Trouble Shooting and Applications

Presented by
D.KANAGARAJAN
Associate Professor
 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 a

Pick and Place application and tool handling.

 Hydraulic circuit for Shaper Machine
o Fig shows the hydraulic circuit for operation of shaper.

o Here meter- out circuit is used.

o It consists of hydraulic power unit which delivers the oil at constant

pressure.

o A double acting cylinder is used to reciprocate the ram

o A pivot actuated D.C. valve is used to alter the direction of stroke

of the piston

o When spool is in right envelop mode, the oil from port P enters the
blind end of cylinder causing the ram to move forward.
Figure. Hydraulic circuit for Shaper Machine
o The oil from other side of piston is discharged through flow
control valve into reservoir. Here quantity of liquid is controlled
while going out hence circuit is meter-out.

o The cutting speed can be changed by controlling the flow control

valve.

o At the end of forward stroke, the ram hits the pivoted lever of
D.C. valve shifting the valve into left envelop mode.

o Thus the oil from pump enters the rod end of the cylinder through
check valve causing the ram to perform the return stroke.

o The oil from blind end returns to reservoir, as there is no

restriction the return is quick.
 Hydraulic circuit for Surface grinder
o Fig. shows the hydraulic circuit for reciprocating the machine
table for surface grinder.

o The circuit consist of a hydraulic power unit, which delivers

oil under pressure.

o It uses pilot operated D.C. valve to alter the direction of stroke

of piston in a double acting cylinder.

o It also consist of two roller actuated three way D.C. valve V1

& V2 to actuate pilot operated four way D.C. valve
o The flow control valve is placed in return line to tank which provides
smooth and equal speed and feed in both direction of table travel.

o When valve V1 is depressed by table, the oil from pump flows through V1
and is supplied to pilot spool E which puts the D.C. valve in left envelop
mode

o Then the oil from pump enters the cylinder through port 1 causing the table
to move forward and oil from other side is delivered to reservoir through
flow control valve.

o At the end of stroke it depress valve V2 , the oil from pilot line operates
spool F to put D.C. valve in right envelop mode.

o Thus oil from pump enters the cylinder port 2 causing machine table to
return and the oil from other side of piston is delivered to reservoir through
Figure. Hydraulic circuit for Surface grinder
 Hydraulic circuit for Hydraulic Press
o Fig. shows the hydraulic circuit for the operation of hydraulic press.

o It consist of manually operated D.C. Valve

o A press operation requires an accurate movement rate of piston so

that the metal flows smoothly without tearing or cracking

o Thus it is necessary to meter the fluid into the blank end of the
cylinder. Here meter-in circuit is used

o Therefore flow control valve is located in the feed line B-1 on the
actuator so that one stroke is to be speed controlled and check valve
permits the rapid retraction.
o When spool of D.C. valve is in left envelop mode, the metered quantity of
oil from pump enters the blank end of cylinder via flow control valve
causing forward stroke.

o The oil from rod end is discharged out into the reservoir via line 2-A-R.
during this stroke operation is done on Workpiece

o When the spool is shifted to right envelop mode the pump supplies the
fluid to rod end of cylinder and the fluid from blank end returns back to
reservoir through check valve causing quick retraction of cylinder.

o When spool is in neutral position the operator unloads the object and load
another object. In this position pump delivery is directed to reservoir.

o The hydraulic presses are slower and more powerful and adapted for
pressing, forming and bending operations.

o These are also employed for fabrication of heavy forgings

Figure. Hydraulic circuit for Hydraulic Press
 Hydraulic circuit for Clamping and Drilling
o In this sequence valve is provided to do the operations sequentially.

o Fig. shows the use of two sequence valve in hydraulic circuit for controlling two operations
performed in the sequence in both directions.

o It consist of hydraulic power unit, two sequence valves A & B with integral check valve,
two double acting cylinders P & Q, and D.C. valve

o When D.C. valve is shifted to left envelop mode, the oil from pump enters the cylinder ‘P’
through line 1-3, causing the piston in cylinder ‘P’ to extend fully.

o The oil from rod end of cylinder passes from port 4 via check valve of the sequence valve
‘B’ to port 2 of the D.C. valve and exhausted to the reservoir.

o As the piston in the cylinder ‘P’ extends completely, the pressure in line 1-3 rises which
causes the sequence valve ‘A’ to open.

o Then the oil from pump enters the blind end of cylinder ‘Q’ through the line 1-6, which
cause the piston in cylinder ‘Q’ to extend completely.
Figure. Hydraulic circuit for Clamping and Drilling
o The oil from rod end of cylinder ‘Q’ is discharged into the reservoir via line 5-2 through
D.C. valve.

o When the D.C. valve is released, the oil from pump enters into the rod end of cylinder ‘Q’
via line 2-5 causing the piston in the cylinder ‘Q’ to retract completely and oil from side
of the cylinder is directed to return into the reservoir through check valve of sequence
valve ‘A’ via line 6-1.

o As the piston in cylinder ‘Q’ retracts completely, the pressure in the line 2-6 is increased.

o The pressure rise in the line 2-6 causes the sequence valve ‘B’ to open, allowing the flow
from pump to enter rod end of cylinder ‘P’ through port 4.
o It causes the piston in cylinder ‘P’ to retracts completely.

o The oil from blind end of cylinder ‘P’ is discharged out to reservoir via line 3-1 through
D.C. valve.

o Thus the extension and retraction of pistons in both the cylinders are performed in
sequence.
 Speed Control Circuits
• In hydraulic operated machine tools and other mechanical equipment, speed control is required to
enhance the functional versatility of the machine.

• Speed control required during different strokes can be done by regulating oil flow to the cylinder.

• Speed control of a single load can be done using variable displacement pump. If the speeds of a
number of loads are to controlled independently, the metering of the oil to individual cylinders is
done by using flow control valves.

• Depending upon the location of flow control

valve for metering the oil, speed control
circuits can be classified as:

1. Meter-in

2. Meter-out and

3. Bleed-off circuits.

Figure: Pressure Compensated

Flow Control Valve
1. Meter-in Speed Control

• This type of circuit consists of a pressure compensated flow control valve

between the pump and cylinder.
• This flow-control valve is placed in pressure line that actuates the cylinder
to work. Oil flowing into the work cylinder is metered through the flow-
control valve.
• Since this metering action involves reducing flow from a pump to the
cylinder, the pump must deliver more fluid than is required to actuate the
cylinder at the desired speed.
• Excess fluid returns to the tank through a relief valve. To conserve power
and avoid undue stress on the pump, the relief valve pressure is kept little
higher than the working pressure.
• A meter-in circuit is considered to be better in applications where a load
always offers a positive resistance to flow during a controlled stroke. These
circuits are used where slow feed rates are required. A meter-in speed
control is shown in Figure.
Figure: Cylinders with Meter-In Speed (Flow) Control
2. Meter-out Speed Control

• In this type of circuit, a flow-control valve is installed on the return side of a

cylinder so that it controls the cylinder actuation speed by metering its discharge
flow.

• A relief valve is kept a little above the operating pressure which is required by the
type of application. These types of circuit are best suited where work resistance is
negative such as climb milling.

• These circuits may also be used for overhauling load applications in which a
workload tends to pull an operating piston faster than pump delivery, like in
drilling, reaming, boring, turning machines.

• A flow-control-and-check valve used in this circuit would allow reverse free flow.
A meter out speed control circuit is shown in Figure.
Figure : Cylinders with Meter-Out Speed (Flow) Control
3. Bleed Off Speed Control
• In this type of circuit flow control valve is not directly
provided in the feed line but is connected to the pressure side
as shown in Figure.

• The flow control valve regulates flow to a cylinder by

diverting a portion of a pump flow to the tank.

• This type of circuit usually involves less heat generation

because pressure on a pump equals the work resistance during
a feed operation.

• This type of circuit is used for constant load applications.

 ACCUMULATORS CIRCUITS

Accumulators are devices that store hydraulic fluid under pressure.

Storing hydraulic fluid under pressure is a way of storing energy for later
use. Perhaps the most common application for an accumulator is
supplementing the pump flow in a hydraulic system in which a high flow
rate is required for a brief period of time.

Types;
1. Weight loaded accumulator
2. Spring loaded accumulator
3. Gas charged accumulator
4. Piston type
5. Bladder type
APPLICATIONS OF ACCUMULATORS

Accumulators are used as:

1. Leakage compensator
2. Auxiliary power source
3. Emergency power source
4. Hydraulic shock absorber
5. Fluid make-up device
 1. Accumulator as leakage compensator
• The stored energy of the accumulator can be used to compensate any possible
loss of energy due to internal or external leakage in a system.
• This application is extremely helpful in circuits, such as are used for hydraulic
presses, which require high pressure for long periods.
• First operator places work piece on the press and shifts handle of the 4/2 DC
valve.
• Now the oil flows to blank end of cylinder and piston extends. The pressure
builds up and oil fills the accumulator. When maximum pressure is reached, the
pressure switch stops the pump motor.
• In these applications, the cylinder and piston arrangement is required to press the
work piece for a longer period of time. During this period, the internal and
external leakage may reduce the cylinder pressure.
• The leakage oil is replaced with the oil from the accumulator. This leakage
replacement of oil is carried for a longer period of time.
• The maximum length of time is determined by the volume of the accumulator
and the rate of leakage in the cylinder.
• When the pressing cycle has been completed, the operator shifts the handle of
the 4/2 DC valve to original position. Thus a cycle is completed.
 2. Accumulator as auxiliary power source

• As we know, the electric motor or pump motor is a primary power source. In

this application, the accumulator stores the oil during one portion of the work
cycle and releases the oil during the remaining cycle.

• Thus accumulator serves as a secondary power source. Figure shows the

circuit using accumulator as a secondary power source. After placing the
work piece on slide table and shifts handle of 4/2 DC valve.

• Now oil flows from the accumulator to blank end of slide cylinder. This
extends the piston until slide table reaches end of stroke.

• When the cylinder is in the fully extended position, the accumulator is

charged with the oil by the pump. Then the operator shifts the handle of 4/2
DC valve for the retraction of the cylinder. Now the oil flows from the pump
as well as from the accumulator to retract the cylinder quickly.
ACCUMULATOR AS AUXILIARY POWER SOURCE
 3. Accumulator as emergency power source

• In some hydraulic applications, it is necessary to retract the pistons of

cylinder to their starting position; even there may be an electrical power
failure. In such applications, the accumulator can be used as an emergency
power source to retract the piston of the cylinder.

• When operator depresses push button energizing solenoid of the 3/2 DCV, oil
flows to blank end of cylinder. At the same time, the oil also unseats check
valve. So the oil under pressure flow to rod end of cylinder and into the
accumulator. When there is a power failure, the solenoid will de-energize.

• In the absence of solenoid energy, the spring pressure forces the valve to shift
to its spring offset mode. Now the oil stored under pressure is forced from
the accumulator to the rod end of the cylinder. Thus the piston of the cylinder
retracts to the starting position.
 4. Accumulator as hydraulic shock absorber

• In many high pressure hydraulic systems, the sudden stoppage of a hydraulic fluid
flowing at high velocity in pipelines can cause considerable damage to the piping.

• This hydraulic shock, also known as water hammer, may snap heavy pipes, loosen
fittings and cause leaks. By installing an accumulator, this high pressure pulsations
or hydraulic shocks can be absorbed. Figure shows the circuit employing
accumulator for serving as a hydraulic shock absorber.

• The accumulator installed near the shut-off point in order to be more effective in
quickly absorbing the shock wave. When the system demands to shut-off the supply
suddenly, a 2/2 shut-off valve is used for the purpose. When operator shifts handle
of the 2/2 emergency shut-off valve, the fluid flow is stopped suddenly.
•
• This results in high-pressure pulsations or hydraulic shock. The pressure pulsation
is blocked by check valve. The surges between the check valve and the shut-off
valve are used to store the oil in accumulator and thus the pressure pulsations of the
oil in the pipe line are absorbed.
 Pressure Intensifier circuit
o Pressure intensifier or boosters are devices used to generate pressure
greater than those achievable with standard hydraulic pumps alone.
They take the inlet flow from the pump and intensify the pressure.

o A simplified cut way of an intensifier is shown in Figure. The

intensifier is shown on the forward stroke. In this situation, the pump
flow (Q pump) is fed into port A of the intensifier, which applies a
pressure (P pump) to the piston, causing it to more right.

o This in turn generates a force that is applied to the rod. The force on
the rod then creates pressure and flow at the outlet to the system.

o When the four way directional control valve is shifted to the opposite
position, the pump flow is sent to port B of the intensifier, causing the
piston to move left. This causes fluid to be drawn into the rod chamber
which completes one cycle.
o The Figure shows the usage of intensifier in the punching machine. After
placing the work piece in the fixture and shifts handle of 4/2 DCV to the right
side, the oil flows to the blank end of the cylinder through the check valve.

o When the pressure in the cylinder reaches the sequence valve pressure
setting, the sequence valve opens and supplies the flow to the intensifier.

o Now the intensifier starts to operate and gives high pressure output. This high
pressure output of the intensifier closes the pilot check valve and pressurizes
the blank end of the cylinder to perform the punching operation.

o When the 4/2 DCV is shifted to the left side position, the oil flows to the rod
end of the cylinder. When it builds-up the pressure, the pilot signal opens the
check valve. Thus the cylinder is retracted to the starting position.
 Pressure Intensifier Circuit

Single Acting Intensifiers

Industrial hydraulic circuits - Regenerative circuit
o It is used to speed up the extending speed of the double acting cylinder. Figure shows a
regenerative circuit that can be used to speed up the extending speed of the double acting
cylinder.

o This circuit uses a manually operated, three position, four way DCV and a double acting
cylinder. It should be noted in this circuit that the pipelines to the cylinder are connected in
parallel and one of the ports of the DCV is blocked.

o When the 4/3 DCV is shifted to the left mode, the oil flows from the pump to the blank end of
the cylinder. This pump flow extends the cylinder.

o When the 4/3 DCV is shifted to the right mode, the oil from the pump bypasses the DCV and
enters into the rod end of the cylinder. Oil in the blank end drains back to the tank through the
DCV as the cylinder retracts.

o The speed of extension in the regenerative circuit is greater than that for a regular double acting
cylinder. But the speed of retraction is similar to the regular double acting cylinder.

o This is because oil flow from the rod end regenerates with the pump flow to provide a total
Regenerative circuit
 Synchronizing hydraulic cylinders

o There are many industrial applications require nearly perfect

synchronization of movement of two or more cylinders in order to
complete some phase of operation.

o To accomplish the identical task from the cylinders at the same rate,
synchronizing circuits are employed.

o This is achieved by using double-end cylinders in series, by using

mechanically linked pistons, by using hydraulic motors as metering
devices and by using flow control valves.

o Figure shows a circuit to synchronize two cylinders by connecting them in

series. This circuit uses a solenoid-operated, spring-offset 4/3 DCV and
two double acting cylinders.
o When the 4/3 DCV is shifted to the left envelope flow path
configuration, oil flows from the pump to the blank end of cylinder-1
and thus the cylinder-1 extends. At the same time, oil from the rod end
of cylinder-1 is forced to the blank end of cylinder-2 and thus the
cylinder-2 also extends.

o Now the oil returns to the tank from the rod end of the cylinder-2
through DCV. Once full extension of cylinder-1 and 2 are over the
DCV is shifted to the right mode.

o When the 4/3 DCV is shifted to the right mode, oil flows from the
pump to the rod end of cylinder-2 and thus the cylinder-2 retracts. As
the same time, oil from the blank end of cylinder2 is forced to the rod
end of cylinder1 and thus the cylinder-1 also retracts.
Synchronizing hydraulic cylinders
 Automatic cylinder reciprocating system

o The sequence valves can also be used to produce continuous reciprocation of a hydraulic
cylinder. Figure shows a circuit that automatic reciprocation of the hydraulic cylinder.

o This can be achieved by using two sequence valves and a pilot pressure operated spring-
centered 4/3 DCV.

o When the 4/3 DCV is shifted to the flow path configuration, oil flows from the pump to the
rod end of the cylinder. This pump flow retracts the cylinder. The check valve-1 prevents
shifting of the 4/3 DCV until the full retraction stroke completes.

o As the piston reaches its end of stroke, the pressure builds up in the sequence valve-1 and it
opens. This allows the pilot pressure signal to shift the DCV to the right mode.

o When the pilot signal shifts the 4/3 DCV to the right mode, the oil flows to the blank end of
the cylinder. This pump flow extends the cylinder. The check valve-2 prevents shifting of the
DCV until the full extension stroke completes.

o As the piston reaches its end of stroke, the pressure builds up in the sequence valve-2 and it
Automatic cylinder reciprocating system