Lab Manual Oil Hydraulics & Pneumatics (2171912)

Lab Manual
Oil Hydraulics & Pneumatics

(2171912)
Department of Mechanical Engineering

Darshan Institute of Engineering and Technology,
Rajkot.
Darshan Institute of Engineering & Technology
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Staff in Charge Head of Department

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
B.E. - SEMESTER - VII
OIL HYDRAULICS AND PNEUMATICS (2171912)
INDEX
Sr. Page Starting Ending

Title of Experiments Sign Remarks
No. no. date date
To demonstrate the motion of a single
1 acting cylinder and double acting
cylinder.
To demonstrate the use of memory
2 valve and quick exhaust valve with
double acting cylinder.
To demonstrate the use of dual pressure
3 valve and shuttle valve with single
acting cylinder.
To perform AND & OR logic for
4 forward stroke of a double acting
cylinder using two manual control.
To control the speed of a double acting
cylinder using metering in and metering
5
out flow control valve (Speed
controlling operation).
To perform single and multicycle
operation of a double acting cylinder
6
using roller lever valve and memory
valve.
To perform continuous operation of a
7 double acting cylinder using double
solenoid valve.
To operate two double acting cylinders
8 electro pneumatically (Sequence of
operation: A+B+A-B-).
To demonstrate the use of an inductive
9 sensor with double acting cylinder and
double solenoid valve.
To demonstrate the auto reset of a
counter after the operation of a double
10
acting cylinder after ‘n’ cycles using
DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
B.E. - SEMESTER - VII
OIL HYDRAULICS AND PNEUMATICS (2171912)
INDEX
Sr. Page Starting Ending

Title of Assignment Sign Remarks
No. no. date date
1 Introduction to oil hydraulic
Hydraulic system component and fluid

2
properties
3 Hydraulic pumps, motors and actuators
Hydraulic valves and hydraulic system

4
accessories
5 Introduction to pneumatic systems
6 Introduction to automation
EXPERIMENT – 1
AIM: To demonstrate the motion of a single acting cylinder and double acting cylinder.
COMPONENTS: -
Reliability of hydraulic system not only depends on the system design but also on factors
such as component design and manufacturing and their correct choice. This is also correct
while selecting the cylinders/ linear actuators, DCVs and other components to be used in the
present experiment.
1.1 Cylinders/ linear actuators
 A correct cylinder in a hydraulic system contributes to:

a) Optimize system maintainability
b) Ensure minimum down time
c) Ease the process of repairing and trouble shooting
d) Ensure maximum work accuracy
e) Maintain least economic liability and financial losses
 Here in our experiment two types of cylinders are used. Which are:
a) Single acting cylinders
b) Double acting cylinder
These are explained as below:
1. Single acting cylinders

 A single-acting cylinder is simplest in design and is shown schematically in Figure
1.1.
 It consists of a piston inside a cylindrical housing called barrel.
 On one end of the piston there is a rod, which can reciprocate. At the opposite end,
there is a port for the entrance and exit of air.
Oil Hydraulics and Pneumatics (2171912)

Department of Mechanical Engineering Prepared By: Jainik Makwana
Darshan Institute of Engineering & Technology, Rajkot Page 1.1
Figure 1.1 - Single-acting cylinder
Figure 1.2 - Single-acting cylinders (JANATICS India Pvt. Ltd.)
 According to the type of return, single-acting cylinders are classified as follows:

a) Gravity-return single-acting cylinder
b) Spring-return single-acting cylinder
2. Double-acting cylinder
 There are two types of double-acting cylinders:
a) Double-acting cylinder with a piston rod on one side.
b) Double-acting cylinder with a piston rod on both sides
 There are two ports at either end of the cylinder or barrel through which air can enter
and exit alternatively.
Figure 1.3 - Double-acting cylinder with a piston rod on one side

Figure 1.4 - Double-acting cylinder (JANATICS India Pvt. Ltd.)
1.2 Direction control valves
 Directional control valves are used to control the distribution of energy in a fluid
power system. They provide the direction to the fluid and allow the flow in a
particular direction.
 For the present experiment, four types of DCVs can be used.
1. Push button type DCV (For SAC)
2. Hand lever type DCV (For DAC)
3. Solenoid operated DCV
4. Single and double pilot operated DCV/ Memory valve
1. Push button type DCV (For SAC)
 These are the manually operated DCVs.
 It has a spool which can be moved using a push button to open and close the air inlet
and exit ports.
 As the push button is released, because of the spring force, push button and spool
gains it original position.
 Air cannot pass through the ports in the normal or ideal condition, so it is also called
normally closed valve.
 In case of electro pneumatic system, it can be available in the form of a box of many
push button switches which can be operated using electronic connections.
 Electronic push button will operate a solenoid of a DCV, which will be having a
similar construction to that of a manually operated DCV has.

Figure 1.5 – Cross section of push button type DCV
 Such push button switches are used for starting and stopping of operation of
machinery.
 Electronic push button switches are of two types.
a) Normally open (NO) type
b) Normally closed (NC) type
Figure 1.6 –Push button type DCV (JANATICS India Pvt. Ltd.)

Figure 1.7 –Push button switch module (JANATICS India Pvt. Ltd.)
2. Hand lever type DCV (For DAC)

 These are also the manually operated DCVs.
 It has a spool which can be moved using a lever to open and close the air inlet and
exit ports.
 As the lever is moved to actuating position, ports are get connected and air can pass
through the ports.
Figure 1.8 –Hand lever type DCV (JANATICS India Pvt. Ltd.)

3. Solenoid operated DCV
 The solenoid actuation is also known as electrical actuation. The schematic of
solenoid actuation is shown in Figure 1.9.
 The energized solenoid coil creates a magnetic force which pulls the armature into the
coil. This movement of armature controls the spool position. T
 he main advantage of solenoid actuation is its less switching time.
Figure 1.9 - Working of solenoid to shift spool of valve
Figure 1.10 – Single solenoid operated DCV (JANATICS India Pvt. Ltd.)
Figure 1.11 – Double solenoid operated DCV (JANATICS India Pvt. Ltd.)

4. Single and double pilot operated DCV
 Mostly, the direct actuation is restricted to use with smaller valves only because
usually lot of force is not available. The availability of limited force is the greatest
disadvantage of the direct actuation systems.
 In practice, the force required to shift the spool is quiet higher. Therefore, the larger
valves are often indirectly actuated in sequence.
 First, the smaller valve is actuated directly and the flow from the smaller valve is
directed to either side of the larger valve.
 The control air can be supplied by the same circuit or by a separate circuit. The pilot
valve pressure is usually supplied internally. These two valves are often incorporated
as a single unit.
Figure 1.12 – Pilot actuation
 It is helpful in hazardous application where other components of the system are to be

protected from any accidents.
 These valves can be operated from a distance thereby providing a long connection.
 Advantage of such valve is that the speed of the actuation can be varies by varying the
cross section area by the needle valve
Figure 1.13 – Single pilot operated DCV for SAC (JANATICS India Pvt. Ltd.)

Figure 1.14 – Double pilot operated DCV for DAC (JANATICS India Pvt. Ltd.)
PROCEDURE: -
1. Prepare a list of components required to prepare a circuit (Separate list for
basic pneumatic module and electro pneumatic module).
2. Prepare a circuit using standard symbols of different components separately
which can be used as a reference for the actual connections.
3. Attach components to the work bench at a proper location.
4. Apply and check necessary connections.
5. Start the air supply and observe the motion.

DESCRIPTION: -

EXPERIMENT – 2
AIM: - To demonstrate the use of memory valve and quick exhaust valve with double
acting cylinder.
COMPONENTS: -
 In the present experiment, double acting cylinder is to be used, hence 5/2 DCV has to
be used for the necessary movement of the cylinder. Other components which can be
used for the experiment are listed and described below:
1. Quick exhaust valve
2. Memory valve or 5/2 double pilot operated DCV
3. Hand lever operated DCV
4. Push button type DCV
2.1 Quick exhaust valve

 It is a type of non-return valve.
 The quick exhaust valve is used to exhaust the cylinder air quickly to atmosphere.
Schematic diagram of quick exhaust valve is shown in Figure 2.1
 In many applications especially with single acting cylinders, it is a common practice
to increase the piston speed during retraction of the cylinder to save the cycle time.
 The higher speed of the 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.

Department of Mechanical Engineering Prepared by: Jainik Makwana
Figure 2.1 - Functional diagram of quick exhaust valve
Figure 2.2 - Quick exhaust valve (JANATICS India Pvt. Ltd.)
2.2 Memory valve or 5/2 double pilot operated DCV
 5/2 double pilot operated DCV, which is already discussed in experiment 1, is also
known as a memory valve.
 In memory valve until the signals are given to second pilot, the first pilot will keep the
spool in operated condition and so the cylinder will remain in its actuated position.
Here the signal to the pilot port will be in the form of supply of compressed air.
 As the signals are given to the second pilot, spool of the DCV will move in the
opposite direction, providing the second port open to the another end of the cylinder.
Thus cylinder will move in opposite direction i.e. extension or retraction position as
per the connections applied.

PROCEDURE: -
1. Prepare a list of components required to prepare a circuit.
2. Prepare a circuit using standard symbols of different components separately which
can be used as a reference for the actual connections.
DESCRIPTION: -

EXPERIMENT – 3
AIM: - To demonstrate the use of dual pressure valve and shuttle valve with single acting
cylinder.
COMPONENTS: -
 A dual pressure valve is also known as AND valve. It is very helpful where chances
of accidents, because of the operator’s distraction or during the operator’s training, are
more.
 A shuttle valve is also known as an OR valve. It is used where two separate controls
are provided, one at each end of the machine, to facilitate an operator in reducing
movement across the floor space of the machine.
 Components which can be used for the experiment are listed and explained below:
1. Dual pressure valve
2. Shuttle valve
3. Push button type DCV
4. Single acting cylinder
5. Double acting cylinder
3.1 Dual pressure valve

 This valve is the pneumatic AND valve. It is also derivate of Non Return Valve. A
two pressure valve requires two pressurized inputs to allow an output from itself. The
cross sectional views of two pressure valve in two positions are given in Figure 3.1.
 As shown in the Figure 3.1, this valve has two inputs and one output. If the
compressed air is applied to either of two input, the spool moves to block the flow,
and no signal appears at output. If signals are applied to both the inputs, the
compressed air flows through the valve, and the signal appears at output.

Figure 3.1 - Working principle of dual pressure valve
Figure 3.2 - Dual pressure valve (JANATICS India Pvt. Ltd.)

3.2 Shuttle valve
 It is also known as a double control valve or double check valve. A shuttle valve has
two inlets and one outlet. At any one time, flow is shut off in the direction of
whichever inlet is unloaded and is open from the loaded inlet to the outlet.
 A shuttle valve may be installed, for example, when a power unit (cylinder) or control
unit (valve) is to be actuated from two points, which may be remote from one other.
Figure 3.3 – Construction of shuttle valve
Figure 3.4 – Shuttle valve (JANATICS India Pvt. Ltd.
PROCEDURE: -

DESCRIPTION: -

EXPERIMENT – 4
AIM: - To perform AND & OR logic for forward stroke of a double acting cylinder using
two manual control.
COMPONENTS: -
 In previous experiment, dual pressure valve and shuttle valve are used with a single
acting cylinder in basic pneumatic module.
 But instead of using those valve, in this experiment, logic will be developed using
electronic instruments with basic pneumatic system. This may allow varieties of
combinations of connections with different valve and actuators.
 Also it may help in developing electro pneumatic system which is much sensitive to
the input.
 Components which can be used in this experiment are listed and explained below.
1. Electrical Push button module
2. Relay logic unit
3. 5/2 single solenoid valve with spring return
4. 5/2 double solenoid valve
4.1 Electrical Push button module
 A push button is a switch used to close or open an electric control circuit. They are
primarily used for starting and stopping of operation of machinery.
 They also provide manual override when the emergency arises. Push button switches
are actuated by pushing the actuator into the housing. This causes set of contacts to
open or close.

 Push buttons are of two types
1. Momentary push button
2. Maintained contact or detent push button
 Momentary push buttons return to their unactuated position when they are released.
Maintained (or mechanically latched) push buttons has a latching mechanism to hold
it in the selected position.
 The contact of the push buttons, distinguished according to their functions,
1. Normally open (NO) type
2. Normally closed (NC) type
Figure 4.1 – Push button switch module (JANATICS India Pvt. Ltd.)
 Here as shown in Figure 4.1, 14 and 22 takes 24V power supply connections and its
output i.e. 13 and 21 are connected with the relay logic unit of a solenoid of the DCV.
First three push buttons (green colored) are momentary push button and red colored
push button is a maintained contact or detent push button.
4.2 Relay logic unit
 A relay is an electro magnetically actuated switch. It is a simple electrical device used

for signal processing.
 Relays are designed to withstand heavy power surges and harsh environment
conditions.

 When a voltage is applied to the solenoid coil, an electromagnet field results. This
causes the armature to be attracted to the coil core.
 The armature actuates the relay contacts, either closing or opening them, depending
on the design. A return spring returns the armature to its initial position when the
current to the coil is interrupted. Cross sectional view of a relay is shown in Figure
4.2.
 A large number of control contacts can be incorporated in relays in contrast to the

case of a push button station. Relays are usually designated as R1, R2, and R3 etc.
 Relays also possess interlocking capability that is an important safety feature in
control circuits. Interlocking avoids simultaneous switching of certain coils.
Figure 4.2 - Cross sectional view of a relay
 Relay 1 can be operated separately by RL1. Similarly relay 2 and relay 3 can be
operated by RL2 and RL3 can be operated separately.
 As shown in Figure 4.3, 41, 31, 21, 11 connections are known as a common
connection of relay 1 which are always given 24V.
 Here 44, 34, 24, 14 are showing that relay is normally open and 42, 32, 22, 12 are
showing that the relay is normally closed.

Figure 4.3 – Relay logic unit (JANATICS India Pvt. Ltd.)
4.3 Solenoid operated DCV

 Solenoid is coil whose length is substantially greater than its diameter, often wrapped
around a metallic core, which produces a uniform magnetic field in a volume of space
(where some experiment might be carried out) when an electric current is passed
through it. A solenoid is a type of electromagnet when the purpose is to generate a
controlled magnetic field.
Figure 4.4 - Functional diagram of solenoid operated DCV

 Electrically actuated directional control valves form the interface between the two
parts of an electro-pneumatic control. The most important tasks of electrically
actuated DCVs include.
1. Switching supply air on or off
2. Extension and retraction of cylinder drives
 Electrically actuated directional control valves are switched with the aid of solenoids.
Solenoid valve may be a single solenoid spring return valve or a double solenoid
valve.
1. Spring return valves only remain in the actuated position as long as current
flows through the solenoid
2. In the initial position, all solenoids of an electrically actuated DCVs are de-
energized and the solenoids are inactive. A double valve has no clear initial
position, as it does not have a return spring. The possible voltage levels for
solenoids are 12 V DC, 12V AC, 12 V 50/60 Hz, 24V 50/60 Hz, 110/120V
50/60 Hz, 220/230V 50/60 Hz.
3. Double solenoid valves retain the last switched position even when no current
flows through the solenoid.
 Generally, for actuating the double acting cylinder, double solenoid DCV and for
acting the single acting cylinder, single solenoid DCV is used.
 Advantage of using solenoid operated DCV is that they are highly sensitive to the
position of the actuator when used with the rid switch and positioning sensor or
inductive sensors. They are mostly used when multi cycle automatic operation of the
actuator is required.
Figure 4.5 – Single solenoid operated DCV (JANATICS India Pvt. Ltd.)

Figure 4.6 – Double solenoid operated DCV (JANATICS India Pvt. Ltd.)
PROCEDURE: -

DESCRIPTION: -

EXPERIMENT – 5
AIM: - To control the speed of a double acting cylinder using metering in and metering out
flow control valve (Speed controlling operation).
COMPONENTS: -
 In industries, actuators of all machines are not working at a same speed. Even
actuators of a same machine may be working at a different speed.
 Actuator of some machine like shaper machine, may reciprocates at different speed.
In a shaper machine, forward stroke is slower than the return stroke.
 Another example is the hydraulic crane. To save the material handling time and so the
cycle time it can be the requirement that crane must move faster during no load than
during loaded condition.
 During the loaded condition, for the safety purpose, to reduce the speed of an
actuator, air flow may be reduced using flow control valve and vice versa.
 Thus, this experiment will lead us to know about the speed control of an actuator by
maintaining the flow using flow control valve.
 To perform this experiment following components may be used.
1. Flow control valves
3. Push button DCV
These are explained as below.
5.1 Flow control valve

 In practice, the speed of actuator is very important in terms of the desired output and
needs to be controlled. The speed of actuator can be controlled by regulating the fluid
flow.

 A flow control valve can regulate the flow or pressure of the air. The air flow is
controlled by varying area of the valve opening through which fluid passes.
 The air flow can be decreased by reducing the area of the valve opening and it can be
increased by increasing the area of the valve opening.
 A very common example to the air flow control valve is the household tap. Figure 5.1
shows the schematic diagram of a flow control valve. The pressure adjustment screw
varies the fluid flow area in the pipe to control the discharge rate.
Figure 5.1 – Working of flow control valve
 Flow control valves can be affected by temperature changes. It is because the

viscosity of the fluid changes with temperature. Therefore, the advanced flow control
valves often have the temperature compensation.
 The temperature compensation is achieved by the thermal expansion of a rod, which
compensates for the increased coefficient of discharge due to decreasing viscosity
with temperature.
 The flow control valves work on applying a variable restriction in the flow path.
Based on the construction; there are mainly four types.
1. Plug valve
2. Butterfly valve
3. Ball valve
4. Balanced valve

1. Plug or glove valve
 The plug valve is quite commonly used valve. It is also termed as glove valve.
Schematic of plug or glove valve is shown in Figure 5.2.
Figure 5.2 - Plug or glove valve
Figure 5.3 – Flow control valve (JANATICS India Pvt. Ltd.)
 This valve has a plug which can be adjusted in vertical direction by setting flow
adjustment screw. The adjustment of plug alters the orifice size between plug and
valve seat. Thus the adjustment of plug controls the fluid flow in the pipeline.
 The characteristics of these valves can be accurately predetermined by machining the
taper of the plug. The typical example of plug valve is stopcock that is used in
laboratory glassware.
 The valve body is made of glass or Teflon. The plug can be made of plastic or glass.
Special glass stopcocks are made for vacuum applications. Stopcock grease is used in
high vacuum applications to make the stopcock air-tight.

2. Butterfly valve
 A butterfly valve is shown in Figure 5.4. It consists of a disc which can rotate inside
the pipe. The angle of disc determines the restriction.
 Butterfly valve can be made to any size and is widely used to control the flow of gas.
These valves have many types which have for different pressure ranges and
applications.
Figure 5.4 - Butterfly valve
3. Balanced valve
 Schematic of a balanced valve is shown in figure 5.5. It comprises of two plugs and
two seats. The opposite flow gives little dynamic reaction onto the actuator shaft. It
results in the negligible dynamic torque effect.
Figure 5.5 - Balanced valve

 However, the leakage is more in these kind of valves because the manufacturing
tolerance can cause one plug to seat before the other.

 The pressure-balanced valves are used in the houses. They provide water at nearly
constant temperature to a shower or bathtub despite of pressure fluctuations in either
the hot or cold supply lines.
PROCEDURE: -

DESCRIPTION: -

EXPERIMENT – 6
AIM: - To perform single and multicycle operation of a double acting cylinder using roller
lever valve and memory valve.
COMPONENTS: -
 It may be requirement that a double acting cylinder or an actuator sometimes
performs an operation for a long period of time as in case of mass production line or
for a few seconds or minutes of time as in case of job production line.
 Sometimes movement of an actuator has to be controlled where enough space is not
available for extra movement or to avoid the accident chances.
 To fulfill these requirements there must be two separate controls to actuate an
actuator. This experiment includes such type of pneumatic circuit.
 In this experiment we can use two limit switches, in addition to other basic
components, to limit the movement of an actuator and to supply the air to the pilot of
a memory valve.
 As pilot of a memory valve gets the air supply from the forwarding limit switch, spool
of DCV will supply air to piston end port of an actuator and plunger of an actuator
will touch the reversing limit switch.
 Similarly, by supplying the air from the reversing limit switch to the another pilot of
DCV, rod end port of an actuator will get air supply and plunger of an actuator will
touch the forwarding limit switch.
 By using two separate controls, single and multi-cycle operation of a double acting
cylinder can be achieved as per the requirement.
 This is also possible if electro pneumatic system is used. In that case, electrical
proximity sensor has to be used in place of limit switch or roller lever valve

 Components which can be used for the purpose are listed and explained as below:
1. 3/2 NC roller lever valve – Forwarding (Limit switch)
2. 3/2 NC roller lever valve – Reversing (Limit switch)
3. Shuttle valve
4. 3/2 push button valve
5. 5/2 hand lever operated valve
6. 5/2 double external pilot operated valve (Memory valve)
These are explained as below.
6.1 3/2 NC roller lever valve – Forwarding (Limit switch)
 It is a linear travel limit switch intended for use with linear actuators only.
 The DCV spool can be operated by using mechanical elements such as roller and cam,
roller and plunger and rack and pinion etc. In these arrangements, the spool end is of
roller or a pinion gear type.
 The plunger or cam or rack gear is attached to the actuator. Thus, the mechanical
elements gain some motion relative to the actuator (cylinder piston) which can be
used for the actuation.
 S1 and S2 are the limit switches corresponding to home position and extended
position.
 Although they are located in the path of the movement of piston rod, normal practice
is to represent the symbol of the limit switches on either side of the 3/2-way control
valve without put signals connected to the pilot ports of the valve. (in this Figure 6.1
pilot signals actuations are shown for clarity)
 The limit switches of Roller lever type are essentially 3/2-way ball seat or disc seat
type of valves handling pneumatic signals.

A) Signal from the valve (Return)
B) Signal from the valve (Forward)

Figure 6.1 – Use of limit switch

Figure 6.2 – Cross sectional view of limit switch (JANATICS India Pvt. Ltd.)
Figure 6.3 – Forwarding limit switch (JANATICS India Pvt. Ltd.)

Figure 6.4 – Reversing limit switch (JANATICS India Pvt. Ltd.)
PROCEDURE: -

DESCRIPTION: -

EXPERIMENT – 7
AIM: - To perform continuous operation of a double acting cylinder using double solenoid
valve.
COMPONENTS: -
 In the mass production line, actuator has to be operated continuously for a long period
of time. Single or double acting cylinder can be operated continuously using single or
double solenoid valve respectively.
 Now, an actuator can be operated continuously as per the requirement either
automatically or manually.
 To operate an actuator manually, we can simply use the push button switch module
only. That means by using two separate pushbuttons an actuator can be operated
intermittently.
 Similarly, to operate an actuator continuously by pressing a push button once, as in
case of mass production line, we can use a relay logic unit along with a push button
switch module.
 In this experiment we will prepare a logic first and then apply it to the system.
Remember that for automatic continuous operation of a double acting cylinder, we
will use detent push button and for separate control we will use momentary push
button.
 Components which we can use for the experiment are listed as below:
1. Push button witch module
2. Relay logic unit
3. Single solenoid valve
4. Double solenoid valve
7. Inductive sensor

PROCEDURE: -
DESCRIPTION: -

EXPERIMENT – 8
AIM: - To operate two double acting cylinder electro pneumatically (Sequence of

operation: A+B+A-B-).
COMPONENTS: -
 In industry, many machines are operated at a time in order to complete the job or
manufacturing of a component. Sequence of operation of these machines are very
important.
 In this experiment we will learn the sequencing of an actuator of an automatic
machine. Here the requirement is that two double acting cylinders must be operated in
sequence.
 Sequence of operation is A+B+A-B-.
1. Cylinder A – Extension
2. Cylinder B – Extension
3. Cylinder A – Retraction
4. Cylinder B – Retraction
 Components which can be used for the experiment are as under.
1. 5/2 Double solenoid valve
2. Double acting cylinders
3. Push button switch module
4. Relay logic unit
5. Flow control valve
6. Magnetic reed switches with clamp
8.1 Magnetic reed switch
 The aluminum pneumatic cylinders that are equipped with an internal magnet can be
used with the Reed Switch.

 By accurately sensing the magnetic field of the piston when it passes beneath the
sensor, its position is determined, and a feedback signal is created.
 Reed Switch is a Normally-Open electronic switch. When the cylinder's magnet-
equipped piston moves to a location where the magnet is positioned below the Reed
Switch, the Switch sends a feedback single to indicate the location of the piston.
 The benefits of reed switches are that they are low-cost, they require no stand by
power, and they can function with both ac and dc electrical loads.
 However, reed switches are relatively slow to operate, and therefore may not respond
fast enough for some high-speed applications.
 Since they are mechanical devices with moving parts, they have a finite number of
operating cycles before they eventually fail. Switching high-current electrical loads
can further cut into their life expectancy.
 The reed switch is encapsulated and is enclosed in an aluminum case, to which the
connecting cables are securely clamped.
 The proximity switches can be very easily adjusted to operate at the required point
along the piston stroke. All parts of the proximity switch are made of corrosion
resistant materials.

Figure 8.1 – Single acting cylinder with reed switch (JANATICS India Pvt. Ltd.)
PROCEDURE: -

DESCRIPTION: -

EXPERIMENT – 9
AIM: - To demonstrate the use of an inductive sensor with double acting cylinder and
COMPONENTS: -
 In a pneumatic system, in order to limit the movement of an actuator, limit switches
were used. But in case of electro pneumatic system, inductive or capacitive sensors
are used as a sensing element to limit the stroke of an actuator.
 In this experiment, inductive sensor is used which will sense the metal and it will send
the signals to the one of the solenoid of a double solenoid DCV.
 An inductive sensor also can be used for counting the number of strokes of an
actuator, switching on the buzzer which is very useful in case of hazardous
environment as well as accident sever areas.
 Components which can be used to perform this experiment are listed as below:
1. Inductive sensor
2. Capacitive sensor
4. Single solenoid valve
9.1 Inductive sensor
 One position-sensing technique is to install external electromechanical limit switches

or inductive proximity switches that detect metal targets on the moving parts of the
machine.
 The disadvantages of this approach include the cost and complexity of the brackets
and associated hardware, the difficulty of making adjustments, and the increased
physical size of the overall assembly.

 Inductive sensors detect ferrous and non-ferrous metals without physical contact; the
detection distance depends on the type of metal; non-ferrous metals have a distance
reduced to about 0.3 times that for steel.
 The sensor consists of an induction loop. Electric current generates a magnetic field,
which collapses generating a current that falls toward zero from its initial trans when
the input electricity ceases.
 The inductance of the loop changes according to the material inside it and since
metals are much more effective inductors than other materials the presence of metal
increases the current flowing through the loop. This change can be detected by
sensing circuitry. This then signals some other device whenever metal is detected.
 According to type the sensing range for mild steel is between 1 mm and 20 mm.
Figure 9.1 – Inductive capacitive sensor (JANATICS India Pvt. Ltd.)

9.2 Capacitive sensors
 Capacitive sensors are similar to inductive sensors but can also detect non-metallic
materials with reduced sensitivity.
 They can also detect through other materials, so they can be mounted externally on
non-metallic containers to sense filling levels.
 The sensing rate is slower, with a maximum sensing distance of 10 mm.

 These sensors are very flexible and can be mounted directly on all standard
pneumatic actuators without any mechanical fittings.
 Capacitive sensors are constructed from many different media, such as copper, indium
tin oxide (ITO) and printed ink.
 Copper capacitive sensors can be implemented on standard FR4 PCBs as well as on
flexible material.
 ITO allows the capacitive sensor to be up to 90% transparent (for one layer solutions,
such as touch phone screens). Size and spacing of the capacitive sensor are both very
important to the sensor's performance.
Figure 9.2 – Inductive capacitive sensor (JANATICS India Pvt. Ltd.)
PROCEDURE: -

DESCRIPTION: -

EXPERIMENT – 10
AIM: - To demonstrate the auto reset of a counter after the operation of a double acting
cylinder after ‘n’ cycles using double solenoid valve.
COMPONENTS: -
 In this experiment all the components which we discussed in previous experiments
will be used. Experiment will lead us to learn about how to reset a counter after ‘n’
numbers of cycles of an actuator along with the use of time delay valve, buzzer and
sensors.
 Components which can be used for the experiment are listed below:
3. Flow control valve
4. Electric push button module
5. Timer
6. Relay logic unit
7. Inductive sensor
8. Electronic counter module
9. Electrical buzzer with indicator
10. Magnetic reed switch
10.1 Timer/ Time delay valve

 Pneumatic timers are used to create time delay of signals in pilot operated circuits.
Available as normally closed timers and normally open timers.
 Usually pneumatic timers are on delay timers. Delay of signals is very commonly
experienced in applications such as bonding of two pieces.
 Normally open pneumatic timers are also used in signal elimination. Normally open
pneumatic timers are used as safety device in two hand blocks

 Time delay valve is a combination of a pneumatically actuated 3/2 direction control
valve, an air reservoir and a throttle relief valve.
 The time delay function is obtained by controlling the air flow rate to or from the
reservoir by using the throttle valve.
 Adjustment of throttle valve permits fine control of time delay between minimum and
maximum times.
 In pneumatic time delay valves, typical time delays in the range 5-30 seconds are
possible. The time delay can be extended with the addition of external reservoir.
 Pneumatic timer can be classified as
1. On –delay timer
2. Off – delay timer
 In on-delay timer, the 3/2 DCV is actuated after a delay with reference to the
application of pilot signal and is rest immediately on the application of the pilot
signal.
 In off delay timer, the 3/2 DCV is actuated immediately on the application of the pilot
signal and is reset only after a delay with reference to the release of the pilot signal.
Figure 10.1 – Symbol of time delay valve
 A shown in Figure 10.2, it is an electronic timer/ time delay valve, so there is no

throttle valve in this case. It receives the signal from the counter module.
 It must be noted that it requires separate power supply to operate a timer module.
 Point C stands for common connections which is always given 24 V DC power supply
and NO and NC are connected as per the requirement.

Figure 10.2 – Timer (JANATICS India Pvt. Ltd.)
10.2 Electronic counter module
 It counts the numbers of strokes of an actuator.

 It receives the signals from inductive sensor or a capacitive sensor and display the
counts on the screen provided to it.
Figure 10.3 – Electronic counter module (JANATICS India Pvt. Ltd.)

 It must be noted that it requires separate power supply to operate the counter module
display the counts on the screen.
 Point C stands for common connections which is always given 24 V DC power supply
and NO and NC are connected as per the requirement.
 R1 and R2 points are used as a reset point which are given 24V DC and 0 V DC
respectively.
 A1 gets the signal from the inductive sensor and A2 is given 0V DC.
PROCEDURE: -

DESCRIPTION: -

ASSIGNMENT - 1 INTRODUCTION TO OIL HYDRAULIC
Theory
1. Write down the advantages and disadvantages of hydraulic system.

2. Explain different elements of hydraulic circuits.
3. Explain the principle of hydraulic fluid power transmission.
4. Compare hydraulic and pneumatic systems.

ASSIGNMENT - 2 HYDRAULIC SYSTEM COMPONENT AND
FLUID PROPERTIES
Theory
1. Explain different types of hydraulic fluids.

2. Explain the properties of hydraulic fluid in detail.
3. Write down the nature and sources of contamination.
4. Explain following terms:
A. Filter and strainer
B. Mesh number
C. Micron rating
D. Slit index
5. Explain different types of filter and general location of filter.

ASSIGNMENT - 3 HYDRAULIC PUMPS, MOTORS AND
ACTUATORS
Theory
1. Give classification of Hydraulic pumps. Explain the construction and working principle
of positive and non-positive displacement pump.
2. Classify the pumps used for the hydraulic system and explain external and internal gear
pump with neat sketches.
3. What is the hydrostatic transmission system? Explain in brief.
4. Explain different types of cylinder on the basis of their construction.
5. Explain the working principle of hydraulics motor. State the types of hydraulic motors.
Also discuss the selection criteria for hydraulic motors.

ASSIGNMENT - 4 HYDRAULIC VALVES AND HYDRAULIC
SYTEM ACCESORIES
Theory
1. Enlist the types of control valves used for hydraulic system and explain types of
pressure control valves in detail with neat sketch.
2. State different types of PCV. Explain working of each one with the help of neat sketch
3. Explain non return valve in brief.
4. Explain with next sketch the working principle of the following:
A) Sequence valve B) counter balance valve C) unloading valve D) pressure reducing
valve
5. Explain different operating methods in direction control valve.

ASSIGNMENT - 5 INTRODUCTION TO PNEUMATIC
SYSTEMS
Theory
1. Draw line sketch of stages of air preparation for pneumatic system and discuss each
component in detail.
2. Explain in short the actuators used for pneumatic control systems. Also explain detail
of components on simple double acting cylinder with neat line sketch and state the
function of each component.
3. What is the service unit in pneumatic system? Why is it provided? Clearly mention
functions of each unit of service unit. Draw detailed and simplified symbols of service
unit.
4. Write a short note on: A) the Quick Exhaust valve B) Time delay shuttle valve C) Twin
pressure valve.
5. Explain ‘cushioning’ of pneumatic cylinder. Explain cushion assembly in detail.

ASSIGNMENT - 6 INTRODUCTION TO AUTOMATION
Theory
1. Discuss the role of automation in pneumatic and hydraulic control systems. List the
applications of pneumatic and Hydraulic control systems. Also explain how the hydraulic
system is used in machine tool application.


Lab Manual Oil Hydraulics & Pneumatics (2171912)

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Lab Manual

Oil Hydraulics & Pneumatics

Department of Mechanical Engineering

This is to certify that Mr./Ms.____________________________________

Enrollment No. ________________Branch_____________________________

Semester ____________ has satisfactory completed the course in the subject

__________________________________ in this institute.

Date of Submission: - __________________________

Staff in Charge Head of Department

Sr. Page Starting Ending

Sr. Page Starting Ending

1 Introduction to oil hydraulic

Hydraulic system component and fluid

3 Hydraulic pumps, motors and actuators

Hydraulic valves and hydraulic system

5 Introduction to pneumatic systems

 A correct cylinder in a hydraulic system contributes to:

These are explained as below:

1. Single acting cylinders

Oil Hydraulics and Pneumatics (2171912)

Figure 1.2 - Single-acting cylinders (JANATICS India Pvt. Ltd.)

 According to the type of return, single-acting cylinders are classified as follows:

Figure 1.3 - Double-acting cylinder with a piston rod on one side

Oil Hydraulics and Pneumatics (2171912)

1.2 Direction control valves

Oil Hydraulics and Pneumatics (2171912)

a) Normally open (NO) type

b) Normally closed (NC) type

Oil Hydraulics and Pneumatics (2171912)

2. Hand lever type DCV (For DAC)

Oil Hydraulics and Pneumatics (2171912)

Figure 1.9 - Working of solenoid to shift spool of valve

Oil Hydraulics and Pneumatics (2171912)

Figure 1.12 – Pilot actuation

 It is helpful in hazardous application where other components of the system are to be

Oil Hydraulics and Pneumatics (2171912)

Oil Hydraulics and Pneumatics (2171912)

Oil Hydraulics and Pneumatics (2171912)

These are explained as below:

2.1 Quick exhaust valve

Oil Hydraulics and Pneumatics (2171912)

Figure 2.2 - Quick exhaust valve (JANATICS India Pvt. Ltd.)

2.2 Memory valve or 5/2 double pilot operated DCV

Oil Hydraulics and Pneumatics (2171912)

Oil Hydraulics and Pneumatics (2171912)

These are explained as below:

3.1 Dual pressure valve

Oil Hydraulics and Pneumatics (2171912)

Figure 3.2 - Dual pressure valve (JANATICS India Pvt. Ltd.)

Oil Hydraulics and Pneumatics (2171912)

Figure 3.3 – Construction of shuttle valve

Figure 3.4 – Shuttle valve (JANATICS India Pvt. Ltd.

Oil Hydraulics and Pneumatics (2171912)

Oil Hydraulics and Pneumatics (2171912)

These are explained as below:

4.1 Electrical Push button module

Oil Hydraulics and Pneumatics (2171912)

4.2 Relay logic unit

 A relay is an electro magnetically actuated switch. It is a simple electrical device used

Oil Hydraulics and Pneumatics (2171912)

 A large number of control contacts can be incorporated in relays in contrast to the

Figure 4.2 - Cross sectional view of a relay

Oil Hydraulics and Pneumatics (2171912)

Enrollment No. Branch_____________