Chapter 5

Hydraulic and Pneumatic Actuating Systems

Q1. Explain the purpose of a pressure sequence valve.

The sequence valve is used in a pneumatic circuit for switching operation depending upon a
preset pressure. The sequence valve opens once its inlet pressure rises above a preset pressure.
The signal output is generated only after the required operating pressure has been reached.
The symbolic representation of a pressure sequence valve is shown in the following figure.
The output signal is generated only if a preset pressure has been reached in the pilot line Z.

Q2. Briefly describe the purpose of an air receiver.

An air receiver is used to store high-pressure air and provide constant supply of air pressure
in the pneumatic system regardless of varying and fluctuating consumption (see the figure
below). Further, one of the functions of a receiver is the emergency supply of air to the
system in case of power failure. Air coming from the compressor will be warm. The large
surface area of the receiver dissipates this heat to the surrounding atmosphere.

Q3. Why are filters used? Sketch various positions of filters in a hydraulic system.
Normally, filters are used to prevent dirt or dust entering important elements of the hydraulic
system such as valves, seals, etc. Filters are used to remove very fine particles and can be
installed in three places as shown in the following figures. The various types of filters are as
follows:

Filter positions.

1. Inlet line filters: Inlet line filters are placed in the system outside the reservoir and near
to the pump in order to protect the pump. They can prevent large particles that may be
in the reservoir from entering the pump.
2. Pressure line filter: The pressure line filter is at the pump outlet which can remove
contaminants passing through or generated by the pump in order to protect the valves.
3. Return line filters: They have high pressure drops and are placed in the system return
line to clean the hydraulic fluid before it enters the reservoir for protecting the pumps.
4. Mechanical filters: They are the most commonly used and utilize fine wire mesh or
disk/screen arrangements. A typical filter is shown in the figure below. These filters are
to be removed, cleaned and refitted frequently. The filter’s element essentially consists
of a cartridge with a fine wire mesh which prevents passing of dirt or dust through it.

Mechanical filter.

Q4. Sketch and explain the working of a time delay valve.

A pneumatic time delay valve is used to delay the switching operation. Referring to the
following figure, a time delay valve essentially consists of one-way flow control valve, a 3/2-
way spool valve and reservoir. The pilot air supply is provided to a reservoir through the one-
way flow control valve. Depending on the setting of the throttling screw, a greater or lesser
amount of air flows per unit time into the reservoir. When the required pressure in the
reservoir has built up, the pilot spool of the 3/2-way valve is moved downwards.
Now, the valve disk is lifted from its seat and ports P and A are linked to generate an
output signal, whereas the air passage is blocked between A and R. The time delay between
application of pilot pressure to port Z and the valve operation is exhibited by the timing
diagram.

Time delay valve: (a) Construction; (b) timing diagram; (c) symbol.

Q5. With annotated diagrams, explain working of OR and AND valves. Give truth tables.

OR Valve

A logic function requires at least one input device to be active in order to cause the output.
The truth table for this function is shown in the figure below.
Symbol and truth table for OR function.
The pneumatic logic OR function is obtained by a shuttle valve as shown in the following
figure. This valve has two inlets and one outlet. If air signal is applied through B, the valve
seat seals the opposing inlet (A) and output signal is generated by connecting B and C. If the
air signal is reversed, the valve seat seals the inlet B and an output signal is generated by
connecting A and C. It also produces the output if either or both input signals are applied.
Any one input simply breaks the flow of air to output port C.

OR valve: (a) Construction; (b) symbol.

AND Valve
The logic AND function requires both input devices to be active for generating the output
signal. The truth table for this function is shown in the following figure.

Symbol and truth table for AND valve.

Q6. What is meant by direct and indirect control of single-acting cylinders?
Direct control of single-acting cylinder
If the cylinder capacity is small, the valve size required can be small. In this situation, the
control valve itself acts as a switching element and could be actuated directly with a small
force of actuation. The source pressure signal is directly fed through the switching element to
the cylinder. This method of operating the cylinder is known as direct control of cylinders.

Indirect control of single-acting cylinder

If the cylinder has a large capacity, the valve size can be of a larger size. Therefore, the
operating force moving the control valve will be larger for direct operation. A smaller valve
known as the pilot valve is used to allow the main valve to be operated by system pressure.
This method of controlling the cylinder is known as indirect control of the cylinder.

Q7. Explain direct control of a double-acting cylinder with a suitable pneumatic circuit.
In the following figure, a practical pneumatic circuit is shown for the direct control of a
double-acting cylinder using two 3/2-way pushbutton valves.
Direct control of a double-acting cylinder.

A 4/2-way pushbutton valve (spring return) can also be used for the control of a double-
acting cylinder with two air connections between valve and cylinder. The figure below
represents the direct control of a double-acting cylinder.

Direct control of a double-acting cylinder: (a) unactuated; (b) actuated.

In the unactuated position, the piston is fully retracted as the air is supplied through port B.
The pneumatic circuit is shown in the following figure. The pressure on the piston side of the
cylinder is exhausted by connecting a return line via A and R. When the pushbutton is
pressed, the 4/2-way valve will supply pressure signal by connecting ports P and A.
Therefore, the piston extends fully, while the piston rod side is connected to the atmosphere
via ports B and R. Once the pushbutton is released, the valve return spring pushes the valve
into the initial position.
Pneumatic circuit
Q8. With a neat diagram, explain how a solenoid-operated sliding spool valve functions.

Actuation of SW in the figure above applies the current to the solenoid. The solenoid
generates an electromagnetic force which moves the armature connected to the valve stem as
shown in part (b). When the current is removed from the solenoid coil, the emf is dissipated
allowing the internal spring to return the valve stem to the original position.
The electrical and mechanical representation of a solenoid-operated valve is shown in
the following figure.

DCVs could be actuated by the solenoids either on one side or on both sides. The
figure below shows a solenoid-operated 3/2 valve.

Q9. A pneumatic system is operated at pressure of 1000 kPa. What diameter cylinder will be
required to move a load requiring a force of 12 kN?

Solution: P = 1000 kPa and F = 12 kN

 Pressure = Force/Area
Area = F/P= 12000/1000000 = 0.012 m2
A= πd2/4 or 0.012 = πd2/4
Therefore
d = 0.1236 m = 124 mm

Q10. Mention the various components of a hydraulic system.

1. Motor
2. Filter
3. Pump
4. Pressure regulator
5. Control valve
6. Piston and cylinder

Q11. Draw the block diagram of a hydraulic power pack and its equivalent hydraulic circuit
diagram.
A typical hydraulic power pack is shown in the figure below. The pump is driven by a motor
and pumps oil from a sump through a non-return valve. The pressure relief valve is included
in the circuit to release excessive pressure. Further, an accumulator is to smooth out any
fluctuations in the output oil pressure
Q12. What are the three types of pressure control valves? Explain the working of these
valves.
1. Pressure regulating (reducing) valve
2. Pressure relief (limiting)valve
3. Pressure sequence valve

1. Pressure Regulating (Reducing) Valve: These valves provide a constant pressure at the
outlet port regardless of the pressure at the inlet port. Simple regulator valve uses a
spring-loaded spool to control the pressure at the output line. The outlet pressure acts
on the spool against spring. If the pressure is above a set level, the spool will lift up
thereby increasing the area in the reservoir to reduce the pressure. If the pressure is
low, the spool moves down to adjust the pressure.

2. Pressure Relief Valves: Relief valves are used to protect hydraulic pumps from over
pressure. The following figure shows the working of a relief valve. The valve is in
closed position under normal conditions due to ball and spring elements. The spring
force is adjustable. When the fluid pressure exceeds a certain value against the spring
force, the valve opens, thereby letting the fluid out through the vent. Hence the
pressure is maintained at constant value.
3. Pressure Sequence Valves: The sequence valve is used in a hydraulic circuit for
switching operation in sequential order depending upon a preset pressure. The
sequence valve opens once its inlet pressure rises above a preset pressure. The signal
output is generated feely through the pressure port (P) and outlet port (A) until preset
pressure is reached. After the required operating pressure has been reached, the spool
is lifted to divert flow through secondary circuit. The working principle and symbolic
representation of a pressure sequence valve is shown in the figure below.