ME 422 INDUSTRIAL HYDRAULICS I

LABORATUAR EXERCISE BOOK

Adopted from Festo Ditactic
Exercise: 1. Lifting station
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for the
direct control of a single- acting cylinder.
Exercise objectives
-Defining the components required.
-Drawing the hydraulic and electrical circuit diagrams.
-Identifying the connections.
-Numbering the components in the circuit diagram.
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
The crates fed via a covey or belt must be lifted to the height of a packing belt by means of a
lifting table. The raising and lowering of the lifting table is to be controlled at which by means
of a single acting hydraulic cylinder. In order to adjust the advance speed a one-way flow
control valve has to be built in.

Positional sketch
Exercise: 2. Component selection on conveyor belt
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for the
direct control of a double -acting cylinder.
Exercise objectives
-Defining the components required
-Drawing the hydraulic and electrical circuit diagrams
-Identifying the connections
-Numbering the components in the circuit diagram
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
Components must be pushed from one conveyor belt on to a second conveyor belt by means
of a cylinder. The speed of forward travel is to be adjustable, while the speed of return travel
should take place uninfluenced. For this, you use a one-way flow control valve.

Positional sketch
Exercise: 3. Bending device
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for a
control with electrical self- ratching on the advance stroke of a double-acting cylinder.
Exercise objectives
-Defining the components required.
-Drawing the hydraulic and electrical circuit diagrams
-Identifying the connections
-Numbering the components in the circuit diagram
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
U-shaped metal plates must be bent in a device, using a double-acting cylinder. The manual
push-button is used to give the start signal for this process. When the sheet-metal component
has been shaped, the second push-button is used to initiate the return stroke. (The safety
devices required for normal industrial practice need not be considered here). The speed of
forward and return travel should be slow and adjustable. What flow control valve do you
employ, so that the speed is adjustable independent of load?

Positional sketch
Exercise: 4. Pressing device
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for the
control of a double acting cylinder; the electrical self -latching for the forward stroke must be
triggered when the preset pressure is reached.
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
A pressing device is to be used to assemble components. If the preset pressure of 30 bar is
exceeded (e.g. because the components are tilted), the piston rod must be retracted for safety
reasons. With a correct press operation, the return stroke is initiated in the same way when the
preset pressure of 30 bar on the pressure switch is reached. A one-way flow control valve has
be-en fitted in the supply port of the cylinder. Describe at what moment after the switching on
of the control system the pressure switch responds, when the pressure before the flow control
valve is interrogated. At what place should the interrogation of pressure correctly take place.
Positional sketch
Exercise: 5. Stamping machine
Subject : Electro-hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for
differential control.
Exercise objectives
-Defining the components required
-Drawing the hydraulic and electrical circuit diagrams
-Identifying the connections
-Numbering the components in the circuit diagram
-Practical construction of the electro-hydraulic control
-Production of component parts list
Description of exercise
A hydraulic power pack with a small pump delivery rate is all that is available for the
operation of a stamping machine. A suitable circuit must be used to increase the advance
speed. (The available force is sufficient).
Positional sketch
Exercise: 6. Door control
Subject : Electro-hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for the
control of a double-acting cylinder in inching operation.
Exercise objectives
-Defining the components required
-Drawing the hydraulic and electrical circuit diagrams
-Identifying the connections
-Numbering the components in the circuit diagram
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
A double-acting hydraulic cylinder is used to open and close a door. It must be possible to
drive the door to any intermediate position by means of inching operation. The cylinder must
be hydraulically clamped at all intermediate positions.
Positional sketch
Exercise: 7. Machining unit I
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for a
stroke dependent differential connection of a double -acting cylinder.
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
The edges of a workpiece must be chamfered. The machining time can be shortened by
improving the tools. The feed speed is to be increased by means of a differential circuit. The
clamping device accepts up to 5 workpieces. In order to allow the working stroke to be
reduced appropriately for a smaller number of workpieces, the return stroke must be initiated
by an adjustable limit switch.
Positional sketch
Exercise: 8. Feed for drilling machine
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for a
quick feed circuit for a double -acting cylinder .
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
The feed of a drilling machine is to be automated. When carrying out drilling with large
diameter drill bits, it is necessary to achieve constant feed characteristics and a finely
adjustable feed speed. The machine must therefore be equipped with a hydraulic feed. It must
be possible to execute a quick feed and an infinitely adjustable working feed. The return
stroke is triggered by the actuation of a push button. At the same time, bypassing the flow
regulator is to take place via a non-return valve.
Positional sketch
Exercise: 9. Press
Subject : Electro-hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for a
stroke dependent and pressure dependent control for a double acting cylinder.
Exercise objectives
-Defining the components required
-Drawing the hydraulic and electrical circuit diagrams
-Identifying the connections
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
A knee lever press is used to shape components. An initial pressure must first be produced to
shape the material slowly. After a pressing movement of approx. 100 mm, a stroke dependent
switchover to a higher pressure is made. After the pressing operation is complete, the pressure
rises to the value which has been preset on the pressure switch. When this value is reached,
the pressure switch must switch over to the return stroke. The delivery rate is to be adjustable
by means of a flow control valve.
Positional sketch
Exercise: 10. Feed device
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for
unloaded pump circulation in conjunction with a double-acting cylinder.
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
The machining time of a work piece has increased. The workpiece must now be ejected at
longer time intervals. In order to prevent an unnecessary heat rise in the hydraulic oil, a
switchover must be made to unloaded pump circulation after ejection.

Positional sketch
Exercise: 11. Assembly device
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for a
pressure dependent sequence control with two double acting cylinders.
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
An assembly device is used to press in components. In order to achieve a reliable pressing
action, and to ensure a correct working sequence, cylinder B must not start until cylinder A
has reached the preset pressure. The pressing speed of cylinders A and B must be adjustable.
Cylinder A must not, sag when the hydraulic power pack is switched off. The two cylinders
must not retract until the return switch has been pressed. The position of the detected return
switch must be displayed visually. It must not be possible to restart until, this return switch
has been released (visual indicator goes out).
Positional sketch
Exercise: 1 2. Lifting device for packages
Subject : Electro -hydraulics
Training aim : To be able to draw and construct the electrical and hydraulic circuit for a
stroke dependent sequence control with two cylinders.
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
The packages are fed in by means of a gravity-roller conveyor and are lifted by cylinder A.
Cylinder B then eject the packages for further transport. Following this, both cylinders must
return to their initial positions.

Positional sketch
Exercise: 13. Circular saw
Subject :Electro-hydraulics
Training aim :To be able to draw and construct the electrical and hydraulic circuit for a rapid
feed circuit with two pumps.
Exercise objectives
-Defining the components required
-Drawing the function diagram
-Drawing the hydraulic and electrical circuit diagrams
-Numbering the components
-Practical construction of the electro-hydraulic control
-Production of the component parts list
Description of exercise
In order to achieve a high rapid-traverse speed with a circular saw, two pumps are used,
during the cutting operation; the delivery of the rapid-traverse pump must be switched to
unloaded flow. When the sawing operation is complete, the saw table must return to its initial
position.

Positional sketch