Intensifier has to produce upto three
times higher pressure than input pressure.

• Set Cracking pressure of Pressure relief valve to 150 bar. Lift Cylinder is having 6000 Kg
of Load. To carry this load Pressure Intensifier is required.

• Start the Simulation. Click on Joystick. Move the Joystick Pointer in horozaontal +X
direction using mouse.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

In simulation you can observe that Intensifier has produced 450 bar pressure to handle the 6000Kg
of load with low input system pressure of 150 bar. Save the Circuit.

Tilt Circuit:

By using Lift Circuit you can lift the given Load/Material, then you can carry that load to the target
location. At that location you have to release that Load or Material. For this a TILT Circuit is
essential.

In Hydraylic Tilt Circuit we have to use two Cylinders because its easy to release the material by
two cylinders than a single cylinder.

Now During the tilt operation, load may be different on both cylinders. Hence it is essential to use
a flow divider component which can divide the flow in same proportioan.

• For Tilt Circuit drag the required Components and build a circuit as shown in following
fig. Don’t use any component from Lift circuit.

Note: We need both circuits on same page. On one side you have Lift Circuit. Now create Tilt
circuit in other side.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

• Flow Divider:

From Hydraulic Library click on "Flow Valves" library. Select Flow divider and drag the
“2 way ratio Rotary Flow Divider” onto working space.

• Double click on it. In technical data it shows you two displacement options.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

• We can connect Joystick to both the proportional valve. Follow similar process for both the
valves which is used for Lift Circuit and then link the Joystick to Both the valves.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

Now simulate the circuit. Operate the Joystick.

In simulation you can observe that, Flow divider is producing same flow of 80.34 L/min on both
the sides which is important task for Tilt Operation. Due to this, both the Cylinders are having
same Linear position while operation.

• Now let us see simulation of both the Circuits.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

USTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 7 TITLE: DESIGN OF HYDRAULIC LIFT

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering & Research, Ravet

Experiment No 8

Design of Hydraulic Drilling System

Hydraulic Drilling System (Manual):

Hydraulics Operations are used for many operations like drilling. In above diagram, manually controlled
hydraulic drilling machine is shown. Cylinder B is used for drilling operation and Cylinder A is used for
Job Fitting operation.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

In this experiment we are going to build above circuit with two cylinders and two joystick operated valves.
Valve A is controlling Cylinder A and Valve B is controlling Cylinder B (Drilling Cylinder).

Components Required:
Automation Studio Software:
• Hydraulic Reservoir
• Displacement Pump
• Pressure Relief Valve
• 4/2 Way Directional Valve
• Double Acting Cylinder
• Filter
• Check Valve

Procedure:

• To open the Automation Studio Software, double click on Automation Studio Software Icon. You
can adjust the Working Area by clicking on Plus sign which is provided in the top menu.

• Now we have to build a Hydraulic Circuit. On the left hand side, Component library is provided
for different systems like Hydraulic, Pneumatic and Electrical Control etc.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

• Click on Hydraulic Module. At the bottom of the modules list, a list of commonly used components
are provided with their symbols.

• Now drag and Drop the following components on to the Working space as shown in following
figure.

Components are Hydraulic Reservoir, Fixed Displacement pump, Pressure relief valve, 4/2-Way
NC Valve, Double Acting Cylinder, Filter and Check Valve.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

Now connect all the components and create the circuit as shown in following figure.

• In this Circuit we are using Overhead Cylinder for Drilling Operation and below one for Job fitting
operation. We have to connect adaptors for the cylinders.

• Double click on overhead cylinder. Click on Builder. Select any one type adaptor for it and change
its Body length to “3”.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

For other Cylinder change its adaptor only.

• Now Double click on directional control valve. Click on Builder.

• In this valve, left hand side valve operator is a Lever. We have to replace the lever with another
valve operator i.e. “Joystick”.

• Double click on Lever which shown in RED color in above diagram. Entire list of different types
of valve operator gets open. Find Joystick valve operator. Click on it. Press Ok. Apply the Changes
and close the window. Do the same for the other valve.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

Now your circuit will look like the following figure.

• You can use TEXT option for comments. Valve A is used for Fitting operation and valve B is used
for Drilling operation.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

In the Simulation you can see that Human is using Joystick A to fit the Object onto drilling machine bed
and with Joystick he is doing Drilling operation.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL FLUID POWER LAB MANUAL
EXPERIMENT NO. 8 TITLE: DESIGN OF HYDRAULIC DRILLING SYSTEM

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.1 Title: TEST ON GEAR PUMP

Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering &Research, Ravet

Experiment No: 1
Test on Gear pump and determination of performance characteristics

Aim: Study of Gear pump and plotting performance characteristics.

Theory

Pump converts mechanical energy into hydraulic energy. Mechanical energy is delivered to
pump via a prime mover such as electric motor, petrol engine, diesel engine etc.
Classification of pump:

1. Non Positive Displacement pumps (Hydrodynamic Pumps):

These pumps are used for low pressure high volume flow applications. They are not capable of
withstanding high pressure and are of little use in fluid power field. They are primarily used for
transporting fluid from one location to other. Types: Centrifugal (impeller) and axial (propeller)
pump.
2. Positive Displacement Pumps:
This type is universally used for fluid power systems. As name implies, a positive displacement
pump is capable of overcoming the pressure resulting from mechanical loads on systems as well
as resistance to flow due to friction.
There are mainly 3 types of pumps:
 Gear pump
 Vane pump
 Piston pump
Advantages of Positive Displacement Pumps over Hydrodynamic Pumps
i) High pressure capacity
ii) Small, compact size
iii) High volumetric efficiency
iv) Small change in volumetric efficiency throughout design pressure range
v) Great flexibility of performance. (Can operate over a wide range of pressure requirements
and speed range)

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.1 Title: TEST ON GEAR PUMP

Pumping Theory:
All pumps operate on the principle where by a partial vacuum is created at the inlet due to
internal operation of the pump. This allows atmospheric pressure to push the fluid out of the oil
tank and into the pump intake. The pump then mechanically pushes the fluid out to the discharge
line. Principle of working of Positive Displacement Pump is shown in Figure 1.
These pumps do not pump pressure. Instead they produce fluid flow; the resistance to this
flow produced by hydraulic system is what determines pressure. If resistance to flow is infinite
there will be no place for fluid to go as pump continues to create flow. Thus pressure rises infinitely
theoretically unless some component fails or pressure relief is provided in same way. Thus for
positive displacement pump a pressure valve is needed.

Fig. 1 Principle of working of Positive Displacement Pump

Gear Pump (Construction and Working):

It develops flow by carrying fluid between its two meshing teeth on external gears. One of the
prime gears is connected to the desired shaft connected to prime mover. The second gear is driven
as it meshes with the driving gear. Oil chamber is formed between gear teeth, pump housing and
side wear plates. The suction side is where teeth came out off mesh and demesh and its here where
the volume expands bringing about reduction in pressure below atmospheric pressure as oil supply
tank is vented to atmosphere. Discharge side is where teeth go into meshing and here volume
decreases between mating teeth since pump has positively internally seal against leakage, oil is
positively ejected in outlet port. Figure 2 shows the schematic of external type Gear pump.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.1 Title: TEST ON GEAR PUMP

Fig. 2 Gear Pump

Experimental Setup

The gear pump is a positive displacement type of pump and consists of a pair of helical spur gears
meshed with each other and house closely in a casing. One gear is fitted with and external shaft
that is coupled to AC motor (1440 RPM). In an oval shaped pump casing, the two involutes curved
double helical gear wheels are mounted on the shafts.

These gear locked during rotation in suction chamber and as they rotate, the liquid between the
pump and casing and the space between the teeth is transferred to the delivery chamber.

The test pump is coupled to a 1 HP AC motor (220 Volts single phase). A suitable switch is
provided. The pump sucks the oil from reservoir and delivers to the collecting tank that is provided
with an overflow arrangement. The collected oil is transferred back to the reservoir through a ball
valve. Suitable pressure and vacuum gauges are fitted in the pipe lines, to measure suction and
delivery head. A modified gate valve is fitted in delivery side that prevents complete shut off. An
energy meter with a stop watch is provided to measure the input power

Note: Regular diesel oil (HSD) can be used as a test oil in the gear pump test rig. This is
economical and widely available.

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.1 Title: TEST ON GEAR PUMP

Procedure

1) Fill the supply tank with oil to the required height say three fourth of the tank .
2) Open the gate valve in the delivery pipe fully.
3) Start the motor. Oil flows in.
4) Throttle the gate valve to get the required head.
5) Note the following reading.
a) Pressure gauge and vacuum gauge reading
b) Time for 1 cm rise in collecting tank – t sec
c) Distance of pressure gauge on delivery side from the pump axis - X m
Take 4 to 5 sets of readings by varying the delivery pressure.

Specifications
1.
Collecting tank area: 0.248*0.248 m2
2. Distance of pressure gauge on delivery side from the pump axis = 0.835 m
3. Oil specific gravity – 0.88 (HSD)
4. Total Head = Suction Head + Discharge Head + Distance of pressure gauge on delivery side
from the pump axis
Pump output = ρ*g*Qa*Hm
Pump Input = Watt Meter Reading
η = Output/input
Observation Table:
Sr. Discharge Vacuum Time Discharge Pump Pump Overall
No Pressure Gauge For 1 cm rise flow (Qa) I/P O/P efficiency
Reading Reading of oil in the tank *10^-3, kW kW ηo
(Pd), in (Ps) in in Sec. m3/sec
kg/cm2 mm of Hg

1 30 390 27 0.0346 650 91.59 18.78

2 50 300 31 0.0301 795 131.40 22.03

3 60 280 35 0.0267 865 139.36 21.48

4 70 260 39.5 0.0237 960 144.11 20.01

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.1 Title: TEST ON GEAR PUMP

Sample Calculations:
Actual Discharge (Qa) = Area of measuring tank * Rise in oil level / Time m3/sec
Power generated by pump = Ɣ*Qa*Hm
Manomatric Head (Hm) = Suction Head + Discharge Head + Distance of pressure gauge on delivery side from
the pump axis -
Efficiency of pump = Output power/ watt meter reading
1.) Qact=V/t= (0.26 x 0.36 x 0.01)/ 27 = 3.466 x 10^-5 m^3/sec
2.) Hd=Pd/Y = (30 x 9.81 x10^4)/9810 = 300 m
Hs= (Ps x 133.33)/Y =(390 x 133.33)/9810 = 5.30 m
Zd = 0.835 m (given)
Hm = Hd + Hs + Zd = 306.135 m
3.) Density = 880 kg/m^3
Pout = (880 x 9.81 x 3.466 x10^-5 x 306.135) = 91.59 Watts
Pin = ( 0.75 x 650 ) = 487.5 watts
4.) Overall Efficiency
ηo = (Pout/ Pin) x 100
ηo = (91.59 / 487.5 ) x 100
ηo =18.78 %
In this way rest of the calculations are done.
Conclusion:

1. The positive displacement vane pump is giving discharge irrespective of pressure (i.e. Qth is
horizontal). Actual discharge (Qa ) is deviating horizontal due to oil leakage from high
pressure side to low pressure side due to eccentricity of rotor and cam ring. Accordingly
efficiency varies.
2. High discharge pressure gives low efficiency as internal leakage increases with pressure.
3. Input to pump will not meet origin but will have a definite value at Pd=0 or at start this power
is used to overcome frictional losses.
Graphs:
Plot following graphs
1. Discharge Vs head
2. Discharge Vs output power
3. Discharge Vs efficiency
4. Discharge Vs input power

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING

HYDRAULICS AND PNEUMATICS LAB MANUAL
Experiment No.1 Title: TEST ON GEAR PUMP

PCCOE&R, DEPARTMENT OF MECHANICAL ENGINEERING