EHP-5 Pneumatics and Hydraulics COURSE 2-1441-1442 New Update

Electric, Hydraulic and Pneumatic Control
WEEK -1
Principles and Application of Pneumatics
Dr Mahmoud Kaoud
Email: mg_rtc@Hotmail.com
Textbook:“Pneumatics Basic Level”, Peter Croser, Frank Ebel, FESTO, Denkendorf 2000
• Dr Mahmoud Kaoud
• Email: mg_rtc@ Hotmail.com
• Grades Component % Weight

Quiz 20
Theoretical Midterm 20 65
Exam
Final Exam 25
Practical 35
Total Mark 100
• Blackboard : homeworks, handouts, quizes, exams,…

References
1. “Fluid Power Engineering”, Mahmood Galal El-Din Mohamed Rabi, McGraw-Hill, 2009
2. “Pneumatics Basic Level”, Peter Croser, Frank Ebel, FESTO, Denkendorf 2000
SECTION 1: PNEUMATICS
Table of Contents
1. Principles and Application of Pneumatics
❑ The Composition of Air
❑The State Variable Pressure
❑ Compression and Expansion of Air
❑ Application of Pneumatics
❑ Advantages of Using Pneumatic Systems
2. Structure and components of pneumatic systems

❑ Components of pneumatic circuits
❑ Drawing and simulating pneumatic systems
3. Symbols and standards in pneumatics

❑ Symbols and descriptions of components
4. Simple pneumatic circuits

❑ Exercise 1:Pneumatic circuit with single acting cylinder
❑Labeling system for pneumatic circuits
❑ Description of included components
❑ Exercise 2:Pneumatic circuit with double acting cylinder
5. Control of piston speed

❑ Exercise 3: Adjusting the speed of piston motion
❑Description of components
❑ Exercise 4:Types of speed control / lab practice
❑Exercise 5: Influence of external load
Learning outcomes
At the end of this semester, Students shall be able to
1. Know the basic terminology of open and closed loop control systems
2. Understand the general mode of work of analog and digital controllers.
3. Develop and plot displacement, signal and flow diagrams and transfer them
to function charts (GRAFCET) and circuit diagrams.
4. Use ladder diagram or function block diagram as programming language, logic controller
for various applications can be designed by the student.
5. The module also provides fundamental knowledge in pneumatics and hydraulics
to enable the student to understand the function and application of pneumatic and
hydraulic components.
6. Design, install and analyze simple circuits of pneumatic and hydraulic systems.
1- Common Properties of Hydraulics and Pneumatics
2- The Composition of Air
Air is a substance which can be found in unlimited quantities practically everywhere on the
planet. Atmospheric air is a gaseous mixture primarily made up of two gases, namely
78% nitrogen (N2) by volume

21% oxygen (O2) by volume
as well as traces of other gases like e.g. carbon dioxide, helium or argon (see the pie chart above).
Furthermore, depending on the climatic conditions, air also contains a certain percentage of condensed water (humidity) as well as
impurities like dust, soot and other solid particles. The basic prerequisite needed for the smooth operation of pneumatic systems is
compressed air that is both dry and clean.
3- The State Variable Pressure
Air that is compressed for the purpose of industrial applications is referred to as compressed air (nowadays the antiquated term
pressurized air which was sometimes in use is rarely found). Besides the temperature, the pressure p is one of the most important
state variables used in physics. It is defined as a force F, which is distributed evenly in all directions over the surface A:
By way of the unit of force, the Newton (N), we can directly derive the unit of pressure, the Pascal (Pa):
A unit of pressure that matches the order of magnitude of atmospheric pressure is represented by the physical unit, the bar:
1 bar = 100,000 Pa = 0.1 MPa
1 mbar = 100 Pa = 0.001 bar
1 bar = 14,5 psi
The various measurements of pressure are distinguished from each other only in terms of their reference point. The most precise
reference point is the pressure of an absolute vacuum. The following table provides an overview.
Example
A piston exerted a pressure on a cylinder of 90 cm diameter. If the
pressure inside the cylinder is 70 bar, find the exerted force by the
piston.
Example
A tank is filled with water of density 1000 kg/m3 to a height of 30 cm
from base. Then it is filled with oil of density 800 kg/m3 to a height of
70 m from base. Considering atmospheric pressure 101325 Pa,
calculate:
A. The gage pressure and absolute pressure at a point on the base of
tank .
B. The force of fluid on the base if the base is circular with 80 cm
diameter.
4- Compression and Expansion of Air
Air is compressible, i.e. it can be pressed into a more compact space. During this process volume V, pressure p and temperature
T are interrelated in a rigid and coherent fashion:
This qualitative relationship can be reproduced mathematically in the formula
As the temperature increases the pressure rises, as long as the volume remains constant (example steam pressure building up in a kitchen
pressure cooker)
If the volume is reduced while the temperature is kept constant, the pressure increases (example: slowly pumping using a bicycle pump)
This qualitative relationship can be reproduced mathematically in the formula
i.e. for two different states (subscript 1 or 2) it holds that
The following animation illustrates this context
Status 1 Status 2
If the temperature remains constant while the state varies (i.e. T 1 = T2), then the change of state is termed isothermal and the
relationship can be expressed in a simplified form using the Boyle-Marriott law
A simple mathematical example should help to illustrate the application of this law: air with an initial volume of V 1 = 2 m3 and an initial
pressure of p1abs = 1 bar is compressed at a constant temperature to a volume of V 2 = 1 m3. How high is the pressure p2abs in its final
state?
To solve this problem we invert the Boyle-Marriott law for p2abs and insert the given numerical values. Thus we obtain
Therefore we can see that by halving the volume the air pressure has just about doubled. It remains to be noted that in actual
technical applications the assumption of constant temperature during compression or decompression can normally only be applied
approximately, due to the fact that the change in volume cannot occur a sufficiently slow rate to keep the temperature at a precisely
constant level.
• Example
• It is required to raise a car of mass 2000 kg by a piston. If the piston
diameter of loading the car is 25 cm and diameter of input cylinder is
4 cm, find the required force F1
5- Application of Pneumatics
Pneumatics - originates from the Greek word "Pneuma", which means breath or wind. As such, it applies to
applications involving compressed air. In most cases the application of compressed air is used to execute
movements and to generate mechanical force. Pneumatic drives are designed to exploit the energy stored in the
compressed air and convert it into kinetic energy. The most important components of pneumatic systems are
comprised of air-operated devices like cylinders and motors on the one hand and control or actuating elements
(valves) on the other hand. Nowadays pneumatic systems are primarily employed in automation engineering and
thus their most frequent application is in the rationalisation of technical processes.
Below you will find a list of some of the most typical areas of application for pneumatics:
• Manipulating tools
Stacking
Delivering
Clamping
Sequencing
Linkage
Robots
• Machining
Drilling
Lathing
Milling
Sawing
Grinding
• Forming
Cutting and punching
Bending, folding and beveling
Embossing
Welding, sealing, cementing
• Identification
Stamping
Labelling
Printing
• Testing and checking

Measuring
Counting
Weighing
Testing
Sorting
• Door and lock control (e.g. in motor vehicles)
• Bottling plants
• Packaging machines
6- Advantages of Using Pneumatic Systems
Compared to other drive technologies pneumatic systems demonstrate a series of advantages:
1. Availability: air is available for compression almost anywhere in a practically unlimited supply.
2. Transport: compressed air can be easily transported in pipes over long distances. No return pipe is needed.
3. Storage: compressed air can be stored in a container. Even transport in bottles is possible.
4. Temperature: compressed air is insensitive to temperature fluctuations. Thus its use can be guaranteed in even
under the most extreme conditions.
5. Explosion-proof: compressed air can also be used in areas where there is a risk of explosion .
6. Cleanliness: leaking pipes, hoses or pneumatic elements do not cause any contamination due to the escaping air.
An important plus in such areas as the food or textile industry.
7. Speed: with compressed air relatively high operating speeds of up to 2 m/s can be achieved in pneumatic cylinders.
8. Controllability: the forces exerted by pneumatic actuators and their speed can be continuously adjusted.
9. Very good load capacity: compressed air tools and actuators can be loaded up to standstill and are thus extremely
capable of handling heavy loads.
As well as some disadvantages:
1. Preparation: compressed air requires good preparation. Dirt and damp must be kept out of the systems as
otherwise this subjects the pneumatic elements to undue depreciation.
2. Compressibility: it is impossible to attain uniform and constant piston speeds using compressed air.
3. Forces: compressed air is only economically viable up to a certain expenditure of force. The traditional operating
pressure is normally around approx. 7 bars.
4. Air exhaust: the air exhaust that is generated causes relatively loud noise. This problem can be mitigated to a
large extent using sound insulation.
5. Costs: compressed air is a relatively expensive energy source. However, these costs can be somewhat offset by
the relatively low cost of the pneumatic components and their high performance (timing rates).
Electric, Hydraulic and Pneumatic Control/TM-EHP-5
Week - 2
Structure and components of pneumatic systems
1. Components of pneumatic circuits
The block diagram describes the general setup of a pneumatic system:
❑ Providers: Air generation and treatment

An air generation unit consists of: compressor, motor,
tank, filters, pressure relief valve with gage
Low noise laboratory compressor Block diagram of an air generation unit

❑ Air service unit
An air treatment unit consist at least of: filter and water separator, lubricator, pressure relief valve, pressure gage
Air service unit
Spare parts
❑ Controllers : Pneumatic valves

The function of pneumatic valves is to control the pressure or flow rate of compressed air. Depending on design, these
can be divided into the following categories:
➢ Directional valves
➢ Flow control valves
➢ Pressure control valves
➢ Combination valves
❑ Directional control valves
The directional control valve controls the passage of air signals by generating, cancelling or redirecting signals.
The valve is described by:
1. Number of ports or openings (ways): 2-way, 3-way, 4-way, etc.
2. Number of positions: 2 positions, 3 positions, etc.
3. Methods of return actuation: Spring return, air return, etc.
4. Methods of actuation of the valve:
➢ manually actuated,
➢ mechanically actuated,
➢ pneumatically actuated,
➢ electrically actuated.
shuttle valve
3/2-way directional valve “ON – OFF”
“ON – OFF”
❑ Directional control valves (Signalling element)
As a signalling element the directional control valve is operated for example, by a roller lever to detect the
piston rod position of a cylinder.
3/2 way roller lever valve

(without and with idle return)
❑ Directional control valves (Processing elements-processors)
As a processing element the directional control valve redirects or cancels signals depending on the signal inputs
received.
3/2 way air actuated valve:

single pilot valve, with spring return
❑ Directional control valves (Control element)
As a control element the directional control valve must deliver the required quantity of air to match the power
component requirements.
5/2 way valve for cylinder

control: double pilot valve
❑ Non-return valves
The non-return valve allows a signal to flow through the device in one direction and in the other direction
blocks the flow. Amongst others, this principle is applied in shuttle valves or quick exhaust valves. The
nonreturn valve in the form of a basic element of other valve types is shown in a broken outline in the
illustration below.
Non-return valve and its derivatives

❑ Flow control valves
The flow control valve restricts or throttles the air in a particular direction to reduce the flow rate of the air and
hence control the signal flow. Ideally it should be possible to infinitely vary the restrictor from fully open to
completely closed. The flow control valve should be fitted as close to the working element as is possible and
must be adjusted to match the requirements of the application. If the flow control valve is fitted with a check
valve then the function of flow-control is unidirectional with full free flow in one direction.
Flow control valve

❑ Pressure control valves
Pressure control valves are utilized in pneumatic systems. There are three main groups:
1. Pressure limiting valves
2. Pressure regulating valves
3. Pressure sequence valves
The pressure limiting valves are utilized on the up-stream side of the compressor to ensure the receiver pressure is
limited, for safety, and that the supply pressure to the system is set to the correct pressure.
The pressure regulating valve keeps the pressure constant irrespective of any pressure fluctuations in the system.
The valve regulates the pressure via a built-in diaphragm.
The pressure sequence valve is used if a pressure-dependent signal is required for the advancing of a control
system.
Pressure sequence valve

❑ Combination valves
The combined functions of various elements can produce a new function. An example is the time delay valve
which is the combination of a one-way flow control valve, a reservoir and a 3/2-way directional control
valve.
Time delay valve

❑ Consumers (Actuators): Pneumatic drives
❖ Linear drives: single acting cylinders, double acting cylinders,

❖ Rotary drives: air motors, rotary cylinders
❖ Handling components: grippers, suckers, clamps
❖ Indicators: optical indicators, pressure gages, displays for timer and counter
Double acting cylinder Pneumatic motor Rotary table
❑ Connectors :Tubes, couplings, fittings, distributors

Plastic tubes are available in different diameters. Common are metric sizes of 4mm, 6mm, 8mm, 10mm, 12mm and 16mm. These
diameters refer to the outside diameter of the tubes. The internal diameter depends upon the wall thickness. Mostly Polyamide or
Polyurethane is used. For permanent installation, tubes can be bent after heating (i.e. in boiling water).
There is a wide selection of push-in fittings for pneumatic applications with a temperature range up to 60°C and a pressure range up
to 10 bar. A nitrile rubber sealing ring guarantees a perfect seal between standard OD tubing and the body of the fitting. Standard
tubing is suitable for use with compressed air and vacuum.
push-in T
push-in connector
plastic tubes spiral tube silencer
❑ Power components
The power section consists of control elements and power components or actuators.
The actuator group includes various types of linear and rotary actuators of varying
size and construction. The actuators are complemented by the control elements,
which transfer the required quantity of air to drive the actuator. Normally this valve
will be directly connected to the main air supply and fitted close to the actuator to
minimise losses due to resistance.
Actuators can be further broken down into groups:
❑ Linear actuators
1. Single-acting cylinder
2. Double-acting cylinder
❑ Rotary actuators
1. Air motors
2. Rotary actuators
Actuator with control element
Actuators, linear and rotary

❑ Systems
Generally, the actuation of a cylinder is effected via a directional control valve. The choice of such a directional control
valve (number of connections, number of switching positions, type of actuation) is dependent on the respective
application.
❖ Control circuit for the single-acting cylinder
Typical problem: The piston rod of a single-acting cylinder is to advance when a push button is operated. When the
push button is released, the piston is to automatically return to the initial position.
Solution: A 3/2-way valve controls the single-acting cylinder. The valve switches from the initial position into the
flow position, when the push-button actuator is pressed. The circuit includes the following primary features:
1. Single-acting cylinder, spring return
2. 3/2-way directional control valve: push button for operation and spring for return force
3. Supply air source connected to the 3/2-way valve
4. Air connection between valve and cylinder
Control of a single-acting cylinder

❖ Control circuit for the double-acting cylinder
Typical problem: The piston rod of a double-acting cylinder is to advance when a push button is operated and to return to the initial
position when the push button is released. The double-acting cylinder can carry out work in both directions of motion, due to the full air
supply pressure being available for extension and contraction.
Solution: A 5/2-way directional control valve controls the double-acting cyliner. A signal is generated or reset on the valve, if a push-
button actuator is pressed or released. The circuit includes:
1. Double-acting cylinder
2. 5/2-way directional control valve: push button for operation and
3. spring for return force
4. Supply air source connected to the 5/2-way valve
5. Air connections between valve and cylinder
Control of a double-acting cylinder

The circuit diagram shows the detailed setup of a pneumatic system:
open
closed
open
2. Drawing and simulating pneumatic systems
Introduction to FluidSim 4 - Pneumatics
FluidSIM 4.2-P is a comprehensive software for the creation, simulation, instruction and study of electro-
pneumatic, electro-hydraulic and digital circuits.
All of the program functions interact smoothly, combining different media forms and sources of knowledge in
an easily accessible fashion. FluidSIM unites an intuitive circuit diagram editor with detailed descriptions of
all components, component photos, sectional view animations and video sequences. As a result, FluidSIM
is perfect not only for use in lessons but also for the preparation thereof and as a self-study program.
Professionals also get their money's worth: The new simulation core does not need to fear a
comparison with more expensive special programs. Despite complex physical models and
precise mathematical procedures, simulation is amazingly fast.
FluidSIM also provides a whole range of possibilities for communication with other software
and thanks to the support of Festo EasyPorts a link up to real hardware is also possible.
FluidSim 4 - Pneumatics
Week -3
Symbols and standards in pneumatics
1. Symbols and descriptions of components
The development of pneumatic systems is assisted by a uniform approach to the representation of the elements and the
circuits. The symbols used for the individual elements must display the following characteristics:
1. Actuation and return actuation methods
2. Number of connections (all labelled for identification)
3. Number of switching positions
4. General operating principle
5. Simplified representation of the flow path
The symbols used in pneumatics are detailed in the standard DIN ISO
1219, "Circuit symbols for fluidic equipment and systems".
Air supply and generation Symbols:
Symbols used in energy

conversion and preparation
Directional control valves: symbol development
Directional control valves: ports and positions (ways)
Examples of designations
A numbering system is used to designate directional control valves and is in accordance with DIN ISO 5599-3. Prior to this a lettering
system was utilised and both systems of designation are presented here:
Examples of designations
Methods of actuation
The methods of actuation of pneumatic

directional control valves is dependent upon the
requirements of the task. The types of actuation
vary, e.g. manually actuated mechanically
actuated pneumatically actuated electrical and
combined actuation.
The symbols for the methods of actuation are
detailed in DIN ISO 1219.
Non-return valves and derivatives
The non-return valve (check valve) is the basis for the development of many combined components. There are two main
configurations for non-return valves, with and without the spring return. In order to release flow, the pressure force on the spring
return design must be greater than the spring force.
Non-return valves and derivatives
Most flow control valves are adjustable and permit flow control in both directions. The arrow shows that the component is adjustable
but does not refer to the direction of flow; it is diagrammatic only. In the case of the one-way flow control valve, a non-return valve is
switched in parallel with the flow control valve. Flow control is effected in one direction only.
Flow control valves

• Pressure valves
The function of pressure valves, is to influence the pressure in an overall pneumatic system or in a part of the system. Pressure
regulating valves are generally adjustable against spring compression. The symbols are distinguished according to the following types:
1. Pressure regulating valve without relief port
2. Pressure regulating valve with relief port
3. Pressure sequence valves
• Linear actuators
The linear actuators or cylinders are described by their type of construction and method of operation.
• Rotary actuators
Rotary actuators are divided into continuous motion and limited angle of rotation.
• Auxiliary symbols
There are a number of important symbols for accessories which are utilised in conjunction with pneumatics.
Week -4
Simple pneumatic circuits
Exercise 1: Pneumatic circuit with single acting cylinder
A simple pneumatic circuit can be built with the components shown in the equipment list below.
• Equipment list:
Quantity Designation
1 Single acting cylinder
1 3/2- way directional valve, manually operated, normally closed
Tubing, fittings
1 Air treatment unit
1 Air generation unit
• Circuit diagram
• Tasks to carry out:

1. Draw the circuit diagram using FluidSIM-P
2. Give all components the respective label
3. Describe the mode of operation of the components included in the circuit
4. Calculate the effective piston force of the advance stroke of the cylinder when a system pressure of
0,6 MPa is applied.
All the necessary data you shall take from the FluidSIM circuit diagram.
Explain the relation between the 3/2-way directional valve and the single acting cylinder
1- Labeling system for pneumatic circuits
The development of pneumatic systems is assisted by a uniform approach to the representation of the elements and the circuits. The
symbols used for the individual elements must display the following characteristics:
1. Actuation and return actuation methods
2. Number of connections (all labeled for identification)
3. Number of switching positions
4. General operating principle
5. Simplified representation of the flow path
The technical construction of the component is not taken into account in the abstract symbol form.
The symbols used in pneumatics are detailed in the standard DIN ISO 1219, "Circuit symbols for fluidic equipment and systems".
As an example, for directional valves the following system applies:
2- Description of included components
❑ Single acting cylinder

With single-acting cylinders compressed air is applied on only one side of the piston face. The
other side is open to atmosphere. The cylinder can produce work in only one direction. The return
movement of the piston is effected by a built-in spring or by the application of an external force. The spring
force of the built-in spring is designed to return the piston to its start position with a reasonably high speed
under no load conditions.
➢ Component parts of a single acting cylinder
Allocated designation for the component parts Number Designation

End cap
Reset spring
Cylinder barrel
Piston
Supply port
Bearing cap
Exhaust port
Piston rod
Calculation of piston force
The theoretical piston force is calculated according to the following formula:

Fth = AP*p
Fth = Theoretical piston force [N]
AP = effective piston surface [m2]
p = Working pressure [Pa, bar]
❖ Units of Measurement
• Piston force: Newton N 1 N = 1 kg * m/s²
A mass of 1 kg corresponds to a weight force of 9,81 N.

• System pressure:Pascal Pa 1Pa = 1 N/mm² 1 MPa = 1 N/mm²
Often the unit bar is still used in pneumatics: 1 bar = 0,1 MPa
In English speaking countries the “pounds per square inch” is more common. 14,5 psi = 1 bar = 0,1 MPa
• Piston area: Meter Square m2 1 m2 = 10000 cm2 = 1000000 mm2
Experiences have shown that it is of advantage to carry along the units while calculating. Use engineering quotations, which
correspond to the prefixes of the units.
Example: 1m = 100 cm = 1000 mm = 1 * 102 cm = 1 * 103 mm
1m 2 = 2
1*(10 cm) = 2 1 *(103 mm)2
= 1* 104 cm2 = 1* 106 mm2
The effective piston force is significant in practice. Frictional resistance is to be taken into account when you calculate this. Friction
force of approx. 10% of the theoretical piston force can be assumed for standard operating conditions (pressure range from 0,4 to 0,8
= 4 to 8 bar).
The following applies to a single acting cylinder:
Feff = AP * p – (FR + FF)

Feff = Effective piston force [N]
FF = Friction force (approx. 10% of Fth) [N]
FR = Return spring force [N]
• Control of a single acting cylinder

Worked example
Air is supplied to a single-acting cylinder at a pressure of 4 N/mm2. The diameter of the
piston is 25 mm. Calculate the force produced as the piston outstroke's.
Step 1
Write down any information that you have from the question.
Pressure = 4 N/mm2
Diameter = 25 mm
Step 2
We need to calculate the surface area.
Step 3
Use the correct formula for what you are trying to find. In this case, calculate the
force.
❑ 3/2-way directional valve
The valve shown here is constructed on the disc seat principle. The sealing is simple but effective. The response time
is short and a small movement results in a large cross-sectional area being available for air flow. Like the ball seat
valves, they are insensitive to dirt and thus have a long service life. The 3/2-way valves are used for controls
employing single-acting cylinders or for generating signals supplied to control elements
• Operation of the valve
3/2 way valve, idle 3/2 way valve, actuated
❑ Air treatment unit
The individual functions of compressed air preparation, i.e. filtering, regulating and
lubricating, can be fulfilled by individual components. These functions have often
been combined into one unit, i.e. the service unit. Service units are connected
upstream of all pneumatic systems.
• Air treatment unit
The compressed air passes through the filter from left to right and is fed through a baffle plate in the filter bowl. The effect of the
baffle plate is that the air is caused to rotate, and the heavier dust particles and water droplets are spun by centrifugal force
against the inner wall of the filter bowl. They then run down the wall of the housing and collect in the filter
bowl. The air which has been pre-cleaned in this way then passes through the filter element, which filters out the smaller dirt
particles. The filter element in this case consists of a highly-porous sintered material. The degree of separation depends on the
pore size of the filter element used. Inserts with different pore sizes are available.
Filter unit with baffle plate

❑ Compressed air generation
The selection from the various types of compressors available dependents upon quantity of air,
pressure, quality and cleanliness and how dry the air should be. There are varying levels of these
criteria depending on the type of compressor.
As a rule, pneumatic components are designed for a maximum operating pressure of 800 to 1000 kPa (8-10 bar). Practical
experience has shown, however, that approximately 600 kPa (6 bar) should be used for economic operation. Pressure losses of
between 10 and 50 kPa (0.1 and 0.5 bar) must be expected due to the restrictions, bends, leaks and pipe-runs, depending on the
size of the piping system and the method of layout. The compressor's system should provide at least 650 to 700 kPa (6.5 to 7 bar) for
a desired operating pressure level of 600 kPa (6 bar).
• Types of compressors
1. Reciprocating piston compressor

A piston compresses the air drawn in via an inlet valve. The air is passed on via an outlet valve.
Reciprocating compressors are very common and provide a wide range of pressures and delivery rates.
For higher pressures multistage compression is used with intercooling between each stage of compression.
The optimum range of pressures for reciprocating compressors are approximately:
up to 400 kPa (4 bar) Single stage
up to 1500 kPa (15 bar) Double stage
over 1500 kPa (> 15 bar) Treble or multi stage
• Double piston compressor – assembly
MINI AIR COMPRESSOR

AC-500 / TC – 1000; TC – 520
PART LIST
Exercise -2: Pneumatic circuit with double acting cylinder
A simple pneumatic circuit can be build with the components shown in the equipment list below.
• Equipment list:
Quant Designation
ity
1 Double acting cylinder
1 5/2- way directional valve, manually operated, selector switch
Tubing, fittings
1 Air treatment unit
1 Air generation unit
• Circuit diagram

1. Draw the circuit diagram using FluidSIM-P
3. Describe the mode of operation of the double acting cylinder and the 5/2-way valve
4. Calculate the piston force of the advance and return stroke of the double acting cylinder. The working
pressure is set to 0,6 MPa.
5. Explain the relation between the 5/2-way directional valve and the double acting cylinder
❑ Double acting cylinder
The construction principle of a double-acting cylinder is similar to that of the single-acting cylinder.
However, there is no return spring, and the two ports are used alternatively as supply and exhaust ports.
The double-acting cylinder has the advantage that the cylinder is able to carry out work in both
directions of motion. Thus, installation possibilities are universal. The force transferred by the piston rod
is somewhat greater for the forward stroke than for the return stroke as the effective piston surface is
reduced on the piston rod side by the cross-sectional area of the piston rod.
If large masses are moved by a cylinder, cushioning is used in the end positions to prevent sudden damaging impacts. Before
reaching the end position, a cushioning piston interrupts the direct flow path of the air to the outside. Instead a very small and often adjustable
exhaust aperture is open. For the last part of the stroke the cylinder speed is progressively reduced. If the passage adjustment is too small, the
cylinder may not reach the end position due to the blockage of air.
The cylinder shown above has a permanent magnet attached to the piston. This allows contactless sensing by special
designed magnetic proxy switches.
• Allocated designation for the component parts

Number Designation
Piston
Adjustment screws for end position cushioning
Cylinder barrel
Bearing cap • Parts of a double acting cylinder
Piston rod
Supply port for piston chamber
Exhaust port
End cap
❑ Calculation of piston force
A double acting cylinder has two working strokes, the advance and the return stroke.
Since the piston area at the piston chamber side is larger than the piston area at the piston rod chamber, the piston force of the
advance stroke is stronger than the piston force of the return stroke.
The following formulas apply:
Advance stroke: Feff = effective piston force = (AP*p) – FF
AP = effective piston surface

= D2*𝝅
4
D = cylinder diameter
p = working pressure
FF = friction force
Return stroke: Feff = (APR*p) – FF

APR = effective annular surface
= D2*𝝅 _ d2*𝝅
4 4
d = piston rod diameter
To get a first idea or a rough estimation, the table

shown aside could also be used to define required
cylinder diameter, necessary system pressure or
created piston force.
Worked example
A double-acting cylinder has a piston with a diameter of 25 mm. The piston rod is
5 mm in diameter. Pressure is supplied to the system at 4 N/mm2. Calculate the force
produced by the cylinder as it outstrokes and instrokes.
Step 1
Write down any information that you have from the question.
Pressure = 4 N/mm2
Piston diameter = 25 mm
Piston rod diameter = 5 mm
Step 2
We need to calculate the surface area.
Step 3
Use the correct formula for what you are trying to find. In this case, calculate the outstroke
force.
Step 4
Calculate the piston rod area.
Step 5
Calculate the effective area. (We already know the piston area from step 2.)
Step 6
Calculate the instroke force.
❑ 5/2-way directional valve with selector switch, spring returned
The valve is manually actuated. Turning the selector switch operates the valve. When actuated, the air passes freely
from supply port 1 to working port 4 while there is a free passage for the exhaust air from port 2 to the exhaust port 3.
Releasing the switch has no effect, the valve remains in its operating position. Turning the switch back in its original
position allows the flow to pass freely from port 1 to port 2. Then, port 4 is connected with exhaust port 5.
Quiz
▪ The ________converts the compressed air energy into mechanical energy in the form of force and linear movement in one direction
only.
A. Double-acting cylinder
B. Piston cylinders
C. Single-acting cylinder
D. Short-stroke Cylinders
• Pneumatic __________ convert the energy in the compressed air into force and motion. The pneumatic drive elements can move in
a linear, reciprocating or rotating motion.
A. Exhaust port.
B. Annular area
C. Drive elements
D. Inlet port
▪ The cylinder has two ports - a pressure inlet port and an exhaust port. The ______ (shaped like or forming a ring) of the
cylinder is connected to the atmosphere.
A. Return spring.
B. Cylinder Tube
C. Annular area
D. Cylinder Cover
• Types of Single-Acting Cylinders
A. Piston cylinders
B. Short-stroke Cylinders
• Typically, the piston can have

diameters of as much as __100____ mm.
• …………….are used in the assembling and packing automated lines to move, lift, feed, eject, press or push objects or to clamp parts.
Practically, they are suitable for oil- free operation.
A. Triple-acting cylinders
B. Double-acting cylinders
C. Single-acting cylinders
D. Piston cylinders
Mass of water vapour in unit volume of air is known as
a. relative humidity
b. absolute humidity
c. saturation quantity
d. none of the above
.Which valve is also known as memory valve?
a. single pilot signal valve

b. double pilot signal valve
c. roller lever valve
d. logic valve
What is a pressure sequence valve?
a. it is a combination of adjustable pressure relief valve and directional control valve

b. it is a combination of nonadjustable pressure relief valve and directional control valve
c. it is a combination of adjustable pressure reducing valve and check valve
d. it is a combination of adjustable pressure reducing valve and flow control valve
Week - 5
Control of Piston Speed
Exercise 3: Adjusting the speed of piston motion
• Short description of the application:
The tank of an automatic filling and dispensing unit for plastic granulate is opened and closed by a pneumatic
shutter. The shutter should open slowly, while the closing needs to be very quick to keep the required dosage
of granulate.
The shutter is actuated by a double acting cylinder. The

advance stroke of the cylinder opens the shutter, the return
one closes.
Pressing one pushbutton opens the shutter gradually,
pressing a second pushbutton closes the shutter quickly.
• Equipment list:
1 5/2- way directional valve
1 One-way flow control valve
1 Quick exhaust valve
2 3/2-way valve with pushbutton, normally closed
1 Pressure gage
1 Air service unit
1 Air supply unit
Tubing, fittings
Adjusting the speed of piston motion

1. Design the pneumatic circuit diagram for the shut-off device
3. Describe the mode of operation of the one-way flow control valve and the quick exhaust valve
4. Explain the memory function of a double piloted 5/2-way valve
5. Carry out the assembly of the pneumatic circuit
• Draft of the circuit diagram
Quanti Designation
ty
1 5/2- way directional valve
1 Quick exhaust valve
2 3/2-way valve with pushbutton, normally closed
1 Pressure gage
1 Air service unit
1 Air supply unit
Tubing, fittings
1- Description of components
• Quick exhaust valve
Quick exhaust valves are used to increase the piston speed of cylinders. Lengthy return times can
be avoided, particularly with single acting cylinders. To reduce resistance to flow, the air is expelled to
the atmosphere close to the cylinder and through a large orifice.
From supply port 1 to working port 2 the air is passing freely via opening of the non-return seal. Exhaust port 3 is blocked by the
disc. When air is supplied to port 2, the disc seal closes port 1. The air is expelled through the large opening of port 3 straight
into the atmosphere. Mount the quick exhaust valve as near as possible to the cylinder.
supply position exhaust position
air flows from port 1 to port 2 air flows quickly from port 2 to port 3
• One-way flow control valve
One-way flow control valves influence the volumetric flow of compressed air. They are
adjustable, the setting can be locked in position. The influence of flow control is in one direction only.
When the compressed air flows from port 1 to port 2 it has to pass through the gap between the adjustment screw and the
valve seat. The direct way is sealed.
In the opposite direction, from port 2 to port 1, the air streams freely through the now open seal.
open direction
restricted direction
• 5/2-way double pilot valve
The pneumatic actuated 5/2-way valve shown below is a suspended disc seat
valve. It has small switching movements. The disc seat seal connects supply port 1
with either working port 2 or working port 4.
This double piloted valve has the characteristic of a memory component. The last
switched position is retained until a new switching position is initiated by a unique
control signal from the opposite side. A short input signal (impulse on control port 12 or
14) is sufficient to create a permanent output (compressed air under working pressure).
flow from port 1 to port 4 flow from port 1 to port 2
actuated by a control signal on port 14 actuated by a control signal on port 12

2. Types of speed control
Exercise 4:Types of speed control / lab practice
• Problem description:
According to the position of the one-way flow control valve in the circuit, either it controls the supply of
compressed air to the cylinder or it controls the flow of exhaust air from the cylinder. Hence, two different types
of speed control are applied:
1. Supply control and
2. Exhaust control
Which type is used depends upon the situation and the significance of the system parameters.
• Circuit diagrams
Set-up to take a
series of
measurements:
Exhaust control
Supply control
1. Connect the required components of the practice board according to the diagrams.
2. Mount the 50 N weight onto the piston rod of the cylinder.
3. Set the system pressure to 0,4 MPa and carry out the two series of measurement
4. Use the measuring log sheet (see next page) to document the results
5. Write down your observations and conclusions about advantages and disadvantages of the 2 types of speed
control.
Exercise 5: Types of speed control / measurement log form
All measurements are taken with a system pressure of 0,6 MPa and an external load of 25 N.
• Adjusted supply:
1V2 1Z1 1Z2 1Z3 travel time, speed,
opening supply travel back other observations
level pressure pressure pressure
open
• Adjusted exhaust:
1V2 1Z2 1Z3 1Z4 travel time, speed,

openin travel back exhaust other observations
g level pressure pressure pressure
open
¼
½
¾
1
5- Speed control under changing external load
Exercise 6: Influence of external load

• Task to carry out:
➢ Set the pneumatic system to the following parameter:
-System pressure = 0,6 MPa
-Type of flow control: Exhaust
-Opening level of one-way flow control valve1V2 = ½ revolution
➢ Measure the travel time of the piston for the advance stroke with external load
-FL1 = 0 N
-FL2 = 25 N
-FL3 = 50 N
➢ Discuss the results of the measurements taken
External Travel Observations

load (N) time (s)
25
50
• Conclusions:
Experiment-3: Speed control with Quick Exhaust valve and one way flow control valve
Quiz
• What is the difference between signal air and control air?
a. signal air actuated final control valve and control air flows to the cylinder through the
final control valve for forward and backward movement of piston rod
b. control air actuates final control valve and signal air flows to the cylinder through the
final control valve for forward and backward movement of piston rod
c. both a and b
• Which of the following is used to sense the initial and final positions of a piston rod?
a. lever operated direction control valve

b. limit switch
c. roller lever valve
d. all the above
• Which numbers are used to denote retraction of a piston rod?
a. even numbers
b. odd numbers
c. both even and odd numbers
• Which of the following is an element of time delay valve?
a. flow control valve

b. direction control valve
c. both a and b
• What is the part, shown in below diagram of 3/2 valve, called?
a. manually operated valve

b. pilot operated valve
c. pressure electric converter
• In electro pneumatic circuits,
a. spool is shifted by signal air

b. spool is shifted by control air
c. spool is shifted by electromotive force
d. all the above
• What is PLC?
a. Process logic control

b. Programmable language converter
c. Programmable logic control
d. Programmable logic converter
Week -6
Pneumatic limit switches
1. Types and mode of operation
Limit switches are commonly used to detect the position of a component of a device. In pneumatics, pneumatic limit switches are
often applied to give a pneumatic signal when the piston has reached one of its end positions, either the retracted or the advanced
end position.
These signals might be used to initiate the next step or next action. In combination with other signals there will be logic operations,
counting- or time-related actions.
Pneumatic limit switches are derived from 3/2 way valves. There are two different methods of actuation:
1. Tactile: when the component observed touches a roller, lever, pin or cam of the switch (valve), the valve (switch) changes
position and produces a pneumatic signal.
2. Proximity: when the component observed comes close to the sensor of the valve, the valve changes position and produces a
pneumatic signal. These sensors could be of magnetic, inductive, capacitive, optical or ultrasonic typ.
• Mechanic roller lever switch

2 The roller lever valve is actuated by pressing the lever, for example through the use of a
switching cam on the piston. The flow passes through freely from supply port 1 to working
port 2. After releasing the lever, the valve returns to its initial position through the use of a
1 3 return spring. Port 1 is closed.
3/2 way valve with roller lever actuation
Tactile limit switch

• Magnetic proximity switch
2
A permanent magnet attached on the piston of a pneumatic cylinder drives this 3/2 way
directional valve and triggers the control signal. There is a free passage from supply
port 1 to working port 2.
1 3
3/2 way valve with magnet actuation
Proximity limit switch
The magnetic sensor consist of a rocker with two permanent magnets. The initial position
of the valve, a connection between port 2 and port 3, is kept via the rocker by means of the
compression spring. The magnetic field of the magnet at the piston of the cylinder courses
the rocker to tilt. This will change the switching position of the valve and opens a connection
between port 1 and 2. Hence, there is a permanent signal at the working port 2 as
long as the magnetic field controls the rocker.
Schematic representation of a
pneumatic proximity sensor
2. Application examples
Exercise 7: Piston end position sensing with roller lever switch

Wooden boards need to by pushed out of a stacking magazine onto a mounting device. The pneumatic cylinder
is actuated via push button switch. After reaching the advanced end position, the piston is returned to its initial
position. A roller lever switch is used to detect the advanced end position of the piston.

1. Design the pneumatic circuit diagram for the device
3. Describe the mode of operation of the roller lever switch
• Equipment list
1 5/2- way directional valve, pneumatic actuated
1 Pushbutton switch, normally closed
1 Roller lever switch
1 Air service unit
1 Air supply unit
Tubing, fittings
2. Application examples
Indirect control of a single-acting cylinder
The Problem: A single-acting cylinder with a large piston diameter is to clamp a work-piece
following actuation of a push button. The cylinder is to retract once the push button is
released.
Positional sketch
Solution: In the initial position, the single-acting cylinder 1A is retracted. A springreturn
3/2-way pneumatic valve is used to actuate the cylinder. Connection 1 of the valve 1V is
closed, connection 2 is exhausted to atmosphere via connection 3.
Circuit diagram
The valve 1S is actuated when the push button is activated and pressure is applied to the
control port 12 of the control valve 1V. The control valve 1V is actuated against spring
force and is thus switched to flow.
The pressure building up at the cylinder piston causes the cylinder piston rod of the single-
acting cylinder to extend. The signal at the control port 12 remains as long as the push
button is operated.
Once the piston rod has reached end position, it returns only after the push
button has been released.
When the push button is released, the valve 1S returns to its initial position.
Control port 12 of the control valve 1V exhausts to atmosphere and the signal is reset. The
control valve also returns to initial position.
The return spring causes the cylinder to retract. The air from the cylinder chamber is
exhausted to atmosphere via the control valve.
Exercise 8: Piston end position sensing with roller lever switch
Packages will be diverted from one conveyor belt to another by means of a diverting device.
The device is advanced when a pushbutton valve is activated. The package is transferred
and transported further.
When the piston of the diverting device has reached its advanced end position, it is returned to its start
position. A magnetic proxy switch is used to sense the end position of the piston.

3. Describe the mode of operation of the roller lever switch
• Equipment list
1 Magnetic proxy switch
1 Air service unit
1 Air supply unit
Tubing, fittings
Quiz
• The compressed air is applied only on the bottom side of the piston that is why the cylinder
can move loads or perform mechanical work in a forward motion only and that the effective force
is reduced by the __________.
a. Exhaust port
b. Annular area
c. Inlet port
d. Return Spring
• Note that the length of stroke is the actual working movement. The ______ enables the cylinder
to lift heavy loads. They can also be equipped with an anti-rotation anchor, external guidance and a
magnetic ring for triggering non- contact signaling elements.
a. Longer stroke
b. Shorter stroke
c. Middle stroke
d. Left stroke
• Note that a _______ is a metal cylinder that slides up and down inside a tubular
housing, receiving pressure from or exerting pressure on a fluid.
Piston
▪ The working speed of piston is in the range of ____________.
a. 10 to 100 mm/s
b. 20 to 200 mm/s
c. 50 to 500 mm/s
d. 40 to 400 mm/s
• Cylinder forces are about __________.
a. 1 kN
b. 2 kN
c. 4 kN
d. 6 KN
• Note that ________ is a device or piece of equipment with a compressible chamber with flexible
sides that can be expanded to draw air in and compressed to force the air out.
Bellows or
Diaphragm
• When the piston area of the cylinder is connected to the atmosphere, the piston of the single-
acting cylinder is pressed by the spring to the ______.
a. Cylinder center
b. Cylinder down
c. Cylinder bottom
d. Cylinder upper
Pneumatics and Hydraulics - 3
Week - 7
Logic circuits
1. Basic logic operations
Pneumatic logic systems (air logic controllers) are often used to control industrial processes, consisting of primary logic units
such as:
1. AND function
2. OR function
3. NOT function
By combination of these basic functions several applications like

1. Latching unit
2. Timer unit
3. Counter unit
4. Booster unit
5. 2 – hands switch
6. 2 – location switch
can be realized.
Pneumatic logic is a reliable and functional control method for industrial processes. In recent years, these systems have
largely been replaced by digital control systems in new installations because of the smaller size, lower cost, greater
precision, and more powerful features of digital controls (programmable logic controllers “plc”).
However, many pneumatic devices are still used in processes, where the advantages of digital controls are outweighed by
such considerations as:
1. The cost of upgrading an entire system from pneumatic to digital control is prohibitive
2. Safety might be compromised (no potential sparks near explosive gases)
3. Compressed air is the most viable energy source available
Similar to logic in electric circuits, some basic logic functions can also be set-up by arranging pneumatic valves in series or
parallel in the pneumatic circuit. A disadvantage of the switching variant is that in practice this often leads to extremely long lines
between the valves.
Logic AND built of valves “in series”

Different means of graphical representation of logic functions
11.2. : Pneumatic valves with logic functions
❑ Double pressure valve AND unit

2
The double pressure valve has two inputs, port 1 and port 1(3), and one output port 2. The
1 1
application of a signal at a single input does not produce any pressure at the output 2. If
pressure is applied at both inputs, the signal applied last passes to output 2.
Two input signals applied:

One input signal applied:
no output signal output signal produced
❑ Shuttle valve OR unit

2 This valve has two input port 1 and one output port 2. If compressed air is applied to one input, the valve
1 1 seat seals off the opposing input and the air flows through output 2.
When the airflow is reversed, i.e. a cylinder or valve is exhausted, the seat remains in its previously
assumed position because of the pressure conditions.
Input signal at port 1 (right). Input signal at port 1 (left)

output signal produced
output signal produced
❑ 3/2 way valve, normally open NOT unit
At this valve the signal input happens at port 10, the output comes from port 2. Port 1 is just the supply
for the output pressure. If there is no input signal, the valve is in its initial position. Port 2 is open and
compressed air can pass from port 1 to port 2. If a signal is applied at port 10, the valve changes and
port 2 is closed. There is no output.
No input signal applied at port 10

output at port 2 produced Input signal at port 10
no output at port 2
❑ 5/2 way valve, double piloted RS unit (Memory)
14
4 2
12
When an input signal is applied at port 14, output port 4 is opened and, at the same time, output
port 2 is closed. The valve is “SET”. When the control signal is applied at input port 12, output
5 3
port 4 is closed and output port 2 is opened. The valve is “RESET”. Hence, only one output
1
signal is possible at the same time, either port 4 is open or port 2.
Control signal at input port 12

Control signal at input port 14 output at port 2, no output at port 4
Output at port 4, no output at port 2
the valve is SET the valve is RESET
3. Application Example
Exercise 9: Pneumatic exchange circuit with logic components
The sliding door of a garage is to be opened and closed from inside or outside the garage. Therefore, two
pneumatic pushbutton switches are used. One is placed outside, the other one inside the garage. Opening and
the closing of the sliding door must only be started, when the door is in the respective opposite end position.
The door is completely closed, when the piston of the pneumatic cylinder is in its advanced end position.

3. Use the simulation programm of FluidSIM to test the function of the circuit.
4. Describe the mode of operation of a shuttle valve and a double pressure valve.
• Equipment list Quantity Designation

2 Pneumatic proximity switch
1 Shuttle valve
2 Double pressure valve
1 Air service unit
1 Air supply unit
Tubing, fittings
Quiz
• An alternative construction is a __________ with a spring in the piston area causing the
piston to extend. Such pistons are used in the automotive industry and these are
mounted in the air brakes for vehicles and trains.
a. Single-acting cylinder, with return spring

b. Single-acting cylinder, without return spring
c. Double-acting cylinder, spring extend
d. Single-acting cylinder, spring extend
• Another special form of single-acting cylinders is ___________ in which the piston’s
return stroke is caused by external forces or by its own weight.
a. Single-acting cylinder, spring extend

b. Single-acting cylinder, without return spring
d. Single-acting cylinder, with return spring
• _________ are used when short strokes are required together with high forces.
a. Short-stroke cylinders
b. Piston cylinders
• The ______ converts the compressed air energy into mechanical energy in the form of of force
and linear movement in both directions.
a. Single-acting cylinders
b. Double-acting cylinders
d. Double-acting cylinder, spring extend
• ___________ valves are screwed directly into the ports of the directional control
valves.
a. Fixed-set throttles
b. Screw-insert throttle
c. Cylinder Botto
Pneumatics and Hydraulics - 3
Week - 8
Designing a complex pneumatic circuit
Chapter-8
Designing a complex pneumatic circuit
Although intuition is always required in design processes, it is advisable to follow a more systematic approach. However, to
produce a pneumatic circuit, the basic requirements are sound fundamental knowledge of pneumatics in general and clear
understanding of the mode of operation of pneumatic components.
1. Development of pneumatic systems

Any pneumatic circuit is usually represented by a circuit diagram. The diagram should be drawn using standard symbols
and labeling. Comprehensive documentation is required, including most of the following:
1. Function diagram
2. Circuit diagram
3. Description of the operation of the system
4. Technical data on the components
Supplementary documentation comprising:
1. Parts list of all components in the system
2. Maintenance and fault-finding information
3. Spare parts list
The structure of the circuit diagram should follow the signal flow indicating the path of a signal from signal input through to
command execution.
Signal flowchart
The following diagram illustrates a few examples for the allocation of components to signal flow:
Irrespective of the actual tubing connections of the installation, the circuit diagram structure is always the same.
1. Physical arrangement of the elements is ignored.
2. Draw the cylinders and directional control valves horizontally wherever possible.
3. The energy flow within the circuit moves from the bottom to the top.
4. Energy source can be shown in simplified form.
5. Show elements in the initial position of the control. Identify actuated elements by a cam.
6. Draw pipelines straight without cross-over wherever possible.
2. Designing, installing and commissioning of a sequential circuit
Exercise 10: Designing a sequential circuit
In a forming device, metal strips are bent to u-shaped brackets. The bending device consists of two pneumatic
cylinders, a single acting cylinder 1A1 for the l-bend and a double acting cylinder 2A1 for the u-bend.
Actuating pushbutton switch S1 starts the bending procedure. After the first bend is done (1A1 in its advanced
end position), the signal from roller lever switch 1B2 is used to initiate the second bend. When this is done (2A1 is
in its advanced end position), the signal from 2B2 starts the return stroke of both cylinders. The signal from 2B1
shows that the sequence has been completed. With this signal and a signal from 1S1 the next bending procedure
could be started. The speed of the bending strokes of both cylinders should be adjustable.
1. Design the pneumatic part of the device by drawing the circuit diagram. Use the simulation function to prove the correct mode of
operation of the device.
2. Calculation of size, strength and stress (SSS)
• Calculate the required cylinder size, when a bending force of 200 N is needed. The device works with a system pressure of
0,6 MPa.
• Chose the best suitable size when cylinders with diameter 12 mm, 16 mm, 20 mm and 25 mm are available.
• Recalculate the maximal piston force for the cylinder selected. Discuss the result!
• Calculate the maximum stress on the piston rod chamber of cylinder 2A1, when it works with maximal force. Discuss the
result!
3. Describe the two different types of speed control (supply control and exhaust control) applied in the circuit. State the advantages
of controlling the exhaust flow.
4. Explain the purpose of the double pressure valve in this circuit.
5. Describe the mode of operation of a pneumatic controlled 5/2 way valve. Explain the memory function of “bistable” valves.
1. Design the pneumatic part of the device by drawing the circuit diagram. Use the simulation function to prove the correct mode
of operation of the device.
2. Calculation of size, strength and stress (SSS)
• Calculate the required cylinder size, when a bending force of 200 N is needed. The device works with a system
pressure of 0,6 MPa.
• Chose the best suitable size when cylinders with diameter 12 mm, 16 mm, 20 mm and 25 mm are available.
• Recalculate the maximal piston force for the cylinder selected. Discuss the result!
• Calculate the maximum stress on the piston rod chamber of cylinder 2A1, when it works with maximal force. Discuss
the result!
3. Describe the two different types of speed control (supply control and exhaust control) applied in the circuit. State the
advantages of controlling the exhaust flow.
4. Explain the purpose of the double pressure valve in this circuit.
5. Describe the mode of operation of a pneumatic controlled 5/2 way valve. Explain the memory function of “bistable” valves.
• Equipment list
1 Single acting cylinder
1 3/2 way directional valve, pneumatic actuated
2 Pneumatic proximity switch
1 Roller lever switch
1 Double pressure valve
1 Air service unit
1 Air supply unit
Tubing, fittings
• Developing the circuit by drawing the diagram
There are two power components needed, a single acting cylinder 1A1 and a double acting cylinder 2A1.
The single acting cylinder is controlled by a 3/2 way valve, the double acting cylinder needs a 5/2 way valve. In this pure
pneumatic circuit, direct pneumatic actuation is required. Since the valves have to react to short signals from pushbutton and limit
switches, double piloted (bistable) valves are the right choice.
To adjust the speed of the working stroke of both cylinders, one-way flow control valves have to be included. Since the single
acting 1A1 only has one port, the position of the one-way flow control valve 1V3 is defined. The air passage is restricted, when it
flows from port 1 to port 2. As the double acting cylinder 2A1 is concerned, the one-way flow control valve 2V2 should be put at
the exhaust side.
The start signal from pushbutton switch 1S1 has to be combined with the signal from the magnetic proxy switch 2B1 by a double
pressure valve. This valve 1V1 works as a logic AND and makes sure, that a new cycle can only start when the previous one is
completed. This is the case when both cylinders are in their retracted end position.
The command for 2A1 to advance is given by the mechanic roller lever switch 1B2. It courses the directional valve 2V1 to change
its initial position.
The signal from the magnetic proxy switch 2B2 is distributed to both directional valves, 1V2 and 2V1 to change and allow the
return stroke of the cylinders.
Circuit diagram developed and drawn with FluidSIM-4.2

• Calculation of piston size and force
In the design process, the common “3-S Approach” should be applied. The three “S” stand for:
1. SIZE: diameter of the cylinder to create a certain piston force F under a fixed system pressure p.
2. STRENGTH: force really available after the cylinder has been chosen according to standards and availability.
3. STRESS: pressure peaks in the system in case of pressure amplifying or any malfunction.
•Calculation of cylinder size (presizing)

Single acting cylinder 1A1:
Fth = psys * AP Feff = Fth – (FF + FR)
FP = psys * AP – (FF + FR)
A P = FP + F F + F R = 200 N + 20 N + 15 N = 235 N *mm2 = 392 mm2

psys 0,6 MPa 0,6 N
D = √ 4*AP = 22,3 mm
𝝅
To guaranty a sufficient working force, diameter 25 mm should be chosen for the single acting cylinder.
Double acting cylinder 2A1:
AP =367 mm2 D= 22,1 mm
Also here a cylinder diameter of 25 mm seems to be appropriate.

• Recalculation of piston force
Single acting cylinder 1A1:
FP = psys * AP – (FF + FR)
The piston area of the 25 mm cylinder shall be taken from FluidSIM. As usual, return spring force is given with 15 N, the friction force
is around 10% of the theoretical piston force.
Fp = 0,6 MPa *491 mm2 – (30 N + 15 N) = 295 N – 45 N = 250 N
Double acting cylinder 2A1
Advance stroke: FP = psys * AP – FF
FP = 0,6 MPa * 491 mm2 – 30 N = 265 N

Since the double acting cylinder does not need to tension any return spring, the available piston force is a bit higher then this of a
single acting cylinder.
Here, the return stroke is an idle one, there is no work done. Nevertheless, it might be of advantage to know the possible force of the
return stroke. Since the piston area at the piston rod side is smaller, the force developed is also smaller.
Return stroke:
The piston rod diameter of a 25 mm cylinder is usually 10 mm. Also here, the area can be found at FluidSIM.
FPR = psys * APR – FF
FPR = 0,6 Mpa * 412 mm2 – 25 N = 222 N
At the return stroke, a piston force of 222 N is created, when the system works with a pressure of 0,6 MPa.
• Types of speed control
Fundamentally, there are two types of throttling circuits for double-acting cylinders:
1. Supply air control
2. Exhaust air control
For supply air control, one-way flow control valves are installed so that the air entering
the cylinder is throttled. The exhaust air can escape freely through the check valve of
the throttle valve on the outlet side of the cylinder. The slightest fluctuations in the load
on the piston rod, such as occur for example when passing a limit switch, lead to very
large irregularities in the feed speed.
With exhaust air control, the supply air flows freely to the cylinder
and the exhaust air is throttled. In this case, the piston is loaded
between two cushions of air. The first cushion effect is the supply
pressure to the cylinder and the second cushion is the exhausting
air being restricted at the one-way flow control valve orifice.
Arranging throttle relief valves in this way contributes substantially
to the improvement of feed behavior. Exhaust air throttling should
be used for double-acting cylinders.
• Advantages:
1. unrestricted supply of compressed air to the cylinder
2. more sensitive adjustment of the throttle
3. steady piston motion, no stick-slip
better load independence
• Purpose of double pressure valve
In this circuit the double pressure valve works as a logic AND, combining signals from 1S1 and 2B1. It means the new
cycle can only start when 1S1 is pressed AND at the same time, 2B1 is actuated. This setting assures that both cylinders
are in there retracted end position and ready to start.
• 5/2 way valve as memory component
4 2
14 12
5 3
1
When an input signal is applied at port 14, output port 4 is opened and, at the same time, output port 2 is closed. The valve is
“SET”. The valve keeps this position even after the SET-signal has stopped.
Unless a signal is applied at port 12. When this is the case, the valve changes position. Output port 4 is closed and output
port 2 is now opened. The valve is “RESET”.
Hence, only one output signal is possible at the same time, either port 4 is open or port 2. The respective setting of the output
is kept until another input signal is applied.
Quiz
• Types of Double acting cylinders
a. Piston cylinders
b. Short-stroke Cylinders
c. Long-stroke Cylinders
d. Annular cylinders
• Stroke lengths are up to 500 mm. The working speed is in the range of 30 to200 mm/s.
Cylinder forces are about 40 kN.
a. Short-stroke Cylinders
b. Piston cylinder
• ____________are connected into the Line as close as possible to the element concerned.
Fixed-set throttles and throttle valves are fitted to special-purpose sub- assemblies like
pneumatic timers.
a. Cylinder Bottom
b. Throttle valves
c. Fixed-set throttles
• _____ are members of the flow control family. Fitting an adjustable __________to
reduce the cross-sectional area enables the compressed-air flow rate to be adjusted, and
with it the working speed.
a. Fixed-set throttles
b. Return Spring
c. Cylinder Bottom
d. Throttle valves
• A _____________ restricts air flow. The air flow going through a throttle valve depends on the
opening percentage and the pressure differential between the input and the output of the valve.
a. Regulating throttle valve

b. Fixed throttle valve
c. Adjustable throttle valve
d. PNEUMATIC CYLINDERS
• A ____________ allows air to flow in one direction and seals it off in the opposite direction.
a. Adjustable throttle valve

b. PNEUMATIC CYLINDERS
c. Return valve
d. Non-return valve
Week -9
Fundamental physical principles of hydraulics
Physical principles of hydraulics
Hydraulics is the science of forces and movements transmitted by means of liquids. It belongs alongside hydro-mechanics. A distinction
is made between hydrostatics – dynamic effect through pressure times area – and hydrodynamics – dynamic effect through mass times
acceleration.
• Hydrostatic pressure
Hydrostatic pressure is the pressure which rises above a certain level in a liquid owing to the weight of the liquid mass:
Force, area
Every body exerts a specific pressure p on its base. The value of this pressure is
dependent on the force due to weight F of the body and on the size of the area A
on which the force due to weight acts.
Pressure transmission
If a force F₁ acts via an area A₁ on an enclosed liquid, a pressure p is produced which extends throughout the whole of the liquid
(Pascal’s Law). The same pressure applies at every point of the closed system.
Power transmission
The same pressure applies at every point in a closed system. For this reason, the shape of the container has no significance.
Displacement transmission
If a load F₂ is to be lifted a distance S₂ in line with the principle described above, the piston P₁ must displace a specific quantity of
liquid which lifts the piston P₂ by a distance S₂.
√
Example
A vehicle is to be lifted by a hydraulic jack. The mass m amounts to 1500 kg. What
force F1 is required at the piston?
Example
Force Multiplication
Flow rate
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 litre bucket from a tap. Thus, the flow rate amounts to 10 l/min.
Continuity equation
If the time t is replaced by s/v (v = s/t) in the formula for the flow rate (Q = V/t) and it is taken into account that the volume V can be
replaced by A⋅s, the following equation is produced:
Example-1
Example-2
Example-3
Energy and power
The energy content of a hydraulic system is made up of several forms of energy. As stated in the law of conservation of energy, the total
energy of a flowing liquid is constant. It only changes when energy in the form of work is externally supplied or carried away. The total
energy is the sum of the various forms of energy:
1. Static: – Potential energy – Pressure energy
2. Dynamic: – Motion energy – Thermal energy
• Potential energy
Potential energy is the energy which a body (or a liquid) has when it is lifted by a height h. Here, work is carried out against the force of
gravity. In presses with large cylinders, this potential energy is used for fast filling of the piston area and for pilot pressure for the pump.
The amount of energy stored is calculated on the basis of an example.
Diagram – press with elevated reservoir

Power
Power is usually defined as work or a change in energy per unit of time. In hydraulic installations, a distinction is made between
mechanical and hydraulic power. Mechanical power is converted into hydraulic power, transported, controlled and then converted back
to mechanical power.
Hydraulic power is calculated from the pressure and the flow rate.
Calculation of hydraulic Pressure
Quiz
• Most hydraulic circuits are designed by:
a) Mechanical engineers.
b) Fluid power engineers.
c) Fluid power distributor salesmen.
d) Civil Engineers
• Atmospheric pressure at sea level is equal to approximately:
a) 14.7 Hg
b) 14.7 psi
c) 14.7 Bar
d) 14.7 Pas
• A pressure gauge reading of 100 bar would be equivalent to:
a) 2940 psi
b) 1070 psi
c) 1470 psi
d) 100 psi
• When a gas or liquid is heated it will:

a) Contract.
b) Stay the same.
c) Expand.
d) Disappear
• What effect does overloading have on fluid power and electrical systems?
a) Electrical components get damaged in electrical systems
b) Fluid power system stops working without damaging the components
c) both a. and b.
d) none of the above
• The resistance offered to the flow of fluid inside a piston develops into
a) Pressure
b) Force
c) Stress
d) all of the above
• In hydraulic systems,
a) the mechanical energy is transferred to the oil and then converted into mechanical
energy
b) the electrical energy is transferred to the oil and then converted into mechanical
energy
c) the mechanical energy is transferred to the oil and converted into electrical energy
• Accessories used in a hydraulic power unit adjust pressure and are used to generate
flow and direction of the fluid.
a) True
b) False
• Basically, the __________ functions the same as the 4/2 version. The only difference
being that due to its design as a spool valve, the 5/2 has an additional exhaust port (5).
a. 1/2 directional control valve

b. 3/2 directional control valve
c. 4/2 directional control valve
d. 5/2 directional control valve
Week – 10
Hydraulic fluids
Introduction
In principle, any liquid can be used to transfer pressure energy. However, as in hydraulic installations, other X
characteristics are also required of hydraulic fluids, the number of suitable fluids is considerably restricted.
Tasks for hydraulic fluids

Some types of Fluids
Characteristics of Liquids
The liquid rises to the same level in all of the tubes, regardless of the shape or angle
of the tube.
Compression of Liquid
Closed cylinder containing Closed cylinder

hydraulic fluid (liquid) containing air (gas)
Types of hydraulic fluid
In DIN 51524 and 51525 hydraulic oils are divided according to their characteristics and composition into three classes:
1. Hydraulic oil HL
2. Hydraulic oil HLP
3. Hydraulic oil HV.
The designations for these oils are composed of the letter H for hydraulic oil and an additional letter for the additives. The code
letter is supplemented by a viscosity code defined in DIN 51517 (ISO viscosity classes).
Characteristics and requirements
For hydraulic oils to be able to fulfil the requirements listed above, they must exhibit certain qualities under the relevant
operating conditions. Some of these qualities are listed here:
1. lowest possible density;
2. minimal compressibility;
3. viscosity not too low (lubricating film);
4. good viscosity-temperature characteristics;
5. good viscosity-pressure characteristics;
6. good ageing stability;
7. low flammability;
8. good material compatibility;
In addition, hydraulic oils should fulfil the following requirements:

1. air release;
2. non-frothing;
3. resistance to cold;
4. wear and corrosion protection;
5. water separable.
The most important distinguishing feature of hydraulics is viscosity.

Application of oil in Control systems
Application of oil in Control systems
Viscosity
The word “viscosity” can be defined as “resistance to flow”. The viscosity of a liquid indicates its internal friction, i.e. the resistance
which must be overcome to move two adjacent layers of liquid against each another. Thus, viscosity is a measure of how easily a
liquid can be poured. The international system of standards defines viscosity as “kinematic viscosity” (unit: mm²/s).
It is determined by a standardised procedure, e.g.:

1. DIN 51562: Ubbelohde viscometer;
2. DIN 51561: Vogel-Ossag viscometer.
The ball viscometer can also be used to determine kinematic viscosity.

It can be used to measure viscosity values precisely across a broad
area. Measurements are made to determine the speed with which a
body sinks in a liquid under the influence of gravity. To find the
kinematic viscosity, it is necessary to divide the value determined using
the ball viscometer by the density of the fluid.
Quiz
• Lubricating oil
a) Minimizes wear in moving parts

b) Helps in keeping the parts cool
c) Washes away and carries away dirt
d) All of the above
• Fluid is a substance that

a) cannot be subjected to shear forces
b) always expands until it fills any container
c) has the same shear stress at a point regardless of its motion
d) cannot remain at rest under action of any shear force
• Fluid is a substance which offers no resistance to change of
a) Pressure
b) Flow
c) Shape
d) Volume
e) temperature.
• Practical fluids
a) are viscous
b) possess surface tension
c) are compressible
d) possess all the above properties
e) possess none of the above properties.
• In a static fluid
a) resistance to shear stress is small
b) fluid pressure is zero
c) linear deformation is small
d) only normal stresses can exist
e) viscosity is nil.
Week – 11
Components of a hydraulic system

Power supply section
The power supply unit provides the necessary hydraulic power – by converting the mechanical
power from the drive motor. The most important component in the power supply unit is the
hydraulic pump. This draws in the hydraulic fluid from a reservoir (tank) and delivers it via a
system of lines in the hydraulic installation against the opposing resistances. Pressure does not
build up until the flowing liquids encounter a resistance.
The oil filtration unit is also often contained in the power supply section. Impurities can be
introduced into a system as a result of mechanical wear, oil which is hot or cold, or external
environmental influences. For this reason, filters are installed in the hydraulic circuit to remove dirt
particles from the hydraulic fluid. Water and gases in the oil are also disruptive factors and special
measures must be taken to remove them.
Heaters and coolers are also installed for conditioning the hydraulic fluid. The extent to which this
is necessary depends on the requirements of the particular exercise for which the hydraulic
system is being used.
The reservoir itself also plays a part in conditioning the hydraulic fluid:
1. Filtering and gas separation by built-in baffle plates,
2. Cooling through its surface.
HYDRAULIC SYSTEM
Components of a hydraulic system
❑ Valves
X
Valves are devices for controlling the energy flow. They can control and regulate the flow direction of the hydraulic
fluid, the pressure, the flow rate and, consequently, the flow velocity.
There are four valve types selected in accordance with the problem in question.
1. Directional control valves

These valves control the direction of flow of the hydraulic fluid and, thus, the direction of motion and the
positioning of the working components. Directional control valves may be actuated manually, mechanically,
electrically, pneumatically or hydraulically. They convert and amplify signals (manual, electric or pneumatic)
forming an interface between the power control section and the signal control section.
2. Pressure valves
These have the job of influencing the pressure in a complete hydraulic system or in a part of the system. The
method of operation of these valves is based on the fact that the effective pressure from the system acts on a
surface in the valve. The resultant force is balanced out by a counteracting spring.
3. Flow control valves

These interact with pressure valves to affect the flow rate.
They make it possible to control or regulate the speed of
motion of the power components. Where the flow rate is
constant, division of flow must take place. This is generally
effected through the interaction of the flow control valve
with a pressure valve.
4. Non-return valves
In the case of this type of valve, a distinction is made between ordinary non-return valves and piloted non-return
valves. In the case of the piloted non-return valves, flow in the blocked direction can be released by a signal.
5. Cylinders (linear actuators)

Cylinders are drive components which convert hydraulic power into mechanical power. They generate linear
movements through the pressure on the surface of the movable piston. Distinction is made between the following
types of cylinder:
6. Motors (rotary actuators)
Like cylinders, hydraulic motors are drive components controlled by valves. They too convert hydraulic power into
mechanical power with the difference that they generate rotary or swivel movements instead of linear
movements.
Hydraulic motor (gear motor)

Quiz
• Which of the following is used as a component in hydraulic power unit?
a) pressure gauge
b) filler gauge
c) Valve
d) reservoir
• Rotary motion in a hydraulic power unit is achieved by using
a) pneumatic cylinder
b) both hydraulic and pneumatic cylinder
c) none of the above
d) hydraulic cylinder
• Which of the following is used as an accessory in hydraulic power unit?
a) Pumps
b) Valves
c) motor
d) reservoir
• Most hydraulic circuits:

a) Operate from a central hydraulic power unit
b) Use air-over-oil power units
c) Have a dedicated power unit
d) Does not have dedicated power unit
• Hydraulic and pneumatic circuits:

a) Perform the same way for all functions
b) Perform differently for all functions
c) Perform the same with some exceptions
d) Does not perform all the functions
• Series circuits work on both hydraulic and pneumatic actuators.
a) True
b) False
• When comparing first cost of hydraulic systems to pneumatic systems, generally

they are:
a) More expensive to purchase
b) Less expensive to purchase
c) Cost is same
d) Cost is not required
• The most common hydraulic fluid is:

a) Mineral oil
b) Synthetic fluid
c) Water
d) Gel
Week – 12
Graphic and circuit symbols
Introduction
X
Simple graphic and circuit symbols are used for individual components to enable clear representation of
hydraulic systems in diagrams. A symbol identifies a component and its function, but it does not provide
any information about its design. The symbols to be used are laid down in DIN ISO 1219. The most
important symbols are dealt with in this chapter.
❑ Pumps and motors
Hydraulic pumps and motors are represented by means

of a circle which shows where the drive or output shaft
is located. Triangles within the circle give information
about the direction of flow. These triangles are filled in,
since hydraulic fluids are used for hydraulics. If a
gaseous pressure medium were being used, as is the
case in pneumatics, the triangles would not be filled in.
The symbols for hydraulic motors and hydraulic pumps
can only be distinguished from one another by the fact
that the arrows indicating the direction of flow are drawn
pointing one way for the pumps and the other for the
motors.
Directional control valves are shown by means of several connected squares.
1. The number of squares indicates the number of switching positions possible for a valve.
2. Arrows within the squares indicate the flow direction.
3. Lines indicate how the ports are interconnected in the various switching positions.
• Methods of actuation for the directional Control valves
The switching position of a directional control valve can be

changed by various actuation methods. The symbol for the
valve is elaborated by the addition of the symbol indicating the
actuation method. In the case of some of the actuation
methods shown, such as push button, pedal, lever with detent,
a spring is always necessary for resetting. Resetting may also
be achieved by switching the valve a second time, e.g. in the
case of a valve with hand lever and detent setting.
Listed aside are the symbols for the most important actuation
methods. Refer to DIN ISO 1219 for other methods of
actuation.
❑ Pressure valves
Pressure valves are represented using squares. The flow direction is indicated by an arrow. The valve
ports can be labeled P (pressure port) and T (tank connection) or A and B. The position of the valve within
the square indicates whether the valve is normally open or normally closed.
A further distinction is made between set and adjustable pressure valves. The latter are indicated by a
diagonal arrow through the spring.
In the case of flow control valves, a distinction is made between those affected by viscosity and those
unaffected. Flow control valves unaffected by viscosity are termed orifices. Throttles constitute
resistances in a hydraulic system.
The symbol for non-return valves is a ball which is pressed against a sealing seat. This seat is drawn as an
open triangle in which the ball rests. The point of the triangle indicates the blocked direction and not the
flow direction. Pilot controlled non-return valves are shown as a square into which the symbol for the non-
return valve is drawn. The pilot control for the valve is indicated by a control connection shown in the form
of a broken line. The pilot port is labelled with the letter X.
❑ Shut-off valves
❖ Cylinders
Cylinders are classified as either single-acting or double-acting.
➢ Single acting cylinder
Single acting cylinders just have one port, i.e. only the full piston surface can be pressurized with hydraulic fluid.
These cylinders are returned either by the effect of external forces – indicated by the symbol with the open bearing
cap – or by a spring. The spring is then also drawn into the symbol.
➢ Double acting cylinder
Double acting cylinders have two ports for supplying either side of the piston with hydraulic fluid. It can be
seen from the symbol for a double acting cylinder with single piston rod that the piston area is greater than
the annular piston surface. Conversely, the symbol for the cylinder with a through piston rod shows that
these areas are of the same size (synchronous cylinder).
❖ Transfer of energy and conditioning of the pressure medium
The following symbols are used in circuit diagrams for energy transfer and conditioning of the pressure medium.
❖ Measuring devices
Measuring devices are shown in the circuit diagrams by the following symbols:
❖ Combination of devices
If several devices are brought together in a single housing, the symbols for the individual devices are placed into a
box made up of broken lines from which the connections are led away.
Quiz
• How is power transmitted in fluid power systems?
a) power is transmitted instantaneously

b) power is transmitted gradually
c) both a. and b.
• Can all hydraulic fluids be compressed when extremely large pressure is applied?
a) Yes
b) No
• At low pressures, liquids are
a) Compressible
b) non-compressible
c) unpredictable
• Which of the following statements are false?
1. Pressure is resistance to flow

2. Friction creates pressure
3. Load cannot create pressure on the system
4. The pressure developed decreases if load offers more resistance
a) 1, 2 and 4
b) 1 and 2
c) 3 and 4
• Rotary motion in a hydraulic power unit is achieved by using
a) hydraulic cylinder
b) pneumatic cylinder
c) both hydraulic and pneumatic cylinder
• Accessories used in a hydraulic power unit adjust pressure and are used to
generate flow and direction of the fluid.
a) True
b) False
Week – 13
Design and representation of a hydraulic system

Introduction
A hydraulic system can be divided into the following sections:
1. The signal control section

2. The power section
Diagrammatic representation of the structure of a hydraulic system

• Signal control section
The signal control section is divided into signal input (sensing) and signal processing (processing). Signal input may be
carried out:
1. manually
2. mechanically
3. Contactless
Signals can be processed by the following means:

1. by the operator
2. by electricity
3. by electronics
4. by pneumatics
5. by mechanics
6. by hydraulics
Hydraulic system (Design)

Hydraulic power section
The hydraulic power can be divided up into the power supply section, the power control
section and the drive section (working section). The power supply section is made up of
the energy conversion part and the pressure medium conditioning part. In this part of the
hydraulic system, the hydraulic power is generated and the pressure medium conditioned.
The following components are used for energy conversion – converting electrical energy
into mechanical and then into hydraulic energy:
1. Electric motor
2. Internal combustion engine
3. Coupling
4. Pump
5. Pressure indicator
6. Protective circuit
The following components are used to condition the hydraulic fluid:

1. Filter
2. Cooler X
3. Heater
4. Thermometer
5. Pressure gauge
6. Hydraulic fluid
7. Reservoir
8. Filling level indicator
The power is supplied to the drive section by the power control section in accordance
with the control problem. The following components perform this task:
1. Directional control valves
2. Flow control valves
3. Pressure valves
4. Non-return valves.
The drive section of a hydraulic system is the part of the system which executes the
various working movements of a machine or manufacturing system. The energy
contained in the hydraulic fluid is used for the execution of movements or the
generation of forces (e. g. clamping processes). This is achieved using the following
components:
1. Cylinders
2. Motors
A suitable type of representation is required in order to reproduce movement sequences
and operating statuses of working elements and control elements clearly. The following
types of representation are of importance:
1. Positional sketch
2. Circuit diagram
3. Displacement-step diagram
4. Displacement-time diagram
5. Function diagram
6. Function chart.
Positional sketch
The positional sketch is a drawing or schematic diagram of a production installation
or machine etc. It should be easily understandable and should include only the most
important information. It shows the spatial arrangement of the components. The
positional sketch in the Figure shows the position of cylinder Z1 and its function: Z1
is intended to lift the hood of the tempering furnace. Z1
Circuit Diagram
The circuit diagram describes the functional structure of the hydraulic system.
Designation of the components
❑ The power supply section of the system with filter (0Z1), pressure-relief valve
(0Z2), pump (0P1) and electric motor (0M1) is depicted in the lower part of the circuit
diagram shown for the hydraulic device of the tempering furnace.
❑ The power control section with the non-return valve (1V1), the 3/2-way valve
(1V3) and the pressure-relief valve (1V2) is located in the centre of the circuit diagram.
The 3/2-way valve (1V3) with the hand lever for signal input forms the “system-
person” interface.
❑ The drive section consists of the single-acting cylinder 1A.

Components plus technical data
In the circuit diagram, the technical data are often additionally specified with the devices
in accordance with DIN 24347.
Furthermore, the circuit diagram can be supplemented by tables:
Quiz
• Which type of motion is transmitted by hydraulic actuators?
a) linear motion
b) rotary motion
c) both a. and b.
• Which energy is converted into mechanical energy by the hydraulic cylinders?
a) hydrostatic energy
b) hydrodynamic energy
c) electrical energy
• What is the advantage of using a single acting cylinder?
a) high cost and reliable

b) honing inside the inner surface of pump is not required
c) piston seals are not required
d) all of the above
• What is the function of a flow control valve?
a) flow control valve changes the direction of oil flow

b) flow control valve can adjust the flow rate of hydraulic oil
c) both a. and b.
• What does the numbers in 4/2 valve mean?
a) 4 positions and 2 ways

b) 4 Ports and 2 positions
c) none of the above
• Why is the pilot operated check valve used in clamping operation?
a) to reduce leakage in spool valve

b) to avoid decrease in pressure during clamping
c) both a. and b.
Week – 14
Components and Function of the Hydraulic control System

❑ Pump and the Electrical Motor
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).
Hydraulic systems (with the exception of hand pumps) are driven by motors (electric
motors, combustion engines). Electrical motors generally provide the mechanical power
for the pump in stationary hydraulics, whilst in mobile hydraulics combustion engines are
normally used.
Hydraulic pump:
Gear pump :Gear pumps are fixed displacement pumps since the displaced volume which
is determined by the tooth gap is not adjustable.
Example: Determining the volume of liquid supplied per minute
Calculation of the delivery of a gear pump.
Given that:
• Number of rotations n = 1450 RPM
• Displacement volume V = 2.8 cm³
To be found: Delivery Q
❑ Valves X
In hydraulic systems, energy is transferred between the pump and consuming device along
appropriate lines. In order to attain the required values – force or torque, velocity or r.p.m.
– and to maintain the prescribed operating conditions for the system, valves are installed
in the lines as energy control components. These valves control or regulate the pressure
and the flow rate. In addition, each valve represents a resistance.
• Poppet valves
Poppet valves and

piston slide valves
are distinguished
from one another by
the difference in
their design.
Actuating force
• Spool valves
To actuate elongated spool valves, it is only necessary to overcome the frictional
and spring forces. Forces resulting from the existing pressure are balanced out by
the opposing surfaces. Actuating force
Positive switching overlap
Port P …… A is opened although port A …..T is not closed yet. Thus, all
ports are briefly interconnected.
❑ Pressure valves
Pressure valves have the task of controlling and regulating the pressure in a hydraulic
system and in parts of the 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 relief valves (sectional diagram)

• Pressure regulators 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.
2-way pressure regulator

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.
Non-return valves block the flow in one direction and permit free flow in the other. As
there must be no leaks in the closed direction, these valves are always of poppet design
and are constructed according to the following basic principle: The sealing element
(generally a ball or cone) is pressed against an appropriately shaped seat. The valve is
opened by volumetric flow in the flow direction, the sealing element being lifted from the
seat. Non-return valves are distinguished as follows:
• Non-return valves (unloaded, spring-loaded)
• Lockable and unlockable non-return valves.
Flow control valves are used to reduce the speed of a cylinder or the r.p.m. of a motor.
Since both values are dependent on the flow rate, this must be reduced. However, fixed
displacement pumps supply a uniform flow rate.
❑ Hydraulic cylinders
The hydraulic cylinder converts hydraulic energy into mechanical energy. It generates
linear movements. For this reason, it is also referred to as a “linear motor”. There are two
basic types of hydraulic cylinder
• single-acting and
• double-acting cylinders.
Quiz
• Which area does the part shown below indicate?
a) rod area
b) full bore area
c) annulus area
Quiz
• Which of the following systems generate more energy when used in industrial
applications?
a) hydraulic systems
b) pneumatic systems
c) both systems generate same energy
d) cannot say
• Which type of compressor requires a reservoir for compressed air and why?
a) rotary compressor to avoid pulsating effect

b) reciprocating compressor to avoid pulsating effect
c) both rotary and reciprocating compressors to avoid pulsating effect
• Which of the following factors is/are considered while selecting a compressor?
a) type of oil filter required

b) volumetric efficiency
c) viscosity of the liquids used
d) all of the above
• Which of the following is a component used in air generation system?
a) pressure switch
b) pressure gauge
c) Drier
d) intercooler

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Electric, Hydraulic and Pneumatic Control

• Grades Component % Weight

• Blackboard : homeworks, handouts, quizes, exams,…

2. Structure and components of pneumatic systems

3. Symbols and standards in pneumatics

4. Simple pneumatic circuits

5. Control of piston speed

At the end of this semester, Students shall be able to

78% nitrogen (N2) by volume

1 bar = 100,000 Pa = 0.1 MPa

1 mbar = 100 Pa = 0.001 bar

1 bar = 14,5 psi

This qualitative relationship can be reproduced mathematically in the formula

i.e. for two different states (subscript 1 or 2) it holds that

The following animation illustrates this context

• Testing and checking

• Door and lock control (e.g. in motor vehicles)

The block diagram describes the general setup of a pneumatic system:

❑ Providers: Air generation and treatment

Low noise laboratory compressor Block diagram of an air generation unit

Air service unit

❑ Controllers : Pneumatic valves

3/2 way roller lever valve

3/2 way air actuated valve:

5/2 way valve for cylinder

Non-return valve and its derivatives

Flow control valve

Pressure sequence valve

Time delay valve

❖ Linear drives: single acting cylinders, double acting cylinders,

Double acting cylinder Pneumatic motor Rotary table

❑ Connectors :Tubes, couplings, fittings, distributors

Actuators, linear and rotary

❖ Control circuit for the single-acting cylinder

Control of a single-acting cylinder

Control of a double-acting cylinder

Introduction to FluidSim 4 - Pneumatics

Symbols used in energy

The methods of actuation of pneumatic

Non-return valves and derivatives

Flow control valves

• Tasks to carry out:

❑ Single acting cylinder

➢ Component parts of a single acting cylinder

Allocated designation for the component parts Number Designation

The theoretical piston force is calculated according to the following formula:

• Piston force: Newton N 1 N = 1 kg * m/s²

A mass of 1 kg corresponds to a weight force of 9,81 N.

• Piston area: Meter Square m2 1 m2 = 10000 cm2 = 1000000 mm2

Feff = AP * p – (FR + FF)

• Control of a single acting cylinder

• Operation of the valve

3/2 way valve, idle 3/2 way valve, actuated

❑ Air treatment unit

Filter unit with baffle plate

1. Reciprocating piston compressor

MINI AIR COMPRESSOR

• Tasks to carry out:

• Allocated designation for the component parts

The following formulas apply:

Advance stroke: Feff = effective piston force = (AP*p) – FF

AP = effective piston surface

Return stroke: Feff = (APR*p) – FF