Professional Documents
Culture Documents
ASSIGNMENT
To ensure assignment reports are written concisely, the length should be restricted to a limit
indicated in the assignment problem statement. Assignment reports greater than this length may
incur a penalty of one grade (5 marks). Each delegate is required to retain a copy of the
assignment report.
Declaration
The assignment submitted herewith is a result of my own investigations and that I have conformed to the
guidelines against plagiarism as laid out in the PEMP Student Handbook. All sections of the text and
results, which have been obtained from other sources, are fully referenced. I understand that cheating and
plagiarism constitute a breach of University regulations and will be dealt with accordingly.
Signature of the Module Leader and date Signature of Head of the Department and date
ii
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Abstract
___________________________________________________________________________
The fluid power control takes the wide role in all machineries as the industries are
focused on the automation. In the present development in the fluid power controls are
interlinked such as electro pneumatics, hydro pneumatics for the effective usage of the power
and to obtain effective output power. Fluid power systems have the capability to control several
parameters, such as pressure, speed, and position, to a high degree of accuracy at high power
levels and also occupy less space.
In Part-A the debate is about the properties of fluid which should be taken care while
selection of hydraulic oil, were the debate states the bulk modulus is the only factor to be
considered while fluid selection but it is been explained what are the other important factors
which is to be considered while selection of the fluid other than bulk modulus.
The Part-B assignment is about the practical problem were the suitable automation is to
be recommended for the Alex pvt ltd, for the paint mixing process for which the circuit is been
designed and the simulation is checked and the results of the simulation is verified justification
is done for selection of each components used to built the circuit and the calculation of the
hydraulic cylinder force and hydraulic rotary motor force is shown.
In Part-C a hydraulic crane is selected and the hydraulic components used in the
hydraulic cranes were identified the hydraulic circuit of the crane and the mode of actuation of
the different control valves is shown.
iii
Contents
____________________________________________________________________________
Contents
Declaration Sheet ......................................................................................................................... ii
Abstract ....................................................................................................................................... iii
Contents ........................................................................................................................................iv
List of Tables ................................................................................................................................vi
List of Figures ............................................................................................................................ vii
List of Symbols ............................................................................................................................ix
1.0 Introduction: ............................................................................................................................ 1
1.1Stance taken on the debate: ...................................................................................................... 1
1.2 The various criteria involved in fluid selection: ...................................................................... 1
1.2.1 Viscosity (ASTM D445-97): ................................................................................................ 2
1.2.2 Viscosity index (ASTM D2270): ......................................................................................... 2
1.2.3 Pour point: ............................................................................................................................ 2
1.2.4 Flash point and fire point: .................................................................................................... 2
1.2.5 Acid number or neutralization number: ............................................................................... 2
1.6 Case study: .............................................................................................................................. 3
1.7Conclusion:............................................................................................................................... 3
2.0 Introduction to hydraulic circuit: ............................................................................................. 4
2.1 Introduction to the process: ..................................................................................................... 4
2.2Function of actuators in the process: ........................................................................................ 5
2.3Automation model: ................................................................................................................... 6
2.4 Choice of fluid power system with justification: .................................................................... 8
2.4.1 Comparison between Pneumatics and hydraulic fluid power: ............................................. 9
2.4.2 Advantage of hydraulic system over pneumatic system: ..................................................... 9
2.4.3 Advantages of solenoid operated valves: ............................................................................. 9
2.5 Hydraulic circuit design: ....................................................................................................... 10
2.6 Bill of materials: .................................................................................................................... 13
2.7 Hydraulic circuit design: ....................................................................................................... 14
2.8 Function of hydraulic circuit: ................................................................................................ 15
2.9 The simulated hydraulic circuit: ............................................................................................ 16
2.10 Displacement step diagram: ................................................................................................ 17
iv
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
2.11Selection of pump:................................................................................................................ 17
2.12Hydraulic cylinder selection:................................................................................................ 18
2.13 Cylinder and piston material selection: ............................................................................... 18
2.14 Calculations: ........................................................................................................................ 19
2.14.1Finding cylinder force of horizontal and vertical cylinder:............................................... 20
2.14.2 Finding the force of rotary motor: .................................................................................... 21
2.15 Conclusion:.......................................................................................................................... 21
3.0 Selection of heavy duty earth moving equipment: ................................................................ 22
3.1 Introduction to hydraulic system: .......................................................................................... 22
3.2 Hydraulic pump in cranes: .................................................................................................... 23
3.3 Parts of hydraulic truck crane:............................................................................................... 24
3.3.1Boom: .................................................................................................................................. 25
3.3.2 Jib: ...................................................................................................................................... 25
3.3.3 Rotex gear: ......................................................................................................................... 25
3.3.4 Outriggers: .......................................................................................................................... 25
3.4 Mode of actuation of the valves: ........................................................................................... 26
3.5 Hydraulic circuit of hydraulic crane:..................................................................................... 27
4.0 Learning outcome: ................................................................................................................. 31
References ................................................................................................................................... 32
Appendix-1 .................................................................................................................................. 33
Appendix-2 .................................................................................................................................. 35
v
List of Tables
____________________________________________________________________________
<
vi
List of Figures
____________________________________________________________________________
vii
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
viii
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
List of Symbols
____________________________________________________________________________
ix
PART-A
CHAPTER 1
1.0 Introduction:
In the modern industries hydraulic oil has to serve multipurpose. The function of hydraulic
oil is to multiply the forces and provide the energy transmission through the system so as the work
will be done. The hydraulic oil are also responsible for lubrication of sliding parts, heat transfer and
contamination control. The three common types of hydraulic oil available in the market are
i) Petroleum based oils, ii) Water based oils and iii) Synthetic based oils. In the debate while
selecting the hydraulic fluid “Bulk modulus of the fluid is the selection criterion in a fluid power
circuit” were the bulk modulus refers to the incompressibility of the fluid, in general hydraulic fluids
are considered as incompressible fluid but practically all fluids have some degrees of compressibility
which depends on bulk modulus value, when the value is high the lesser the compressibility and when
the value is less more the compressibility of the fluid.
1.1Stance taken on the debate:
For the debate the stance taken is “Bulk modulus of the fluid is not the only selection
criteria in fluid power circuit” the reason behind why the bulk modulus cannot be the only factor
which involves in the fluid selection is.
∆ Pressure X Initial volume ∆P . Vo
K MPa
∆ Volume ∆V
Were, K = Bulk modulus of the fluid, ∆P = change in pressure, ∆V = change in volume and Vo =
Initial volume of the fluid.
In the graph shown in the Fig1.1 The graph is plotted
between the bulk modulus and the pressure at the
various temperature, from which it can be identified
that bulk modulus increases with the increase in
pressure and the bulk modulus decreases with the
increase in the temperature from this it can be noted
Fig1. 1 Bulk modulus to pressure at various that the operating temperature of the hydraulic circuit
in the system. The ASTM (American standards of testing materials) has recommended and
standardized these properties.
1.2.1 Viscosity (ASTM D445-97):
Viscosity is the resistance to the flow of the fluid. The higher the viscosity the higher will be
the resistance to the flow, higher contribution of the fluid temperature and consumes high energy.
The low viscosity can damage the system and the pressure generation will be less. The viscosity
changes with temperature and pressure and therefore it is required that viscosity grade should match
with the operating temperature of the system. Determining the correct grade of viscosity involves.
i) Starting viscosity of the minimum ambient temperature.
ii) Maximum expected operating temperature which influences the maximum ambient temperature.
iii) Permissible optimum viscosity range for the system.
1.2.2 Viscosity index (ASTM D2270):
Viscosity index is the measure of viscosity change
with respect to the change in temperature. When the VI
(viscosity index) number is high it maintains viscosity to the
broader range of temperature. The high VI oils are used were
the systems are operated at high extreme temperature. The Fig1. 2 Recommended viscosity values
bulk modulus is the inherit property of the oil which cannot be for various pumps
changed but the Viscosity index can be changed by adding additives. The recommended viscosity
values for the hydraulic components are shown in the Fig 1.2.
1.2.3 Pour point:
Pour point is the minimum temperature at which the fluid will flow. This property is
required when the fluid is to be operated at very low temperature. While selecting the pour point of
the oil it should be 10ᵒC less than the hydraulic system temperature. So when fluid power systems
used at very low temperatures should be considered not only bulk modulus of the fluid but also the
pour point of the fluid.
1.2.4 Flash point and fire point:
The flash point is the temperature at which the hydraulic oil will be heated up and converted
into vapor and when vapor mixes with the air will start igniting and will not continue to burn. The
fire point is temperature at which the hydraulic oil will continuously burn. The flash and fire points
are useful in determining a lubricant’s and fire resistance usually 8-10% above the flash point
1.2.5 Acid number or neutralization number:
This number indicates the life of the oil used in fluid power system and helps to determine
when the oil must be changed. Generally the acids are formed as oils oxidize due to continuous
usage which contaminate the oil, the acid number helps to determine duration of replacement of oil
is the other factor which is to be considered other than bulk modulus while selection of the fluids.
1.6 Case study:
In [Appendix-1][3] the comparison of the various hydraulic oils are shown which shows the
various properties to be considered along with the bulk modulus. “[4] Steven Herzog, Evonik
Rohmax USA, inc. conducted a case study on the high efficiency hydraulic fluid for skid steer
loader and excavator. The improvement of productivity was 14-16% by selecting efficient hydraulic
fluid. The two types of losses in hydraulic fluid is mechanical efficiency- relates the frictional loss
between the components and volumetric efficiency- relates to internal leakage and flow losses. The
high efficiency hydraulic fluid is formulated DYNAVIS
technology, with high viscosity index so as the energy
consumption is less as the viscosity remains same at different
operating temperature. The Fig1.3 shows the hydro mechanical
energy loss in vane pump for oil with viscosity Index (VI) = 100
and VI=200. From this it has been observed that the volumetric
efficiency of the pumps is very sensitive to the viscosity. In lab Fig1. 3 Hydro mechanical energy loss
the tests are carried out at 100ᵒC were the relative efficiency of in Vane pump
the various fluids and high efficiency fluid results are taken and
shown in the Fig1.4. Were the result shows when the viscosity
index increases the efficiency of the pump also increases. To
verify the results obtained from the lab, Caterpillar 318L
medium size excavator is tested with OEM recommended 10W Fig1. 4 Results of comparison of efficiency
oil (104VI) to 179VI high efficiency fluid. The final result is the average gain from the OEM 10W
was 22.4% the result from the laboratory test is 22%. By using the high efficiency fluid the
productivity also increase to the great extent as shown in the Fig1.5. In
this case study proves that the viscosity index increases the efficiency
of the pump and therefore it is to be noted that the bulk modulus is not the Fig1. 3 Results of improvement
only factor to be considered while oil selection. in Productivity
1.7Conclusion:
From the above justifications it can concluded that the bulk modulus is not only factor to be
considered while selecting the hydraulic fluids there are many other properties which has to be
considered based on the area of application of the hydraulic system as per the area of .
PART-B
CHAPTER 2
________________________________________________________________________________
2.0 Introduction to hydraulic circuit:
Hydraulic circuit comprises of various components such as electric motor which converts
electric energy into mechanical energy and the pump converts mechanical energy into hydraulic
energy and the actuator converts back hydraulic energy into mechanical energy. Control elements
like valves are used which controls the fluid in the circuit such as direction control valves, flow
control valves & pressure relief valves etc.
4
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
5
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
6
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Justification:
The cylinder-2 grip arm is designed in such a way that it will travel inside the grip arm of
cylinder-1 so that the bucket will be lifted up to the position of the hydraulic motor as shown in the
Fig2.9 below.
Justification:
When the bucket reaches to the position of hydraulic motor the bucket is clamped to the
motor using an adaptor a pipe with an internal thread and the motor has the external thread with this
arrangement the bucket is locked to the hydraulic motor and the motor is rotated to 90ᵒ so that that
is poured out of the bucket.
By making the above considerations the circuit shown in the Fig() will be used for the
automation of the paint mixing as per the requirement of the Alex Pvt. Ltd.
2.4 Choice of fluid power system with justification:
The fluid power is basically classified into two branches:
i) Pneumatics – Compressed air is used for energy transmission.
ii) Hydraulics – Liquids (Generally oil) is used for energy transmission.
8
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
9
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Solenoid Valves have only three moving parts and no packing to maintain or replace
Simplified Controls
Valves are connected to simple wires
No air or oil system required to actuate the valves
Low Installed Cost
No safety related nitrogen backup system required for Post Accident Operation
No heavy power cable are used
Low power requirement to actuate the valves
No motor control center - Simple relay on switch outlets.
10
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
iii) Pressure relief valve - It is also called as safety valve, it maintain the safe operating
pressure in the circuit if the pressure exceeds in the circuit it discharges the excess fluid
back to the reservoir as shown in the Fig2.13.
11
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
vi) Proximity sensor - This sensors are used to provide signals to the solenoids to change the
position of 4/2 DCV as shown in the Fig2.16.
12
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
control over retraction as during retraction the bucket will be empty as shown in the
Fig2.19.
13
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
in the extended position itself as shown in the Fig 2.25 so as the bucket will engage in the hydraulic
motor.
When the cylinder-22 extends the bucket gets engaged to the hydraulic motor and the bucket
rotates to the 90ᵒ and the mixed paint will be poured out from the bucket as shown in the Fig2.26.
Fig2.26
Fig2. 25 Cylinder-2
Cylinder positioning to rotary actuator
2.11Selection of pump:
By usingg the chart shown in [Appendix
[Appendix-3]] by comparing the various types of the pump for
the paint mixing automation the “Internal gear pump” is selected for the operation.
Justification:
i) External gear pump – The noise level is too high in operation which cannot be suitable for the
continuous operating condition.
ii) Screw spindle pump – The cost wise it is too costly and the usable range of pressure is less than
internal gear pump.
iii) Piston pumps (Axial &Radial) – Noise level and cost is too higher than the internal gear pump.
2.13.2 Piston: Piston rod is made of cast iron with chrome plated in order to avoid the rust and
corrosion the plating is done either chrome or nickel plated based on the application. Generally 0.02
to 0.04mm depth the piston is chrome plated with the hardness of 900- 1100HV and the surface
finish with the 0.8 roughness value.
18
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
2.14 Calculations:
For calculations considering the bucket internal diameter as 0.75m and the length of 0.5m the
cylinder force required to move the force of the bucket by the cylinder-1(horizontal) at a constant
velocity.
Given data:
External diameter = 0.75m
Length = 0.5m
Wall thickness = 0.01m.
19
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Frequency selection:
Frequency = 1/time.
= 1/4 Hz. (Frequency is selected as 0.25 Hz).
Stroke length selection:
Stroke length = 1.5m
Finding acceleration:
V = u +at; were Final V =0.375m/s, u=0 & t=0.25s
0.375 = 0 + a (0.25)
a = 1.5 m/s2.
As the bucket is supported by the guide rail the bucket will be in contact with the steel guide rail
and therefore the frictional co efficient () for steel to steel is taken as 0.39
20
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
ɽ=IXa
Torque ( ɽ ) = Force X perpendicular distance.
Moment of inertia (I) = d4/64
= (3.14 X 0.754)/64
= 0.015 m4.
Considering (a) = 1145.9 rad/s
Torque ( ɽ ) = 0.015 X 6875.49
= 103.13N-m.
Rotary motor force = Torque / perpendicular distance.
= 103.13/0.5
=206.26 N.
2.15 Conclusion:
As per the requirement of the Alex pvt ltd, for the automation of the paint mixing the
hydraulic circuit is shown above built with different components the selection of components are
justified the simulation is shown the force on cylinders and rotary actuator is calculated and shown
and the following circuit is recommended for paint mixing operation.
21
PART-C
CHAPTER 3
________________________________________________________________________________
3.0 Selection of heavy duty earth moving equipment:
Hydraulic Cranes are generally used for lifting the heavy loads and to do transportation of
the load. The cranes works based on the mechanical advantage by changing the direction or
magnitude of force using hydraulic power system. Hydraulic cranes are a type of crane that uses
hydraulics instead of cables to raise and lower workloads. Hydraulic cranes have simple hydraulic
construction which makes it to perform huge tasks like lifting the beams of the bridges, in
manufacturing industries to move heavy assemblies as shown in Fig.
Gear pump:
Generally hydraulic truck cranes will have two gear pumps which has pair of intermeshing
gears to pressurize the oil. When pressure needs to increase, the operator pushes the foot throttle or
23
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
pedal operated throttle to run the pump faster. In a gear pump, the only way to get high pressure is
to run the engine at full power.
In gear pump driver gear and driven gear is used to pressurize the hydraulic oil. The
disadvantages of this gear pump is the pressure will be increasing and decreasing with respect to the
engine rpm, and in order to obtain the high pressure the engine should be run at full power.
“A 70-ton hydraulic truck crane uses a 12.7-L diesel engine that generates up to 365 horsepower.
The engine is connected to three two-gear pumps”, including:
i) Main pump
ii) Pilot pressure counter weight pump
iii) Steering/outrigger pump
Main pump:
This pump is used to operate the cylinder which raises and lowers the boom, as well as the
hydraulic telescoping sections that extend the boom. The main pump is used to generate the
pressure of 24MPa or (3500 Psi). It generates the higher pressure than other two pumps as this is
responsible for moving weights.
Pilot pressure counter weight pump:
A hydraulic truck crane uses counterweights on the back of the cab generated by the
counter weight pumps to keep it from tipping over. The loads are added and removed by a
hydraulic lift that has its own pump. The counterweight gear pump can generate around 10MPa
(1,400 psi). By the hydraulic pilot line the pump will be operated.
Steering/Outrigger pump:
To control the steering and outriggers the one more pump is used. The outriggers are used to
stabilize the truck during the lifting operation by providing the counter weight. As the steering and
the outrigger operation are not performed at a time for the both the operation is run by the same
pump. This pump generates the pressure of 11MPa (1600 psi).
3.3 Parts of hydraulic truck crane:
In hydraulic truck crane almost all parts are connected with the hydraulic components.
There are many other components involved in lifting of loads they are
• Boom
• Jib
• Rotex gear
• Outriggers
24
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
• Counter weights
• Reinforced steel cables
• Hook
3.3.1Boom:
The most important part of the crane is the boom which is of structural steel arm which
raises the load which raises the loads just behind the operators cab, the boom is the essential part of
the crane which is operated by telescopic cylinder and is used to raise the loads to the various levels
of heights. “A 70-ton Link-Belt hydraulic truck crane has a boom with three telescoping sections.
This particular boom has a length of 38.7 meters (127 feet)”.
3.3.2 Jib:
Some of the cranes are equipped with the jib which is the rectangular section connected to
the boom. When the telescopic cylinder is extended the jib will be extending out of the boom. “On
the 70-ton hydraulic truck crane, the jib is 20.4 meters (67 feet) long, giving the crane a total length
of 59.1 meters (194 feet)”
3.3.3 Rotex gear:
In order to rotate the boom to in clock wise and anti clockwise while lifting and placing or
moving of loads the rotex gear provides the motion. Rotex gear is placed on the turntable bearing
that turns at the 2 rpm. It is driven by bi directional hydraulic motor; the rotation is controlled by
the foot operated pedal. The rotex gear is shown in Fig 3.4.
3.3.4 Outriggers:
The outriggers are the mechanism which is used to balance the crane during the lifting
operation. It is operated by the hydraulic cylinder and these are provided at the back side of the
cranes for counter balancing. The amount of counterweight needed for a particular lift is determined
25
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
by the weight of the load, the radius of the boom and the boom's angle during operation. The
outriggers are shown in Fig3.5
Fig3. 5 Outrigger
26
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
The joy stick or foot pedal is connected to the hoses or pipes which connects various
hydraulic rams and spool operated direction control valves. When the joy stick is operated the spool
inside the direction control valve changes its position so that the oil will be flowing in to the
cylinder for the extension or for the retraction as shown in the Fig3.7 were by operating the joy
stick the position of the cylinder is shown.
27
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
In the above hydraulic circuit of the crane the fluid pressure is generated by the bent axis
piston pump and the hydraulic oil is directed to the hydraulic cylinders by the 4/3 direction control
valve with mid position as were ever can be stopped and the slewing gear for the rotation of gear
outriggers and boom telescopic cylinders are inter connected with the direction control valve and
the flow control valve then connecting to the actuators.
The Fig3.8 shows the hydraulic components inter linked to actuate the slewing gear initially the
signal is sent by the 4/3 lever operated direction control valve which is connected with the pressure
relief valve to maintain the safe operating pressure in the circuit and is connected to the slewing
motor (rotary actuator) which is connected to the helical gear arrangement, when these gears rotates
it drives the slewing gear and the boom arrangement turns in clock wise or anti clock wise as per
the direction of the rotation of the rotary motor.
28
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
The Fig3.11 shows the boom elevation arrangement were the 4/3 direction control valve is used
along with the one way flow control valve to actuate the cylinder.
29
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Determining the force on the cylinder by considering the crane as third class lever.
Moment at the load = Moment at the cylinder
MFL = MFC
FC X (L1 + L2) cosө = FL X L2 cosө
FC = (L1 + L2 /L2). FL
As the cylinder is not positioned straight and tilted to the angle ⏀.
(FC X L2) cos⏀ = FL X (L1 + L2)
FC (FL X (L1 + L2)) / L2 cos⏀
3.6 Conclusion:
The fluid power used for cranes and the various components used to built the hydraulic
circuit and the function of the components and the mechanism, working principle of the hydraulic
crane and the design principle is explained above.
30
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
4.0 Learning outcome:
In the module fluid power control the knowledge gained in the following area.
• The basics of fluid power control and the applications of fluid power comparison of various
power systems like mechanical, electrical, pneumatic and hydraulic system and their advantages
and disadvantages, practical applications of pneumatics and hydraulic system, properties of
fluids and calculation related to the fluid properties.
• Introduction to hydraulic system, various components of hydraulic system, Pumps – various
types of the pumps, advantages and disadvantages of the pumps, practical problem solving in
pump selection, selection of pump based on the application using the pump selection chart for
practical application.
• Introduction to actuators, various types of actuators, advantages and application of each type
design of actuators, problems solved related to first class lever, second class lever and third class
lever, practical application calculations of cylinder diameter, force calculation, selection of
cylinder for practical application from the Bosch catalogue.
• In the lab session practical was carried out in hydraulic kit were the circuits are connected using
different hydraulic components and using “Automation studio” software hydraulic circuit design
with simulation was learned.
31
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
References
________________________________________________________________________________
32
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Appendix-1[3]
33
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
34
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Appendix-2
35
MSRSAS - Postgraduate Engineering and Management Programme - PEMP
[Appendix-3][5]
36