Basic Hydraulic System

1
Assembly & Maintenance of

Pneumatic & Hydraulic System
(SED 23103)
Basic Automation System
(SRD 23403)
Malaysian Spanish Institute

MSI Pneumatic System
v5
Assembly & Maintenance of Pneumatic & Hydraulic System
(SED 23103) - (Assessment)
1. Basic Pneumatic System
Technical Report 10%
Mini Project 10%
Test 10%
Exam Practical 20%

2. Basic Hydraulic System
Mini Project 10%
Test 10%
Exam Practical 20%

Total Marks (SED 23103)
Mini Project 20%
Test 20%
Exam Practical 40%
100%
2

MSI Electrical System
(SED 23103) - (Assessment)
Pneumatic Power
Pneumatic Control
Pneumatic Actuator

Hydraulic Power
Hydraulic Control
Hydraulic Actuator

End of Course
Comparison of Power System
Selection of Power System

3

(SED 23103) (Study Planning)
Week 1 6 (Study week)
Week 7 (Practical Test)

Week 8 13 (Study Week)

4

Extra Assessment
Attitude marks
1. Attendant (per/minute = 0.019%)
2. Cheating (per/cheat = 1%)
3. Attire (per/day = 5%)
4. Behavior (per/hour = 5%)

(SRD 23403) - (Assessment)
Technical Report 7%
Mini Project 7%
Test 7%
Exam Practical 14%

Technical Report 7%
Mini Project 7%
Test 7%
Exam Practical 14%

3. Basic Electrical System
Technical Report 6%
Mini Project 6%
Test 6%
Exam Practical 12%

Total Marks (SRD 23403)
Technical Report 7+7+6%
Mini Project 7+7+6%
Test 7+7+6%
Exam Practical 14+14+12%
100%
5

(SRD 23403) - (Content Summary)
Electrical Power
Electrical Control
Electrical Actuator

Pneumatic Power
Pneumatic Control
Pneumatic Actuator

Hydraulic Power
Hydraulic Control
Hydraulic Actuator

End of Course
Comparison of Power System
Selection of Power System

6

Basic Automation System (SRD 23403)
(Study Planning)


Week 11 13 (Study Week)

Extra Assessment
Attitude marks
Attendant (per/minute = 0.019%)
Cheating (per/cheat = 1%)
Attire (per/day = 5%)
Behavior (per/hour = 5%)

7

8

MSI Hydraulic System
Basic Hydraulic System
9
Introduction to Didactic Unit
Objective of Module

Why hydraulic system?

Because: hydraulic system is amazing in its strength and agility. It is uses in medium
and heavy application. It is a basic control system. Uses liquid as its medium.
Uses in medium and heavy application.

Why learn hydraulic system?
Its a basic control system.

Why learn maintenance of hydraulic system?
To describe the methodology of preventive and corrective maintenance technique of
Hydraulic System.

10
Basic Control System

signal
processing
output
signal
input
pushbutton valve cylinder
11

Control & Maintenance
signal
processing
output
signal
input
Assembly / Maintenance / Troubleshoot
12
Content of Module
CHAPTER X INTRODUCTION TO DIDACTIC UNIT
CHAPTER 0 SAFETY IN HYDRAULIC SYSTEM
CHAPTER 1 INTRODUCTION TO HYDRAULIC SYSTEM
CHAPTER 2 FUNDAMENTAL IN HYDRAULIC SYSTEM
CHAPTER 3 TANK PIPING AND COUPLINGS
CHAPTER 4 HYDRAULIC PUMPS
CHAPTER 5 HYDRAULIC ACTUATOR
CHAPTER 6 DISTRIBUTOR VALVES
CHAPTER 7 PRESSURE VALVES
CHAPTER 8 FLOW VALVES
CHAPTER 9 BLOCK VALVES
CHAPTER 10 ELECTRO HYDRAULIC SYSTEM

13
Safety In Hydraulic System
chapter 0
General safety
High pressures, temperatures and forces occur in
Hydraulic System. Energy is also stored, sometimes in
large quantities. A whole series of safety measures is
necessary to rule out the possibility of danger to
personnel and equipment during the operation of
hydraulic systems. In particular, the valid safety
regulations for hydraulic systems are to be OBSERVED.

14
Regulations and standards
The following safety regulations apply for the field of hydraulics:

1. Accident prevention regulations, directives, safety rules and the testing
guidelines,

2. Regulations on pressure vessels, pressurized gas vessels and filling
systems (pressure vessel regulations),

3. DIN standards, VDI directives, VDMA standard sheets and technical
rules for pressure vessels, containing in particular, notes and regulations
on dimensions, design, calculations, materials and permissible loads as
well as conditions on functions and requirements.

4. Electro-hydraulic systems must comply not only with the regulations on
hydraulic systems but also with the regulations on electrical systems and
components (e.g. DIN VDE 0100).

15
Safety Recommendations

Install the EMERGENCY STOP push-button in a place where it can be easily
reached.

Use standardized parts only.

Enter all alterations in the circuit diagram immediately.

The rated pressure must be clearly visible.

Check whether the installed equipment can be used at the maximum operating
pressure.

The design of suction lines should ensure that no air can be drawn in.

Check the oil temperature in the suction line to the pump. It must not exceed 60 C.

The piston rods of the cylinders must not be subjected to bending loads or lateral
forces. Protect piston rods from dirt and damage.
16
Start-up of Hydraulic System

Do not operate systems or actuate switches if you are not totally sure what function they perform.
All setting values must be known.
Do not switch on the power supply until all lines are connected.
Important: check that all return lines (leakage lines) lead to the tank.
When starting up the system for the first time, open the system pressure relief valve almost
completely and gradually set the system to the operating pressure. Pressure relief valves must
be installed in such a way that they cannot become ineffective.
Carefully clean the system prior to start-up, then change the filter cartridge.

Vent system and cylinders.

In particular, the hydraulic lines to the reservoir are to be carefully vented. It is generally
possible to effect venting at the safety and shut-off block of the reservoir.
Special care is needed when handling hydraulic reservoirs.
Before the reservoirs are started up, the regulations determined by the manufacturer are to be
studied carefully.
17
Repair and Maintenance

Repair work may not be effected on hydraulic systems
until the fluid pressure of the reservoir has been
release. If possible, separate the reservoir from the
system (using a valve). Never drain the reservoir un-
throttled.

When repairs are completed effect a new start-up in line
with the safety regulations listed above.

All hydraulic reservoirs are subject to the provisions of
the pressure vessel regulations and must be inspected
at regular intervals.
18
General Lab rules

1. You are prohibited from entering
Hydraulic Lab without SAFETY
BOOT (all time), DUST COAT
(practical uses)

2. Do not be afraid to ask questions.
We are here to assist you.

3. Do not step on any signal or
actuator controller cable.

4. Never use your finger to align bolt-
holes.

5. You must keep your work area
clean and free of rubbish.

6. Never place any part of your body in
an area that is considered a crush
point.
7. If you break or notice any defects in
the equipment you are using,
immediately inform the TTO. This
ensures that you will not be held
responsible for repairing the
equipment.

8. Do not leave tools on load frames or
specimens, and at the end of the
day put all tools back where they
belong.

9. Work methodically and at a steady
pace, and do not be afraid to ask
your fellow students or Mr. FATHUL
to assist you.

10. USE COMMON SENSE.
19
Introduction to Hydraulic System
chapter1
Hydraulic means the generation of forces and motion using hydraulic
fluids. Hydraulic fluids represent the medium for power transmission.

Advantage of hydraulic system

Great power intensity

Precise positioning

Start-up under heavy load

Independent of load

Smooth operation and reversal

Good control and regulation

Favorable heat dissipation
Disadvantage of hydraulic system

Pollution

Sensitivity to dirt

Danger resulting from excessive pressures

Temperature dependence

Unfavorable efficiency factor

20
Application Of Hydraulic System
Stationary Hydraulic
(Vise, clamp, stamping machine, injection moulding machine, and etc).

Mobile Hydraulic
(bulldozers, backhoes, shovels, loaders, fork lifts, cranes and etc).

21

Hydraulic System Overview
22
Hydraulic System vs. Pneumatic System

Drive section
Control section
Power section
23

Schematic Diagram Of A Hydraulic System
Single Acting Cylinder Double Acting Cylinder
24
The Basic Idea
The basic idea behind any hydraulic system is very simple: Force
that is applied at one point is transmitted to another point using
an incompressible fluid.
The picture below shows the simplest possible hydraulic system:

25
Working Principle
Retract position Extend position

26
Fundamental in Hydraulic System
Chapter 2
1. Pressure
2. Pressure Transmission
3. Power Transmission
4. Displacement
Transmission
5. Pressure Transfer
6. Flowrate
7. Pressure Measurement
8. Type of Flow
9. Friction, heat & pressure
drop
10. Energy & Power
11. Power
12. Cavitations & Throttle
point
13. Hydraulic Fluid

27
1. Pressure

Pressure (symbol: p) is
the force per unit area
acting on a surface in a
direction perpendicular
to that surface.
Mathematically:
where:

A
p
F
Area of double
acting cylinder
= (d/2)
28
example

29
2. Pressure Transmission
If a force F1 acts at area A1 on an
enclosed liquid, a pressure p is
produced which extends
throughout the whole of the liquid
(Pascals Law).
This will cause a same pressure
acting at every point of the closed
system.

30
example

31
3. Power Transmission
If same pressure applies at every point in a closed
system, the shape of the container has no significance.

32
example

Therefore
33
4. Displacement Transmission
If load F2 is to be lifted to a distance s2, Piston 1 must be displace at
distance s1, at a specific quantity of liquid which lifts the Piston 2 by a
distance s2.

34
example

35
5. Pressure Transfer
The pressure P1 exerts F1 force on area A1 which is transferred thru piston rod onto
the small piston. Force F1 will acts on area A2 and produces pressure P2. Since
piston area A2 is smaller than piston area A1, the pressure P2 will be greater than
the pressure P1.

36
example

37
6. Flowrate
Flow rate is the term used to describe the volume of liquid flowing
through a pipe in a specific period of time.
For example, approximately one minute is required to fill a 10 liter
bucket from a tap. Thus, the flow rate amounts to 10 l/min.

38
6. Flowrate

Other derivation
Well have
39

7. Pressure Measurement
To measure pressures in the lines or at the inputs and outputs of
components, a pressure gauge is installed in the line at the
appropriate point.
40

1. Laminar flow
fluid moves through the
pipe in cylindrical layers
order.

8. Type of flow
2. Turbulence flow
when flow velocity of fluid
rises above a certain point
the fluid particles stop to
move in ordered layers.
41

Reynolds number (Re).
A method of calculating the type of flow in
a smooth pipe is enabled by the Reynolds
number (Re). This is dependent on:

the flow velocity of the liquid v (m/s) (flowrate)
the pipe diameter d (m)
and the kinematics viscosity (m/s) (viscosity)
laminar flow: Re < 2300
turbulent flow: Re > 2300
42

Reynolds number (Re).
The value 2300 is termed the critical Reynolds
number (Re
crit
) for smooth round pipes.
Turbulent flow does not immediately become laminar on
falling below (Re
crit
). The laminar range is not reached
until (Re
crit
).
To prevent turbulent flow causing considerable friction
losses in hydraulic systems, (Re
crit
) should not be
exceeded.
43

Example:
1
2
3
4
1. Draw line from piping dia. to
liquid flow velocity(1-2)
2. From point (2) draw a line to
flowrate in the pipe, (2-3)
3. The Reynolds number are on
point (4)
44

Guideline Hydraulic flowrate
45

9. Friction, Heat & Pressure droop
Friction occurs in all devices and lines in a hydraulic system.
Mainly at the line walls (external friction and between the layers of
liquid (internal friction).
The friction causes heat. As heat generation, the pressure in the
system drops and reduces the actual pressure at the drive section.
The size of the pressure drop is based on the internal resistances in
a hydraulic system. These are dependent on:
Flow velocity (cross-sectional area, flow rate),
Type of flow (laminar, turbulent),
Type and number of cross-sectional reductions in the system of lines
(throttles, orifices),
Viscosity of the oil (temperature, pressure),
Line length and flow diversion,
Surface finish,
Line arrangement.
46

The energy of a hydraulic system is made
up of several forms of energy.
Static
Potential energy
Pressure energy
Dynamic
Motion energy
Thermal energy

10. Energy & Power
47

Type of Energy
Static
Potential energy: energy which a body (or a
liquid) has when it is lifted by a height h.
Pressure energy: pressurized volume
Dynamic
Motion energy: when a force F acting on the
body that moves at a certain speed. (also
known as kinetic energy)
Thermal energy: is the energy required to
heat a body (or a liquid) to a specific
temperature.
In hydraulic installations, part of the
energy is converted into thermal energy
as a result of friction. This leads to
heating of the hydraulic fluid and of the
components. Part of the heat is emitted
from the system, i.e. the remaining
energy is reduced. The consequence of
this is a decrease in pressure energy.
48

11. Power
Power is usually defined as work or a change in
energy per unit of time.
Hydraulic power is calculated from the pressure
and the flow rate.

49

Example
50

Efficiency
The input power in a hydraulic system does not correspond to the output
power since line losses occur. The ratio of the output power to the input
power is designated as efficiency (h).
In practice, distinction is made between volumetric power loss caused by
leakage losses and hydro-mechanical power loss caused by friction. In the
same way, efficiency is divided into:
Volumetric efficiency (
vol
): This covers the losses resulting from internal and
external leakage losses in the pumps, motors, and valves.
Hydro-mechanical efficiency (
hm
): This covers the losses resulting from friction
in pumps, motors, and cylinders.
51

Example
52

12. Cavitations & Throttle point
Refers to the releasing of the
smallest particles from the surface of
the material.
Motion energy is required for an
increase in flow velocity of the oil at a
narrowing. This motion energy is
derived from the pressure energy.
Because of this, pressure drops at
narrow points may move into the
vacuum range.
From a vacuum of 0.3bar onwards,
dissolved air (Gas bubbles) are
formed. If the pressure now rises
again as a result of a reduction in
speed, the oil causes the gas
bubbles to collapse.
53
13. Hydraulic Fluid
Hydraulic fluids represent the medium for power
transmission.

Function

Pressure transfer
Lubrication for moving parts / devices
Cooling agent: - diversion of heat produced by energy
conversion
Cushioning of oscillations cause by pressure jerks.
Corrosion protection
Scuff removal
Signal transmission

54

Characteristic of hydraulic fluid
lowest possible density
minimal compressibility
viscosity not too low (lubricating film)
good viscosity-temperature characteristics
good viscosity-pressure characteristics
good ageing stability
low flammability
good material compatibility

example of hydraulic fluid
HLP 68
H:- hydraulic fluid,
L:- with additives to corrosion protection and/or ageing stability,
P:- with additives to reduce and/or increase load carrying ability
68:- viscosity code as defined in DIN 51517
55

Viscosity
can be defined as resistance to flow. The viscosity of a
liquid indicates its internal friction.
Ball Viscometer
56

Tank, Piping & Coupling
Chapter 3

Tank / Reservoir
acts as intake and storage reservoir for the hydraulic fluid required for operation of
the system;
dissipates heat;
separates air, water and solid materials;
supports a built-in or built-on pump and drive motor and other hydraulic
components, such as valves, accumulators, etc.

Reservoir size, dependent on:
pump delivery
the heat resulting from operation in connection with the maximum permissible
liquid temperature
the maximum possible difference in the volume of liquid which is produced when
supplying and relieving consuming devices (e.g. cylinders, hydraulic fluid
reservoirs)
the place of application
the circulation time.
57

Tank / Reservoir
Reservoir shape
High reservoirs are good for heat dissipation,
wide ones for air separation.
Intake and return lines
These should be as far away from one another
as possible and should be located as far
beneath the lowest oil level as possible.
Baffle and separating plate
This is used to separate the intake and return
areas. In addition, it allows a longer settling
time for the oil and, therefore, makes possible
more effective separation of dirt, water and
air.
Base plate
The base of the tank should slope down to the
drain screw so that the deposited sediment and
water can be flushed out.
Ventilation and exhaust (air filter)
To balance the pressure in case of a
fluctuating oil level, the reservoir must be
ventilated and exhausted. For this purpose, a
ventilation filter is generally integrated into the
filler cap of the feed opening.
58

Piping (Flexible Hoses)
These are flexible line connections which are used between mobile
hydraulic devices or in places where there is only limited space
(particularly in mobile hydraulics).
The inner tube (1) is made of synthetic rubber, Teflon, polyester-elastomer, perbunan or neoprene. The pressure carrier
is a woven intermediate layer of steel wire and/or polyester or rayon.
This woven section (2) may consist of one or more layers depending on the pressure range.
The top layer (3) is made of wear-resistant rubber, polyester, polyurethane elastomer or other materials. The pipelines
may be additionally protected against mechanical damage by external spirals or plaited material.
59

Installation of Hose Lines
60

Coupling
Hose lines may either be connected
to the various pieces of equipment or
else connected together by means of
screw fittings or quick connection
couplings.

Hose support connectors ensure that
connections do not affect operation:

61

HYDRAULIC PUMP
Chapter 4
The pump in a hydraulic system, also known as a hydraulic pump, converts the
mechanical energy in a drive unit into hydraulic energy (pressure energy).
The pump draws in the hydraulic fluid and drives it out into a system of lines.

62

The Basic Concept
Low pressure
High pressure
63

Hydraulic pumps
Gear Pump Rotary Vane Pump Piston Pump
External Gear Pump
Internal Gear Pump
Single Chamber
Double Chamber
Radial Piston Pump
Axial Piston Pump
TYPE OF HYDRAULIC PUMP
64

TYPE OF HYDRAULIC PUMP

External Gear Pump Internal Gear Pump Single Chamber
Double Chamber Radial Piston Pump Axial Piston Pump
65

Gear Pump: Working Principle
Volume
increase
From tank
To hydraulic
system
Volume
increase
From
tank
To
hydraulic
system
Internal gear
External gear
Working Operation
(Gear Pump)
The suction area S is connected to the reservoir. The
gear pump operates according to the following
principle:

One gear is connected to the drive, the other is
turned by the meshing teeth. The increase in volume
which is produced when a tooth moves out of a mesh
causes a vacuum to be generated in the suction
area. The hydraulic fluid fills the tooth gaps and is
conveyed externally around the housing into
pressure area P. The hydraulic fluid is then forced
out of the tooth gaps by the meshing of teeth and
displaced into the lines.

Fluid is trapped in the gaps between the teeth
between suction and pressure area. This liquid is fed
to the pressure area via a groove since pressure
peaks may arise owing to compression of the trapped
oil, resulting in noise and damage.
66

67

Rotary Vane: Working Principle
Volume
increase
Volume
increase
From tank
To hydraulic
system
From tank
To hydraulic
system
Single chamber Double chamber
68

Piston Pump: Working Principle
compression
From tank
To hydraulic
system
Radial chamber Axial chamber
From tank To hydraulic
system
compression
From tank Hyd sys
69

Pump
Specification
Assignment 2
70

MSI Pneumatic System
Working operation for:
1. Internal Gear Pump,
2. Vane Pump and
3. Piston Pump
71
There are two basic types of hydraulic actuator:
Rotary actuator
(motor / rotary)

Linear actuator
(cylinder)

Hydraulic Actuator
Chapter 5
72

Hydraulic Motor (Rotary Movement)
Hydraulic motor comes various type same
as hydraulic pump. It working operation
are similar.
Gear motor
Vane motor
Piston motor
73

Linear Actuator (Linear Movement)
Single Acting Cylinder
Double Acting Cylinder
There are two basic types of hydraulic cylinder
single-acting and
double-acting cylinders.
74

Type of Linear Actuator
75

Type of Linear Actuator
76
Distribution Valve
Chapter 6
Introduction
Directional control valves are components which change, open or close flow paths in
hydraulic systems. They are used to control the direction of motion of power
components and the manner in which these stop. Directional control valves are
shown as defined in DIN ISO 1219.
Type
2/2-way valve
3/2-way valve
4/2-way valve
5/2-way valve
4/3-way valve

77

Symbols for directional
control valves
The following rules apply to the representation of directional control valves:
Each different switching position is shown by a square.
Flow directions are indicated by arrows.
Blocked ports are shown by horizontal lines.
Ports are shown in the appropriate flow direction with line arrows.
Drain ports are drawn as a broken line and labeled (L) to distinguish them
from control ports.

78

The switching position of a directional control valve can be changed by various
actuation methods, such as push button, pedal, lever with detent, a spring is always
necessary for resetting.
Methods of Actuation
79

Port Designation
80

Type of Distribution Valve (symbol)
81

Working Principle
2/2 way valve, Normally close
Release position
Press position
82

Circuit Example
Release 2/2 WV Cylinder Extend
Pressed 2/2 WV Cylinder Retract
83

Basic Construction of 3/2 way valve
(3/2 way valve N.C)
84

85

(4/3 way valve, mid position pump re-circulating)
86

Basic Construction of valve
(2/2 way valve N.C)
(3/2 way valve N.C)
(4/3 way valve, mid position pump
re-circulating)
87

Conversion of Valve
88

Pressure Valve
Chapter 7
Pressure valves have the task of controlling and regulating the pressure in a
hydraulic system.

Pressure relief valves
The pressure in a system is set and restricted
by these valves. The control pressure is
sensed at the input (P) of the valve.
Pressure regulator
These valves reduce the output pressure where there
is a varying higher input pressure. The control
pressure is sensed at the output of the valve.
Symbol

2 way pressure regulator 3 way pressure regulator Pressure relief valves
89

Working Principle
(pressure relief valve)
90

Working Principle
(2 way pressure regulator)
91

Working Principle
(3 way pressure regulator)
92

Basic Construction
Pressure Relief Valve
2 Way Pressure Regulator
3 Way Pressure Regulator
93

Flow Valve
Chapter 8
Introduction
Flow control valves are used to reduce the speed of a cylinder or a motor.

Type of control valve:
2. Throttle Valve
(two way flow control valve)
- Restrict both direction of flow.

1. One Way Flow Control Valve
- Restrict one direction of flow only.
94

Working Principle
One-way flow control valve
The one-way flow control valve where the restrictor is only effective in one direction is a
combination of a restrictor and a non-return valve. The restrictor controls the flow rate in a
single direction dependent on flow. In the opposite direction, the full cross-sectional flow is
released and the return flow is at full pump delivery. This enables the one-way flow control
valve to operate.
Control Not control
95

Circuit Example
(One way flow control valve)
Fluid is block
by check valve
Fluid enter cylinder
with normal flow
Fluid have to flow
through throttle valve
Extend slow
96

Circuit Example
(One way flow control valve)
Fluid is block
by check valve
Fluid enter cylinder
with normal flow
Fluid have to flow
through throttle valve
Retract slow
97

Working Principle
Throttle Valve
Flow control valves
influence the
volumetric flow of the
fluid in both directions.
Control flow in both direction
98

Circuit Example
(Throttle valve)
Extend & Retract
slow
99

Block Valve (Non Return Valve)
Chapter 9
100

Check Valve
Check valves can stop the flow completely
in one direction. In the opposite direction
the flow is free with a minimal pressure
drop due to the resistance of the valve.

Spring loaded
Spring un-loaded
101

De-lockable Valve
In de-lockable valve, flow can be released in the closed position by pilot control of
the valve poppet. This takes place according to the following principle:

1. Flow is possible from A to B.
2. Flow is blocked from B to A.
3. In order permits flow from B to A,
signal X is produce.

102

Circuit Example
(De-Lockable valve)
Signal x must
be connected to tank
In order to release
pressure at port x.
Uses when cylinder
is vertically install
103

Circuit Example
(De-Lockable valve)
Change input
To suite
existing valve
with practical task
104

Shuttle Valve
This shuttle valve has two inlets X and Y and one
outlet A. If Hydraulic fluid is applied to the first inlet X,
the valve seals the opposing inlet Y, the fluid flows
from X to A. Inlet X is closed, if fluid passes from Y to
A. A signal is generated at the outlet. When the Fluid
flow is reversed, i.e. a cylinder or valve is exhausted,
the seat remains in its previously assumed position
because of the pressure conditions. This valve is also
called an OR element.
X Y
A
X Y A
0 0 0
0 1 1
1 0 1
1 1 1
TRUTH TABLE
105

De-lockable Double Non-Return Valve
The piloted double non-return valve operates according to the following principle:

Free flow is possible either in the flow direction from A1 to B1 or from A2 to B2, flow is
blocked either from B1 to A1 or from B2 to A2.

If flow passes through the valve from A1 to B1, the control piston is shifted to the
right and the valve poppet is lifted from its seat. By these means, flow is opened
from B2 to A2 (the valve operates in a corresponding manner where there is flow from
A2 to B2).
106

Circuit example
107
Electro-Hydraulic System
Chapter 10
Malaysian Spanish Institute

MSI Electro-Hydraulic System
108
Schematic
Design Of An
Electro-Hydraulic
System

109

Hydraulic Pump
Pushbutton
Cylinder
Power
Supply
Pushbutton
Relay,
Timer,
Solenoid
Electro-Hydraulic Overview
From electro
110

Electro Hydraulic Automatons
Switching
control
Manual
actuation
Electrical
actuation
111
Content of Electro-Hydraulic
Safety precaution
Introduction
Advantages
Comparison
Electrical Fundamental
Electrical Input Element
Sensor
Relay
Solenoid
Electrical Timer
Sequence Control

112
Safety Precaution

1. Pneumatic safety must be apply
2. DO NOT wear sandals, wear covered shoes
3. DO NOT wear excessive jewelry
4. DO NOT wear swing-loose-long hair style, neatly tie-up the long hair or
place under a proper head gear.
5. DO NOT wear shoes with heel higher than 1" (2.5 cm)
6. DO wear lab-coat all the time
7. DO NOT disturb people who are conducting experiments! (or any time)
8. NO eating or drinking inside the lab.
9. NO social gathering is allowed in the labs. The labs should not be
crowded for non-working purposes.
10. In case of spilling water on a lab bench near power points, first SWITCH
OFF the electrical power before cleaning.
11. TO INSPECT any electrical equipment, first turn the power off and ask for
the instruction/help from the lab officer in charge. Any faulty equipment
should be attended by trained personnel only. DO NOT do it on your
own.
113
Introduction
Electro-Hydraulic Systems are made up of
hydraulic and electrical components:

The movements and forces are generated by
Hydraulic means (e.g. by cylinders).

Signal input and signal processing, on the other hand,
are effected by Electrical and Electronic
components (e.g. electromechanical switching
elements or stored-program controls).

114
Advantages

Electrical signals can be transmitted via cables quickly and easily
and over great distances. Mechanical signal transmission (linkages,
cable-pulls) or hydraulic signal transmission (tubes, pipes) are far
more complex.

In the field of automation, signal processing is generally effected
by electrical means. This enhances the options for the use of
electro-hydraulic systems in automatic production operations (e.g.
in a fully automatic pressing line for the manufacture of car wings).

Many machines require complex control procedures (e.g. plastics
processing). In such cases, an electrical control is often less
complex and more economical than a mechanical or hydraulic
control system.
115

Comparison
116

Electrical Fundamental
The relationship between voltage, current strength and resistance is
described by Ohms law. Ohms law states that in a circuit with constant
resistance the current strength changes in proportion to the change in
voltage:

if the voltage increases, the current strength also increases.
if the voltage falls, the current strength also decreases.
117

In the field of mechanical engineering, power can be defined in terms of the
work performed. The faster a task is performed, the greater the required
power. Power therefore means work per unit of time.
In the case of a consuming device in a circuit, electrical energy is converted
into kinetic energy (e.g. electrical motor), light radiation (e.g. electrical lamp)
or thermal energy (e.g. electrical heater, electrical lamp). The faster the
energy is converted, the greater the electrical power.
Electrical power
118

A power supply unit consists of
the following modules:
the mains transformer which
transforms the alternating
voltage of the mains supply
(e.g. 220 V) into the output
voltage (mostly 24 V).
a smoothed direct voltage is
generated by the rectifier G and
the capacitor C.
the direct voltage is then
stabilized by the in-phase
regulator.
Power Supply
119

Electrical controls are generally supplied with a direct current of 24V.
The alternating voltage from the power supply therefore has to be
stepped down to 24V and then rectified.

Conversion AC to DC
AC DC
120

Electrical input elements
NORMALLY OPEN CONTACT
circuit is open when the push-button is in the normal position
121

NORMALLY CLOSED CONTACT
circuit is closed when the push-button is in the normal position
122

CHANGEOVER SWITCH
These contacts combine the
functions of normally closed and normally open contacts in one unit.
123

Circuit example
Pressed S1, H will on
Pressed S1, H will off
Pressed S1, H will on,
Pressed S2, H will off.
124

Practical
(Electrical Input Element)
And
Function
Or
Function
And
Function
Or
Function
Switching ON Command
Switching OFF Command
S1 AND S2 H1 on S1 OR S2 H1 on S1 AND S2 H1 off S1 OR S2 H1 off
125

Sensor Limit switch
A mechanical limit switch is an
electrical switch which is activated
when a machine part or a workpiece
is in a certain position.
Normally open limit switch
1-4
Normally closed limit switch
1-2
126

Sensor Pressure switch
requires a pressure to activated the sensor
the pressure acts on a cylinder surface (x).
If the pressure exerted exceeds the spring
force of the return spring, the piston moves
and operates the contact set.

Normally open limit switch
1-4
Normally closed limit switch
1-2
127

Circuit Example
128

Relay
Relays are electromagnetically
actuated switches.
They consist of a housing with
electromagnet and movable
contacts.
An electromagnetic field is created
when a voltage is applied to the coil
of the electromagnet.
This results in attraction of the
movable armature to the coil core.
The armature actuates the contact
assembly.
This contact assembly can open or
close a specific number of contacts
by mechanical means.
If the flow of current through the coil
is interrupted, a spring returns the
armature to its original position.

129

Concept of a Relay
(Electromagnet)
An electromagnet is a type of magnet in which the
magnetic field is produced by the flow of an electric
current. The magnetic field disappears when the current
ceases.
130

Working Principle
Relay
1 pole
Relay
2 pole
131

Example
132

Circuit Example
Direct Control
In-direct Control
133

9. Solenoids
In electro-hydraulics, valves are actuated via solenoids. It has the
same concept of electromagnet.

solenoid
Directional control Valve
134

Circuit Example
135

Electromechanical Switching Element
(Symbol)
136

Holding Element / Latching
S1 H1 ON
S2 H1 OFF
S1
S2
k1
K1
k1
137

A timer is used to control the sequence
of an event or process.

Two type of timer
1. Delay-On Timer
2. Delay-Off Timer
Electrical Timer
138

Electrical Timer
S1 5sec H1 ON
S2 H1 OFF
24V
0V
S1
S2
K1
K1
T1
K1
H1
T1
The Coil with ON delay activates its
associated contacts when current is
applied.
139

Electrical Timer
S1 H1 ON
S2 5sec H1 OFF
The Coil with OFF delay deactivates
its associated contacts when current
is applied, but only after the preset
delay.
24V
0V
S1
S2
K1
K1
T1
K1
H1
T1
140

Electrical Timer
24V
t
S1
0V
H1
Timer for Practical installation
Note:
For ON Delay:
Select selector to
DES.

For OFF Delay:
Select selector to
CON.
141

Electro Hydraulic System
Hydraulic Circuit Diagram /
Power Circuit /
Schematic Diagram
Control Circuit Diagram /
Electrical Circuit Diagram

142


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