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Lab Manual Hydraulics & Pneumatic Machines Version 2.

0 1

K. J. Somaiya Polytechnic,
Mumbai 400 077

Department of Mechanical Engineering.

Laboratory Manual

Hydraulics and Pneumatics Machines

Prepared by

Shri. C. R. Khaire Shri. U. N. Palve


Lecturer (Selection Grade) in Lecturer (Senior Scale) in
Mechanical Engineering Department Mechanical Engineering Department

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 2

K. J. Somaiya Polytechnic
Mumbai – 400 077

Controlled Copy No. : 03


Copy Issued To : Refer to Distribution List
Issue No. : 01 Issue Date: 30/06/2017 (First Issue)
Revision: : 02 Issue Date: 01/12/2020

Title: Lab Manual - Hydraulic & Pneumatic Machines (M18RC61)


Document : Lab Manual Main Document No. : Lab Manual/HMP
Issue: 01 Date : 30/06/2017
Level: Mechanical Engineering Department
Revision: 02 Date : 01/12/2020
Prepared by:
Shri. C. R. Khaire, Shri. U. N. Palve Approved by : Head of Department

This Lab Manual is the property of K. J. Somaiya Polytechnic. Any unauthorized copying
of this Lab Manual is strictly prohibited.

Distribution List
Sr. No. Copy Holder Location No. of Copies
1 Head of Department Department 01
2 Head of Department Document File 01
3 Batch In-charge Respective Faculties 01

Document History
Version No. Revision Revision No. Revision Date
1.0 Original Copy 0 30/06/2017
2.0 Revised Copy 1 01/12/2020

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 3

Mechanical Engineering Department


Vision of the Department
To develop excellent Mechanical Diploma Engineers by shaping their
overall personality

Mission Statements of the Department


1. Developing the curriculum to enhance skills and capability of
students to make them competitive.
2. Making students aware of industrial safety practices.
3. Providing sustainable environment for over all faculty development.
4. Giving exposure to foreign language and creative arts.
5. To develop entrepreneurial attitude through curricular and co-
curricular activities.
6. Using ICT (Information and communications technology) for more
effective teaching learning throughout the course.
7. Prepare the students to pursue life-long learning, serve the
profession and meet intellectual, ethical and career challenges.
8. To prepare the students for diverse careers in mechanical
engineering and related fields.
9. To provide students with a sound mechanical engineering education
and application of mechanical engineering principles.
10. To prepare students to be immediately productive and able to adapt
to and lead in a rapidly changing environment and to create and
apply knowledge for the benefit of society.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 4

PREFACE

The objective of this manual is to familiarize the students with practical


skills, measurement techniques and interpretation of results. It is intended to
make this manual self contained in all respects, so that it can be used as a
laboratory manual. In all the experiments, the relevant theory and general
guidelines for the procedure to be followed have been given. Tabular sheets
for entering the observations have also been provided in each experiment
while graph sheets have been included wherever necessary.

Diploma engineering students are introduced for the subject of


Hydraulic and pneumatic to understand and visualize the basic concepts of
various circuits using pneumatic and hydraulic trainer kit, hydraulic and
pneumatic devices & circuits cover basic concepts of application of
pressurised oil and air for automation to increase production rate.

This lab manual provides a platform to the student’s for understanding


the basic concepts of hydraulic & pneumatic devices and circuits. This
practical will help students to gain confidence in qualitative and quantative
approach to circuit and components.
It is suggested that the students should complete the computations in
the laboratory itself. However the students are advised to refer to the
relevant text before interpreting the results and writing a permanent
discussion.

Shri. C. R. Khaire

Shri. U. N. Palve

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 5

K. J. Somaiya Polytechnic, Mumbai – 400 077


CERTIFICATE
INDEX

Sr. Page Date of Date of Date of


Experiment/ Assignment Remarks
No. No. Performance Submission Correction

1 To study of hydroelectric power plant, the


constructional details of Francis turbine,
Kaplan turbine and Pelton wheel.
2 To Determine the efficiency of centrifugal
pump.
3 To Determine the efficiency of
reciprocating pump.
4 To perform basic pneumatic circuit for
direct & indirect control of single acting
cylinder.
5 To perform basic pneumatic circuit for
direct & indirect control of double acting
cylinder.
6 To perform various pneumatic circuits of
double acting cylinder using direction
control valves.
7 Perform basic hydraulic circuit for the
working of double acting cylinder and a
hydraulic motor.
8 To perform speed control hydraulic circuits.
(meter-in& meter-out circuit)
9 Study of hydraulic counter-balancing
circuit, regenerative circuit, sequencing
circuit, unloading circuit, industrial
application
10

This is to certify that Bro./Sis. _______________________________ Enrollment No. _____________

has completed the specified term work in a satisfactory manner in the course of MEP XII (Hyd. & Pneu.

M/c’s) (M18RC61) inside the polytechnic as laid down by the Board of Studies of Polytechnic during the

academic year 20___ to 20___ (S / W – 20__ )

Lab. In-charge Head of Department Principal

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 6

Content

Sr.
Description Page No.
No.
1 Syllabus 7
2 General instructions 8
3 Exp. 1:To study of hydroelectric power plant, the constructional 9
details of Francis turbine, Kaplan turbine and Pelton wheel.
4 Exp. 2:To Determine the efficiency of centrifugal pump. 14
5 Exp. 3:To Determine the efficiency of reciprocating pump. 19
6 Exp. 4:To perform basic pneumatic circuit for direct & indirect 23
control of single acting cylinder.
7 Exp. 5:To perform basic pneumatic circuit for direct & indirect 25
control of double acting cylinder.
8 Exp. 6:To perform various pneumatic circuits of double acting 27
cylinder using direction control valves.
9 Exp. 7: ToPerform basic hydraulic circuit for the working of 30
double acting cylinder and a hydraulic motor.
10 Exp. 8:To perform speed control hydraulic circuits. (meter-in & 33
meter-out circuit)
11 Exp. 9: To Study of hydraulic counter-balancing circuit. 35
12 Exp. 9A: To Study of hydraulic or pneumatic regenerative circuit. 37
13 Exp. 9B: To Study hydraulic or pneumatic sequencing circuit. 38

14 Exp. 9C: To Study of hydraulic unloading circuit. 39


15 Exp. 9D: To Study of hydraulics and pneumatics circuit, based on 40
the industrial application

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 7

Department Mechanical Engineering


Course Title MEP XII (H&PM + CNC)
Course Code: M18RC61 No. of Credits Th- -- Pr : 02+04 Total-06
Pre-requisites Course Practical Level of the course:
&Code Core Course
Marking Scheme # Progressive Test- -- End Theory- -- End Practical Exam: 70
@ Progressive TW- 30
Course Type Core Course Compulsory
Offered in V Semester( FTD)
Course Outcomes:
Student will be able to:
1. Understand working principle and performance characteristics of pumps.
2. Acquire skills in cognitive, psychomotor and affective domain to represent symbols, develop circuits, classify valves,
operate and maintain various hydraulic and pneumatic devices
3. Identify different axes, machine zero, home position, systems and controls CNC machines and Select, mount and set
cutting tools and tool holders on CNC.
4. Prepare part programmes.
5. Interface software application for auto part programming.
Detailed Course Contents
SECTION: I Hydraulic Machines & Pneumatics
Sr. No. Topic Name Details of Topic Hrs CO PO PSO
1 centrifugal pump Trial on centrifugal pump 6 1 1, 2, 3, 5, 2
8, 10
2 reciprocating Trial on reciprocating pump 4 1 1, 2, 3, 5, 2,3
pump 8, 10
3 Pneumatics Direct control of single acting cylinder & double acting 4 2 1, 2, 3, 5, 3,4
cylinder 8, 10
4 Pneumatics Indirect control of single acting cylinder & double 4 2 1, 2, 3, 5, 4
acting cylinder 8, 10
5 Pneumatics Study of various pneumatic circuits 4 2 1, 2, 3, 5, 2,4
8, 10
6 Pneumatics Study and operation of simple equipment’s/ Tools 4 2 1, 2, 3, 5, 1,3,5
based on pneumatic control 8, 10
7 Oil Hydraulics Study/ demonstration simple hydraulic circuits for 6 2 1, 2, 3, 5, 4,5
actuation of single/ double acting cylinder 8, 10
References:
I) Internet references
http://www.logiclab.hu/
https://nptel.ac.in/courses/112103174/38
https://www.autodesk.com/products/fusion-360/blog/cnc-programming-fundamentals-g-code/
https://www.quora.com/How-do-I-learn-CNC-programming
http://www.helmancnc.com/cnc-programming-for-beginners-a-simple-cnc-programming-example/

II) Audio visuals


https://www.youtube.com
III)Related Magazines/E Journals :
IV) Reference Books:

REFERENCE: Laboratory Manual

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 8

GENERAL INSTRUCTIONS

Rough record and Fair record are needed to record the experiments conducted in the
laboratory. Rough records are needed to be certified immediately on completion of
the experiment. Fair records are due at the beginning of the next lab period. Fair
records must be submitted as neat, legible, and complete.

On the right side page of the record following has to be written:

• Title: The title of the experiment should be written in the page in capital letters.
• In the left top margin, experiment number and date should be written.
• Aim: The purpose of the experiment should be written clearly.
• Apparatus/ Tools/ Equipments/ Components used: A list of the
Apparatus/Tools/ Equipments/ Components used for doing the experiment should
be entered.
• Principle: Simple working of the circuit/experimental set up should be written.
• Procedure: steps for doing the experiment and recording the readings should be
briefly described
• Results: The results of the experiment must be summarized in writing and
should be fulfilling the aim.
• Inference: Inference from the results is to be mentioned. On the Left side page
of the record following has to be recorded:
• Circuit/Program: Neatly drawn circuit diagrams/experimental set up.
• Design: The design of the circuit/experimental set up for selecting the
components should be clearly shown if necessary
• Observations:
Data should be clearly recorded using Tabular Columns.
Unit of the observed data should be clearly mentioned.
Relevant calculations should be shown. If repetitive calculations are needed, only
show a sample calculation and summarize the others in a table.
• Graphs: Graphs can used to present data in a form that show the results
obtained, as one or more of the parameters are varied. A graph has the
advantage of presenting large amounts of data in a concise visual form.

TO PROTECT EQUIPMENT AND MINIMIZE MAINTENANCE:


DO:
SET MULTIRANGE METERS to highest range before connecting to an unknown
source.
INFORM YOUR INSTRUCTOR about faulty equipment so that it can be sent for repair.

DO NOT: Do not MOVE EQUIPMENT around the room except under the supervision
of an instructor.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 9

Experiment No.: 1

AIM:- To Study Of Hydroelectric Power Plant, The Constructional Details Of Francis


Turbine, Kaplan Turbine And Pelton Wheel.

THEORY AND WORKING:-


The purpose of hydroelectric power plant is to provide power from water flowing
under pressure. It has two forms of energy, kinetic energy and potential energy.
Kinetic energy depends upon the mass velocity of flow while the potential energy
exists as a result of difference in water level below two points. The turbine converts
potential and kinetic energy possessed by water in to mechanical energy. Thus the
turbine is a prime mover which when coupled to a generator produces electricity.

ELECTRIC POWER:-
Hydroelectric power can be developed when water continuously flowing under
pressure is available. Dam is constructed to restrict the river water flow. Essential
components of a hydroelectric power plant are as follows:-
• STORAGE RESERVOIR:- The water available from an attachment area is
stored in a reservoir so that it can be utilized to run the turbine for producing
power according to requirement.

• DAM WITH CONTROL WORKS:- Dam is a structure ejected on a suitable site


to provide for the storage of water and create head. Dam may be built to make
an artificial reservoir from valley or it may be created in a river to control the
flowing water.

• WATER WAYS:- Water way is a passage through which the water carried from
the storage reservoir to the power house. It may consist of tunnel control, force

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 10

pipe and penstock. Tunnel is water passage made by cutting the mountain to
save the distance for bay in an enlarged section of a canal spread out to
accommodate the required width of intake. Its function is to store temporarily
water ejected by plant.

• PENSTOCK:- It is a pipe of large diameter caring water under pressure from


storage to turbine.

• POWER HOUSE:- It is a building to house the turbine, penstock and other for
operating the machines.

THEORY:-
Francis turbine is an inward flow reaction turbine which was designed and developed
by American engineer James B Francis. The m modern
odern Francis turbine is however a
mixed flow unit in which water enters the radial at its outer periphery and leaves
axially at its center.
Kaplan turbine is a reaction turbine which is particularly suited for low heads
(up to 30 m) and high flow rate installations.
installations. In a Kaplan turbine water flow is
purely axial.

CONSTRUCTIONAL DETAILS AND OPERATION:-OPERATION:


PENSTOCK: - it is large sized conduit which conveys water from upstream of the
dam to the turbine runner. It is made of steel. Tamaracks are provided at inletinl of
penstock to obstruct entry of any foreign matter.
SCROLL CASING: - it constitutes of a closed passage whose cross section area
gradually decreases along the flow direction. Area is maximum at inlet
and nearly zero at outlet. The decrease in area is in
in proportion to decreasing volume
of water to handle and that velocity of water is constant along its path. The casing is
made of cast steel and plate steel and concrete depending upon the pressure head.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 11

GUIDE VANES OR WICKET GATES: - a series of air foil shaped vanes called guide
vanes are arranged inside the casing to form a no of flow passages between casing
and runner blades. Guide vanes direct the water on to runner at an angle
appropriate to design. These are fixed in position, however they can swing around
their own axis and that helps to bring about a change in the flow area between two
consecutive runner blades.

RUNNER AND RUNNER BLADES: - the runner is in the form of a boss which is
nothing but extension of bottom end of shaft into bigger diameter. On the periphery
of the boss are mounted equidistantly 3 to 6 vanes made of stainless steel. The
runner blades are directly attached to the hub and this feature eliminates the
frictional losses with proper adjustment of the blades during its running. The Kaplan
turbine is capable of giving a high efficiency for a wide range of load conditions.

REGULATION: - Kaplan turbine has double regulation which comprises movement


of guide vanes and rotation of runner blades. The mechanism employs two
servomotors, one control guide vanes and the other operates the runner vanes. The
governing is done by governors (servomotors). From the inside of the hollow shaft
of turbine runner and the movement of piston is employed to twist the blades
through suitable linkage. The double regulation ensures a balanced and most
satisfactory relationship between relative position of guide and working vanes.
DRAFT FUBE:- After passing through the runner the water is discharged to tail race
through a gradually expending tube called draft tube. The free end of draft tube is
submerged deep into tailrace. Because of its gradually increasing cross section, the
discharge velocity from turbine runner is not all wasted, it is partially converted into
a useful pressure head and water discharges at a relatively low velocity to the tail
race.

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Lab Manual Hydraulics & Pneumatic Machines Version 2.0 12

GUIDE WHEEL AND GOVERNING MECHANISM:-


The governing mechanism changes the position of guide blades to effect a variation
in water flow rate in the wake of changing load conditions on the turbine. The
system consists of a centrifugal governing mechanism. When the load changes the
governing mechanism rotates all the guide blades so that water flow rate and its
direction remains same at all passages.

SALLIENT POINTS:-
Francis turbine Kaplan Turbine
Radial inward or mixed flow turbine. Purely axial flow turbine
Horizontal or vertical disposition of Only vertical shaft disposition
shaft
Runner vanes are not adjustable Runner blades are adjustable
Large number of vanes 16 to 24 Smaller no of vanes, 3 to 8
Medium head turbine (60 to 250 m) Low head turbine(30 m)
and works under medium flow rate
Specific speed ranges from 50 to 250. Specific speed ranges from 250-850
Ordinary governor is sufficient for Heavy duty governor is essential for
speed control. speed control due to smaller sizes of
the servomotors.
CONSTRUCTIONAL DETAILS OF PELTON TURBINE
The Pelton wheel is a free jet impulse turbine named after American engineer Lesteo
Pelton. It is simple, robust and only hydraulic turbine which operates efficiently and
is used for heads in excess of 450 m. smooth running and good performance are
other common features of this unit.

NOZZLE AND SPEAR:-


At its down stream end the penstock is fitted with an efficient nozzle that converts
the whole of hydraulic energy into a high speed jet. To regulate the water flow
through the nozzle and to obtain a good jet of water at all loads, a spear or needle is
so arranged that it can be moved forward or backward thereby decreasing or
increasing the angular area of nozzle flow passage. The movement of spear is
controlled either manually by a hand wheel or automatically by governing
mechanism.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 13

RUNNER WITH BUCKETS:-


The turbine rotor called as the runner is a circular disc caring a no of cup shaped
buckets which are arranged equidistantly around the periphery of the disc. The
runner is generally mounted on a horizontal shaft supported in small thrust bearings
and the buckets are either cast integrally with disc or fastened separately. For low
heads the buckets are made of cast iron, but for higher heads they are made of
bronze, cast steel or stainless steel. Further in surface of buckets are polished to
reduce frictional resistance to water jet. Each bucket has a splitter which distributes
the striking jet equally into two halves of the hemispherical bucket.

CASING:-
Out flow from the runner buckets is in the form of a strong splash which scatters in
all directions. To prevent this and to guide the water to tail race, a casing is
provided all around the runner. The casing also acts as a safe guard against
accidents. Evidentially the casing has no hydraulic function to perform. A baffle is
arranged in the casing to prevent the discharged water being carried along runner
direction.

GOVERNING MECHANISM:-
The speed of turbine runner is required to be maintained constant so that the
electric generator coupled directly to turbine shaft runs at constant speed under
varying load conditions. The task is accomplished by a governing mechanism that
automatically regulates the quantity of water flowing through the runner in
accordance with any variations in the load.

Result: From this experiment, we have undersood the construction & working of
various types of water turbines.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 14

Experiment No.: 2

AIM:- To conduct trial on centrifugal pump and draw its characteristic curve.

APPARATUS:-
Centrifugal pump, stop watch, scale, collecting tank.
THEORY:-
Centrifugal pump belongs to the category of dynamic pressure pumps where in the
pumping of liquid or generation of head is affected by rotary motion of one or more
rotating wheels called the impellers.
CONSTRUCTIONAL DETAILS AND OPERATION:-
A centrifugal pump consists essentially of the following elements:-
ROTATING ELEMENT:-
It consists of shaft and a vane rotor called impeller. The vanes are curved, cylindrical
or have more complex surfaces. The unit has a finite number of vanes. The number is
selected to assure motion of the liquid in the desired direction and varies with diameter
of the impeller eye and radial depth of the vanes. The number usually ranges 6 to 12.
The impeller is mounted on a shaft coupled to the driving unit which may be
internal combustion engine or an electric motor. By virtue of force interaction between
the vanes and the liquid the mechanical energy of the driver is transformed into the
energy of flow.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 15

STATIONARY ELEMENT:- It consists of casing, stuffing box and bearings. The casing
is an airtight chamber surrounding the pump impeller. It collects liquid from the
impeller and leads it away under high pressure to the delivery side. Packing and glands
are needed to reduce the shaft leakage, both internal and external.

SUCTION PIPE, STRAINER AND FOOT VALVE:-


Suction pipe connects the center (eye) of the impeller to the sump from which the
liquid to be lifted. The pipe is load airtight so that there is no possibility of formation of
air packets. Strainer is used in pipe to prevent the entry of solid particles into the
pump. Foot valve is used to fill up the pipe with water before it starts its work.
DELIVERY PIPE AND DELIVERY VALVE:- Delivery pipe leads the liquid from the
pump outlet to the point of use. A regulating valve provided just near the pump
outlet serves to control the flow of liquid into the delivery pipe.
The pump is initially primed where in the suction pipe, casing and portion of the
delivery pipe up to the delivery valve are completely filled with the liquid to be
pumped. Rapid motion imparted to the impeller then builds up centrifugal force which
throws the liquid towards the impeller periphery. This cause’s pressure gradients in the
suction pipe i.e. partial vacuum exist at the impeller eye. While the liquid in the sump
is at atmospheric pressure. The process is continuous as long as motion is given to the
impeller and there is supply of liquid to draw upon.
Theory:
A centrifugal pump consists of an impeller rotating inside a casing .The impeller has a
number of curved vanes. Due to the centrifugal head impressed by the rotation of the
impeller, the water enter at the Centre and flows outwards to the periphery.Then it is
collected in a gradually increasing passage in the casing known as volute chamber
which serves to convert a part of the velocity head into pressured head.
For a higher heads multi stage centrifugal pumps having two or more impellers in
series will have to be used. This single stage centrifugal pump of size (50mm x 50mm)
is coupled to 3 HP capacity Squirrel cage induction motor. The suction side is 50 mm
dia and delivery side is 50 mm dia. An energy meter is provided to measure the input
to the motor and collecting tank to measure the discharge. A pressure gauge and
vacuum gauge are fitted in delivery and suction sides to measure the head of water.
The pump must be full of water upto delivery valve before starting. For this reason it
should not be allowed water to drain and hence a foot valve is provided. But after the
long run the leather valve in the foot valve becomes useless and so the foot valve
becomes leaky.In this case the pump should be primed by pouring water.
Tools required: Stop watch, measuring scale and Energy meter etc.
Procedure:
1. Check the pressure gauges. Make sure both of them show atmospheric pressure.
2. Observe the suction and delivery pipe diameters. Measure the dimensions of
collecting tank.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 16

3. Measure the difference in elevation between the suction and delivery pressure
tapings.
4. Prime the centrifugal pump. Keep the delivery valve fully closed.
5. Start the pump.
6. Open the delivery valve slightly. Observe the pressure gauge readings.
7. Measure the discharge using the collecting tank stopwatch setup.
8. Note the time for n revolutions of the energy meter disk.
9. Open the delivery valve gradually to maximum.
10.Repeat the above observations for different discharges.
11.Tabulate the readings. Draw the performance characteristics; H Vs. Q, PI/P Vs. Q
and η Vs. Q.
Observations:
1. Size of the collecting tank, l = 400 mm; b = 300 mm
2. Energy meter constant, N = 3200 rev / kWH
3. Difference in the levels of pressure and vacuum gauges, z = 0.4 m.
Observation Table
Sr. Pressure gauge Vacuum gauge Time for 50mm Time for 10
No. reading, (kg/cm2) reading, (mm of rise in collecting pulses in energy
Hg) tank, t (sec) meter, T (sec)
1.
2.
3.
4.
5.

Calculation Table
Time
Pressure Vacuum Time for for 10
gauge gauge Total 50mm pulses Actual
Output Input Efficiency,
Sr. reading, reading, Head, rise in in Discharge,
Power, Power, η
No. Hg Hv H collecting energy Qa
(kW) (kW) (%)
(m of (m of (m) tank, t meter, (m3/s)
water) water) (sec) T
(sec)
1.
2.
3.
4.
5.
Mean Efficiency

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Lab Manual Hydraulics & Pneumatic Machines Version 2.0 17

Model Calculations:
1. Actual discharge : Q = AR/t = ________ m3/s Where
A: Cross-sectional area of collecting tank = l * b =0.4 x 0.3 = 0.12 m2
R: Rise of water column in collecting tank in meters = 50 mm = 0.05 m
t: Time taken for 50 mm rise of water column in seconds
Q =__________ m3/s
2. Pressure gauge reading in metres of water column (Hg)
1 kg/cm² = 10 m
Pressure Head = ____ kg/cm² x 10 = ______ meters.
____  ∗.
3. Vacuum Head = m

4. Datum head = Distance between pressure and vacuum gauge in meters, z
5. Total head ( H ) = Pressure Head (Hg) + Vacuum Head (Hv) + Datum Head (z)
6. Output of the pump, (O/P)
.∗!" ∗#
  = kW

where w= weight density of water = 9810 N/m3

&∗∗.
$%  = kW
'∗(
Where,
n= Number of revolutions of energy meter = 10
N= Energy meter constant rev/ kWh = 3200
T= Time for ‘n’ revolutions of energy meter in sec.
0.6 = combined motor (0.75) and transmission losses (0.8).
9. Overall efficiency (η)= Output power/Input power in %

Graph:
Discharge (x-axis) Vs Head (y-axis)
Discharge (x-axis) Vs Input power (y-axis)
Discharge (x-axis) Vs Efficiency (y-axis)

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Lab Manual Hydraulics & Pneumatic Machines Version 2.0 18

Result:
1. The performance or characteristic curve of the pump provides information on
the relationship between total head and flow rate.
2. From the experiment, we know variables in the pump are the head ( h ), brake
horsepower (bhp) and the efficiency (η). The efficiency depends upon the size
of machine and hence, the capacity handled.
3. The larger the machine, the higher is the efficiency.
4. As the speed of pump increases, the torque (T) increases, followed by the
brake horse power (bhp) and also the volume flow rate (Q). Since the pump
speed increase, the head value of the pump will also increase.
5. The efficiency of the pump was found to be __________%.

Review Questions:

1. What is priming? Statethe use of foot valve.


2. Define the term: manometric head, NPSH, Hydraulic efficiency.
3. What is the function of the casing used in centrifugal pump?
4. What is the minimum starting speed of a centrifugal pump?
5. ‘The centrifugal pump should be so installed above the water level in the sump’
Justify.
6. What is meant by a Roto-dynamic machine?
7. What energy is converted in a pump?
8. What type of fluids are pumped by centrifugal pumps?
9. What are the pumping characteristics of a centrifugal pump?

Applications:
The most commonly used pumps for domestic, agricultural and industrial purposes are
Centrifugal pumps.
These pumps fall into the main class, namely, Rotodynamic pumps.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 19

Experiment No.: 3

Aim: To determine the efficiency of reciprocating pump.

Model:

Fig. Reciprocating pump with air vessel


Principle:
Reciprocating pump is a positive displacement pump, which
which causes a fluid to move by
trapping a fixed amount of it then displacing that trapped volume into the discharge
pipe. The fluid enters a pumping chamber via an inlet valve and is pushed out via a
outlet valve by the action of the piston or diaphragm. They are either single acting;
independent suction and discharge strokes or double acting; suction and discharge in
both directions.

Reciprocating pumps are self priming and are suitable for very high heads at low flows.
They deliver reliable discharge flows and is often used for metering duties because of
constancy of flow rate. The flow rate is changed only by adjusting the rpm of the
driver. These pumps deliver a highly pulsed flow. If a smooth flow is required then the
discharge flow system has to include additional features such as accumulators. An

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 20

automatic relief valve set at a safe pressure is used on the discharge side of all positive
displacement pumps.

Procedure
1. Check the pressure gauges. Make sure both of them show atmospheric pressure.
2. Observe the suction and delivery pipe diameters.
3. Measure the dimensions of collecting tank.
4. Measure the difference in elevation between the suction and delivery pressure
tappings.
5. Open the delivery valve fully. Never close this valve below a critical level to
reduce the flow rate. The fluid has no place to go and something will break.
6. Start the pump.
7. Throttle the gate valve to get the required head.
8. Note
a) Pressure gauge (G) and Vacuum gauge (V) readings
b) Time taken for n (=10) revolutions/ pulses of the energy meter (T) in sec.
c) Time taken for R(=0.05m) rise of water in the collecting tank (t) in sec
d). The position (X in meter) of pressure gauge above the vacuum gauge
9. Tabulate the readings. Draw the performance characteristics; H Vs. Q, PI/P Vs. Q
and h Vs. Q.

Tools required: Stop watch, measuring tape, Energy meter etc.

Observations:
1. Size of the collecting tank = lc x bc = 0.30 m * 0.40 m
2. Difference in the levels of vacuum gauge and pressure gauge, z = 0.75 m.
3. Energy meter constant, N = 3200 rev/kwh
Observation Table

Sr. Pressure gauge Vacuum gauge Time for 50mm Time for 10
No. reading, (kg/cm2) reading, (mm of Hg) rise in collecting pulses in energy
tank, t (sec) meter, T (sec)
1.
2.
3.
4.
5.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 21

Calculation Table
Time
Pressure Vacuum Time for for 10
gauge gauge Total 50mm pulses Actual
Output Input Efficiency,
Sr. reading, reading, Head, rise in in Discharge,
Power, Power, η
No. Hg Hv H collecting energy Qa
(kW) (kW) (%)
(m of (m of (m) tank, t meter, (m3/s)
water) water) (sec) T
(sec)
1.
2.
3.
4.
5.
Mean Efficiency

Model Calculations:
1. Actual discharge : Q = AR/t = ________ m3/s Where
A: Cross-sectional area of collecting tank = l * b =0.4 x 0.3 = 0.12 m2
R: Rise of water column in collecting tank in meters = 50 mm = 0.05 m
t: Time taken for 50 mm rise of water column in seconds
Q =__________ m3/s
2. Pressure gauge reading in metres of water column (Hg)
1 Kg/cm² = 10 m
Pressure Head = ____ Kg/cm² x 10 = ______ meters.
____  ∗.
3. Vacuum Head = 
m
4. Datum head = Distance between pressure and vacuum gauge in meters, z
5. Total head ( H ) = Pressure Head (Hg) + Vacuum Head (Hv) + Datum Head (z)
7. Output of the pump, (O/P)
.∗!" ∗#
  = kW

where w= weight density of water = 9810 N/m3
&∗∗.
$%  = kW
'∗(
Where,
n= Number of revolutions of energy meter = 10
N= Energy meter constant rev/ kWh = 3200
T= Time for ‘n’ revolutions of energy meter in sec.
0.6 = combined motor (0.75) and transmission losses (0.8).
10. Overall efficiency (η)= Output power*100/Input power %

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 22

Graph: Operating characteristics curves

Result:
1. The experiment on Reciprocating Pump was performed. The pump efficiency,
volumetric efficiency and overall efficiency of the pump was calculated.
2. The efficiency of the pump was found to be ___________.

Applications:
1. To drill oil from deep wells.
2. To pump any liquid which is free from debris.

Questions:
1. What is meant by a positive displacement pump?
2. List the types of fluids which are pumped by Reciprocating pumps.
3. What are the pumping characteristics of a Reciprocating pump?
4. Define the term “efficiency” of a Reciprocating pump.
5. State the normal precautions to be taken when operating a pump.
6. State the function of air vessel?

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 23

Experiment No.: 4

Aim: To Study of Basic pneumatic circuit for direct & indirect control of single
and double acting cylinder

Apparatus: - Air tank, filter, compressor, junction box, manually operated, 2x3
D.C. valve single acting cylinder, double acting cylinder, pipes,

Circuit Diagram:

Fig. Direct & Indirect control Single acting pneumatic cylinder


Theory
Connect all components as per above shown fig.high pressurized air enters in
3X2 Valve manually forward positions of lever air enters in cylinder, When lever
operated backward the air exhausted in surrounding through port E due to
force of compressed spring.
Forward motion-Due to pressurized air enters in cylinder.
Backward motion- spring pressure applied on area of piston surface

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 24

Compresso
Compresso

Fil Fil

A Ai B Ai
Fig- Working of single acting cylinder operation
A] In fig. there is return movement of piston due to spring force. So air is
delivered (exhausted) to atmosphere. Here 3x2 direction control valve is used.
The air is exhausted to atmosphere through port 2 to 3.

B] In fig. there is forward movement of piston due to high pressure air. So air
is entered to cylinder. And apply the force on piston surface Here 3x2 direction
control valve is used. The air is entered in cylinder through port 1 to 2.

RESULT:

Thus a single acting cylinder is simulated in the direct & indirect method with
help of direction control valves.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 25

Experiment No.: 5

Aim: To Study of Basic pneumatic circuit for direct & indirect control of double
acting cylinder

Apparatus: - Air tank, filter, compressor, junction box, manually operated, 2x3
D.C. valve single acting cylinder, double acting cylinder, pipes,

Circuit Diagram:

Direct Control of double acting Indirect Control of double acting


pneumatic cylinder pneumatic cylinder

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 26

Theory:

In above pneumatic circuit we have used 4x3 D.C. valves. The valve is
having four ports Port 1 is connected to compressor
Port 3 is relieved to atmosphere through muffler.
Port 4 & 2 are connected to pneumatic cylinder
Forward position - At forward movement of piston, port 1 is connected to port 4
and port 2 is connected to port 3
Retract position - At reverse movement of piston, port 1is connected to port 2
and port 4 is connected to port 3
Procedure
1] Switch on the compressor to store high pressure air.
2] Connect the pipes as per circuit shown above.
3] Connect air reservoir to junction box
4] Check pressure level in tank to be full shown by indicator
5] Observe the reciprocating motion of Single acting and double acting cylinder.
6] Observe the rotary motion of hydraulic motor.

Applications- used in industries for fitting the component of job.

RESULT:
Thus a double acting cylinder is simulated in the direct & indirect method with
help of direction control valves.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 27

Experiment No.: 6

AIM: - To study of various pneumatic circuits of double acting cylinder using


pneumatic direction control valves.

THEORY: -
INTRODUCTION
A double acting cylinder is to advance when a push button is operated. Upon
release of the push button the cylinder is to retract. The cylinder is 250 mm in
diameter and consumes a large volume of air. Draw the circuit diagram for the
problem. Designate the valves and indicate the numbering system for the connections.
For controlling cylinders at high speed or of large diameter, the air flow required
determines that a large size control valve
should be used. The operating force to actuate
the valve may be relatively large and in this
case indirect control is preferable.
4/2-way or 5/2-way direction control
valve controls the double acting cylinder if the
piston is not to be stopped in between and 4/3
way or 5/3 way direction control valve controls
the cylinder in which the piston can be stopped
anywhere required.
A signal is generated or reset on the
valve, if a push button actuator is pressed or
released. The circuit includes:
• Supply air source(Compressor)
• Air connections among supply,
• FRL Unit for conditioning of air
• Double acting cylinder
• 4/2-way/5/2-way/4/3-way/5/3-way
directional control valve: push button
and lever for operation and spring for
return force
• Adjustable Non return flow control valves for speed control(throttling out)
• Fluid Lines

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 28

Speed Control of Single Acting Speed Control of Double Acting Cylinder


Cylinder

Automatic To & Fro motion of a Double Acting Use of Quick Exhaust Valve
Cylinder

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 29

4/2 Roller Operated Valve In Sequence


Pneumatic Motor Circuit

Sequence Circuit

RESULT:
Thus various pneumatic circuits are prepared and operated for double acting
cylinder with help of direction control and other valvesvalves.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 30

Experiment No.: 7
Aim- Perform Basic hydraulic circuit for the working of double acting cylinder
and a hydraulic motor.

Apparatus: - Oil tank, filter, pump, manually ope


operated,
rated, 4x3 D.C. valve, double
acting cylinder, hoses, hydraulic motor

Theory:
This system could be used for
positioning a work table or other
machine element. Direction of cylinder
cyli
movement is controlled by shifting the
handle of direction control valve #7.
When shifted to left, oil flows from the
pump (#1) through the valve, P to A
and to the cap end of cylinder #12,
causing the cylinder rod to extend. Oil
from the rod end of tthe cylinder flows
back through the four-way
four directional
valve, B to T, and to the reservoir.

Type: Basic Hydraulic Circuit (Linear)


Operation: Extend, Retract and Stop

When the handle of the valve is shifted to the right, oil from the pump is
directed through the valve, P to B, and to the rod end of the cylinder, causing
the rod
d to retract. Discharged oil from the cap end of the cylinder is directed
back to the reservoir through the directional valve, A to T.
When the cylinder rod reaches either end of its stroke, pressure in the
system will build up to the setting of relief valve
valve #2. The relief valve will then

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 31

open and by-pass


pass the pump’s volume back to the reservoir, while at the same
time holding pressure on the cylinder equal to the relief valve setting.
In the neutral position (as shown), cylinder port A and B of the directional
directio
valve are blocked and pressure port P is open to tank. Oil is trapped between
the cylinder and directional valve, thus preventing any cylinder movement.
However, oil delivered by the pump can flow freely through the directional
valve, P to T, and back to the reservoir. This unloads the pump at little or no
pressure.
At the ends of the stroke, there is no system demand for oil. Thus, the pump
flow goes through the relief valve at its pressure level setting unless the four-
four
way valve is deactivated.
Hydraulic motor:
1. When the 4/3 valve is in its neutral
position (tandem design), the
hydraulic motor is hydraulically
locked and the pump is unloaded
back to the tank.
2. When the 4/3 valve is actuated
into the flow path, the hydraulic
motor is rotates clockwise direction
against its load as oil flows from
port P through port A. Oil in the
hydraulic motor is free to flow back
to the tank through the four-way
four
valve from port B through port T.
3. When en the 4/3 valve is actuated
into the right-envelope
right
configuration, the motor rotates
anticlockwise direction as oil flows
from port P through port B. Oil in
the blank end is returned to the
Fig- Working of double acting cylinder tank via the flow path from port A
and hydraulic motor Connections to port T.

Hence we get rotary


ry motion of hydraulic motor in form of mechanical energy

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 32

Procedure
1. Switch on the three phase connection given to Induction motor
2. Rotate pressure relief valve anticlockwise direction for two minutes
3. By observing the pressure gauge of pressure line adjust pressure between
12 to 15 kgf/cm²
4. Check oil level in tank to be full shown by indicator
5. Observe the reciprocating motion of double acting cylinder and hydraulic
motor by varying the Pressure, using pressure knob.
6. Observe the rotary motion of hydraulic motor.

Observations- Observe the reciprocating motion of double acting cylinder and


hydraulic motor by varying the Pressure, using pressure knob.

Applications - Used in for fitting of screw, assemble screwed parts

RESULT:
Thus basic hydraulic circuit is connected & operated for a double acting
cylinder, single cylinder and hydraulic motor with help of direction control
valves.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 33

Experiment No.: 8

Aim- To Study of Speed control circuits. Different Metering methods Inlet


& outlet flow control (meter
(meter-in& meter-out circuit)

Apparatus: - Air tank, filter, compressor, junction box, manually


operated, 2x3 D.C. valve single acting cylinder, double acting cylinder,
pipes,
Components of Meter in hydraulic
circuit- hydraulic cyl
cylinder,flow control
check valve, 4X3 D.C. valve, pressure
relief valve,oil tank, hoses for
connections
Procedure
1] Switch on the three phase
connection given to Induction motor
2] Rotate pressure relief valve
anticlockwise direction for two minutes
3] By observing
bserving the pressure gauge of
pressure line adjust pressure between
Fig Meter in speed control circuit 12 to 15 kgf/cm²
4] Check oil level in tank to be full
shown by indicator

When the DCV is deactivated, the


cylinder retracts as oil from the
cylinder
nder passes through the check
valve. Thus, the retraction speed of a
cylinder is not controlled. Figure
shows meter-outout circuit; when DCV is
actuated, oil flows through the rod
end to retract the cylinder.

Fig - Meter out speed control circuit

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 34

Theory:

The speed control of a hydraulic cylinder circuit can be done during the
extension stroke using a flow-control valve (FCV). This is done on a meter-in
circuit and meter-out circuit as shown in following figures.
When the Direction Control Valve is actuated, oil flows through the FCV to
extend the cylinder.
The extending speed of the cylinder depends on the FCV setting.

Meter-In Versus Meter-Out Flow-Control Valve Systems


FCV is placed in the line leading to the inlet port of the cylinder. Thus, it
is called the meter-in control of speed. Meter-in flow controls the oil flow rate
into the cylinder meter-out flow control system is one in which the FCV is
placed in the outlet line of the hydraulic cylinder. Thus, a meter-out flow control
system controls the oil flow rate out of the cylinder. Meter-in systems are used
primarily when the external load opposes the direction of motion of the
hydraulic cylinder. When a load is pulled downward due to gravity, a meter-out
system is preferred. If a meter-in system is used in this case, the load would
drop by pulling the piston rod, even if the FCV is completely closed.

One drawback of a meter-out system is the excessive pressure build-up in the


rod end of the cylinder while it is extending. In addition, an excessive pressure
in the rod end results in a large pressure drop

Applications- Used in shaper tool

RESULT:
Thus basic hydraulic circuit is connected & operated for a double acting
cylinder, single cylinder and hydraulic motor with help of direction control
valves.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 35

Experiment No.: 9

Aim- To Study of Hydraulic


ydraulic Counter
Counter-balancing circuit.
Components required
required:: hydraulic cylinder, direction control valve, pump,
pressure relief valve, oil tank, Counter balance valve

Procedure
1] Switch on the three phase connection given to Induction motor
2] Rotate pressuree relief valve anticlockwise direction for two minutes
3] By observing the pressure gauge of pressure line adjust pressure between
12 to 15 kgf/cm²
4] Check oil level in tank to be full shown by indicator

Fig –Working
Working circuit of Counterbalance

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 36

Theory:
A counterbalance valve is applied to create a back pressure or
cushioning pressure on the underside of a vertically moving piston to prevent
the suspended load from free falling because of gravity while it is still being
lowered.

Valve Operation (Lowering)


The pressure setting on the counterbalance valve is set slightly higher
than the pressure required preventing the load from free falling. Due to this
back pressure in line A, the actuator piston must force down when the load is
being lowered. This causes the pressure in line A to increase, which raises the
spring-opposed spool, thus providing a flow path to discharge the exhaust
flow from line A to the DCV and then to the tank. The spring-controlled
discharge orifice maintains back pressure in line A during the entire
downward piston stroke.

Valve Operation (Lifting)


As the valve is normally closed, flow in the reverse direction (from port
B to port A) cannot occur without a reverse free-flow check valve. When the
load is raised again, the internal check valve opens to permit flow for the
retraction of the actuator.

Valve Operation (Suspension)


When the valve is held in suspension, the valve remains closed.
Therefore, its pressure setting must be slightly higher than the pressure
caused by the load. Spool valves tend to leak internally under pressure.

This makes it advisable to use a pilot-operated check valve in addition to the


counterbalance valve if a load must be held in suspension for a prolonged
time.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 37

Experiment No.: 9 A
Aim – Study of Hydraulic
ulic or Pneumatic Regenerative circuit.

Components required
required:: hydraulic cylinder, direction control valve, pump,
pressure relief valve, oil tank.
tank
Figure shows basic concept of a regenerative circuit that is used to speed up
the extending speed of a double-acting
doubl cylinder.

Procedure
1] Switch on the three phase connection given to Induction motor
2] Rotate pressure relief valve anticlockwise direction for two minutes
3] By observing the pressure gauge of pressure line adjust pressure between
12 to 15 kgf/cm²
4] Check oil level in tank to be full shown by indicator

Figure connection of a regenerative circuit


Theory:
Figure shows a regenerative circuit that is used to speed up the
extending speed of a double
double-acting
acting cylinder. The pipelines to both ends of th
the
hydraulic cylinder are connected in parallel and one of the ports of the 4/3
valve is blocked by simply screwing a thread plug into the port opening.
During retraction stroke, the 4/3 valve is configured to the right envelope.
During this stroke, the pum
pumpp flow bypasses the DCV and enters the rod end
of the cylinder. Oil from the blank end then drains back to the tank through
the DCV.

Applications- used in industries for saving energy required for machining


operations.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 38

Experiment No.: 9 B
Aim - Study
y Hydraulic or Pneumatic Sequencing circuit.

Fig. Working Sequencing


circuit

Components required-
required
Hydraulic cylinders, pump,
sequencing valve, 4X3
direction control valve
Hydraulic cylinders can be
operated sequentially using a
sequence valve.

Procedure
1] Switch on the three phase connection given to Induction motor
2] Rotate pressure relief valve anticlockwise direction for two minutes
3] By observing the pressure gauge of pressure line adjust pressure between 12
to 15 kgf/cm²
4] Check oil level in tank to be full shown by indicator
Theory:
Figure shows that two sequence valves are used to sequence the
operation of two double-acting
double acting cylinders. When the DCV is actuated to its
right-envelope
envelope mode, the bending cylinder (B) retracts fully and then the
clamp cylinder (A) retracts.
This sequence of cylinder operation is controlled by sequence valves.

Application - This hydraulic circuit can be used in a production operation


such as drilling. Cylinder A is used as a clamp cylinder and cylinder B as a
drill
ll cylinder. Cylinder A extends and clamps a work piece. Then cylinder B
extends to drive a spindle to drill a hole. Cylinder B retracts the drill spindle
and then cylinder A retracts to release the work piece for removal.
removal

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 39

Experiment No.: 9 C
Aim – Study
dy of Hydraulic Unloading circuit.

Figure shows a hydraulic circuit to unload a pump using an unloading valve

Components required:
required
hydraulic cylinder, direction
control valve, pump, pressure
relief valve, oil tank, and
unloading valve.

Procedure
1] Switch on the three phase connection given to Induction motor
2] Rotate pressure relief valve anticlockwise direction for two minutes
3] By observing the pressure gauge of pressure line adjust pressure between
12 to 15 kgf/cm²
4] Check oil level in tank
nk to be full shown by indicator

Theory:
When the cylinder reaches the end of its extension stroke, the
pressure of oil rises because the check valve keeps the high-pressure
high oil.
Due to high-pressure
pressure oil in the pilot line of the unloading valve, it opens
and unloads the pump pressure to the tank.

When the DCV is shifted to retract the cylinder, the motion of the
piston reduces the pressure in the pilot line of the unloading valve. This
resets the unloading valve until the cylinder is fully retracted. When this
happens, the unloading valve unloads the pump due to high high-pressure oil.
Thus, the unloading valve unloads the pump at the ends of the extending and
retraction strokes as well as in the spring-centered
spring centered position of the DCV.
Application - This hydraulic circuit can be used in a production operation
such as drilling.
Cylinder A is used as a clamp cylinder and cylinder B as a drill cylinder

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 40

Experiment No.: 9 D
Aim- Study of hydraulics and Pneumatics circuit, based on the industrial
application

Theory: Hydraulic shaping machine


A shaping machine is also called shaper is mainly used for producing
flat surfaces, which may be horizontal, vertical or inclined. Sometimes curved
or irregular surfaces are also produced by shapers

In past years, Conventional mechanical shaper machine is used in


industries. In this shaper machine gear arrangement is used to give liner
motion to the machine tool towards to the work piece. The work piece
mounts on a rigid, box shaped table in front of the machine. The height of
table can be adjusted suitable to the work piece. In all shaper machine
cutting stroke is controlled and return stroke is fast, this can be done by a
mechanism which is named as ‘whit worth quick return mechanism’. In
conventional shaper machine stroke length can be adjusted by shaper dogs.

In modern era, whole mechanical shaper machine is replaced by


hydraulic shaper machine due its ease operation and reliability In this
modern shaper machine whole construction is same, but method of actuation
is changed. The gear arrangement is totally replaced by a double acting
hydraulic cylinder. Hydraulic cylinders are the device which uses hydraulic
energy to achieve mechanical movement i.e. linear. A machine tool is used as
per application

For example producing v slots v shape tool is used in this hydraulic


shaper machine quick return is achieved by placing flow control valve and
check valve in return line.

The following component are used for hydraulic shaper machine


In which following parts are used.
• Double acting cylinder
• 4/3 Direction control valve
• Pressure relief valve
• Filter
• Gear pump
• Hoses and fitting

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 41

Fig. Meter out circuit for shaping machine

Generally Meter out circuit is used for hydraulic shaper machine. Meter
out circuit is as shown in fig below.

It consists of pneumatic cylinder, compressor, solenoid valve, electric


control unit, forging hammer and table.
Fig. shows schematic block diagram
of pneumatic forging machine.

Air is compressed by compressor,


this high pressure air tthrough
direction control valve goes inside
the pneumatic cylinder causing
upward and downward movement
of piston.

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 42

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Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77


Lab Manual Hydraulics & Pneumatic Machines Version 2.0 43

Department of Mechanical Engg. K. J. Somaiya Polytechnic, Mumbai -77

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