FLUID POWER CONTROL - Prabhakar Purushothaman

MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Module Code Module Name Course Department
MMD 510 Fluid Power Control M.Sc [Engg] in Machinery design Mechanical & Manufacturing Engineering.
Name of the Student Reg. No Batch Module Leader
Prabhakar.P BAB0911001 Full-Time 2011. Prof. Arup Bhattacharya
M.S.Ramaiah School of Advanced Studies

Postgraduate Engineering and Management Programmes(PEMP)
#470-P Peenya Industrial Area, 4th Phase, Peenya, Bengaluru-560 058 <Fluid power control> Tel; 080 4906 5555, website: www.msrsas.org
POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)
ASSIGNMENT
Declaration Sheet Student Name Reg. No Course Batch Module Code Module Title Module Date Module Leader Prabhakar.P BAB0911001 Machinery design FT11 MMD510 Fluid Power Control 16-04-2012 Prof. Arup Bhattacharya To 12-05-2012 Batch Full-Time 2011.
Extension requests:
Extensions can only be granted by the Head of the Department in consultation with the module leader. Extensions granted by any other person will not be accepted and hence the assignment will incur a penalty. Extensions MUST be requested by using the Extension Request Form, which is available with the ARO. A copy of the extension approval must be attached to the assignment submitted.
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Unless you have submitted proof of mitigating circumstances or have been granted an extension, the penalties for a late submission of an assignment shall be as follows: Up to one week late: Penalty of 5 marks One-Two weeks late: Penalty of 10 marks More than Two weeks late: Fail - 0% recorded (F) All late assignments: must be submitted to Academic Records Office (ARO). It is your responsibility to ensure that the receipt of a late assignment is recorded in the ARO. If an extension was agreed, the authorization should be submitted to ARO during the submission of 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.
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<Fluid Power Control>
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Abstract
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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.
<Fluid power control>
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Contents
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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
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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
List of Tables
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Table No. Title of the table
Pg.No.
Table 2. 1 Comparison of pneumatics and hydraulics .................................................................. 9 Table 2. 2 Bill of materials of hydraulic circuit .......................................................................... 14
<
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List of Figures
____________________________________________________________________________ Figure No. Title of the figure Pg.No
Fig1. 1 Bulk modulus to pressure at various temperatures........................................................... 1 Fig1. 2 Recommended viscosity values for various pumps ......................................................... 2 Fig1. 3 Results of improvement in Productivity .......................................................................... 3 Fig1. 4 Results of comparison of efficiency ................................................................................. 3 Fig2. 1 Various energy conversions in hydraulics ....................................................................... 4 Fig2. 2 Process layout................................................................................................................... 5 Fig2. 3showing cylinder-1 vibrating motion ................................................................................ 5 Fig2. 4 Showing cylinder-2 lifting motion ................................................................................... 6 Fig2. 5 Showing rotary actuator tilting motion ............................................................................ 6 Fig2. 6 Showing bucket and cylinder-1 grip arm ......................................................................... 7 Fig2. 7 Section view of grip arm of cylinder-1 ............................................................................ 7 Fig2. 8 showing cylinder-2 grip arm ............................................................................................ 7 Fig2. 9 Showing grip arm movement of cylinder-2 ..................................................................... 8 Fig2. 10 Locking arrangement of bucket with rotary actuator ..................................................... 8 Fig2. 11 Atmospheric reservoir .................................................................................................. 10 Fig2. 12 Suction filter ................................................................................................................. 10 Fig2. 13 Pressure relief valve ..................................................................................................... 11 Fig2. 14 Showing 2/2 lever operated DCV ................................................................................ 11 Fig2. 15Showing 4/2 solenoid operated DCV ............................................................................ 11 Fig2. 16 Proximity sensor........................................................................................................... 12 Fig2. 17 Throttling valve ............................................................................................................ 12 Fig2. 18 Double acting hydraulic cylinder ................................................................................. 12 Fig2. 19 One way flow control valve ......................................................................................... 13 Fig2. 20 Rotary actuator ............................................................................................................. 13 Fig2. 22 Hydraulic circuit for automation .................................................................................. 14 Fig2. 23 Switching the 2/2 DCV ................................................................................................ 15 Fig2. 24 showing cylinder-1 vibratory motion ........................................................................... 15 Fig2. 26 Cylinder-2 positioning to rotary actuator ..................................................................... 16 Fig2. 25 Cylinder-2 lifting motion ............................................................................................. 15 Fig2. 27 Stimulated hydraulic circuit ......................................................................................... 16 Fig2. 28 Displacement step diagram .......................................................................................... 17
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Fig2. 29 Foot mounted hydraulic cylinder ................................................................................. 18 Fig2. 30 Bucket dimension ......................................................................................................... 19 Fig2. 31 Coefficient of friction values........................................................................................ 20 Fig2. 32 Showing tilting of bucket ............................................................................................. 21 Fig3. 1Hydraulic crane ............................................................................................................... 22 Fig3. 2 Hydraulic cylinder actuation .......................................................................................... 23 Fig3. 3Variable displacement axial piston pump ....................................................................... 23 Fig3. 4 Rotex gear ...................................................................................................................... 25 Fig3. 5 Outrigger ........................................................................................................................ 26 Fig3. 6 Showing operator cab ..................................................................................................... 26 Fig3. 7 Hydraulic cylinder function ........................................................................................... 27 Fig3. 8 Hydraulic crane circuit ................................................................................................... 27 Fig3. 9 Slewing gear circuit........................................................................................................ 28 Fig3. 10 Winding and unwinding circuit of hoist....................................................................... 28 Fig3. 11 Boom elevation cylinder circuit ................................................................................... 29 Fig3. 12 Outrigger actuation circuit ........................................................................................... 29
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List of Symbols
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Symbol F MFL MFC K m d l f Force Torque Moment at the Load
Description N
Units
N-m N-m N-m N/m2 kg m m Hz
Moment at the cylinder Bulk modulus Mass Diameter Length Frequency Frictional co efficient
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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. K Pressure X Initial volume Volume P . Vo MPa 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 temperatures that the operating temperature of the hydraulic circuit causes the significant change in the bulk modulus as in most of the operation due to the continuous working there will be difference in temperature exists in the fluid.
1.2 The various criteria involved in fluid selection:

While selecting the hydraulic fluids the following characteristics are to be considered Viscosity, viscosity index, pour point etc. These characters determine the functionality of the fluids
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 10C 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 lubricants 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 100C 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 in Productivity only factor to be considered while oil selection.
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.
Fig2. 1 Various energy conversions in hydraulics
2.1 Introduction to the process:

The process is of paint mixing were the different color of paint with mass m= 290.88kg are to be poured into the bucket of the diameter d=0.75m length L = 0.5m and the bucket is to be vibrated to and fro so that the mixing with the frequency f= 0.25Hz has to be take place and the bucket has to be lifted and the bucket has to be rotated to 120 so as the paint is poured in to the bin for the storage. The process lay out is shown in Fig2.2.
Fig2. 2 Process layout For the automation of the paint mixing process the actuators used are Two double acting cylinder (linear actuator). One hydraulic motor (rotary actuator).
2.2Function of actuators in the process:

The cylinder-1(horizontal) is used for creating to and fro vibratory motion as the cylinder continuously extends and retracts to the particular time; the bucket connected to the cylinder vibrates which in turn the paint will be mixed as shown in Fig2.3
Fig2. 3showing cylinder-1 vibrating motion The cylinder-2 (vertical) is used to lift the bucket to the position of the hydraulic motor so that the bucket will be released from the cylinder-1 grip arm and will be ready to engage in hydraulic motor as shown in Fig2.4.
Fig2. 4 Showing cylinder-2 lifting motion The hydraulic motor is used to tilt the bucket to 120 so that the mixed paint will be poured out from the bucket as shown in Fig2.5.
Fig2. 5 Showing rotary actuator tilting motion After pouring out of paint the motor rotates back to 90 and the bucket will be in the vertical position. The cylinder-2 collects back the bucket and engages the bucket into the grip arm of the first cylinder.
2.3Automation model: 2.3.1 Suggesting a proper automation model:

For performing the operation of the paint mixing by automation using the hydraulic circuit shown below the following consideration are made: i) The shape of the bucket and the shape of the grip arm are to be provided as shown in the Fig2.6.
Fig2. 6 Showing bucket and cylinder-1 grip arm cylinder Justification: The bucket is made into taper can be of mores taper which is used in machine tool for the clamping of the tools in the spindles which provides self locking and automatic alignment of the bucket in the grip arm. As shown in the Fig2.7.
Fig2. 7 Section view of grip arm of cylinder-1 ii) In the vertical cylinder the grip arm should b provided as shown in the Fig2.8. be rovided Fig2.8
Fig2. 8 showing cylinder-2 grip arm 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.
Fig2. 9 Showing grip arm movement of cylinder-2 iii) In the hydraulic motor the provisions is to be provided as shown in the Fig2.10.
Fig2. 10 Locking arrangement of bucket with rotary actuator 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 90 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.
2.4.1 Comparison between Pneumatics and hydraulic fluid power:

System properties Input energy source Pneumatics IC engine, Electric motor and pressure tank. Energy transfer element Energy carrier Power to weight ratio Torque/Inertia Response to speed Control (acceleration) Dirt sensitivity Relative cost Pipes and hoses Compressed air Best Good Fair Good Fair Good Hydraulics IC engine, Electric motor and Accumulators. Pipes and hoses Hydraulic fluid Best Best Good Very good Fair Fair
Table 2. 1 Comparison of pneumatics and hydraulics From the above table the comparison between the Pneumatics and Hydraulics system, the hydraulic system has more advantages than Pneumatics the only disadvantage it has is the cost but when the load exceeds the 10 bar it is not possible to operate the system with pneumatics only the hydraulic system has to be selected.
2.4.2 Advantage of hydraulic system over pneumatic system:

In pneumatic system the exhaust air generates noise but noise generation is less in hydraulics for the paint mixing operation the cylinders are operated continuously so noise should not be generated and therefore hydraulic is suitable. Can be used for heavy load applications and accurate positioning or stopping at the stations are possible in the hydraulics system.
2.4.3 Advantages of solenoid operated valves:

Reliability Solenoid Valves have no friction between the parts as the will have no contact with armature which results in unlimited cycle life Process fluid is confined to a full static pressure related boundary There are no chances of leak or fail Ease of Maintenance Elimination of valve mounted components decreases overall maintenance activities
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.
2.5 Hydraulic circuit design:

The hydraulic circuit comprises of the following major components. The bill of materials is shown below in the Fig (): i) Atmospheric reservoir It is used to store the hydraulic oil which is to be supplied to the circuit and also stores the oil which comes back in return line as shown in the Fig2.11.
Fig2. 11 Atmospheric reservoir ii) Suction filter It is used in circuit to filter the dirt and foreign particles present in the oil. This prevents the entry of the dirt particles in the circuit as shown in the Fig2.12.
Fig2. 12 Suction filter
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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.
Fig2. 13 Pressure relief valve iv) 2/2 Lever operated DCV It is used in the circuit for actuating the first horizontal cylinder, as this cylinder will be moving to and fro continuously by the solenoids to start and stop the motion of the cylinder this valve is used as shown in the Fig2.14.
Fig2. 14 Showing 2/2 lever operated DCV v) 4/2 Solenoid operated DCV this valve is used to control the direction of the fluid to double acting cylinder as the double acting cylinder has two working port 4/2 DCV is used as shown in the Fig2.15.
Fig2. 15Showing 4/2 solenoid operated DCV
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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.
Fig2. 16 Proximity sensor vii) Throttling valve This valve controls the flow of the fluid enters in to the cylinder which in turn motion of the piston as shown in the Fig2.17.
Fig2. 17 Throttling valve viii) Double acting cylinder It is connected with the bucket while it is extending and the retracting the paint poured in the bucket gets mixed as shown in the Fig2.18.
Fig2. 18 Double acting hydraulic cylinder ix) One way flow control valve - This valve is the combination of check valve and throttling valve controls the flow of the fluid enters in to the cylinder for extension and there is no
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control over retraction as during retraction the bucket will be empty as shown in the Fig2.19.
Fig2. 19 One way flow control valve x) Hydraulic motor This is used to tilt the bucket to 90 so that paint stored in the bucket will be poured out as shown in the Fig2.20.
Fig2. 20 Rotary actuator
2.6 Bill of materials:

The following components with the quantity as shown in the bill of materials in Fig 2.21 are used for designing the hydraulic circuit in automation studio.
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Table 2. 2 Bill of materials of hydraulic circuit
2.7 Hydraulic circuit design:
Fig2. 21 Hydraulic circuit for automation

2.8 Function of hydraulic circuit:

Initially when the motor is switched on there is no flow of fluid into the circuit as the 2/2 DCV is normally closed as shown in the Fig2.22. n Fig2.22 When the 2/2 DCV is actuated using lever the position of the valve changes and the hydraulic fluid will gets connected to the 4/2 solenoid operated DCV.
Fig2. 22 Switching the 2/2 DCV When the fluid is flowing through the cylinder the proximity sensor senses the movement of the piston in the cylinder and changes the position of the valve with respect to this the piston will be extending and retracting as shown in the Fig2.24 were the extension and the retraction will be tension continuously takes place until or unless the supply is cut by the lever operated 2/2 DCV.
Fig2. 23 showing cylinder-1 vibratory motion After the cycle time of mixing of the pain the cylinder cylinder1(Horizontal) is stopped in the extended position and the vertical cylinder is actuated by 4/2 solenoid operated DCV by pressing the push button by this time the bucket is released from the first cylinder and pulled up by the second cylinder. The cylinder is kept
Fig2. 24 Cylinder lifting motion Cylinder-2
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-2 extends the bucket gets engaged to the hydraulic motor and the bucket 2 rotates to the 90 and the mixed paint will be poured out from the bucket as shown in the Fig2.26. Fig2.26
Fig2. 25 Cylinder positioning to rotary actuator Cylinder-2
2.9 The simulated hydraulic circuit:
Fig2. 26 Stimulated hydraulic circuit

2.10 Displacement step diagram diagram:
Fig2. 27 Displacement step diagram
2.11Selection of pump:
By using the chart shown in [Appendix ] by comparing the various types of the pump for g [Appendix-3] 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.
2.12Hydraulic cylinder selection:

2.12.1Cylinder mounting: Both the hydraulic cylinders (Cylinder-1 and Cylinder-2) can be used as Tie rod hydraulic cylinder, which can be easily dismantled and the replacing of the worn out parts is possible and maintenance is easy. The mounting used can be foot mounted which can be easily clamped on the base with screws and can be easily removed whenever is required as shown in Fig 2.29.
Fig2. 28 Foot mounted hydraulic cylinder 2.12.2 Cylinder type: The double acting cylinder with cushioning ends can be selected for the paint mixing operation as in the single acting cylinder it is possible to do the work only in forward direction, in mixing operation the cylinder has to move continuously to and fro the work has to be done in both the direction so double acting cylinder should be used. The telescopic cylinder is not required as the required stroke length is less and the cost of the telescopic cylinder is too high.
2.13 Cylinder and piston material selection:

2.13.1 Hydraulic Cylinder Barrel: These are Generally manufactured with seamless steel tubes, high pressure cylinder with a forged and the low pressure casting alloys is also used, the more important requirements is to be quenched and tempered after welding. The hardness lies between 28-32 HRC. 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.
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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.
Fig2. 29 Bucket dimension Volume of the bucket = r2 h - r2 h = 3.14 X 0.3752 X 0.5 - 3.14X0.3742 X 0.49 = 0.220 0.215 = 5.0 X 10-3 m3 Volume of the paint = r2 h = 3.14X0.3742 X 0.49 = 0.21 m3 Mass of the bucket = Volume of the bucket X density of the steel (considering material as steel) = 5.0 X 10-3 X 7850 = 39.25kg. Mass of the paint = Volume of the Paint X Density of the paint [Appendix -2]. = 0.21 X 1198.26 = 251.63 kg. Total mass = mass of the bucket + mass of the paint. = 39.25 + 251.63 = 290.88 kg.
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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.
2.14.1Finding cylinder force of horizontal and vertical cylinder:

Force on the cylinder = Frictional force = XN = X mg cos 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
Fig2. 30 Coefficient of friction values = 0.39 X (290.88 x 9.81) = 1112.87N
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2.14.2 Finding the force of rotary motor:
Fig2. 31 Showing tilting of bucket =IXa Torque ( ) = Force X perpendicular distance. = (3.14 X 0.754)/64 = 0.015 m4. Considering (a) Torque ( ) = 1145.9 rad/s = 0.015 X 6875.49 = 103.13N-m. Rotary motor force = Torque / perpendicular distance. = 103.13/0.5 =206.26 N. Moment of inertia (I) = d4/64
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.
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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.
Fig3. 1Hydraulic crane
3.1 Introduction to hydraulic system:

The hydraulic cranes work on the simple concepts transmission of forces from point to point through the hydraulic oil as per the Pascals law. Were the incompressible fluid and is of maximum density is used in hydraulic cranes. In this simple hydraulic system were the piston pushes the oil and in turn the oil transmits the power to all the pistons and drives the cylinders. It functions as shown in the Fig3.2 below when one piston is pushed down the other piston will be raised. The design of the cylinder is based on the piston displacement without considering the cross sectional area.
Fig3. 2 Hydraulic cylinder actuation
3.2 Hydraulic pump in cranes:

Hydraulic pump generates the pressure which is required to actuate the piston the pressure in the hydraulic crane is generated using the following any one of the pumps: i) Variable displacement pump (axial piston) ii) Gear pump Variable displacement pump (axial piston): In the axial piston pump the series of piston arranged inside the barrel. These pistons are attached to the swash plate which is tilted to an angle the pistons will always be in contact with swash plate. When the engine spins the barrel is connected so that the pistons will rotate. As the barrel spins around due to the tilted swash plate the piston will move inside and outside of the barrel and therefore the oil is sucked in and pressurized and sent out with great force. The Fig 3.3 shows axial piston pump.
Fig3. 3Variable displacement axial piston pump 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
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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) ii) iii) Main pump Pilot pressure counter weight pump 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
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Counter weights Reinforced steel cables Hook The most important part of the crane is the boom which is of structural steel arm which
3.3.1Boom:
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.
Fig3. 4 Rotex gear
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
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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
3.4 Mode of actuation of the valves:

In crane the several control elements are used such as direction control valve, flow control valve etc. to rise and lover the boom, rotate the cab and the boom and to wind and unwind the winch and to control other equipments. To give signals to the valves two types of the signaling elements are used i) Joy stick ii) Foot pedals as shown in Fig 3.6. Joy stick: There are two joy sticks were used one is to control left and right movement of the boom and the other is for the forward and return movement of the boom. Foot pedal: The foot pedal is used to actuate the telescopic cylinder present in the boom and also control the amount of the pressure generation in the pump.
Fig3. 6 Showing operator cab
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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.
Fig3. 7 Hydraulic cylinder function
3.5 Hydraulic circuit of hydraulic crane:
Fig3. 8 Hydraulic crane circuit

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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.
Fig3. 9 Slewing gear circuit
Fig3. 10 Winding and unwinding circuit of hoist

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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.
Fig3. 11 Boom elevation cylinder circuit The Fig3.12 shows the outrigger actuation using 4/3 direction control valve along with the pilot operated pressure relief valve.
Fig3. 12 Outrigger actuation circuit

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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) cos = FL X L2 cos 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.
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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. Benefits derived by solving this assignment: By solving this assignment, Automation studio software is been familiarized and the symbols of various components and the working principle of hydraulic crane with the hydraulic components and the various factors to be considered while selecting the hydraulic fluids was learned. The assignment is able to access the module learning out come.
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References
________________________________________________________________________________ 1. Besiktas, Istanbul,Effect of bulk modulus on performance of a hydrostatic transmission control system http://www.ias.ac.in/sadhana/Pdf2006Oct/543.pdf. retrieved on 12-05 2012 2. Sauer danfoss, Hydraulic fluids and lubrication technical information http://www.sauerdanfoss.com/stellent/groups/publications/documents/product_literature/520l0463.pdf retrieved on 12-05 -2012 3. Gilbert Gedeon, P.E. Lubricants and hydraulic fluids http://www.cedengineering.com/upload/Lubricants%20and%20Hydraulic%20Fluids.pdf retrieved on 13-05 -2012 4. Steven Herzog, Evonik Rohmax USA, A case study : Improving fuel economy and productivity of mobile equipment through hydraulic fluid selection http://www.nfpa.com/events/PDF/2011_EEHPC/06-HERZOG-Evonik-Hydraulic-EnergyEfficiency-Handout.pdf retrieved on 09-05 -2012 5. Arup bhattacharya, module notes, fluid power control MSRSAS, Bengaluru. 6. Festo dedatic Proportional hydraulics http://www.iranfluidpower.com/pdf/proportional/Festo-Proportional.pdf retrieved on 04-05 -2012. 7. Toro university Hydraulics Circuits, Components, Schematics, Hydrostatic Drives and Test Equipment http://www.toro.com/customercare/commercial/education/pdf/09169sl.pdf retrieved on 02-05-2012.
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Appendix-1[3]
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Appendix-2
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[Appendix-3][5]
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FLUID POWER CONTROL - Prabhakar Purushothaman

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MSRSAS - Postgraduate Engineering and Management Programme - PEMP

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Prabhakar.P BAB0911001 Full-Time 2011. Prof. Arup Bhattacharya

M.S.Ramaiah School of Advanced Studies

POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)

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