FACULTY OF MECHANICAL

ENGINEERING AND MANUFACTURING

BDA 18301
MECHANICAL ENGINEERING WORKSHOP 2
(ELECTRO-HYDRAULIC REPORT)
SEMESTER 2 (2017/2018)

Lecturer: Dr. MOHD SALLEHUDDIN BIN YUSOF

NO NAME MATRIC NUMBER

1 MUHAMMAD ADIB NAQIYUDDIN BIN ROSLAN AD170057

2 MUHAMMAD AIMAN BIN NASRI AD170274

3 MUHAMMAD FAKRUL SHAKIRIN B ABDUL RAHMAN AD170189

4 MUHAMMAD AMMAR HAZIQ BIN UNIG KUTTI CD170028

5 KOK WIN LEONG AD170244

6 MUAMMAR SAYMIM HAMIZAN BIN MOHD HISHAM AD160035

7 ARFIZAN BIN KAHA AD160156

8 STEVE BURNETT AK PETRUS CD170032

9 MUSTAQIM BIN MAMAT AD170278

10 MUHAMMAD AMIN BIN MOHD YASIN AD160187

 CONTENT

NO DESCRIPTION PAGES
1 INTRODUCTION 3
2 OBJECTIVE, SCOPE 4
3 SAFETY 5
PRECAUTION
4 EQUIPMENT 5
5 PRACTICE 1 8
6 PRACTICE 2 12
7 CONCLUSION 18
8 REFERENCES 18

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INTRODUCTION:

Hydraulic is a topic in applied science and engineering dealing with mechanical

function that operates through the force of liquid pressure. In electro- hydraulics system is the
combination of electrical and hydraulic system. The range of applications for electro-
hydraulics systems is diverse, and includes manufacturing systems, materials test machines,
suspension system, mining machinery, fatigue testing, flight stimulation, paper machines and
etc. hydraulics pumps, motor and cylinders can be combined into hydraulics drive systems.
One or more hydraulics pumps, coupled to one or more hydraulic motors, constitute a hydraulic
transmission.

In a hydraulic device, power is transmitted by pushing on a confined liquid. The transfer

or energy takes place because a quantity of liquid is subject to pressure. By applying a
downward force on the small piston, the jack can be made to lift a heavy mass on the large
piston. The liquid fills the entire volume between the two pistons, and because it is in
compressible, some liquid must move into the large piston chamber when the small piston is
pushed downward. Hydraulic systems operate according to Pascal’s law. The law of Blaise
Pascal says: ' The pressure, in a static hydraulic fluid in a closed system is everywhere the same
'. However, when the velocity of the flow is constant one may apply Pascals Law as well

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OBJECTIVES:

1. Understand the concept of hydraulic system

2. To determine how the concept of hydraulic is work
3. Explore the fundamental principles of fluid mechanics through experimentation
4. Understand hydraulic system and its components
5. Draw, install and commission an electro-hydraulic circuit to control the movement a
double acting cylinder using 4/2 way directional control valve single solenoid.
6. Install mechanical sensors components correctly in electro-hydraulic control system.
7. Apply safety and regulations in workshop.

SCOPE:

By the end of this task, we should able to know the types and the shape of 4/2 way
single solenoid Directional Control Valve (DCV),double acting cylinder, sensor ,relay
,contactor hydraulics hoses and board system. Besides that, we also know both of its function
and application. Futhermore, we able to know the equipment that we never use before, such as
tachometer. Thus, we should able to know how to conduct an experiment based on the task
given.

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SAFETY PRECAUTION:

1. Make sure that the power source is switched off when doing the connection.
2. Ensure safe clamping and decamping procedure for automatic system.
3. Ensure the hydraulics components are in good condition
4. Use goggles for eyes protection against pressure actuated system and machine tools.
5. Be careful for oil leakage, it will make the floor become wet and slippery, as the result
causing the accident.
6. Wear proper clothing that will not catch in rotating or moving parts.
7. Avoid the cable wires from getting tangled.

EQUIPMENT:

Hydraulic Relief Valves

Relief valves are the most common type of pressure-control valves. The relief valves’
function may vary, depending on a system’s needs. They can provide overload protection for
circuit components or limit the force or torque exerted by a linear actuator or rotary motor.

The internal design of all relief valves is basically similar. The valves consist of two
sections: a body section containing a piston that is retained on its seat by a spring(s),
depending on the model, and a cover or pilot-valve section that hydraulically controls a body
piston’s movement. The adjusting screw adjusts this control within the range of the valves.

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 Valves that provide emergency overload protection do not operate as often since other
valve types are used to load and unload a pump. However, relief valves should be cleaned
regularly by reducing their pressure adjustments to flush out any possible sludge deposits that
may accumulate. Operating under reduced pressure will clean out sludge deposits and ensure
that the valves operate properly after the pressure is adjusted to its prescribed setting.

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RELAY

The relay is an electromechanical switch that used as a protecting device and also as a
controlling device for various circuits and electrical networks in a power system. The
electromechanical relay can be defined as an electrically operated switch that completes or
interrupts a circuit by physical movement of electrical contacts into contact with each other.

A relay is a mechanical device that connects one circuit to another. It should be thought
of as a switch. Think of two electrical circuits that are joined via a relay. When current flows
into the primary circuit from a power source current causes another switch to be thrown (the
relay) and power now flows into a secondary circuit as well. However, this can be done in
reverse, so that when power is no longer flowing in the primary circuit it trips a relay, and
power comes from a secondary circuit. This is the way that automatic generators work during
power outages to make sure that the flow of electricity isn't interrupted.

Solenoid:

In engineering, the term may also refer to a variety of transducer devices that convert
energy into linear motion. The term is also often used to refer to a solenoid valve, which is an
integrated device containing an electromechanical solenoid which actuates either a pneumatic
or hydraulic valve, or a solenoid switch, which is a specific type of relay that internally uses an
electromechanical solenoid to operate an electrical switch; for example, an automobile starter
solenoid, or a linear solenoid, which is an electromechanical solenoid.

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Practice 1

OBJECTIVES:

Upon completing this task, student be able to:

 Understand a hydraulic control system

 Draw and install pure hydraulic circuit to control the movement a double acting cylinder
using 4/ way directional control valve.

TASK:

1. Draw, install and commission a basic hydraulic control circuit to move a double acting
cylinder by pressing a starting lever A. Use the following requirement
a. 1 unit 4/3 way directional control single lever operated spring returned.
b. 1 unit pressure relief valve set at 40 bar
c. The cylinder speed 20cm/min
2. Record the gauge pressures at the inlet port and outlet ports of the directional control
valve during the cylinder extending and retracting. Set the system pressure at 20 bar,
25 bar, 30 bar and 35 bar. Record on the Table, Plot a graph. Thus explain the graph
with a technical reason.

METHOD AND STANDARD OPERATION PROCEDURES (S.O.P)

1. 1 unit of 4/2 Way Directional Control Single Lever, one check valve and is obtained and
clamped to the wire grid.
2. The oil that remains inside all ports is released so that hydraulic hoses can fully plug-in to
the parts.
3. By using suitable length of hydraulic hoses, connect to the respective coupling and
between the hydraulic components refer to figure for hydraulic control circuit drawn.
4. 3 units of pressure gauges are connected to the inlet port and outlet ports of the directional
control valve respectively.

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5. Ensure the hose connected correctly, where port P to port A and port T to port B.
6. After all the hose are connected correctly to the end fitting, the power source is switched
on.
7. By operating the hand lever of DCV, the double acting cylinder will extend the retract.
8. By operating the control valve, where the pressure are 20 bar, 25 bar, 30 bar and 35 bar,
the gauge pressures at the inlet ports and outlet ports of DCV during the cylinder
extending and retracting are recorded respectively.

ANALYSIS / FINAL PRODUCT / OUTPUT

1.Oil level is important to a hydraulic system and requires to be checked for optimum
functionality.

2.A fluid can be move and change which makes the hydraulic system to be varied in power
conversion with minimum mechanical behaviour.

3.Hydraulics have unlimited application in the production of goods and services in all sectors.

4.Leaks are a major problem in hydraulics as it decreases in operation performance.

5.Hydraulics is used in heavy equipment in log splinters. It is the most basic hydraulics
system which consists a hydraulic pump, engine, hydraulics cylinders, various valves and
hydraulic pistons. Another example that can be seen using hydraulic properties is in wheel
chairs that is use to push upwards of the seat and the hydraulic system in an aeroplane which
enables it to push out or close out of its landing gear.

6. Function of components:

 Hydraulic cylinders: Part of a component where pressure is applied on the fluid where
desired force is achieved. They are used to power hydraulic machine of car brakes,
cranes, turbine and excavators. Inside the cylinders lies a hydraulic piston which are
use to push down the fluids to other cylinder and exerts pressure and push it back
again.
 Hydraulic pumps: The pump is a component that is responsible for supplying the
fluids to the other essential parts of the hydraulic system. The power ratio of a
hydraulic pump to a electric motor is 10:1. Piston pump is considered the best among

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 other pumps such as vane pumps and gear pumps. It is long lasting and it is
considered very durable under heavy loads.
 Hydraulic wrench: Used to tighten the nuts and bolts.
 Hydraulic lifts: Hydraulic lifts are the similar components used for hydraulic lifts in
cars such as low riders.
 Hydraulic press: A process in which the pressure is compressed to a full extent. It
involves two cylinders of different diameters and sizes of pistons. Pascal’s Law is
used to generate powerful pressure. A great force is usually exert when using this
machinery as it is usually use to crush cars into thin sheets of metal.
 Hydraulic motors: The power in hydraulic motors is achieved with the help of
exerting pressure on the hydraulic fluids, which is oily. A benefit of using a hydraulic
motor is it tendency to rotate in the opposite direction which acts as a hydraulic pump
when the power source is mechanically driven.

7. In Practice 1, the gauge pressure at the inlet port and outlet ports of the directional control
valve during the cylinder extending and retracting have been recorded. Directional control
valves are usually design to be stackable, with one valve for each hydraulic cylinder, and one
fluid input supplying all the valves in the stack. Flow control valve is adjustable which
controls the flow rate.

Here the results are shown:

Gauge Pressure Cylinder extending (bar) Cylinder retracting (bar)

(bar) Inlet Port Outlet Port Inlet Port Outlet Port
20 4 16 20 0
25 4 21 25 0
30 4 26 30 0
35 4 31 35 0
Table 1

From table 1, we can conclude that, the pressure that insert to the system which caused the
cylinder to extend is the same with the pressured that leave in the system.

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 DOUBLE
ACTING
CYLINDER

FLOW
CONTROL
VALVE

PRESSURE
GAUGE

4/2 WAY
DIRECTONAL
CONTROL
VALVE

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Practice 2

OBJECTIVES:

Upon completing this task, student be able to:

1. Draw, install and commission hydraulic circuit to control the movement of a double
acting cylinder using 4/3 way directional control valve.
2. Measure the flow rate of hydraulic fluid in the cylinder.
TASK:

3. Press the starting switch A of a hydraulic cylinder will move the piston for 10 cm, 15cm
and 20 cm stroke. The piston will return to initial state when the switch is depressed.
Record the time each of the distance in second, “s”
4. Measure the flow rate of the hydraulic cylinder during extending and retracting by
replacing the existing cylinder with the measuring flow rate cylinder. Record the time
for filling the 1 liter. Record the rpm in table and plot a graph.
5. Replace the cylinder with a hydraulic motor. Set the motor at 3 different speeds. Set the
pressure bar at 10, 15 and 20. Record the rpm in table and plot a graph.

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METHOD AND STANDARD OF PROCEDURES
Task 1

1. One unit of 4/3 Way Directional Control Valve, one check valve and is obtained and
clamp to the wire grid.
2. The oil that remains inside all ports is released so that hydraulic hoses can fully plug-
in to the parts.
3. By using suitable length of hydraulic hoses, connect to the respective coupling and
between the hydraulic components refer to figure for hydraulic control circuit drawn.
4. 3 units of pressure gauges are connected to the inlet port and outlet ports of the
directional control valve respectively.
5. Ensure the hose connected correctly, where port P to port A and port T to port B.
6. After all the hose are connected correctly to the end fitting, the power source is switched
on.
7. By operating the hand lever of DCV, the double acting cylinder will extend and retract.
8. By setting the pressure at 10 bar, record the time of the piston to extract and retract at
10 cm, 15 cm and 20cm stroke.

Double acting
cylinder

Pressure
gauges
Hose

4/3 Way directional

control valve

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Task 2

1. From the hydraulic that setting up at task 1, take out the only cable that connect from
DCV to the piston.
2. Connect the cable that was take out to the cylinder cage at the side of the station
3. Check whether it is correctly connect or not by testing the flow out of the oil.
4. By set up the time from the task 1, measure the flow of the oil at the cylinder in Litre.

Double acting
cylinder

4/3 way directional

control valve

Pressure gauges

Hydraulic
cylinder

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Task 3

1. By putting the RPM metre, connect the in and out flow of cable at the RPM metre.
2. Measure rotation per minute when the oil is flow in and out from the supply box.

Hydraulic motor 4/3 way directional

Hydraulic control valve
cylinder

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DISCUSSION

Hydraulic systems can be found today in a wide variety of applications, from small
assembly processes to integrated steel and paper mill applications. Hydraulics enable the
operator to accomplish significant work (lifting heavy loads, turning a shaft, drilling precision
holes, etc.) with a minimum investment in mechanical linkage through the application of
Pascal’s law, which states:

“Pressure applied to a confined fluid at any point is transmitted undiminished throughout the
fluid in all directions and acts upon every part of the confining vessel at right angles to its
interior surfaces and equally upon equal areas.”

Hydraulic systems are complicated fluid-based systems for transferring energy and converting
that energy into useful work. Successful hydraulic operations require the careful selection of
hydraulic fluids that meet the system demands. Viscosity selection is central to a correct fluid
selection. There are other important parameters to consider as well, including viscosity index,
wear resistance and oxidation resistance. Fluids can often be consolidated to reduce complexity
and material storage cost. Caution should be exercised to avoid sacrificing fluid performance
in an effort to achieve fluid consolidation.

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RESULT AND ANALYSIS

In task 2, the flow rate of the hydraulic cylinder during extending and retracting with
measurement of 10cm, 15cm and 20cm is measured using flow rate cylinder. The piston
duration of extending and retracting is measured using stopwatch. The flow rate cylinder is
then replaced with a 3 speed motor where it is measured using a tachometer.

The table below shows the result obtained;

Length (cm) Time (s)

10 0.91
15 2.56
20 3.15
Task 1

Piston length (cm) Flow rate (l/s) Time (s)

10 0.10 1.38
15 0.19 1.87
20 0.21 2.53
Task 2 (Extend)

Piston length (cm) Flow rate (l/s) Time (s)

10 0.25 2.06
15 0.35 2.87
20 0.45 3.40
Table 3 (Rectract)

Task 3

The speed of the motor obtain at 10bar used in this experiment is 2231 rpm for task 3

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CONCLUSION:

For the conclusion, the electro-hydraulic control system mainly helps in the simpleness of
handling hydraulic units. The main purpose of our practice is to draw, install and commission
an electro-hydraulic circuit to control the movement of a double acting cylinder using 4/2 way
directional control valve single solenoid. We be able to apply mechanical motor to electro-
hydraulic control system by its mechanism in board mounted condition and its works properly.
By using sensors and the solenoid, the previously three step work had been reduced to one step
work. The relay acts an electrical storage for the motor to turn up. Thus, we can conclude that
using electro-hydraulic control system makes the control function becomes easier and friendlier
user towards the operators.

REFERENCE:

1. https://www.quora.com/What-is-the-function-of-relay

2. https://www.pc-control.co.uk/relays.htm

3. https://itstillruns.com/purpose-solenoid-7461399.html

4. https://tameson.com/solenoid-valve-types.html

5. https://www.elprocus.com/different-types-of-solenoid-working-applications/

6. http://blog.wika.com/knowhow/what-is-meant-by-the-normally-open-
switching-function-with-pressure-switches/

7. https://www.theautomationstore.com/electrical-contacts-normally-open-and-
normally-closed-contacts/

8. http://www.te.com/global-en/products/relays-contactors-
switches/relays/intersection/application-notes.html

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