Fundamentals of Electrohydraulics: Collection of Transparencies TP 601

Fundamentals of
Electrohydraulics
Collection of
Transparencies
TP 601
Festo Didactic
095051 en
Order no.: 095051
Designation: E.-HYDR-FOLIEN.
Description: D:OT-TP601-GB
Edition: 07/2001
Author: Dieter Scholz
Graphics: Doris Schwarzenberger
Layout: 18.07.2001, Beatrice Huber
© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2001

Internet: www.festo.com/didactic
e-mail: did@festo.com
The copying, distribution and utilization of this document as well as the

communication of its contents to others without expressed authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Foreword
This set of overhead transparencies has been designed for use with the basic level
of the technology package TP600 “Electrohydraulics”. The set of overhead
transparencies and the technology package form part of the Learning System for
Automation from Festo Didactic GmbH & Co.
The 30 transparencies in this set have been optimised from the didactic and
methodological points of view. Each transparency is accompanied by a short text
which provides the trainer with a quick overview of the training contents of the
transparency concerned.
Training contents · Basic principles of electrohydraulics

· Function and use of electrohydraulic components
· Basic principles of electrical engineering
· Production and interpretation of standard hydraulic and electrical circuit
diagrams
The text sheet includes a complete illustration of the transparency, in certain cases
with additional explanations and legends which the trainer can enter on the
transparency in the course of a training session.
The advantages of this concept are:

· The trainer can add to the transparencies step by step in the course of a training
session.
· The trainer is thus able to create a lively and interesting atmosphere.
· The provision of accompanying text means less preparation work for the trainer.
New! The enclosed CD-ROM contains the entire overhead transparencies and
Electronic presentation accompanying text of this edition in an electronically presentable form in the files
„Electrohydraulics _transparencies.pdf“ and „Electrohydraulics _text.pdf“. In
addition to the screen presentation, which can be made in any order, the contents
can be printed out and text and graphics can be used for your own training
® ®
preparations, insofar as the functionality of the required Adobe Acrobat Reader
permits this. This freely distributable software is available on the CD-ROM in the
currently valid English version for Windows 95/98/NT for installation in the directory
„Acrobat_Reader“. Please start the file „rs405eng.exe“ and follow the subsequent
dialogue.
© Festo Didactic GmbH & Co. • Electrohydraulics

Contents
Electrohydraulic press _______________________________________ Transparency 1

Schematic layout of an electrohydraulic installation ______________ Transparency 2
Electrical power supply unit __________________________________ Transparency 3
Electrical circuit ____________________________________________ Transparency 4
Measuring circuits __________________________________________ Transparency 5
Ohm’s law _________________________________________________ Transparency 6
Rectifiers __________________________________________________ Transparency 7
Analogue, digital and binary __________________________________ Transparency 8
Momentary and sustained contact switches _____________________ Transparency 9
N/O, N/C and changeover contacts ___________________________ Transparency 10
Limit switches _____________________________________________ Transparency 11
Proximity switches _________________________________________ Transparency 12
Solenoid (electromagnet) ___________________________________ Transparency 13
Electrohydraulic converters (solenoid valves)___________________ Transparency 14
Dry solenoids – wet solenoids________________________________ Transparency 15
Solenoid valve connections__________________________________ Transparency 16
Relays and contactors ______________________________________ Transparency 17
Direct activation – indirect activation __________________________ Transparency 18
Signal inversion ___________________________________________ Transparency 19
Latching__________________________________________________ Transparency 20
Circuit diagram ____________________________________________ Transparency 21
Hydraulic power pack_______________________________________ Transparency 22
Hydraulic circuit ___________________________________________ Transparency 23
Electrical power – hydraulic power ____________________________ Transparency 24
Power losses______________________________________________ Transparency 25
Pressure switches__________________________________________ Transparency 26
4/3-way solenoid valve _____________________________________ Transparency 27
4/3-way solenoid valve, piloted ______________________________ Transparency 28
Electrical safety____________________________________________ Transparency 29
Hydraulic safety ___________________________________________ Transparency 30

1
Electrohydraulic press
Function units · Motor with hydraulic pump

· Control panel
· Valve manifold
· Cylinder
The hydraulic press is controlled via the electrical control panel.
Electrical signals are used to activate the valves in the hydraulic installation.
The electrohydraulic press is used to form rectangular troughs.
Motor with
hydraulic pump
Valve manifold
Actuator
(cylinder)
Control pane

Electrohydraulic press
© Festo Didactic GmbH & Co. TP 601, Transparency 01

2
Schematic layout of an electrohydraulic installation
Division of installation into signal control section and hydraulic power section.
Signal control section Input and processing of electrical signals.
Solenoid valves form the interface between the electrical signal control section and
the hydraulic power section.
Hydraulic power section Controls the flow of hydraulic fluid by means of solenoid valves. Actuators convert
hydraulic energy into motions.
Power section
Signal control section Hydraulic

cylinder
Signal Signal
input processing
è è Solenoid
valve
è
Hydraulic
Power power
supply supply
(conversion)
è

Schematic layout of an electrohydraulic installation
Power section
Signal control section
è è
è
è
è
3
Electrical power supply unit
Connection to mains supply.
Supplies signal control section with specified or maximum voltage and current
values.
Functions in · Voltage transformation

power supply unit · Rectification
· Smoothing
· Stabilisation
· Fuse protection
In mobile hydraulic systems, rechargeable battery systems or generators are used

as a power supply for the signal control section.
230V
AC DC
24V
50 °C
TR G C T T
Transformer Rectifier Smoothing Stabilisation Fuse

Electrical power supply unit
230V
AC DC
24V
TR G C T T

4
Electrical circuit
A circuit consists of at least a power source, a load device and connecting lines.
Electrical current will flow only in a closed circuit.
Technical direction Electrical current flows from the positive terminal of the power supply to the
of current flow negative terminal.
Figure A Closed circuit without power supply.
Figure B Introduction of a power supply to complete the circuit.
A B

Electrical circuit
A B

5
Measuring circuits
Voltage measurement The voltage drop across a load device is measured in parallel with the device.
Current measurement Electrical current is measured in series.
+ +
Voltage measurement Current measurement

Measuring circuits
+ +
- -

6
Ohm’s law
Ohm’s law Describes the relationship between current (I), voltage (V) and resistance (R).
With ohmic resistances, the current rises in linear proportion to the voltage.
Graph The value pairs for a constant resistance lie on a straight line. The current I is
proportional to the voltage V.
Mathematical formula for Ohm’s law: V=R•I

I=V:R
Voltage V
Resistance R 10 V 20 V 30 V 40 V
Relay 0.5 A 1.0 A 1.5 A 2.0 A
V=R•I Solenoid coil 0.33 A 0.66 A 1.0 A 1.33 A
V
I= 2.0
R
A
A 1.5
+
R 1.0
V
I
0.5
0
0 10 20 30 V 40
V

Ohm’s law
Voltage V
Resistance R 10 V 20 V 30 V 40 V
Relay
Solenoid coil
2.0
A
A 1.5
+
R 1.0
- V
I
0.5
0
0 10 20 30 V 40
V
7
Rectifiers
Rectifiers convert AC to DC.
Diodes are conductive in only one direction.
The polarity of the negative half-wave of the alternating voltage is reversed.
The pulsating voltage is smoothed using a capacitor and filters (reactance coil,
resistor).
L
~
Diodes C R =
Voltage Voltage
retification smoothing
V
t t t

Rectifiers
=
V
t t V t
8
Analogue, digital and binary
Analogue values Analogue values describe continuous functions, such as the continuous filling of a
bucket of water.
Digital values Digital values describe integer parts of a maximum value. A dice, for example, shows
one of six possible numbers.
Binary values Binary values are a special form of digital values. They can assume only two values,
such as in the case of a switch, which can only be on or off.
6
full 5 On 1
4
Volume V
half- 3
Value
full 2
Light
1
empty 0 Off 0
Switching
Filling time t Experiments with dice time point Time t

Analogue, digital and binary
-
Volume V
Value
Light
Filling time t Experiments with dice Time t
9
Momentary and sustained contact switches
Actuation of contacts.
Momentary contact switch A momentary contact switch has a “rest position” and an “actuated position”.
Sustained contact switch A sustained contact switch has two detents. It thus has two rest positions.
Momentary and sustained switches can close or open current paths or switch from
one current path to another.
3 3
4 4

Momentary and sustained contact switches

10
N/O, N/C and changeover contacts
N/O Contact normally open in rest position.
N/C Example: Momentary-contact switch
Changeover contact N/O and N/C contacts in a single housing; one contact is open while the other is
closed.
The designations of the switch contacts are governed by the European standard
EN 50012.
Switch elements
Connection
(N/O contact)
Connection
(N/C contact)
3 1 2 4
4 2 1

N/O, N/C and changeover contacts

11
Limit switches
Determining the position of a positioning slide.
Electrical contacts are actuated when a defined intermediate or end position is

reached.
Limit switches can be connected up as N/O, N/C or changeover contacts.
Switch lever
Stem (insulated)
Contact
Snap-action
mechanism

Limit switches

12
Proximity switches
Inductive Signal is generated by the presence of any material with good conductivity in an
oscillating magnetic field.
Capacitive Signal is also generated by all insulators with high dielectric constants in an
electrical field.
Optical Signal is generated when light barriers are interrupted or when light is reflected
back to an optical sensor.
Reed switches Signal is generated by magnets whose fields close the built-in contacts in the switch.
inductive Metal Reed switch
Magnet
Metal
capacitive or
Insulator
reflective
optical compo- magnetic
nent

Proximity switches

13
Solenoid (electromagnet)
A magnetic field with concentric field lines is created around a conductor carrying an
electrical current.
A coil carrying an electrical current develops a uniform magnetic field in its axial
direction due to the overlapping of field lines.
By appropriate alignment of elementary magnets, an iron core can be made into a

switchable electromagnet.
Field around
a conductor
Iron core
Coil
Coil

Solenoid (electromagnet)
+
-

14
Electrohydraulic converters (solenoid valves)
Convert electrical signals into hydraulic switching operations.
The switching armature is drawn into the coil, which acts as a magnet.
This produces a displacement of the actuating piston in the hydraulic 4/2-way valve.
Switching armature
A B
P T
4/2-way solenoid valve
T A P B L

Electrohydraulic converters (solenoid valves)
A B
P T

15
Dry solenoids – wet solenoids
Dry solenoid The solenoid is separated from the hydraulic fluid; a seal is required on the stem.
Advantage · Simple construction
Wet solenoid The armature chamber of the solenoid is filled with hydraulic fluid, the solenoid
operates in oil.
Advantages · Low friction

· Little abrasion
· Good heat dissipation
· Long service life
seal
Dry solenoid Wet solenoid

Dry solenoid Wet solenoid

16
Solenoid valve connections
Connector components · Solenoid with plug base

· Cable with connector socket
Electrical signals are transmitted via standard connectors.
Advantages · Reliable alignment of connections

· Connections can be attached and detached quickly
· Protected against dust and water
Electrical
connections
Protective earth connection

Plug base

Solenoid valve connections

17
Relays and contactors
Definition Switches which are actuated and held in their actuated positions
electromagnetically.
Used to separate control and power circuits.
Special feature · Hinged-armature design

of relays · Single-break contacts
· Used for logic gating of signals
· (generally) changeover contacts
Special feature Each main contact is of double-break type (contacts used as main contacts),
of contactors suitable for
· all power ratings from small to very large
· only N/O and N/C contacts
Iron core Return spring

Coil Armature Contacts
Contacts Coil
Return spring
Hinged-armature solenoid Plunger-armature solenoid

Relays and contactors
- +

18
Direct activation – indirect activation
Direct activation Connection of a solenoid valve via a switch (Fig. A).
Indirect activation Connection of a solenoid valve via a relay (Fig. B).
Advantage of · Separation of control and power circuits

indirect activation · The current passing through switch S1 (Fig. B) is lower, and the service life of the
switch is significantly greater.
A B
24 V 1 24 V 1 2
3 3 3
S1 S1 K1
4 4 4
Y1 K1 Y1
0V 0V

Direct activation Indirect activation
24 V 1 24 V 1 2
0V 0V

19
Signal inversion
The output signal is inversely proportional to the input signal.
Figure A Signal inversion at relay K1.
Figure B Signal inversion at switch S1.
The switching elements are shown under zero-voltage conditions.
A B
24 V 1 2 24 V 1 2
3 1 1 3
S1 K1 S1 K1
4 2 2 4
K1 Y1 K1 Y1
0V 0V
S1 K1 Y1 S1 K1 Y1
0 0 1 0 1 1
1 1 0 1 0 0

Signal inversion
A B
24 V 1 2 24 V 1 2
3 1 1 3
S1 K1 S1 K1
4 2 2 4
K1 Y1 K1 Y1
0V 0V
S1 K1 Y1 S1 K1 Y1
0 0
1 1

20
Latching
Latching only with indirect activation.
Actuation of switch S1: Relay K1 reverses holding the current path of K1 closed.
The actuation of switch S2 interrupts the latched current path.
24 V 1 2 3
3 3 3
S1 K1 K1 S1 S2 K1 & Y1
4 4 4
0 0 0
1 0 1 0
S2
2 1 0 1
1 1 1
K1 Y1 dominant on
0V

Latching
24 V 1 2 3
3 3 3
S1 K1 K1 S1 S2 K1 & Y1
4 4 4
0 0
1 0 1
S2
2 1 0
1 1
K1 Y1
0V

21
Circuit diagram
Lines of potential with constant voltage are drawn horizontally.
Current paths are drawn vertically and numbered consecutively.
Circuit symbols are shown in the direction of current flow.
Switching elements are generally shown under zero-voltage conditions.
Latching to guard against sticking of relay contacts in current paths 6 and 7.
24 V 1
3
S0
4
2 3 4 5 6 7
3 3 3 3 3 3
S1 K1 S2 K2 K1 K2
4 4 4 4 4 4
1 1
K2 K1
2 2
A1 A1
K1 K2 Y1 Y2
A2 A2
0V

Circuit diagram
3
S0
4
3 3 3 3 3 3
S1 K1 S2 K2 K1 K2
4 4 4 4 4 4
1 1
K2 K1
2 2
A1 A1
K1 K2 Y1 Y2
A2 A2

22
Hydraulic power pack
Hydraulic power pack for use in stationary hydraulic systems.
Power is delivered via the pressure medium using a pump and drive motor.
The pack incorporates devices to remove air, water and solid particles from the
hydraulic fluid.
Pressure relief valve

(safety valve)
Pressure line
Electric motor n = 1500 rpm
Hydraulic pump Return line
Suction pipe Air filter
Filler filter
Suction filter Fluid level indicator
Cleaning aperture
Baffle plate
Drain screw

Hydraulic power pack

23
Hydraulic circuit
Hydraulic systems consist of open or closed circuits.
Hydraulic fluid is used as an energy carrier.
This energy is output via cylinders and motors.
Relieved hydraulic fluid is returned to the tank or hydraulic pump.
Hydraulic cylinder
Electrohydraulic
power valve
Feed pump
(top-up for Hydraulic
Hydraulic Motor leakage losses) motor
pump
Motor
Filter
Return
Safety Safety
line
valve valve
Hydraulic pump Safety valve

open closed

Hydraulic circuit
open closed
24
Electrical power – hydraulic power
Electric motor Driven by electric current on the basis of a potential difference.
Electrical power is the product of voltage and current

Pelectr. = V • I (unit: watts).
Hydraulic motor Driven via fluid flow on the basis of a pressure difference.
Hydraulic power is the product of pressure and flow rate

Phydr. = p • Q (unit: watts).
Pelectr. = V • I Phydr. = p • q
Flow
Current I rate q
Pressure p
Voltage V
Electric motor
Gear motor

Electrical power Hydraulic power

25
Power losses
Efficiency of electric motors · Frictional losses

· Magnetic losses
Efficiency of hydraulic pump · Frictional losses

· Volumetric losses
Valves, piping, tubing · Pressure losses dp

· Power losses expressed by P = dp • Q
Hydraulic motors · Frictional losses

and cylinders · Volumetric losses
Frictional and
volumetric losses
Power losses
Frictional and
pressure losses
Frictional,
volumetric and
magnetic losses
Phydr. loss = ,p • q

Power losses

26
Pressure switches
Actuation of electrical contacts when a defined minimum pressure is reached.
The minimum pressure (switching point) can be varied by means of an adjustable

spring.
Example shows switching at approx. 4 bar with rising or falling pressure.
Generally connected up in practice as a changeover contact.
2 3
Symbolic representation p Symbolic representation

p
in hydraulic circuit diagram in electrical circuit diagram
1
1
3 Pressure
2 p
a c
4 bar Hysteresis
b
Time t
a/c Switching point with rising pressure

b Switching point with falling pressure

Pressure switches
2 3
p
p
1
3 Pressure
2 p
4 bar
Time t

27
Valve spool is directly actuated by solenoids.
Actuation on left The piston spool is displaced to the right and creates the connections P – A
and B – T.
Rest position Rest position produced by spring centring of piston spool. All inputs of the 4/3-way
valve are closed in this position.
A B
a b
a b
P T
T A P B
a b
T A P B

A B
a b
P T
T A P B
T A P B

28
4/3-way solenoid valve, piloted
Direct activation of pilot spool via solenoids.
Actuation on left The pilot piston spool is displaced to the right, and hydraulic fluid is directed to the
right-hand side of the main control spool, creating the connections P – A and B – T.
Rest position Rest position produced by spring centring of pilot and main piston spools. All ports
of the 4/3-way valve are closed at the main valve.
A B
P T
Simplified symbol
A B
T B P A P T
Detailed symbol

4/3-way solenoid valve, piloted
A B
P T
A B
T B P A P T

29
Electrical safety
· EMERGENCY STOP button placed in an easily accessible position

· Protection against voltages
· Protection by means of insulation
· Protection by means of earthed conductive housings
· Safety isolation by means of transformers
1) Switch off
2) Check
3) Carry out work
EMERGENCY
STOP
Safety insulation Protective earth Safety isolation
Additional
insulation
L1
PE
220 V AC 24 V
Basic insulation

Electrical safety
Safety insulation Protective earth Safety isolation

30
Hydraulic safety
Safety regulations must be observed.
· Switch off motor/pump

· Depressurise accumulator
· Lower load
· Check pressure
Work can now be carried out by authorised trained personnel.
1) Switch off 2) Depressurise 3) Lower 4) Check

motor/pump accumulator load pressure

Hydraulic safety

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Fundamentals of

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2001

The copying, distribution and utilization of this document as well as the

Training contents · Basic principles of electrohydraulics

The advantages of this concept are:

© Festo Didactic GmbH & Co. • Electrohydraulics

Electrohydraulic press _______________________________________ Transparency 1

© Festo Didactic GmbH & Co. • Electrohydraulics

Function units · Motor with hydraulic pump

The hydraulic press is controlled via the electrical control panel.

The electrohydraulic press is used to form rectangular troughs.

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 01

Schematic layout of an electrohydraulic installation

Signal control section Input and processing of electrical signals.

Signal control section Hydraulic

© Festo Didactic GmbH & Co. • Electrohydraulics

Signal control section

Electrical power supply unit

Connection to mains supply.

Functions in · Voltage transformation

In mobile hydraulic systems, rechargeable battery systems or generators are used

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 03

Electrical current will flow only in a closed circuit.

Figure A Closed circuit without power supply.

Figure B Introduction of a power supply to complete the circuit.

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 04

Current measurement Electrical current is measured in series.

Voltage measurement Current measurement

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 05

Mathematical formula for Ohm’s law: V=R•I

© Festo Didactic GmbH & Co. • Electrohydraulics

Rectifiers convert AC to DC.

Diodes are conductive in only one direction.

The polarity of the negative half-wave of the alternating voltage is reversed.

© Festo Didactic GmbH & Co. • Electrohydraulics

Analogue, digital and binary

© Festo Didactic GmbH & Co. • Electrohydraulics

Momentary and sustained contact switches

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 09

N/O, N/C and changeover contacts

N/O Contact normally open in rest position.

N/C Example: Momentary-contact switch

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 10

Determining the position of a positioning slide.

Electrical contacts are actuated when a defined intermediate or end position is

Limit switches can be connected up as N/O, N/C or changeover contacts.

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 11

inductive Metal Reed switch

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 12

By appropriate alignment of elementary magnets, an iron core can be made into a

© Festo Didactic GmbH & Co. • Electrohydraulics

© Festo Didactic GmbH & Co. TP 601, Transparency 13

Electrohydraulic converters (solenoid valves)

Convert electrical signals into hydraulic switching operations.

4/2-way solenoid valve