Autumn 2023-24

Mining Machinery Laboratory

Experiment 7 & 8: Hydraulic and Pneumatic Trainer

Instructor:

Dr. Ketan Arora

Assistant Professor
Department of Mining Engineering
IIT Kharagpur
Email: [email protected]
 Hydraulic Trainer

Hydraulic trainer/Hydraulic training system/hydraulic simulator

• Piece of equipment/system designed to teach and train individuals in the principles and
applications of hydraulic systems and components.

• Hydraulic systems use pressurized fluid (usually oil) to transmit power and control the movement of
various mechanical components, such as cylinders, motors, and valves.

• These systems are widely used in various industries, including mining, manufacturing,
construction, and aerospace.

• Provides hands-on experience and practical knowledge about hydraulic systems

2
 Components of Hydraulic Trainer
1. Hydraulic Power Unit (HPU)
2. Hydraulic Fluid Reservoir
3. Hydraulic Pump
4. Hydraulic Valves
5. Hydraulic Actuators Components include
6. Hydraulic Filters but not limited to
7. Sensors
8. Pressure Gauges
9. Control Panel
10. Safety Features
11. Hydraulic Lines and Hoses
12. Educational Material
3
 1. Hydraulic Power Unit (HPU)
The HPU is the heart of the hydraulic trainer. It generates hydraulic pressure by using a pump and stores
hydraulic fluid in a reservoir. It may also include a motor to power the pump.

4
 2. Hydraulic Fluid Reservoir
This component stores the hydraulic fluid (usually hydraulic oil) and allows for the cooling and filtration
of the fluid.

5
 3. Hydraulic Pump
The pump is responsible for creating hydraulic pressure by drawing in hydraulic fluid from the reservoir
and delivering it to the rest of the hydraulic system.

6
 4. Hydraulic Valves

a) Directional Control Valves: These valves control the direction of fluid flow in the system,
determining the movement of actuators.

7
 4. Hydraulic Valves

b) Pressure Control Valves: Pressure control valves regulate the pressure within the hydraulic
system.

8
 4. Hydraulic Valves

c) Flow Control Valves: Flow control valves manage the rate of

fluid flow in the system.

9
 5. Hydraulic Actuator

These are used to convert hydraulic pressure into linear motion. They often have a piston rod that
extends or retracts when pressurized.

10
 6. Hydraulic Filter

Filters are used to remove contaminants and impurities from the hydraulic fluid to maintain system
cleanliness.

Outer Inner

11
 7. Sensors

Sensors, such as pressure sensors and temperature sensors, provide real-time data on the hydraulic
system's performance.

12
 8. Pressure Gauge

These gauges measure the hydraulic pressure at different points in the system, allowing users to
monitor and adjust pressure levels.

13
 9. Control Panel

The control panel typically includes various controls, switches, and knobs that allow users to operate
and control the hydraulic system. It may also include indicators and displays for monitoring system
parameters.

14
 Safety Features; Lines & Hoses; Educational Material

• Hydraulic trainers often include safety features like emergency stop buttons, pressure relief
valves, and protective enclosures to ensure safe operation.
• Lines and Hoses connect various parts of the hydraulic system, allowing hydraulic fluid to flow
between them.
• Instructors may provide educational materials such as manuals, diagrams, and exercises to guide
students through the training process.

15
 Pneumatic Trainer

Pneumatic trainer/Pneumatic training system/Pneumatic simulator

• A piece of equipment/system designed to teach and train individuals in the principles and applications
of pneumatic systems and components.

• Pneumatic systems use compressed air to transmit power and control the movement of various
mechanical components, such as cylinders, motors, and valves.

• These systems are used in various industries, including manufacturing, automation, and robotics.

16
 Components of Pneumatic Trainer
1. Compressor
2. Air Reservoir
3. Pneumatic Cylinders
4. Pneumatic Valves
5. Control Panel Components include
6. Sensors and Gauges but not limited to
7. Safety Features
8. Tubing and Pneumatic Hoses
9. Educational Materials

17
 0
a
0

o/J •·

f5 ·. ·~
f ·,-

;·;~
Q .., • f• ~ ;

z
..... '

;::! ·' ,.·

u

g
SEO~E:
VALVt

0 RE:Tl.RN Lit-IE: AIR ~E:flTHE:~

_ _ _ _ FIL TERrt_ _ _ _ _ :FfLL/NG STRAINER 0

.J I

OIL RESERVQID
!im I
i :·
Ii
iI
Ii
I ii
I I l
t :
I
0
I i!
! I
I

11
PEECO iI
HYDRAULIC PRIVATE I 1'I1 -'] /
:JGN DY ~•1 l ; n.,
,\M8l CA lWNDU lANE, RAMRAJATALA, HOWRAH - u _ ... . ! 1

- --- ------~---------- ------ -

.'f. :f31c..t» ""'
TI TLE I I
I '

WN IlY .:f'. X" -''''""'

-CKEJJ
- --1 _ __ G,A;; Fon TRAINNER JOT

____
DATE SCAIJE DRG, NO. !,
BY · .A, ""'"-• IO /7 /00 N, T.S. GSPL/l'R/ 1220 ,•
---------__,_ _.._ -'----'-------..----- - -..._: ;

~ -_A_n__-~-E=·==·-=======.Jl=
F• .a,=
,., r.uJ
===============----
-~--
S_H_~-: !_1:1 J . -- t
 /

/ - LIST Of COMPONENTS FOR liYPRAUI,Ic TRAINER KIT

· DE~CRIPTION .,
..'
/=:~=B=O=:;=L•===,=~·pfF.c=.T=i,==~~~===79~~F,=============~R7'~~~======
QTY . MAKE
-rn- 2
TANK.
c~ ,(. , ..
-
. DRAIN PLUG .:, lNU
m
, / PEECO
JNQ ·PEE CO

----·-·--r---11----·~:-:-..._____________~~~---:----,~--.,~--
3 OIL LEVEL GAUGE•LG"-03
JNQ '
41,0 Ll~f AIR BREATH[R/rJLLING ~TRAINE:R-rs.9:.05 !MA'>'!
__v____·--,---,t-,_..r-'......._____s.ts_u_·i_,_¥"""-·-~_._/t:.t'ti;..:.'7.::i,..,:.=';;.;l"CM;.;.;..._...;4.o;..:l.:.;,o;....;~;.;..·.;;;.·TOn;.;.;;._· --,1---n----
() 5 STRAINER·SC3-D07 ·
. JNQ HY DP.CLINE -
JNQ HYI:RDLJNE
6 ' I ''
1

" '. " ,~,:;:.UMP-PVR]T-JO-L:.... .,,.. I , I) . &w-~'!'1' •JNQ

I".' " - 10 4 /ty.n//1'),4,.,"V!J p,.~ /?57/1' YUKEN
0 7
HOTOR'-2H.P-J 440R .P.M.
JNQ CRO~P.
8
PR.RELlRF' VAL VE :-DPRS-06- Tl 00
PPL

Jt-0, - ..' f-lYDRDLIN[

dGJJLlJ 10 LEVER OPERATED 3VA'f ~ALV[--41)L.,-IO-SCD

JND•. PPL
-
.Jltl@Xb ll
SDLJIIOJD OP. D,C ·. VALVt:_.DSG-:Ol;;,3C60· A-240 i
IND. -YUKCN ,.
1e
lliH1xuf LEVER QP: O.C VALV(-4DL·l~S ·-

---·----t---.,11----- ·--------------------11----11,-------
PPL
L~-fftil
M
J
SEQUtNct VAL VE .:DPS-S'-06:-s..:y
IND. · PPL
,.,
, ·.
. ]4
· INT£:NSlfIER !
P[E;CD
. :· ' .·
rI
15 ISDLAlit,(j VAL[
-
J3N_QS.: · :,

I 16
llAMPER VAL VE.
3-NDS.
, ·., ~~ECO· , ·
=='
- '-':-==:-===1=====i===== = = = = = = = = = = = = = = =====11===11 , = = =.. ==1=1
0 17
PR. GAUGE ro~ PUt-P PRCSSURE-CIIIOO DIAL
IND. 'fEIBIG--

L __ 2,1 ·
PILOT OP. CH. VALVE:..CL-Jo->r Cr111~...a
. . u Preloli.,c,•4t."->t
· IND. PPL ' . [- .;.

. ,=====:f=:=22==/F==P=R,=
=6== ,.,=b.=JU=S=T=ll=~G==\/=A=LV
==E-=D=P=R=H=-0=6=-=,_=l=O=O=..========_=, ~!==P=F'L ===
·_,=_.c:_ T/.
r l·
? _·1,,_,··'
L.:.J .. . -..

-9---==*==J===
_==~'f'!\,;
=\:?=?===u===
F ==C==H=E=Cr.:=
•. =V=A=L=V=E=-=rc=G=-=0)= .[' :';N.=
i.l

,' M,11,,)(
Flow
~"t.~ ev~~ 1Lto,i,.fieim1..
, .
==-====:=== _J ~, r1__i_,.,•. c"E ..,<~~ , r» 0_2- f.;1-/ tw ,1

L
 \:·===============================-..!E:!le~c;!tr~o:_-:.!P!n~e!!u!m~a~n~·c~Tr~a;!!in~i~n!g~K~it

U!XPERIMENT 1:

AIM:
5 ports and 2 positions
TO STUDY 5/2 WAY SINGLE SOLENOID VALVE.

EQUIPMENT USED:

1. FRL Unit.
2. Manifold.
3. 5/2 Way Single Solenoid Valve.
4. Double Acting Cylinder.

DOUBLE ACTING
CYLINDER

512 WAY SINGLE

SOLENOID VALVE

•,, ,r i IN

m
SWITCH

F~L 000
MANIFOLD

Make the connection as shown in figure.

5/2 Way Single Solenoid valve is Electrical Operated Valve.
Beside the solenoid valve push button is provided. To actuate the valve press the button and observe the motion of
double acting cylinder the cylinder piston ext~nds.
After realizing the button cylinder piston retracts.
While pressing the electr.ical button electro magnet creates in the coil and the valve change its position after realizing
the button de - magnet the coil.
 Electro - Pneumatic Training Kit

-vf~PERIMENT 2:

AIM :

TO STUDY 5/2 WAY DOUBLE SOLENOID VALVE .

EQUIPMENT USED:

1. FRL Unit.
2. Manifold.
5/2 Way Double Solenoid Valve.
Double Acting Cylinder.

DOUBLE ACTING
CYLINDER

CYL CYL

5/2 WAY DOUBLE

SOLENOID VALVE

SW1 SW2

FRL --- 0 0 0 0
MANIFOLD
PROCEDURE:

1. Make the connection as shown in figure.

5/2 way double solenoid valve is also electrical operated valve as the experiment is with double solenoid valve . Two
individual press buttons is provided beside the solenoid valve.
Beside the solenoid valve push button is provided . To actuate the valve press the button and observe the motion of
double acting cylinder the cyl inder piston extends.
After realizing the button cylinder piston retracts .
While pressing the electrical button electro magnet creates in the coil and the valve change its position after realizing
the button de - magnet the coil.
 Electro - Pneumatic Training Kit

EXPERIMENT 3:

AIM :

TO STUDY THE LOGIC 'AND' FUNCTION.

EQUIPMENT USED:

q,
i,
';· 1. Single Acting Cylinder ( 01 Nos)
2.
t AND valve.

.,
:I, 3.
4.
3/2 way hand lever valve
3/2 way palm operated valve
~. 5. Service Unit
single acting cylinder which uses only
6. Compressor. one ports for the intake of pressurized

l
I,
7. Distributor. fluid

il
SINGLE ACTING
CYLINDER

l
i
DUAL PRESSURE VALVE
'' "AND" ELEMENT
. ,

'
cs ~.
' ' v3/2WAY
PALM OPERATED VALVE
A palm 3/2WAY
HAND LEVER VALVE
operated valve
is a manually Hand Operated Valve is a
operated valve mechanically operated industrial
that is controlled valve that is designed to control the
0 0 0 0
by pressing flow rate of pressurized fluids
down on a palm MANIFQ.O

button.
 Electro - Pneumatic Training Kit

PROCEDURE:

1. Make the connections as shown in the figure . When palm operated valve is actuated.
2. The signal is generated at one of the port of the shuttle valve and is transmitted through the dual pressure valve to
single acting cylinder.
3. And the cylinder extended.
4. Similarly, if the valve that is 3/2 way hand lever valve is actuated, the valve gets reverse.
5. This signal is generated at another port of the shuttle valve.
6. If both the signals are removed from the two valves, the dual pressure valve releases the signal back through the
exhaust port of one of the valve.
7. Also, the return spring of the control valve causes the cylinder to retract.
8. If signals are present at both the ends of the dual pressure valve then the cylinder extends fully.
 Electro - P11eumatic Trai11i11g Kit
I -

EXPERIMENT 4:

AIM :

TO STUDY THE LOGIC 'OR' FUNCTION.

EQUIPMENT USED:

1 Shuttle valve.
2 312 way hand lever valve
3 312 way palm operated valve
4 Service Unit
5 Compressor.
6 Distributer.
7 Single Acting Cylinder ( 01 Nos )

SINGLE ACTING
CYLINDER

SHUTTLE VALVE

p
3/2WAY
PALM OPERATED VALVE

3/2WAY
HANO LEVER VALVE

0 0 0 0
MANIFQ.O
 Electro - Pneumatic Training Kit

PROCEDURE:

1. Make the connections as shown in the figure. When palm operated valve is actuated.
2. The signal is generated at one of the port of the shuttle valve and is transmitted through the shuttle valve to single
acting cylinder.
3. And the cylinder extended .
4. Similarly, if the another valve that is 3/2 way hand lever valve is actuated, the valve gets reverse .
5. This signal is generated at another port of the shuttle valve.
6. If both the signals are removed from the two valves, the shuttle valve releases the signal back through the exhaust port
of one of the valve.
7. Also, the return spring of the control valve causes the cylinder to retract.
8. If signals are present at both the ends of the shuttle valve then the cylinder extends fully.
 6)
Electro - Pneumatic Training Kit

EXPERIMENT 5: /

AIM :

STUDY OF FLOW CONTROL VALVE.

: EQUIPMENT USED:

1. FRL Unit. ·
2. Manifold.
3. Flow Control Valve.
· 4. 3/2 Way pilot operated valve
' 5. Single Acting Cylinder.

SINGLE ACTING
CYLINDER

FLOW CONTROL
VALVE

3/2 WAYf!A_L-M
_____,..,f OPERATED VALVE

A IN

FRL 000
MANIFOLD

'·
 PROCEDURE:

1. Make the connection as shown in figure.

2. At first the single acting cylinder will be in the retracted position .
3. Initially keep the flow control valve completely open.
4. Now press the button of 3/2 way Aodloperated valve.
5. This reverses the 3/2 way valve position and the single acting cylinder piston extends on realizing the button the spring
action of the cylinder causes it to retract.
Note the speed of the piston movement in forward and reverse direction.
6. Now adjust the flow control valve with turning the know in clockwise its reduced the pressure.
7. Now press the button of 3/2 way fllu,operated valve again.
8. Observe that cylinder extends with slower speed.
' 9. Now release the button to retract the cylinder piston.
rd
10. Repeat the above procedure to various other setting of flow control valve. To study the relation of speed of the forwa
movement with that of opening or closing of the flow control. The same expe.riment also can be possible wrth double
acting cylinder.
 Electro - Pneumatic Training Kit

..,.i'xPERIMENT 6:

AIM:

OPERATION OF SINGLE ACTING CYLINDER 2/2 WAY DIRECT ACTING SOLENOID VALVE

EQUIPMENT USED:

1. FRL Unit.
2. 212 way direct acting solenoid valve.
·-· 3. Single Acting Cylinder.
4. Manifold.

SINGLE ACTING CYLINDER

p
2/2 WAY DIRECT
ACTING SOLENOID VALVE

0 0 0 0
MONIFOLD

OCEDURE:

Connect the components as shown in circuit pneumatically/ electrically.

Start the air compressor.
Energize the solenoid coil through push button.
And observe the movement of the cylinder.