Hydraulics and Pneumatic Controls 3e

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Author(s): Srinivasan R

Product Code: vn194

Tags: Hydraulics and Pneumatic Control book fluid power systems hydraulic circuits pneumatic circuits pumps and compressors

This textbook provides a strong foundation to the basic principles, concepts and applications of fluid power. Concise and student-friendly, this book adopts a step-by-step approach, lays emphasis on concepts, and instills learning of design and system applications of hydraulic and pneumatic controls.

Cover
Title Page
Copyright Page
Dedication
Contents
Preface
CHAPTER 1 INTRODUCTION
- 1.1 What is Fluid Power
- 1.2 History of Fluid Power
- 1.3 Basic Law
- 1.4 Applications of Fluid Power
- 1.5 Advantages of Fluid Power Systems
- 1.6 Comparison of Hydraulic, Pneumatic and Electrical Systems
- 1.7 Types of Fluid Power System
  - 1.7.1 Based on Control System
  - 1.7.2 Based on the Type of Control
- 1.8 Fluid Power Industry in India
- Solved Problems
- Exercise
- Review Questions
CHAPTER 2 HYDRAULIC FLUIDS AND PROPERTIES
- 2.1 Fluids: Liquids and Gases
- 2.2 Various Hydraulic Fluids
  - 2.2.1 Water
  - 2.2.2 Petroleum Oils
  - 2.2.3 Water Glycols
  - 2.2.4 Water-in-Oil Emulsion
  - 2.2.5 Oil-in-Water Emulsion
  - 2.2.6 Phosphate Esters
  - 2.2.7 Silicones
- 2.3 Properties of Fluids
  - 2.3.1 Viscosity
  - 2.3.2 Viscosity Index
  - 2.3.3 Oxidation Stability
  - 2.3.4 Demulsibility
  - 2.3.5 Lubricity
  - 2.3.6 Rust Prevention
  - 2.3.7 Pour Point
  - 2.3.8 Flash Point and Fire Point
  - 2.3.9 Neutralisation Number
- 2.4 Comparison of Properties
- Solved Problems
- Review Questions
CHAPTER 3 BASIC PRINCIPLES OF HYDRAULIC FLOW
- 3.1 Laminar and Turbulent Flow
- 3.2 Reynolds Number
- 3.3 Darcy–Weisbach Equation
- 3.4 Losses in Valves and Fittings
- 3.5 Circuit Calculations
- Solved Problems
- Exercise
- Review Questions
CHAPTER 4 PUMPS
- 4.1 Basic Elements of an Oil Hydraulic System
  - 4.1.1 Hydraulic Pump Unit
  - 4.1.2 Control Valves
  - 4.1.3 Hydraulic Motor (or) Cylinder
- 4.2 Pumps
- 4.3 Hydrodynamic or Non-Positive Displacement Pumps
- 4.4 Hydrostatic or Positive Displacement Pumps
  - 4.4.1 Classification of Positive Displacement Pumps
- 4.5 Gear Pumps
  - 4.5.1 External Gear Pumps
  - 4.5.2 Internal Gear Pumps
  - 4.5.3 Lobe Pumps
  - 4.5.4 Gerotor Pump
  - 4.5.5 Screw Pumps
- 4.6 Vane Pumps
  - 4.6.1 Unbalanced Vane Pump
  - 4.6.2 Pressure Compensated Variable Delivery Pump
  - 4.6.3 Balanced Vane Pump
- 4.7 Piston Pumps
  - 4.7.1 Bent Axis Type Piston Pump
  - 4.7.2 Swash Plate Type Piston Pump
  - 4.7.3 Radial Piston Pump
- 4.8 Pump Performance
  - 4.8.1 Volumetric Efficiency
  - 4.8.2 Mechanical Efficiency
  - 4.8.3 Overall Efficiency
- Solved Problems
- Exercise
- Review Questions
CHAPTER 5 HYDRAULIC ACTUATORS
- 5.1 Hydraulic Motors
  - 5.1.1 Gear Type Motors
  - 5.1.2 Vane Type Motors
  - 5.1.3 Piston Type Motors
  - 5.1.4 Hydraulic Motor Efficiencies
- 5.2 Semi-Rotary Actuators
  - 5.2.1 Vane Type Actuators
  - 5.2.2 Piston Type Semi-Rotary Actuator
  - 5.2.3 Helical Screw Semi-Rotary Actuator
- 5.3 Hydraulic Cylinders
  - 5.3.1 Single Acting Cylinders
  - 5.3.2 Double Acting Cylinders
  - 5.3.3 Special Type Cylinders
  - 5.3.4 Mounting Configurations
  - 5.3.5 Methods of Applying Linear Motion
- Solved Problems
- Exercise
- Review Questions
CHAPTER 6 HYDRAULIC VALVES
- 6.1 Pressure Controls
  - 6.1.1 Pressure Relief (Spring Loaded Type) Valve
  - 6.1.2 Compound Relief Valve
- 6.2 Direction Control Valves
  - 6.2.1 Classification of Direction Control Valves
  - 6.2.2 Two Way Valves
  - 6.2.3 Actuating Devices
  - 6.2.4 Rotary Spool Valves
- 6.3 Unloading Valve
- 6.4 Sequence Valve
- 6.5 Counterbalance Valve
- 6.6 Brake Valve
- 6.7 Pressure Reducing Valve
- 6.8 Flow Control Valve
  - 6.8.1 Non-Pressure CompensatedFlow Control Valve
  - 6.8.2 Pressure CompensatedFlow Control Valve
  - 6.8.3 Location of Flow Control Valves
- 6.9 Flow Dividers
  - 6.9.1 Valve Type
  - 6.9.2 Motor Type
- 6.10 Deceleration Valve
- 6.11 Modular Valves
- 6.12 Cartridge Valves
  - 6.12.1 Cartridge Insert Valves
  - 6.12.2 Cartridge Logic Valves
  - Solved Problems
- Exercise
- Review Questions
CHAPTER 7 SEALS AND FILTERS
- 7.1 Seals
  - 7.1.1 Static Seals
  - 7.1.2 Dynamic Seals
  - 7.1.3 Materials for Seals
  - 7.1.4 Conditions Affecting theSelection of Sealing Devices
- 7.2 Fluid Contamination
  - 7.2.1 Cleanliness Standards
- 7.3 Filtration of Fluids
  - 7.3.1 Strainers
  - 7.3.2 Filters
  - 7.3.3 Filter Media
  - 7.3.4 Types of Filters
  - 7.3.5 Filter Location
- Solved Problem
- Review Questions
CHAPTER 8 ACCUMULATORS
- 8.1 Weight Loaded Type Accumulator
- 8.2 Spring Loaded Accumulator
- 8.3 Gas Loaded Type Accumulator
  - 8.3.1 Non-separator Type
  - 8.3.2 Separator Type
  - 8.3.3 Gas Loaded Accumulator Operation
  - 8.3.4 Bellows Type Accumulator
- 8.4 Accumulator Circuits
  - 8.4.1 Leakage Compensation
  - 8.4.2 Auxiliary Power Source
  - 8.4.3 Emergency Source of Power
  - 8.4.4 Shock Suppressor
  - 8.4.5 Thermal Expansion Compensator
- 8.5 Sizing of Accumulator
- Solved Problems
- Exercise
- Review Questions
CHAPTER 9 SERVO VALVES AND PROPORTIONAL VALVES
- 9.1 Mechanical Hydraulic Servo Valve
- 9.2 Electro Hydraulic Servo Valves
  - 9.2.1 Single Stage Servo Valves
  - 9.2.2 Two Stage Servo Valves
  - 9.2.3 Flapper Type Servo Valve
  - 9.2.4 Jet Pipe Servo Valve
  - 9.2.5 Speed Control Circuit with a Servo Valve
- 9.3 Proportional Valves
  - 9.3.1 Control of Proportional Valves
  - 9.3.2 Spool Position Control
- 9.4 Proportional Pressure Relief Valves
- 9.5 Proportional Pressure Reducing Valve
- 9.6 Proportional Direction Control Valve
  - 9.6.1 Speed Control Circuit with a Proportional Valve
- 9.7 Comparison of Proportional and Servo Valves
- Review Questions
CHAPTER 10 INDUSTRIAL HYDRAULIC SYSTEMS
- 10.1 Intensifier Circuit
  - 10.1.1 Intensifier Press Circuit
- 10.2 Regenerative Circuit
  - 10.2.1 Drilling Machine Application
- 10.3 Synchronising Circuits
- 10.4 Automatic Cylinder Reciprocation Circuit
- 10.5 Multiple Circuitry using Banked Units
- 10.6 Sequencing Circuits
  - 10.6.1 Sequence Operation using Sequencing Valve
  - 10.6.2 Sequence Operation by use of Cam Valve
- 10.7 Circuits for Operations of Machine Tools
  - 10.7.1 Hydraulic Operation of a Planning Machine
  - 10.7.2 Hydraulic Operation of a Vertical Milling Machine
  - 10.7.3 Hydraulic Operation of a Surface Grinding Machine
  - 10.7.4 Hydraulic Operation of a Press
- 10.8 Safety Circuits
  - 10.8.1 Two-hand Safety Control Circuit
  - 10.8.2 Fail-safe Control Circuit Using Emergency Cut-off Valve
- 10.9 Hydraulic Circuit for a Robot Arm
- 10.10 Hydrostatic Transmission
  - 10.10.1 Open Circuit Transmission
  - 10.10.2 Closed Circuit Transmission
  - 10.10.3 Applications
- 10.11 Power Pack
- Solved Problems
- Exercise
- Review Questions
CHAPTER 11 DESIGN OF HYDRAULIC CIRCUITS
- 11.1 Design Informations Required
- 11.2 Selection of a Hydraulic Cylinder
  - 11.2.1 Preferred Sizes
  - 11.2.2 Piston Rod Buckling
- 11.3 Selection of Hydraulic Motors
  - 11.3.1 Hydrostatic Drives
  - 11.3.2 Hydrostatic Drive Characteristics
  - 11.3.3 Braking of Hydrostatic Drives
  - 11.3.4 Hydraulic Motor Characteristics and Performance Curves
  - 11.3.5 Matching Motor to Load
- 11.4 Selection of Control Valves
  - 11.4.1 Selection of Relief Valves
  - 11.4.2 Selection of Flow Control Valve
  - 11.4.3 Selection of DirectionControl Valve
- 11.5 Selection of Filters
- 11.6 Selection of Hydraulic Conduits
  - 11.6.1 Tubing
  - 11.6.2 Hoses
- 11.7 Pressure Losses
  - 11.7.1 Pressure Drop in Pipelines
  - 11.7.2 Pressure Losses in Valves and Filters
- 11.8 Selection of Pump
- 11.9 Reservoir
  - 11.9.1 Functions of a Fluid Reservoir
  - 11.9.2 Reservoir Design
- 11.10 Sizing of Accumulator
- Solved Problems
- Exercise
- Review Questions
CHAPTER 12 PNEUMATICS
- 12.1 Comparison of Pneumatic System with Hydraulic System
- 12.2 Properties of Air
- 12.3 Basic Pneumatic System
- 12.4 Compressors
  - 12.4.1 Piston Compressors
  - 12.4.2 Vane Compressors
  - 12.4.3 Screw Compressors
- 12.5 Primary Air Treatment
- 12.6 Receiver
- 12.7 Air Filter
- 12.8 Pressure Regulator
- 12.9 Lubricator
- 12.10 Pneumatic Valves
  - 12.10.1 Direction Control Valves
  - 12.10.2 Pneumatic Check Valve
  - 12.10.3 Flow Control Valve
  - 12.10.4 Pneumatic Shuttle Valve or ‘OR’ Type Valve
  - 12.10.5 ‘AND’ Type or Two-Pressure Valve
  - 12.10.6 Quick Exhaust Valve
  - 12.10.7 Time Delay Valve
- 12.11 Pneumatic Actuators
  - 12.11.1 Pneumatic Cylinders
  - 12.11.2 Air Motors
  - 12.11.3 Vacuum Suction Cups
- 12.12 Mufflers
- 12.13 Pneumatic Circuits
  - 12.13.1 Basic Pneumatic Circuit
  - 12.13.2 Speed Control Circuit
  - 12.13.3 Quick Exhaust Circuit
  - 12.13.4 Two Step Feed Control Circuit
  - 12.13.5 Time Delay Circuit
  - 12.13.6 Automatic Cylinder Reciprocation Circuit
  - 12.13.7 Two Hand Safety Control Circuit
- 12.14 Selection of Pneumatic Components
  - 12.14.1 Selection of Pneumatic Cylinders
  - 12.14.2 Selection of Air Motors
  - 12.14.3 Sizing of Control Valves
  - 12.14.4 Pressure Losses in Pipes
  - 12.14.5 Selection of Filter, Regulator, Lubricator
  - 12.14.6 Sizing of Compressors
  - Solved Problems
  - Exercise
  - Review Questions
CHAPTER 13 HYDROPNEUMATICS
- 13.1 Air-Oil Reservoir
- 13.2 Air-Oil Cylinder
- 13.3 Air-Oil Intensifier
- 13.4 Comparison of Hydropneumatic, Hydraulic and Pneumatic System
- Review Questions
CHAPTER 14 PNEUMATIC LOGIC CONTROLS
- 14.1 Pneumatic Sensors
- 14.2 Position Sensors
  - 14.2.1 Pneumatic Limit Valves
  - 14.2.2 Back Pressure Sensor
  - 14.2.3 Proximity Sensor
  - 14.2.4 Gap Sensor or Interruptible Jet Sensor
  - 14.2.5 Limit Switch
  - 14.2.6 Comparison between the Different Position Sensors
- 14.3 Pressure Sensors
- 14.4 Switching Elements
  - 14.4.1 Miniature Control Valves
  - 14.4.2 Moving-Part Logic Elements
  - 14.4.3 Fluidic Element
  - 14.4.4 Comparison between the Different Switching Elements
- Review Questions
CHAPTER 15 DESIGN OF PNEUMATIC LOGIC CIRCUITS
- 15.1 Classic Method
- 15.2 Cascade Method
- 15.3 Step-counter Method
- 15.4 Logic Circuit Design with Karnaugh-Veitch Mapping Method
- 15.5 Combinational Circuit Design
- Solved Problems
- Exercise
- Review Questions
CHAPTER 16 ELECTRICAL CONTROL OF FLUID POWER
- 16.1 Components of Electrical Controls
  - 16.1.1 Switches
  - 16.1.2 Solenoids
  - 16.1.3 Relays
  - 16.1.4 Timers
- 16.2 Electro-Hydraulic / Pneumatic Circuits
  - 16.2.1 Reciprocation of a CylinderUsing Pressure Switches
  - 16.2.2 Control of a Cylinder Using a Single Limit Switch
  - 16.2.3 Dual Cylinder Sequencing Circuit
  - 16.2.4 Regenerative Circuit
- 16.3 Cascade Method for Electropneumatic Circuits
- Review Questions
CHAPTER 17 MICROELECTRONIC CONTROL OF FLUID POWER
- 17.1 PLC Construction
  - 17.1.1 Central Processing Unit
  - 17.1.2 Memory
  - 17.1.3 I/O Module
- 17.2 Programming the PLC
  - 17.2.1 Ladder Diagram Based
  - 17.2.2 Low-level Language Based on Boolean Functions
  - 17.2.3 Functional Blocks
  - 17.2.4 High-level Languages
- 17.3 PLC Operation
- 17.4 Microprocessor Construction
  - 17.4.1 Microprocessor
  - 17.4.2 Memory
  - 17.4.3 Input/Output
  - 17.4.4 DC Power Supplies
  - 17.4.5 Bus
  - 17.4.6 Interfacing
- 17.5 Programming the Microprocessor
  - 17.5.1 Low-level Language Programming
  - 17.5.2 High-level Language Programming
- 17.6 Microprocessor Operation
- 17.7 Difference between PLCs and Microcomputers
- Exercise
- Review Questions
CHAPTER 18 INSTALLATION, MAINTENANCE AND TROUBLESHOOTING OF FLUID POWER SYSTEMS
- 18.1 Installation of Hydraulic Systems
  - 18.1.1 Installation of Pumps
  - 18.1.2 Installation of Cylinders
  - 18.1.3 Installation of Valves
  - 18.1.4 Installation of Tubing
  - 18.1.5 Power Pack Installation
  - 18.1.6 Filling the System
- 18.2 Maintenance of Hydraulic Systems
  - 18.2.1 Maintenance Schedule
- 18.3 Troubleshooting of Hydraulic System
  - 18.3.1 Fault Finding Procedure
- 18.4 Trouble — Possible Causes and Remedies
  - 18.4.1 Pumps
  - 18.4.2 Relief Valves
  - 18.4.3 Directional Valves
  - 18.4.4 Sequence Valves
  - 18.4.5 Unloading Valves
  - 18.4.6 Counterbalance Valves
  - 18.4.7 Flow Control Valves
  - 18.4.8 Remote Flow Control Valves
  - 18.4.9 Hydraulic Motors
  - 18.4.10 Hydraulic Cylinders
  - 18.4.11 Accumulators
  - 18.4.12 General Circuit Problems
- 18.5 Installation of Pneumatic Systems
  - 18.5.1 Installation of FRL Unit
  - 18.5.2 Installation of Pneumatic Cylinder
  - 18.5.3 Installation of Pipelines
  - 18.5.4 Installation of Compressor
- 18.6 Maintenance of Pneumatic System
  - 18.6.1 Maintenance Schedule
- 18.7 Troubleshooting of Pneumatic Systems
- 18.8 Trouble — Possible Causes and Remedies
  - 18.8.1 Compressor
  - 18.8.2 FRL Unit
  - 18.8.3 Air Cylinders and Air Motors
  - 18.8.4 Valves
  - 18.8.5 Pipe Lines and Hoses
- Review Questions
CHAPTER 19 LOW – COST AUTOMATION
- 19.1 Concepts of Low-cost Automation
- 19.2 Technologies Used for LCA
- 19.3 Applications
Appendices
- Two-mark Questions and Answers
References
Index

Dr. R. Srinivasan is Professor and Head of the Department of Mechanical Engineering in RVS College of Engineering, Dindigul. He completed his doctorate in Anna University, Chennai. He has been in teaching and research for the past 25 years. He has published number of research papers in International / National Journals and conferences. His textbooks on Hydraulic & Pneumatic Controls, and Engineering Materials & Metallurgy are recommended text / rNumerous solved problems and review questions • Dedicated chapters on hydraulic and pneumatic components • Includes industrial systems, design of hydraulic and pneumatic circuits and selection of components • Elaborate coverage of Hydropneumatics, electrical and electronic control of fluid power • Covers pneumatic logic controls and logic circuit designeference in various universities in India for undergraduate and postgraduate students. His research areas include materials, manufacturing and low cost automation