Malaysian Spanish Institute
Assembly & Maintenance Maintenance of Pneumatic & Hydraulic System (SED 23103) Basic Automation System (SRD 23403) v5
1
Assembly & Maintenance of Pneumatic & Hydraulic System (SED 23103) - (Assessment) 1. Basi Basic c Pne Pneum umat atic ic Syst System em
2.
Basic Hy Hydraulic Sy System
–
Technical Report
10%
–
Technical Report
10%
–
Mini Project
10%
–
Mini Project
10%
–
Test
10%
–
Test
10%
–
Exam Practical
20%
–
Exam Practical
20%
•
Total Marks (SED 23103) –
Technical Report
20%
–
Mini Project
20%
–
Test
20%
–
Exam Practical
40%
100%
2
Assembly & Maintenance of Pneumatic & Hydraulic System (SED 23103) - (Assessment) 1. Basi Basic c Pne Pneum umat atic ic Syst System em
2.
Basic Hy Hydraulic Sy System
–
Technical Report
10%
–
Technical Report
10%
–
Mini Project
10%
–
Mini Project
10%
–
Test
10%
–
Test
10%
–
Exam Practical
20%
–
Exam Practical
20%
•
Total Marks (SED 23103) –
Technical Report
20%
–
Mini Project
20%
–
Test
20%
–
Exam Practical
40%
100%
2
Assembly & Maintenance of Pneumatic & Hydraulic System (SED 23103) - (Assessment) 1. Basi Basic c Pne Pneum umat atic ic Syst System em
2.
Basic Hy Hydraulic Sy System
–
Pneumatic Power
–
Hydraulic Power
–
Pneumatic Control
–
Hydraulic Control
–
Pneumatic Actuator
–
Hydraulic Actuator
•
End of Course –
Comparison of Power System
–
Selection of Power System
3
Assembly & Maintenance of Pneumatic & Hydraulic System (SED 23103) (Study 1. Basic Pneumatic System
2.
Planning) Basic Hydraulic System
–
Week 1 – 6 (Study week)
–
Week 8 – 13 (Study Week)
–
Week 7 (Practical Test)
–
Week 14 (Practical Test)
Extra Assessment Attitude marks 1. 2. 3. 4.
Attendant (per/minute = 0.019%) Cheating (per/cheat = 1%) Attire (per/day = 5%) Behavior (per/hour = 5%)
4
Basic Automation System (SRD 23403) - (Assessment) 1.
2.
Basic Pneumatic System
3. Basic Electrical System
–
Technical Report
7%
–
Technical Report
6%
–
Mini Project
7%
–
Mini Project
6%
–
Test
7%
–
Test
6%
–
Exam Practical
14%
–
Exam Practical
12%
Basic Hydraulic System –
Technical Report
7%
–
Mini Project
7%
–
Test
7%
–
Exam Practical
14%
• 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
Basic Automation System (SRD 23403) - (Content Summary) 1. Basic Electrical System
3. Basic Hydraulic System
–
Electrical Power
–
Hydraulic Power
–
Electrical Control
–
Hydraulic Control
–
Electrical Actuator
–
Hydraulic Actuator
2. Basic Pneumatic System –
Pneumatic Power
–
Pneumatic Control
–
Pneumatic Actuator
• End of Course –
Comparison of Power System
–
Selection of Power System
6
Basic Automation System (SRD 23403) (Study Planning) 1. Basic Pneumatic System
3. Basic Electrical System
–
Week 1 – 4 (Study week)
–
Week 11 – 13 (Study Week)
–
Week 5 (Practical Test)
–
Week 14 (Practical Test)
2. Basic Hydraulic System –
Week 6 – 9 (Study week)
–
Week 10 (Practical Test)
• Extra Assessment – Attitude marks • Attendant (per/minute = 0.019%) • Cheating (per/cheat = 1%) • Attire (per/day = 5%) • Behavior (per/hour = 5%)
7
Basic Hydraulic System
8
Introduction to Didactic Unit • Objective of Module Why hydraulic system? Because: hydraulic system is amazing in its s t r e n g t h and agility . It is uses in medium and heavy application. It is a b a s i c c o n t r o l s y s t e m . Uses l i q u i d as its medium. Uses in m e d i u m and h e a v y application.
Why learn hydraulic system? Its a basic control system.
Why learn maintenance of hydraulic system? To describe the methodology of p r e v e n t i v e and c o r r e c t i v e maintenance technique of Hydraulic System. 9
•Basic Control System
signal input
pushbutton
signal processing
valve
output
cylinder
10
•Control & Maintenance
Assembly / Maintenance / Troubleshoot
signal input
signal processing
output
11
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
12
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.
13
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).
14
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.
15
Start-up of Hydraulic System •
Do not operate not operate systems or actuate switches if you are not totally not totally sure what sure what function they perform.
•
All setting values must be known.
•
Do not switch on the power supply until all lines are connected.
•
Important: Important: check that all return lines (leakage lines (leakage lines) lead to the tank.
•
When starting up the up the system for the first time, open the system pressure relief valve almost completely and gradually set the set the system to the operating pressure. 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 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. reservoirs.
•
Before the reservoirs are started up, the regulations determined by the manufacturer are to be studied carefully.
16
Repair and Maintenance • Repair work may not be effected on hydraulic systems until the fluid pressure of the reservoir has been release. release. If possible, separate the reservoir from the system (using a valve). Never drain the reservoir unthrottled. • 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.
17
General Lab rules 1.
You are prohibited from entering Hydraulic Lab without SAFETY BOOT (all BOOT (all time), DUST COAT (practical uses)
2.
Do not be afraid to ask questions. questions. We are here to assist you.
3.
Do not step on step on any signal or actuator controller cable.
4.
Never use your finger to align boltalign boltholes.
5.
You must keep must keep your work area clean and clean and free of rubbish. rubbish.
6.
Never place any part of your body in in an area that is considered a crush point.
7.
If you break or break or notice any notice any defects in the equipment you are using, immediately inform the TTO. 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 methodically and at a steady pace, and do not be afraid to ask your fellow students or Mr. FATHU FATHUL L to assist you.
10.
USE COMMON SENSE.
18
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
Disadvantage of hydraulic system
•Great power intensity
•Pollution
•Precise positioning
•Sensitivity to dirt
•Start-up under heavy load
•Danger resulting from excessive pressures
•Independent of load
•Temperature dependence
•Smooth operation and reversal
•Unfavorable efficiency factor
•Good control and regulation •Favorable heat dissipation 19
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).
20
Hydraulic System Overview
21
Hydraulic System vs. Pneumatic System Drive section Control section Power section
22
Schematic Diagram Of A Hydraulic System
Single Acting Cylinder
Double Acting Cylinder
23
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:
24
Working Principle
Retract position
Extend position
25
Fundamental in Hydraulic System Chapter 2
1.
Pressure
7. Pressure Measurem rement
2.
Pressure Transmission
8. Type of Flow
3.
Power Tr Transmission
4.
Displacement Transmission
9. Fri Friction tion,, hea heat & pre pressure sure drop 10. 10. Ener Energy gy & Pow Power er
5.
Pressure Transfer
11. Power
6.
Flowrate
12. 12. Cavit Cavitati ations ons & Thrott Throttle le point 13. 13. Hydr Hydrau aulilic c Fluid Fluid
26
1. Pressure • Pressure (symbol: Pressure (symbol: p p)) is the f o r c e per per unit area acting on a surface in a direction p e r p e n d i c u l a r to that surface. • Mathematically:
F
A
p
where:
Area of double acting cylinder = π (d/2)² 27
example
28
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 (Pascal’s Law). This will cause a same pressure acting at every point of the closed system.
29
example
30
3. Power Transmission • If same pressure applies at every point in a closed system, the shape of the container has no significance. significance.
31
example
Therefore
32
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.
33
example
34
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 wil l be greater than the pressure P1.
35
example
36
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.
37
6. Flowrate Other derivation
We’ll have
38
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.
39
8. Type of flow
1. Laminar flow fluid moves through the pipe in cylindrical layers order.
2. Turbulence flow when flow velocity of fluid rises above a certain point the fluid particles s t o p to move in ordered layers.
40
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
(m²/s)
(viscosity)
laminar flow: Re < 2300 turbulent flow: Re > 2300
41
Reynolds’ number (Re). • The value 2300 is termed the “critical Reynolds’ number” (Recrit) for smooth round pipes. • Turbulent flow does not immediately become laminar on falling below (Recrit). The laminar range is not reached until ½ (Recrit). • To prevent turbulent flow causing considerable friction losses in hydraulic systems, (Re crit) should not be exceeded.
42
Example:
3
1
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)
4
2
43
Guideline Hydraulic flowrate
44
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.
45
10.Energy & Power • The energy of a hydraulic system is made up of several forms of energy. – Static • Potential energy • Pressure energy
– Dynamic • Motion energy • Thermal energy
46
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.
47
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.
48
Example
49
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 (ŋvol): This covers the losses resulting from internal and external leakage losses in the pumps, motors, and valves. – Hydro-mechanical efficiency (ŋhm): This covers the losses resulting from friction in pumps, motors, and cylinders.
50
Example
51
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.
52
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
53
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
54
Viscosity • can be defined as “resistance to flow”. The viscosity of a liquid indicates its internal friction.
Ball Viscometer 55
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.
56
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.
57
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.
58
Installation of Hose Lines
59
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:
60
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.
61
The Basic Concept
High pressure
Low pressure
62
TYPE OF HYDRAULIC PUMP Hydraulic pumps
Gear Pump
Rotary Vane Pump
Piston Pump
External Gear Pump
Single Chamber
Radial Piston Pump
Internal Gear Pump
Double Chamber
Axial Piston Pump
63
TYPE OF HYDRAULIC PUMP
External Gear Pump
Double Chamber
Internal Gear Pump
Single Chamber
Radial Piston Pump
Axial Piston Pump
64
Gear Pump: Working Principle
Volume increase
To hydraulic system
To hydraulic system
From tank
From tank
Volume increase
External gear
Internal gear 65
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
Rotary Vane: Working Principle To hydraulic system Volume increase
To hydraulic system
From tank
Single chamber
Volume increase From tank
Double chamber 67
Piston Pump: Working Principle
Hyd sys
From tank
To hydraulic system
compression To hydraulic system
From tank compression
Radial chamber
From tank
Axial chamber 68
Pump Specification
69
Assignment 2 • Working operation for: 1. Internal Gear Pump, 2. Vane Pump and 3. Piston Pump
70
Hydraulic Actuator Chapter 5
• There are two basic types of hydraulic actuator: – Rotary actuator (motor / rotary)
– Linear actuator (cylinder)
71
Hydraulic Motor (Rotary Movement) • Hydraulic motor comes various type same as hydraulic pump. It working operation are similar. – Gear motor – Vane motor – Piston motor
72
Linear Actuator (Linear Movement) • There are two basic types of hydraulic cylinder – single-acting and – double-acting cylinders.
Single Acting Cylinder
Double Acting Cylinder 73
Type of Linear Actuator
74
Type of Linear Actuator
75
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
76
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.
77
Methods of Actuation •
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.
78
Port Designation
79
Type of Distribution Valve
(symbol)
80
Working Principle
Release position
Press position
2/2 way valve, Normally close
81
Circuit Example
Release 2/2 WV – Cylinder Extend Pressed 2/2 WV – Cylinder Retract
82
Basic Construction of 3/2 way valve
(3/2 way valve N.C)
83
Basic Construction of 4/2 way valve
84
Basic Construction of 4/3 way valve
(4/3 way valve, mid position –pump re-circulating)
85
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)
86
Conversion of Valve
87
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 Pressure relief valves
2 way pressure regulator
3 way pressure regulator
88
Working Principle (pressure relief valve)
89
Working Principle (2 way pressure regulator)
90
Working Principle (3 way pressure regulator)
91
Basic Construction Pressure Relief Valve
2 Way Pressure Regulator
3 Way Pressure Regulator
92
Flow Valve Chapter 8
Introduction Flow control valves are used to reduce the speed of a cylinder or a motor.
Type of control valve: 1. One Way Flow Control Valve - Restrict one direction of flow only.
2. Throttle Valve (two way flow control valve) - Restrict both direction of flow.
93
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 94
Circuit Example (One way flow control valve) Extend slow
Fluid is block by check valve
Fluid enter cylinder with normal flow
Fluid have to flow through throttle valve
95
Circuit Example (One way flow control valve) Retract slow
Fluid enter cylinder with normal flow
Fluid have to flow through throttle valve
Fluid is block by check valve
96
Working Principle Throttle Valve – Flow control valves influence the volumetric flow of the fluid in both directions.
Control flow in both direction
97
Circuit Example (Throttle valve)
Extend & Retract slow
98
Block Valve (Non Return Valve) Chapter 9
99
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
100
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.
101
Circuit Example (De-Lockable valve)
Uses when cylinder is vertically install Signal x must be connected to tank In order to release pressure at port x.
102
Circuit Example (De-Lockable valve)
Change input To suite existing valve with practical task
103
Shuttle Valve A 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. TRUTH TABLE
X
Y
A
0
0
0
0
1
1
1
0
1
1
1
1
X
Y
104
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).
105
Circuit example
106
Malaysian Spanish Institute
Electro-Hydraulic System Chapter 10
107
Schematic Design Of An Electro-Hydraulic System
108
Electro-Hydraulic Overview Relay, Timer, Solenoid
From electro
Cylinder
Pushbutton Pushbutton
Power Supply
Hydraulic Pump
109
Electro Hydraulic Automatons Switching control
Electrical actuation
Manual actuation
110
Content of Electro-Hydraulic •
Safety precaution
•
Introduction
•
Advantages
•
Comparison
•
Electrical Fundamental
•
Electrical Input Element
•
Sensor
•
Relay
•
Solenoid
•
Electrical Timer
•
Sequence Control
111
Safety Precaution 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Pneumatic safety must be apply DO NOT wear sandals, wear covered shoes DO NOT wear excessive jewelry DO NOT wear swing-loose-long hair style, neatly tie-up the long hair or place under a proper head gear. DO NOT wear shoes with heel higher than 1" (2.5 cm) DO wear lab-coat all the time DO NOT disturb people who are conducting experiments! (or any time) NO eating or drinking inside the lab. NO social gathering is allowed in the labs. The labs should not be crowded for non-working purposes. In case of spilling water on a lab bench near power points, first SWITCH OFF the electrical power before cleaning. 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. 112
Introduction are made up of E l ec t r o -H y d r au l i c S y s t em s 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 E l e c t r o n i c components (e.g. electromechanical switching elements or stored-program controls).
113
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.
114
Comparison
115
Electrical Fundamental •
The relationship between voltage, current strength and resistance is described by Ohm‘s law. Ohm‘s 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.
116
Electrical power • •
In the field of mechanical engineering, power can be defined in t erms 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.
117
Power Supply • 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.
118
Conversion AC to DC •
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.
AC
DC
119
Electrical input elements
NORMALLY OPEN CONTACT circuit is open when the push-button is in the normal positi on
120
Electrical input elements
NORMALLY CLOSED CONTACT circuit is closed when the push-button is in the normal positi on
121
Electrical input elements
CHANGEOVER SWITCH These contacts combine the functions of normally closed and normally open contacts in one unit.
122
Circuit example Pressed S1, H will on Pressed S1, H will off
Pressed S1, H will on, Pressed S2, H will off. 123
Practical (Electrical Input Element)
Switching ON Command S1 AND S2
And Function
H1 on
S1 OR S2
Or Function
H1 on
Switching OFF Command S1 AND S2
H1 off
And Function
S1 OR S2
H1
Or Function 124
off
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 1-2 125
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 1-2 126
Circuit Example
127
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.
128
Concept of a Relay (Electromagnet) • An electromagnet is a type of m a g n e t in which the m a g n e t i c f i el d is produced by the flow of an electric current . The magnetic field disappears when the current ceases.
129
Working Principle
Relay 1 pole
Relay 2 pole
130
Example
131
Circuit Example
Direct Control
In-direct Control
132
9. Solenoids •
In electro-hydraulics, valves are actuated via solenoids. It has the same concept of electromagnet. solenoid
Directional control Valve
133
Circuit Example
134
Electromechanical Switching Element (Symbol)
135
Holding Element / Latching S1 H1 ON S2 H1 OFF
S1
k1
k1
S2
K1
136
Electrical Timer • 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
137
Electrical Timer The Coil with ON delay activates its associated contacts when current is applied.
S1 5sec H1 ON S2 H1 OFF 24V
S1
K1
K1
T1
T1
H1
S2
K1
0V
138
Electrical Timer The Coil with OFF delay deactivates its associated contacts when current is applied, but only after the preset delay.
S1 H1 ON S2 5sec H1 OFF 24V
S1
K1
K1
T1
T1
H1
S2
K1
0V
139
Electrical Timer Timer for Practical installation
Note: For ON Delay: Select selector to DES.
24V
S1
t
For OFF Delay: Select selector to CON.
H1
0V
140
Electro Hydraulic System Hydraulic Circuit Diagram / Power Circuit / Schematic Diagram
Control Circuit Diagram / Electrical Circuit Diagram
141