Professional Documents
Culture Documents
applied sciences in the world. Almost concivable type of machine requires the use of
some form of control not only for starting and stopping but also for regulating
the motion and providing the means by which the machine can think it self in various
degrees.
strengthening our economy and increasing our standard of living has necessitated more,
automation in every field dealing with consumers goods, since the machine tool industry
is one of the basic industries, controlling and automation of them is of much importance.
1) Mechanical.
2) Electrical.
3) Fluid.
decision for selecting the control systems the advantages and disadvantages. Limitations
variation, lubrication problems, space problems, uneven load application and inclusion of
and loads has certain advantages. The fluid control system provides mechanically stiff
systems that can be designed to give very fast operation and more enormous loads. They
can be employed more economically over greater distances than mechanical systems, but
1) It permits large power and forces to be transmitted i.e. power t weight ratio is
high.
3) It offers reversible means of obtaining stepless and infinity variable speed and load.
5) It provides very accurate position control for both rotary and linear elements.
6) Smooth working increases the tool life and allows high speed and feed rates.
contaminated with dirt and other foreign material. Hence good filtration system is also
and military applications. Their high power to weight ratio results in it's wide use in
1) Hydraulic fluid.
1) Hydraulic fluid :-
Water was the earliest hydraulic fluid used, but finds little
application in modern high performance control systems. It has many limiting features
which include low lubricity, danger of rusting and its useful working temperature range is
restricted.
pertrolium base, notably five risk. This includes phosphate or silicate ester compounds
halogenated fluid give off toxic vapours. Care has t be taken in. designing equipment for
compatible with the fluid. The lubricity of silicone fluid is less than that of petrolium
products and it is poor lubricant for farous materials sliding on farous material.
1) Viscocity.
2) Viscocity index.
3) Lubricating properties.
4) Chemical stability.
5) Compressibility.
9) Low toxicity.
Viscocity :- The viscocity of the fluid is the measure of its resistance to shearing
displacement. Fluids used in hydraulic control systems must have adequate viscocity to
give good seal at pistons, glands, valves but not to viscous that it adds excessive load to
the moving parts wearing rapidly and loss of fluid from the system.
Lubricating properties :-
contact between moving parts. Lubrication breaks down when the film of fluid is
punctured, resulting in damage to the surfaces between which relative movements takes
place.
Chemical stability :-
formation of sluge and gum. The fluid is churned when it passes through the pumps,
valves, pipings and motors and absorbs oxygen in the process. This results information
sluge and gum. Some hydraulic fluids form emulsions in use which reduces their lubricity
practice fluids exhibits some degree of compressibility due to absorbed gases and
aeration. The compressibility is expressed in terms of bulk modulus B and is given by,
P
B = ---------- Kg/Cm2
dv/v
actuator and power pack. Due to the flexibility of electrical equipment and the fact that
large physical distance between output and input point signals are usually electrical. As
shown in block diagram, a Hydraulic power pack suplies high pressures fluid. Actuator is
the element of the circuit which is directly connected to that part of Machine tool of
which movement is to be control. Control valve is a valve which control the flow and
the diagram is shown the actuator will be having some load depending on the load of the
machine tool to be operated. When the control valve is completely open, the whole flow
will pass through the valve to the sump and the actuator will be remain at its original
position. Now if the ball is given a signal in such a way so that it is partially open, then
the flow through the valve will be proportional to the area of the opening. Due to control
flow through the valve some pressure is built up in the system which acts on the actuator
and operating the actuator, when the vlave is completely closed, then whole power from
Constant flow power pack have closed loop pipe line with
controlled leakage as shown in fig. The fluid drawn from the reservoir by the pump
usually of cnstant displacement type, to provide a constant flow. Any foreign particles is
filtered out before it passes on to the control valve of own center type which permits fluid
When the controlled system imposes no load on the power pack all
the fluid is returned to the reservoir by control valve. This type of power pack can
control only one load, and should be individually matched to its requirements Constant
flow supplies are most efficiently utilised where the load uses the full flow of pump for
long period.
4. COMPONENT SELECTION AND TYPES
1) Pump ;- It has been already seen that for the supply of high pressure fluid pumps are
used and reciprocating and rotary are only used. The different type of pumps used are as
follows.
a) Gear pump
b) vane pump
c) Piston pump
For low and medium pressure range i.e. upto 1500 psi, and
capacity upto 120 gpm, gear pumps are used. Their volumetric efficiency is 96% and
mechanical efficiency is 90%. Helical gear pumps can be operated at high speeds but
they are limited by end thrust hence used upto 100 psi and herring bone upto 500 psi,
i) Balance
hence the casing is symmetrically accentric. Hence as pressure n both sides balances each
Balanced load pump operates at max. 200 psi and unbalanced load
Axial piston pump are used at above 5000 psi and some of them
gives discharge above 100 gpm Their volumetric efficiency is 95% and mechanical
efficiency is 90% Radial piston pump is used upto 25000 psi and 20 to 150 hp; with
cylindrical piston 6000 psi max. with 1.5 gpm; with ball shaped piston. 7000 rpm fro 35
gpm,
Single piston pups are not generally used because they do not gives
continuous pressure. Multi piston or plunger pumps are used which gives continuous
discharge.
Valves :- Types of valves are already given before. So now see some details about them.
1) Relief valves
3) Check valves
4) Flow control valves
over load, pumps must be provided with devices to protect them and their associated
circuits from over pressure. In case of fixed displacement pumps, for example that the
piston has clamped a wokr piece and that pressure should be maintained but flow reduced
to a trickle to make up clearance losses. The pump would try to force more fluid into the
pipe lines, and pressure rise unchecked unlimited pressure may destroy pump or cylinder
Relief Valves :-
limiting devices; since every pump should have the protection this valve offers. The relief
valve automatically creates a passage way between the pressure line and reservoir, large
enough to diver all the excess fluid supplied by a pump back to the reservoir when the
and then hold that pressure constant regardless of how much oil must be diverted to the
reservoir"
spring loaded valves will permit the pressure to rise some what when larger flows must
be handled. The simplest true relief valve is sliding spoor two way valve spool
movement gradually open a passage or orifice between the pressure input port and the
port connected to the reservoir. One end of the spool is exposed to the input pressure and
the other end is loaded with a coil spring. The pocket enclosing the spring is drained to
the reservoir either directly or through he reservoir connection. In some circuits the main
configurations. In this case spring pocket pressures in spring pocket would add the forces
exerted by the spring effectively raising the relief valve pressure setting.
from single pressure source. The pressure reducing valve is designed to supply low
pressure oil to a branch circuit from high pressure line. These low pressure circuits may
be used for hydraulic clamps or other mechanical devices they would be damaged by the
from the low pressure connection is directed through an orifice to the back of spool. As
pilot to control oil pressure in the spring pocket. Tightening the pilot valve spring permits
higher pressure be developed in the spring pocket requiring higher secondary pressure
Check valves :-
A valve which permits flow of fluid in one direction only and self
In its simplest form this valve consists of a drilled inlet port that is
closed off by a spring of gravity held ball. Flow to the inlet port lifts the ball off its seat,
and oil flows freely to the outlet ports. Reverse pressure forces the ball against the seat
characteristics. If the ball always seats in the same position, it can be expected t seat
satisfactorily. If it reseats in the one position often enough to wear a groove at the seals
line, any later rotation of the ball with the seal. For this reason balls are of the guided or
poppets are substituted The poppet design always maintains the relationship with its seat.
services. But they may be too expensive so warrant installation is some circuits. Flow
reasonable cost.
pressure drop as well as areas when pressure at the cylinder or fluid motor fluctuates in
responses to load changes, flow rate changes also. Some additional pressure sensitive
between the high pressure lien and the orifice. The reducing valve controls flow to the
orifice sod that pressure drop across the orifice is maintained constant.
to meter fluid in or out of cylinder. The flow will vary with temperature and pressure
even thought he orifices locked in one position. Non compensated flow control devices
are not recommended for by pass or bled off service except in very simple gravity return
circuits. Broaches, planner, and other more sensitive machine use compensated flow
A two way valve is intented to open and close two functional flow
ports connected to the valve body. Many of the valves described above may be termed as
two way valves. However, relief valves, pressure limiting or reducing valves, and check
valves are ordinarily not reversible, that is flow between the two posts is dependent on
direction and their primary function goes beyond simply stopping or permitting flow.
To way directional valve opens or closes flow between its two
ports in response to some external signal, either mechanical, as with can or lever
operating the steam, or electrical, as with a solenoid, or air or oil pilot operator.
pilot valve is added. In small pipe size two way valves this solenoid may even be
control speed of the main two way spool movement independent of the speed of signal to
the solenoid
controlled opened to closed actuation would be possible in the solenoid were directly
connected to the main two way spool. However, with a pilot valve connected to the
solenoid the degree of spool shift speed and hence acceleration and deceleration of main
two way flow will be a function of the size of pilot spool and physical configuration of
main spool. Ground angles on the pilot spool or notches of various kinds can also be used
to establish a delay in opening or closing of the main two way valve. This type of control
The term three or four way directional valve indicate the number
of functional flow ports a valve is intented to control. Porting in three way valve consists
both sides of the piston, and so fourth connection is added. The arrows in the symbol
indicate that the pressure may be applied to either cylinder and by changing the vlave
position. The opposite cylinder connection is always ported to the tank, possibly through
As the valve shifts between none extreme position and the other, it
goes through a highly neutral position. If the spool is held on center by ball retainer,
balance of spring
5. ANALYSIS OF THE CIRCUIT
material into finished product is very impotent step. The preference requirement of
finished products largely depend on processing condition and material properties .The
moulder can only use the raw material as of finished and hence the processing parameters
processing parameters like time, temperature and pressures. A typical mould cavity
The moulding operator feeds the plastic material into the hopper
which is normally dried to a prescribed temperature. The injection unit receive for further
processing. The schematic diagram of injection moulding unit is shown in fig. (B).
ram, drive shaft and hydraulic motor. The screw is inserted it no a hard barrel that
becomes a part of the stationary feed chamber. A material hopper is mounted on top of
feed chamber. The screw is inserted and keyed in to the injection ram.
The screw remains in the forward position after injection. The
rotation of the screw causes the plasticized material to move forward while absorbing
heat. The could and pattern are locked tighted to a predetermined high pressure. The
hydraulic fluid is supplied to the injection ram for injection material. The screw moves
Fig (c) shows the basic hydraulic circuit normally used in open loop control moulding
machines. The open loop hydraulic system uses separate flow control valves to control
injection and pressure control valves to control the injection unit. These valve are set
compensation for draft due to wear, temperature variations, load and plastic viscosity
elements monitor molding process through feed back and automatically adjusting the
designing the hydraulic circuit for clamp unit. A simplified hydraulic circuit for clamp
unit is shown in fig (E), The faster the ram moves, the more critical it becomes to have an
accurate and repeatable stroke to avoid mold damage. Hence the clamp hydraulic circuit
offens two operational speeds. Initial closing stroke is faster to save time and finally
depend on processing conditions and material properties. The moulder can only use the
raw material as furnished and hence the processing parameters and specification become
of prime importance to moulder. In this experiment we will study the moulding cycle and
hydraulic. These machines have to meet specific moulding processing parameters like
time, temperature and procedures. The schematic diagram of injection moulding machine
follows.
1. The injection unit consist of a reciprocating screw, injection ram, drive shaft and
hydraulic motor.
3. Due to rotation of the screw, the plasticised material move forward while absorbing
by moving the whole assembly backward against on adjustable pressure until the volume
5) At this instant, the screw stops rotating and is ready for injection.
6) The mold and platters are locked tight to a predetermined high pressure and calls for
7) The hydraulic fluid is supplied to the injection ram and brings about the forward
movement of the screw to inject the plasticised material into the mold.
8) The contact between injection unit and mold is made by a nozzle assembly.
9) The screw moves forward injecting the plasticised material into the mold.
10) Injection pressure is held on the material as per the time set on injection timer.
i) Opening mold.
iii) Clamping pressure - A low pressure pump controlled the damping pressure.
iv) Mould breakaway - When mold is ready a low volume high pressure pump
remove mould.
v) Fast return - Rapid opening due to high volume high pressure pump.
MACHINE
1. Initially electrical signal pass to the electric motor (#l ) through set point signal
pannel.
2. Due to rotation of electric motor <#l) , hydraulic pump (#3) pump oil from tank,
3. Due to actuation of solenoid, part 'p' connect with port 'A' and port 'T connect with
part 'B'.
4. Therefore oil pump into the piston moves to the right hand side. Oil from rod end
side directly goes to the tank, through part 'B ' connect with port 'T'
5. Due t this action, mold closed and ready for injection of plasticised material into if.
7. Due to electric signal pass to the hdyraulic motor (#5), rotation of screw take place.
10. Due to backward movement of screw, oil from piston end are directly goes to the
tank through part 'A' connect with part 'T of 2/3 direction control valve (#6), as shown in
11. Now sensor gives signal to the setpoint signal pannel and rotation hydraulic motor
(#5) stop.
13. Due to rotation of electrical motor (# 2) , hydraulic pump (#4), pump oil from tank
through filter to the 2/3 direction control valve (#6) and (#7) and 4/4 direction control
valve 0#8).
14. However, as per hydraulic circuit their is blockage for pumped oil.
] 5. Due to blockage for pumped oil. Now hydraulic signal goes to the hydraulically
operated pilot valve of 2/3 direction control valve (#7) and part 'p' connect with part 'A'
and oil goes to the empty side of double acting, double ended, rod end side injection unit
cylinder.
16. Now by continous flow of oil, empty side fill up with oil and their is again
17. Now electrical signal goes to the microprocessor (#9), which give signal to the
18. Due to this, part 'P' connect with part 'A' and part 'B' connect with part 'T' of 4/4
direction cntrol valve (#8) and oil flow and give signal to the hydraulically operated pilot
(#6) and oil flows into the piston end side of double acting, double ended injection unit
cylinder.
20. By entrance of oil into cylinder, screw moves to the left hand side and electrically
heated homogenous material forcely moves into the mold cavity and achieve the required
shape of mold.
21. Remaining oil from rod end of double acting cylinder directly goes to the tank
through port 'A' connect with port 'T' of the 2/3 direction cntrol valve (#7).
22. After predetermined time signal goes to the microprocess (# 10) which transmit
23. Now oil goes to the piston end cylinder of mold through port ' P' to part 'B' &
remaining oil goes to the tank through port 'A' to part 'T' of 3/4 direction control valve (#
11).
6. Fast opening
By -Harry L. Stewart
By Flint, Michigan
By Hadeke R.
4) Industrial Hydraulics
By S.S. Patil