Basic hydraulic and pneumatic

circuit design

INTRODUCTION
A pneumatic or hydraulic system consists of large number of equipment's
like power unit, service unit, accessories, valves, actuators, etc.
These components are shown diagrammatically by using certain standard
symbols of components, constitutes a fluid circuit.
Sequence components according to functions.

Designation of components in a circuit diagram

Allocation of group number
Group-0 (all items involved in supply of energy)
Group-1(one group allocated to one cylinder)
Serial no. are used by prefixing the group no. before them
.1-control components
.01,.02-components between moving and control components
like flow control, pressure control or check valves, etc.
.2, .4(even numbers)- all components influencing forward stroke
.3, .5(odd numbers)-all components influencing backward stroke

Circuit showing designation of various components

Basic pneumatic circuits

Hydraulic control circuits

single and double acting cylinder control

Cylinder synchronizing circuits

Cylinders connected in parallel

Loads identical Moves in exact synchronization
Loads Not exactly Identical (practical situation)
Cylinders also not exactly identical (packing Friction)

Cylinder synchronizing circuits

Cylinders connected in Series

For two cylinder to be synchronized
Piston Area of Cylinder 2 = Piston Area of Cylinder 1- Rod area
Pump should be capable of actuating both cylinder.

Fail Safe Circuit

Designed to prevent injury to operator or damage to equipment.
Prevent Cylinder from accidentally falling on an Operator in the event of:
1. Hydraulic line ruptures
2. Person inadvertently operates manual override on Pilot actuated DCV
when pump not operating

Fail Safe Circuit with Overload Protection

DCV-1 controlled by Push button valve-2.
When Overload Valve -3 is in spring offset mode, it drains the pilot line of
valve 1.
If Cylinder experience excessive resistance, Valve-4 actuates overload
valve -3. This drains pilot line of Valve1, causing it to return to spring offset
mode.
Nothing happen if push button 2 pressed unless overload valve shifted
manually into blocked configuration.

Two hand Safety Circuit

Designed to protect an operator from injury.
For circuit to function, operator must depress both manually actuated
valves.
Any one button prevents operation.

Regenerative Circuit
Pressurized fluid discharge returned to system
Speed up actuating piston

Speed Control of a Hydraulic Motor

Hydraulic Motor Rotary Motion

Spring Center Position (Motor hydraulically locked)
Left Envelop (Rotates Clockwise)
Right Envelop (Rotates Anticlockwise)

Pneumatic control system

Actuation of a Single Acting Cylinder in Basic pneumatic system with

solenoid DC valve

Pneumatic vacuum systems

A pneumatic vacuum can be used to lift smoothly objects that have flat
surfaces
Ex. Glass plates, sheet metal, floor covering material
Consists of vacuum cup is used to establish the force capability to lift a flat
sheet.
Vacuum pump is turned on to remove air from the cavity between the
inside of the cup and top surface of the flat sheet.
As the pressure in the cavity falls bellow atmospheric pressure, the
atmospheric pressure acting on the bottom of the flat sheet pushes the
flat sheet up against the lip of the cup.
Causes an upward force to be exerted on the flat sheet.

Pneumatic vacuum systems

Accumulator system analysis

Used to avoid effect of flow fluctuations caused by pump.
Works on the principle of pressure difference.
Whenever the pressure in supply line falls the accumulator fills the line
with fluid stored in it.

Accumulator system analysis

GUD LCK FOR MT