Hydraulics and Pneumatics

Complex Engineering Problem

Submitted By:
Muhammad Hassan (2020-MC-274)
Submitted to:
Dr. Awais Hafeez

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Department of Mechatronics & Control Engineering

University of Engineering & Technology Lahore,
Faisalabad Campus.
Attributes:
Range of conflicting requirements, Depth of Knowledge required, Familiarity of issues,
Extent of applicable codes
Hydraulics & Pneumatics (MCT-313) Session 2020, Fall 2022
CLO – 3: PLO – 1 (5), CLO – 4: PLO – 3 (10) Total Marks 15

TARGET SUBMISSION DATE: 12 December, 2022

NAME: Muhammad Hassan (2020-MC-274)

I agree to the assessment as contained in this assignment. I confirm that the work submitted is my own work.

Date Issued: 13 October, 2022

Signature: Date submitted: 12 December, 2022

This assignment will be used to grade the sections highlighted.

Assessment Criteria for a pass Achieved

CL04 Be able to design and construct 4.1 design and produce a circuit design diagram for either a pneumatic
the circuits of pneumatic and orhydraulic multi-actuator sequential operation circuit, that includes
hydraulic systems. emergency stop functions
4.2 design and produce a circuit design diagram for either a pneumatic
orhydraulic rotary actuation system that includes speed control in both
directions
4.3 design and produce a circuit design for either a pneumatic or
hydraulic‘fail-safe circuit application

CLO3 Explain the structure and 3.1 design and produce a circuit design diagram for either an electro-
working principles of pneumatic or electro-hydraulic system arrangement
hydraulic, pneumatic and 3.2 Conclusions have been arrived at through synthesis of ideas and should
electro- pneumatic/hydraulic be justified
components

Rubrics Achieved
Excellent (12-15) Good (8-11) Satisfactory (4-7) Not-Satisfactory (0-3)
• identify and apply • effective judgments have been made
strategies to find • complex problems with more than one variable have been explored
appropriate solutions • an effective approach to study and research has been applied
(CLO4).

• select/design and apply • relevant theories and techniques have been applied.
appropriate methods/
techniques (CLO4) • a range of methods and techniques have been applied.
• a range of sources of information has been used.
• the selection of methods and techniques/sources has been justified
• the design of methods/techniques has been justified
• complex information/data has been synthesized and processed
• appropriate learning methods/techniques have been applied
• present and • the appropriate structure and approach has been used
communicate the • coherent, logical development of principles/concepts for intended
appropriate findings audience
(CLO3)
• a range of methods of presentation have been used and technical
language has been accurately used
 • communication has taken place in familiar and unfamiliar contexts
• the communication is appropriate for familiar and unfamiliar
audiences and appropriate media have been used

Feedback Comments:

Teacher’s Signature:
Date:
Obtained Marks
GENERAL INTRODUCTION TO ASSESSMENT STRATEGY

Throughout the module you should do the following.

• Study relevant course notes.

• Study the recommended textbooks.

• Use the standards publications available in the library.

• Make use of suitable web sites.

• Make use of journals on fluid power.

• Make use of manufacturers catalogues. (RS, NORGREN, REXROTH and so on).

• Make use of the standard information pack from the British Fluid Power Association.

In the design parts, you should use the computer software “Festo FluidSim”. The context help contains diagrams, pictures
and symbols.

Your assignment should be structured with headings and subheadings. The work must be your own. Copies of pages from
the internet or from any other source should only be added as reference material. This should be clearly identified and
cross-referenced in your text (e.g., diagram numbers and appendix numbers).

You may use computer packages such as “word” to produce your work and scan in pictures. You may do the work in
handwriting and paste in pictures and diagrams. Whatever method you use, make sure that the work is identifiable as your
own unique style and your research.

Students who address all the issues in full are more likely to obtain a merit or distinction but so long as the main points are
addressed you should obtain a pass grade.

Parts of this assignment may be used as evidence of achievement in the PLC module.

IMPORTANT: Consult with your tutor to ensure that you understand the work to be done before you commit
yourself to any substantial amount of work.

SYSTEMS

At the end of this assignment seven fluid power systems are described. You will be allocated or asked to select ONE of
them in order to complete this assignment.
 DETAILS

PART 1 CIRCUIT DESIGN

You will be allocated or asked to select of the seven systems described in the last section. Design a pneumatic or hydraulic
system to the specification given.

• The machine must use electric control systems.

• Decide whether to use hydraulics or pneumatics. Explain all the points considered in arriving at
your answer.

BASIC HARDWARE CIRCUIT

At this point you should not design the control system, only the basic circuit.

You need not consider the materials, style or quality of the hardware at this stage.

You should produce your drawing to the ISO standard. All the main control valves must be solenoid operated.

• Using Festo FluidSim, design and test the circuit if possible (e.g., using manual overrides
on the valves)

• Explain in detail the strategy used to arrive at your design.

PART 2 CONTROL AND OPERATION

You should now consider how control of the system is to be produced and automatic operation achieved. Remember that
electric control must be used. If you have already studied the PLC module, you may use any of the techniques taught there.

• List the sequence of operations and use a suitable graphic aid such as a cycle diagram or a step
sequence diagram.

• Consider whether to use a PLC or a hardwired electric circuit. Discuss the benefits and
disadvantages of both.

• Identify sensors that can be used to make the system work automatically in the correct sequence.

• Modify your circuit drawing by adding the sensors and/or additional valves.

• Construct a separate circuit diagram (within the same project) showing the electric wiring diagram
and produce a control circuit if require. This will be either a grafset or ladder diagram. You may
need help and advice on this.

• Demonstrate the system working by using the simulation feature.

PART 3 SAFETY ASPECTS
This section concerns the safe design and operation of the machine. Consider the safety legislation that is appropriate to
this installation.

• Identify and discuss the main safety legislation applicable to the installation, commissioning
operating and maintaining the machine.

• Identify the main dangers to look out for when commissioning, operating, and maintaining this
particular machine.

• Find out about and explain the reasons for using the following safety features.

o Lock out facility.

o Automatic cut out.
o Emergency stop.
o Fail safe. (e.g. safe parking position).
o System protection.

• Identify which you need to incorporate in your design and give your reasons. You should consider
things such as :

o Prevention of unauthorised tampering.

o Possibility of the machine becoming jammed or clogged.
o Overheating.
o Overpressure.
o Fluid levels.
o Power overloads

• Modify your circuit diagram to include appropriate safety features and add suitable text notations if
required. This must include an emergency stop

PART 4 SPECIFICATION AND COST

• When costing the system, the following should be considered. Explain what each meansand list what
would be included in each for this machine.

o Capital cost.
o Running cost.

PART 5 COMMISSIONING AND MAINTAINING THE SYSTEM

In this section you should consider commissioning and maintenance aspects of the machine.

• Write a brief report outlining the commissioning procedures to be used.

• Write a brief report outlining the maintenance procedures to be used.
SYSTEM 2 DRILLING MACHINE

The diagram shows an outline design for a proposed machine to be used for drilling a hole in a work piece. First
the work piece is put in position. Next the guard must be lowered, and the work piece clamped by cylinder C. Three
seconds after the guard is lowered, the drilling commences automatically. The work piece is fed against the drill by cylinder
B and this is a double rod type with the rod fixed at each end. The speed of the feed must be controllable.
 Solution
Part-1 Circuit Design:
First of all, I designed the circuit of the given system(which is Drilling System).
Strategy:
1. First of all, I placed three cylinders in Fluid-Sim Simulation Software as were required in our
system and a motor.
2. After that, I used a 5/2 double solenoid valve for the control of guard cylinder D.
3. I have also attached a sensor with the Guard Cylinder D for its extended position detection
because this cylinder controls the guard of the machine and when the guard is closed, there is
a sensor which detects its closed state and then the other procedure begins.
4. And the clamp cylinder C also acts and clamp the workpiece when we initiate the process
(along with the Guard Cylinder D).
5. After the Guard cylinder D has reached to its extracted position, the sensor senses the extracted
position and it closes the switch S.
6. There is a relay with switch On-Delay attached just after the switch S. I have set 3 seconds for
delay as per requirement of the system.
7. After the 3 seconds, it power on the motor which then commences the drilling process.
8. There is also a relay after the relay with switch On-Delay which is connected after the switch
S, which controls the 5/2 single solenoid valve attached with the Cylinder B to Feed Work
Piece.
9. I have connected a Flow control Valve with the Cylinder B to controls the Feed speed as per
required in the system.

Figure 1: Basic Circuit

Part-2 Control and Operation:
In this part of our design, we used a Hardware Electric Circuit since we have not studies PLC so far.
Following are the parts to design the Electric Operation for Control.
➔ Sequence Operation: Our sequence operation in the Drilling Machine is as follows.
The Cylinder D and Cylinder C extends when we on the switch means that our guard must be lowered
at the start of the drilling system and work piece must be clamped.
Then the sensor sensed the extended position of Cylinder D and motor rotates after 3 seconds of the
sensing and the cylinder attached with the workpiece feeds it against the drill.
A Flow Control Valve is used with Cylinder B to control the feed rate.
Following is Functional Diagram of our system.

Figure 2: Functional Diagram

➔ Hardware Circuit: We deigned the following Hardware circuit.

Figure 3: Hardware Circuit to Control and Operation

Sr. No. Advantages Disadvantages

1. No air compressor and associated The system requires uninterrupted power
machinery required. supply with no voltage fluctuations.
2. High efficiency since there is no leakages. Standby batteries required in case of
power failure.
3. Instantaneous response. There is risk of fire due to overheating.
Expensive intrinsically safe / explosion
 proof equipment may be required.

4. Very little affected by normal temperature Moisture may cause damage to the
variations. system.
5. Electric cables are cheap and easy to lay. Damage readily occurs in the event of a
And very accurate. fire.

➔ Sensor Used: We have used one sensor which senses the extracted position of the Cylinder
D and then turn on the motor and gives feedback to the Cylinder B.
➔ Complete Circuit Diagram:

Figure 4: Complete Circuit

 ➔ Grafcet Diagram: Following is the grfcet diagram for Drilling System.

➔ System Working:
First of all, we will press the switch button S1

Then it allows the 5/2 double sided solenoid valve to move and extends the cylinder piston D.
As the Cylinder D extends, the sensor S senses the extended position and closes the S switch.

After the switch S closes, it energizes a relay with relay with switch On delay which counts to 3
seconds (as set into it) and then starts the motor after that.

After the switch S closes, it also energizes the K3 relay which then closes the K3 switch and also F
solenoid of 5/2 single sided solenoid and the cylinder B extends towards the drill and drillings
commences.
After the drilling commences, we closes the Switch S2 which close the process and all the cylinders
moves to their initial position.

Part-3 Safety Aspects:

➔ Safety Legislation: Following are the safety aspects that we considered during the circuit
design for safety purposes when the machine is used.
A 3/2-way single sided manually operated valve as an emergency stop of the pneumatic supply to stop
it in case of emergency placed right after the pneumatic service unit.

A Push Button right after the 24V supply in the electric circuit for emergency stop.
 ➔ Dangers to Look out for when commissioning, operating and maintaining this machine:

1. Run drill at correct RPM for diameter of drill bit and material.
2. Always hold work in a vise or clamp to the drill table.
3. Use the proper cutting fluid for the material being drilled.
4. Remove chips with a brush, never by hand.
5. Ease up on drilling pressure as the drill starts to break through the bottom of the material.
6. Don't use a dull or cracked drill. Inspect the drill before using.
7. Don't drill with too much pressure.
8. Always try to support part on parallels or a backing board when drilling thru material.
9. Never place taper shank tools such as large diameter drills or tapered shank reamers in a drill
chuck. Only straight shank tools such as standard drills can be clamped in chucks.
10. Always clean drill shank and/or drill sleeve, and, spindle hole before mounting.
11. Remove taper shank tools from spindle or sleeve with a drill drift and hammer.
12. Never try to loosen the drill chuck while the power is on.
13. Lower the drill spindle close to the table when releasing the drill chuck or taper shank drill to
reduce the chance of damage should they fall onto the table.
14. Never clean a machine while it is in motion!!
15. If the drill binds in a hole, stop the machine and turn the spindle backwards by hand to release
the bit.
16. When drilling a deep hole withdraw the drill bit frequently to clear chips and lubricate the bit.
17. Always remove the drill chuck key, or, the drill drift from the spindle immediately after using
it.
18. Wear safety eye protection while drilling.
19. Let the spindle stop of its own accord after turning the power off. Never try to stop the spindle
with your hand.

➔ Reason for using Safety Features: Following are the safety features which should be used in
our drilling machine and their reason to use.
Lock out facility: Lock Out Facility is used to avoid unauthorized Tampering with the drilling
machine.
Automatic cut out: A fuse must be used for automatic cut out of the power to avoid any mishap in
case of short-circuit.
Emergency stop: Emergency stop Button must be placed for case of any emergency during operation
to shut the system down.
Fail safe: Safety switches (like fuse) must be used for Fail Safe so that the machine should be safe in
case of any failure.
System protection: There should always be a guard while using drilling system so that the system is
protected.
➔ Things need to be incorporated in drilling machine system:
Prevention of unauthorized tampering: There is no such unauthorized tampering in our drilling
system.
Possibility of the machine becoming jammed or clogged: There is a possibility of the machine
becoming jammed or clogged.
If the pistons are properly managed and maintained, then their seal may break and dust particles can
be clogged in the piston of the cylinder and they may jam.
Overheating: There is a chance the electric components like switches, relays and other components
may heat up due to continuous use of the machine system. This can be reduced using heat sink or
exhaust depending upon the use of the machine. If the machine is to be used continuously then there
must be proper arrangement like exhaust system using fans or some heat sinks to cool the electroni
components.
Also the drilling tool can also heat up due to drilling operation and some coolant must always be used
to cool it down.
Overpressure: If the air service unit is not maintained properly, then there is a chance of over-
pressure. So, the service unit must be properly checked.
Power overloads: There must be safety switches to avoid any loss during power overloads like fuse
or circuit breakers.
➔ Circuit Diagram Using Proper Safety Features:
Part-4 Specification and Cost:
Following are the components used in drilling machine system while costing the system.
➔ Capital Cost:
For Pneumatic System: Following are the components required for the pneumatic circuit.
o 1- Double-acting Cylinder
o 1- Single-acting Cylinder
o 1- 5/2 Double Sided Solenoid valve
o 1- Double-acting Cylinder with In and Out Piston Rod
o 1- Flow Control Valve
o 1- 5/2 Single Solenoid Valve
o 1- Roller Sensor
o 1- 3/2 Manually operated Valve
o Air Service Unit
For Electric Control System: Following are the components used in electric control system.
o 24 Volts DC Power Supply
o 1- Push Button
o 7- Relays
o 1- Relay with switch on Delay
o 1- Motor
➔ Running Cost:
Following Components should be properly managed for proper operation of the drilling machine.
o Seals of the pistons must be properly checked and changed if necessary
o Valve must be checked for their leakage or any other damage
o Electric Circuit must be checked after a specified period of time for any fault.
o Drilling tool must be checked before every drilling operation.

Part-5 Commissioning and Maintaining the System:

➔ Commissioning the System:
o Check the tool health before every drilling operation and the type of the material to be drilled
according to the tool type.
o Put the workpiece in the machine clamp and switch on the machine. It will automatically lower
the guard and clamp the work piece.
o The motor will start rotating along with the tool attached to it.
 o After 3 seconds of the closing of the guard, the cylinder B will move toward the drill according
to the feed rate set using Flow Control Valve and the drilling process will commence
automatically.
o Then the user with switch off machine using the S2 and cylinder B will move away from the
tool and motor will stop rotating.
o It will then unclamp the workpiece and open the guard.
➔ Maintaining the System:
Following components must be maintained properly for proper operation of the drilling machine.
o Drilling Tool
o Piston Seals to avoid dirt clogging and jamming
o Air Service Unit for required pressure supply
o Valves to avoid leakage
o Roller Sensor for proper control
o DC Power supply for required 24 volts
o Electronics Components to check for any kind of damage.