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Grade“Resub” P ” repeat unit” P ” repeat unit”

Student Name: ID Number

Eslam Mohamed Abdallah Abdrabu 17
Unit Number and
29 Electro Pneumatic and hydraulic systems
Title:
Qualification Pearson BTEC Level 5 Higher National Diploma in Engineering (Mechanical) RQF (Y1)

Academic Year: 2020/2021 Assessor Name: Dr. Mohamed Sokar

Assignment Design and maintenance of pneumatic Internal Verifier Eng. Huda A. Farahat
Title: and hydraulic systems Name:
Assignment 14/3/2021
2 Issue Date:
No.
Submission Format: Submission 20/3/2021
Type of Evidence
Report Date:

STUDENT DECLARATION
Plagiarism
Plagiarism is a particular form of cheating. Plagiarism must be avoided at all costs and students who break the rules,
however innocently, may be penalised. It is your responsibility to ensure that you understand correct referencing
practices. As a university level student, you are expected to use appropriate references throughout and keep
carefully detailed notes of all your sources of materials for material you have used in your work, including any
material downloaded from the Internet. Please consult the relevant unit lecturer or your course tutor if you need
any further advice.
Student Declaration
Student declaration
I certify that the assignment submission is entirely my own work and I fully understand the consequences of
plagiarism. I understand that making a false declaration is a form of malpractice.

Also, I acknowledge that I have received the feedback about my work from the assessor.
Student signature: ESLAM Date: 20 /3/2021

FORMATIVE FEEDBACK

Assessor’s Formative Feedback: Confirm action completed:

Assessor Signature: Date: /3/2021

IV assessment brief approval

IV’s signature: Date: /3/2021

Prepared by: Ameeria ITEC based on BTEC guidance/ Ref, Approved by: QAU
Version 3.0 – February 2020
Learning Outcomes and Assessment Criteria:
Learning
Pass Merit Distinction
Outcome
3-Examine the P6: Investigate and analyse the M3: Justify the D3: Evaluate the design
applications of design and function of a simple measures taken to modifications that can
pneumatic hydraulic or pneumatic system improve circuit design be introduced to
and hydraulic in a production environment. in respect of improve the
systems. performance. functionality and
P7: Define the purpose and maintenance of
function of electrical control pneumatic and
elements in a given hydraulic hydraulic systems
or pneumatic system. without creating
reliability issues.
P8: Recognise system faults M4: Compare D4: Evaluate the
4-Investigate and potential hazards in construction and importance of
the pneumatic and hydraulic operation of hydraulic maintenance,
maintenance systems. and pneumatic systems inspection, testing and
of pneumatic P9: Determine regular testing with regards to fault finding in respect
and hydraulic procedures to ensure efficient legislation and safety of improved system
systems. maintenance of pneumatic and issues. performance.
hydraulic systems.

Page 1 of 5
Assignment Brief and Guidance:

Scenario
Hydraulic and pneumatic power systems have a lot of importance in
engineering applications, they are widely used from simple hand tool till giant
heavy equipment and production lines. In production line, there are many
sequential control applications using pneumatics and hydraulics.
Imagine that you are working as a senior technician in MCV Automotive Co.
that has some sequential control systems to move spare parts, one is
automatically controlled by mechanical limit switches and the other is
controlled by electro-pneumatic one. If you are a member of the operation
team, where your task is to design and produce circuit diagram and
investigate system operation.
During your work in this company and with the help of your knowledge in the
fundamentals of electro-pneumatic and -hydraulic circuits design you are also
asked by a colleague to help him in modifying circuit, design, and analysis
and investigate the design and function of hydraulic and pneumatic circuits
and try to solve some troubleshooting problems related to equipment that
uses hydraulic or pneumatic systems.

Page 2 of 5
Task 1
In a new production line, a pneumatic sequence system as shown in Fig. 1 will be
implemented to move boxes containing spare parts. The compressor supply pressure and
flow rate are 6 bar, 30 litter/min respectively. If the weight of each product is 600 N,
which assumed to move without friction.
The required sequence of operation is as flows, cylinder (A) should first extend to supply
the products from the magazine (product holder) to the line tray and stay in place. Cylinder
(B) is responsible for delivering the products to the final packaging by extension and forcing
the product to the packaging section. After the product is delivered, cylinder A retracts first,
and cylinder B follow it in sequence. Consider the technical specification of FESTO
standard cylinders model DNC, ISO15552 is given in the Table 1. Assume the stroke of
cylinders is 400 mm.

Fig. 1: Pneumatic sequence system

Table 1: Technical specification of FESTO DNC, ISO15552 cylinders

Page 3 of 5
The design of the multi-actuator sequential system must include two cylinders A and B.
Investigate your proposed pneumatic circuit design and sequential function of the above
given industrial application by drawing the step motion diagram of cylinders A and B,
consider in your investigation the selection of the components (i.e. single acting or double
acting cylinder, DCV 4/2, 4/3, 5/3 …etc ), Also analyse the design and function of the
system using FluidSim software by inserting state diagram to check the position movements
of the cylinders, the position of elements that should be used in order to control the
sequential function (i.e. limit switches position), and consider also the required diameter to
move the product to be in the range of technical specification of FESTO DNC, ISO15552.
- The sequential system shown Fig. 1, can be designed by electro-pneumatic control circuit
as shown in Fig. 2. Define the aim and function of the following control elements (Push
button S1, Relay K1 and proximity switches 2B1) used in the circuit.
2B1 2B2
1B1 1B2

Designation 14 15 16 17 18
1

1B3

100
80

1A1 60
40
20

100
80
1M1 2A1 60
40

20

+24V 1 2 3 4 5 7 9 10 11 12 13

BN BN
13 14 14 14 14
4 4
BK BK S1 K1 K2 K4 K1
2B1 2B2 1B3

Fig. 2 Electro-pneumatic circuit of the sequential system

- Justify which model size 40, 50, 80 of FESTO DNC will improve the performance in
order to give minimum cycle time to perform the required sequence. You should consider
the performance curves (position, velocity, and pressure) for each size of the multi- actuator
sequential system by using FluidSim software.
Hint:  Inserting state diagram to plot the performance curves
 Use print screen function to indicate the cycle time in each case.
Page 4 of 5
- Modify the design of the electro-pneumatic circuit shown in Fig. 2 by adding some
elements that allow the sequence to repeat unless off switch is pressed and add also
emergency stop. Then evaluate the modification performed on the functionality of the
system by drawing state flow diagram and then get valid conclusion.
- Then evaluate the effect of the above-mentioned modification on service
maintenance that should be performed on the pneumatic without affecting reliability
of the units.
Task 2
(2-A) The hydraulic drill press machine can be designed by an electro-hydraulic circuit
shown as shown in Fig. 3 is used to punch sheet metal. Modify the design of the electro-
hydraulic circuit shown by adding some elements that allow the sequence to repeat unless
off switch is pressed and add also emergency stop. Evaluate the modification performed
on the functionality of the circuit and get valid conclusion by drawing state flow diagram.
Then evaluate the service maintenance that should be performed on the hydraulic system
without affecting reliability issues.
A1

+24V 1 3 4

Fig. 3 Hydraulic press and its electro-hydraulic circuit

(2-B) Recognise common faults and potential hazards that occur in the pneumatic and
hydraulic systems shown in Fig. 2 and Fig. 3, or any similar systems.
(2-C) Determine the regular inspection and testing procedure done on the pneumatic and
hydraulic systems shown in Fig. 2 and Fig. 3, or any similar systems to guarantee efficient
maintenance of pneumatic and hydraulic systems in order to work out of failures. (2-D)
Legislation and safety issues is considered in both hydraulic and pneumatic systems.
Compare the construction (such as power unit components, safety valve, range of
conductors or hoses, weight of the components . . . etc.) and compare the operation (range
of pressure, velocity control, moving speed of actuators) considering legislation and safety
issues (i.e. relevant health and safety requirements for the design, installation, and the use
of the system).
(2-E) Evaluate the necessities of maintenance, inspection, testing, and fault finding to
improve hydraulic drill press system performance.

Page 5 of 5
Higher Nationals - SummativeAssignmentFeedbackForm

Student Name Student ID

Unit Title Electro Pneumatic and hydraulic systems

Assignment Number 2 Assignment Title Design and maintenance of pneumatic and
hydraulic systems
Assessor Summative Feedback: Feedback should be against the learning outcomes and assessment criteria to
help students understand how these inform the process of judging the overall grade. *should be constructive and useful
including:
- Feedback should give full guidance to the students on how they have met the learning outcomes and assessment criteria

a) Strengths of performance

b) Limitations of performance

c) Any improvements needed in future assessments

Assessor Signature: Date: /3/2021

Actual Date Received

Re-submission Date /3/2021 /3/2021
Re- submission
Resubmission Feedback:
*Please note resubmission feedback is focussed only on the resubmitted work

Assessor Signature: Date: /3/2021

Internal Verifier’s Comments:

Signature: Date: /3/2021

* Please note that grade decisions are provisional. They are only confirmed once internal and external moderation has
taken place and grades decisions have been agreed at the assessment board.

Summative Assignment Feedback Form

Prepared by: Ameeria ITEC based on BTEC guidance/ Ref, Approved by: QAU
Investigate and analyse the design and function of a simple hydraulic or
pneumatic system in a production environment.
Component list:

NO Componet Number

1 Throttle valve 4

2 compressor 1

3 Duble acting cylinder 2

4 Direction control valve 5/2 penumatic 2

5 Direction control valve 3/2 ( mechincal roller) 4

normaly closed

6 Manul Direction control valve 3/2 normaly 4

closed .spring return
The circuit:
B0 B1
A0 A1

B
A

4 2 4 2

5 3 5 3 2
1 2 1
2
A0
2 A1
B0 1 3
1 3
1 3
B1

2 1 3

1 3

Designation Quantity v alue 0 1 2 3 4 5 6 7 8 9 10

Position 100
A 50
mm
Position 100
B 50
mm
Switching position a

0
Switching position a

0
Switching position a

0
Switching position a

0
Switching position a

Explain the circuit:

1- open the Manual Direction control valve 3/2 normally closed .spring return

2- There is signal make pass to (1-3/2) DCV from- B0- when push on the push button of Manual Direction control valve
3/2.

3- the Cylinder A will be move to forward position when there is signal in the other side of (1-3/2) DCV

4-when it will able to move the -A1 - signal will be generating a limit switch that will be passing to (2-3/2) DCV when
Cylinder A fully his sequence then Cylinder B will go to forward position

5- B1 signal will be generate a limit switch that will be passing to (1-3/2 ) DCV when Cylinder B fully his sequence and
then the A0 will be pressed and Cylinder A will be return to the place it

6- A0 signal will be generate a limit switch that will be passing to (2-3/2 ) DCV when Cylinder A fully his sequence then
Cylinder B will be return to the place it.
Define the purpose and function of electrical control elements in a given
hydraulic or pneumatic system:
Function of push button
push buttons are used with electric circuits; Push buttons allow us to power the circuit or make any particular
connection only when we press the button. They are used to switch devices on and off, for example light switches.

Function of Relay
Relays are the switches which aim at closing and opening the circuits electronically as well as electromechanically. It
controls the opening and closing of the circuit contacts of an electronic circuit. The relays perform two basic functions,
such as high voltage application and low voltage application. In the case of high voltage, arcing is reducing while in the
low voltage applications, overall circuit noise is reducing to a minimum.
Function of proximity switches
proximity switch is one detecting the proximity of some object. By definition, these switches are non-contact
sensors, using magnetic, electric, or optical means to sense the proximity of objects. proximity switches are
often used instead of direct-contact limit switches , with the advantage of never wearing out over time due to
repeated physical contact

direction control valve 3/2 (mechanical roller) Normally closed

direction control valve 3/2 (mechanical roller) Normally closed (NC) 3 way valves block the path between the
inlet and outlet ports until the coil is energized. The outlet port is connected to the exhaust port when de-
energized and this path becomes blocked once the coil is energize . the operat is The two states of the valve
are open and closed. When the valve is open, air flows from the inlet (P, 1) to the outlet (A, 2). When the
valve is closed, air flows from the outlet (A, 2) to the exhaust (R, 3). A valve that is closed in non-actuated
state is normally closed (N.C.), the opposite is called normally open (N.O.).
Recognise system faults and potential hazards in pneumatic and
hydraulic systems.
faults of pneumatic system
1-Pressure Loss

Most often, pressure is lost between the distribution header pipe and the compressed air powered
equipment. All end-use components in-between – connectors, filters, hoses and regulators – should be of an
appropriate size to prevent pressure loss.

2-Leaks

Small leaks in compressed air systems are common but cause significant loss of energy.

3-Over-pressurisation

Excessive pressurisation may be a result of user error, overcompensation due to unidentified leaks in the
system, a shortage of storage or poor pressure control
4-High temperature

Overheating may result in pipelines bursting and system failure

5-Dirty or damaged filter

It leads to the appearance of impurities inside the air pipes and the air pipes are clogged

6-The directional control valve does not change direction

System malfunction and not functioning well

faults of hydraulic system
1-Heat degradation;

Increased fluid temperatures can be the result of the system’s inability to dissipate heat. Heat can cause the fluid to
thin, which prevents proper lubrication and may cause pump leaks,

2-Air contamination

When air bubbles contaminate the fluid, it’s referred to as aeration and results in banging or knocking noises due to
the compression and decompression of the air as it moves through the system.Air also causes wear due to the
implosion of air bubbles under immense system pressure.

3-Water contamination

Water contamination can corrode the pump and other critical components, which can shorten component life.

4-Faulty installations:

Improper installation of any component in a hydraulic system can result in severe errors.
potential hazards of pneumatic system
1- Flying particles and debris: can result in eye injuries and cuts/scrapes or other significant injuries to almost any body
part

2- High pressure air: can result in air injection into the body leading to potential injuries such as air embolism, ruptured
ear drums or organs, and dislodged eye balls.

3- High noise: can result in temporary or permanent hearing loss.

4-Blindness: The pressure from the air can cause very serious injury when it comes in contact with your eyes. The
damage can happen in an instant, and result in permanent blindness.
potential hazards of hydraulic system

1- A hose burst resulting in the release of hydraulic fluid may cause burns to both operators and bystanders in the
immediate vicinity.

2-High pressure oil easily punctures skin causing serious injury, gangrene or death

3- Employee was burned when a hydraulic hose, neglected during maintenance, burst and spewed hydraulic oil, at
normal operating temperature, over his entire body.
Determine regular testing procedures to ensure efficient maintenance
of pneumatic and hydraulic systems:
testing procedures of hydraulic system:
1-The cylinders are operated into the system with appropriate posisteions
2-The valves are operated into the system with appropiate position.
Check the outside of a hydraulic tank
3-Hydraulic analyzers are available with pressure loading valves, pressure gauges (high and low
pressure), flow meters, and temperature gauges to precisely analyze a complex hydraulic system
4-Temperature : The oil should be checked for correct operating temperature to assure accuracy of
the tests that follow.
5-Flow :The flow check determines if the pump is developing its rated output.
6-Pressure : Pressure checks test relief valves for proper operation. In a closed-center system, pressure
checks indicate the operation of the main pump.

7-Leakage :The leakage test isolates leakage in a particular component.

8- Check the oil level and slowly close the tester load valve to load the system. Do not exceed the
system’s rated pressure. Continue loading until the normal operating temperature of the system is
reached.
9-Be sure the tester load valve is OPEN before starting any tests. The load valve can develop
tremendous pressure on a component if it is closed too far
10-Check the oil cooler, is it free of trash and mud: Look closely at the components. Inspect for cracked
welds hairline cracks, loose tie bolts, or damaged linkages. While you inspect, make a note of all the
trouble signs.
11- Ensure that the suction strainer, which is located either in the line between the reservoir and
pump or inside the reservoir, is clean. Restrictions in the pump’s suction line will cause pump
cavitations and loss of high pressure and can cause excessive pump noise and premature wear
Regular inspection of hydraulic system:

NO Name check
1 The cylinders are operated intothe system with
appropriate posisteions

2 The valves are operated into the system with appropiate
position.

3 The oil should be checked for correct operating

temperature
4 The flow check determines if the pump is developing its
rated output
5 The leakage test isolates leakage in a particular component
6 Check the oil level and slowly close
10 Check the oil cooler
11 Check the outside of a hydraulic tank

13 checks test relief valves

14 Check filter before Access to pump.
15 Check the valves of system
testing procedures of pneumatic system:
1-make sure that the valves that were working or not and check the direction.
2-make sure that the air compressor dont be a Small leaks
3-Make sure that the Limit switch is worked
4-make sure that The all valves are worked
5-make sure that the air pressure dont dirty
6-make sure that the air service unit is working
7-make sure the the direction control valves are working with regular
movement

Regular inspection of hydraulic system:

NO Name check
1 check the air compressor

2 check the Limit switch

3 check all valves are

4 check the air pressure

5 Check air service unit

6 Check the direction control valves


7 Check pump flow

8 Check the air regulator 

9 Check the Inspection Pump