ME8694 - HYDRAULICS AND PNEUMATICS

By,

Arulprakasam G
Assistant Professor
Dept.of.Mech.Engg.,
KIT-CBE.

HYDRAULICS AND PNEUMATICS

 ME8694 - HYDRAULICS AND PNEUMATICS

OBJECTIVES: L T P C
3 0 0 3

To provide student with knowledge on the application of fluid power in process,
construction and manufacturing industries.
To provide students with an understanding of the fluids and components utilized
in modern industrial fluid power system.
To develop a measurable degree of competence in the design, construction and
operation of fluid power circuits.

HYDRAULICS AND PNEUMATICS

 ME8694 - HYDRAULICS AND PNEUMATICS

UNIT V
TROUBLE SHOOTING AND APPLICATIONS

Installation, Selection, Maintenance, Trouble Shooting and Remedies in Hydraulic and Pneumatic
systems, Design of hydraulic circuits for Drilling, Planning, Shaping, Surface grinding, Press and
Forklift applications. Design of Pneumatic circuits for Pick and Place applications and tool handling
in CNC Machine tools – Low cost Automation – Hydraulic and Pneumatic power packs.

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS
TROUBLE SHOOTING AND MAINTENANCE:
The following is a list of the most common causes of hydraulic system breakdown:

1. Clogged or dirty oil filters

2. Inadequate supply of oil in the reservoir

3. Leaking seals

4. Loose inlet lines that cause the pump to take in air

5. Incorrect type of oil

6. Excessive oil temperature

7. Excessive oil pressure

 

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

TROUBLE SHOOTING AND MAINTENANCE:

Most of these kinds of problems can be eliminated if a planned preventive
maintenance program is undertaken. This starts with the fluid power designer in the
selection of high-quality properly sized components.
The next step is the proper assembly of the various components. This includes
applying the correct amount of torque to the various tube fittings to prevent leaks and,
at the same time, not distort the fitting.
 Parts should be cleaned as they are assembled, and the system should be
completely flushed with clean oil prior to putting it into service.
It is important for the total system to provide easy access to components
requiring periodic inspection such as filters, strainers, sight gages, drain and fill plugs,
flow meters, and pressure and temperature gages.
Over half of all hydraulic system problems have been traced directly to the oil.
This is why the sampling and testing of the fluid is one of the most important
preventive maintenance measures that can be undertaken.

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

TROUBLE SHOOTING AND MAINTENANCE:

A hydraulic fluid test kit, which provides a quick, easy method to test for
hydraulic system contamination. Even small hydraulic systems may be checked.
The test kit may be used on the spot to determine whether fluid quality permits
continued use. Tests that can be performed include the determination of viscosity,
water content, and particulate contamination level.
Viscosity is measured using a visgage viscosity comparator. Water content is
determined by the hot plate method.
Contamination is evaluated by filtering a measured amount of hydraulic fluid,
examining the particles caught on the filter under a microscope, and comparing what is
seen with a se ries of photos indicating contamination levels.
The complete test requires only approximately 10 min.
It is vitally important for maintenance personnel and machine operators to be
trained to recognize early symptoms of potential hydraulic problems.

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

TROUBLE SHOOTING AND MAINTENANCE:

For example, a noisy pump may be due to cavitation caused by a clogged inlet
filter. This may also be due to a loose intake fitting, which allows air to be taken into
the pump.
If the cavitation noise is due to such an air leak, the oil in the reservoir will be
covered with foam. When air becomes entrained in the oil, it causes spongy operation
of hydraulic actuators.
A sluggish actuator may be due to fluid having too high a viscosity. However, it
can also be due to excessive internal leakage through the ac Customer or one of its
control valves.
Proper maintenance procedures for external oil leaks are also essential. Safety
hazards due to oil leaking on the floor and around machinery must be prevented.
In some process industries, external oil leakage is prohibitive because of
contamination of the end product.

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

TROUBLE SHOOTING AND MAINTENANCE:

Loose mounting bolts or brackets should be tightened as soon as they are
detected because they can cause misalignment of the shafts of actuators and pumps,
which can result in shaft seal or packing damage.
A premature external oil leak can occur that will require costly downtime for
repair.
Environmental rules and regulations have been established concerning the
operation of fluid power systems. The fluid power industry is responding by
developing efficient, cost-effective ways to meet these regulations, which deal with the
following four issues:
1. Developing biodegradable fluids
2. Maintaining and disposing of hydraulic fluids
3. Reducing oil leakage
4. Reducing noise levels

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

DRILLING & FORK LIFT CIRCUIT : (A+B+B-A-)

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

ACCUMULATOR AS AUXILIARY POWER SOURCE :

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

ACCUMULATOR AS LEAKAGE COMPENSATOR:

HYDRAULICS AND PNEUMATICS

 UNIT V - TROUBLE SHOOTING AND APPLICATIONS

ACCUMULATOR AS SHOCK ABSORBER :

HYDRAULICS AND PNEUMATICS